Polymer Overlay Projects

Page 1 of 9 March 2024 REQUEST FOR BIDS Polymer Overlay Projects Sealed bids will be accepted up to and publically read by the Waupaca County Highway Department at 10:00 a.m. Monday, April 15, 2024 at the Waupaca County Highway Department Office, 2670 County Rd. A, Waupaca, WI for “Polymer Overlay Projects”. Bid information can be found at: https://www.waupacacounty-wi.gov/departments/current_bid_packages.php on the “Current Bid Packages” page. The Highway Committee reserves the right to reject any or all bids or to accept any bid that may be most advantageous to Waupaca County. Most advantageous includes a performance comparison of the material with any like or similar type of material; a comparison of the manufacturer's and suppliers' ability and reputation for prompt delivery. Bid envelopes must be sealed and marked as "Polymer Overlay Projects” and include a

completed “Polymer Overlay Projects” Bid Proposal Form. Questions should be addressed to Al Kriesel, Bridge Foreman, Waupaca County Highway Department, 2670 County Rd. A, Waupaca, Wisconsin at 715-258-7152. Sincerely, WAUPACA COUNTY HIGHWAY DEPARTMENT WAUPACA COUNTY HIGHWAY DEPARTMENT 2670 County Rd. A, Waupaca, WI 54981 Telephone: (715) 258-7050 https://www.waupacacounty-wi.gov/departments/current_bid_packages.php Page 2 of 9 SPECIFICATIONS FOR POLYMER OVERLAY Waupaca County is requesting bid proposals for six (6) bridges located in Waupaca County. Time shall be allotted to complete one-half (1/2) bridge per day. One-half of the bridge will be closed to traffic and flagged. Polymer overlay shall only be performed inside the bridge rail, eliminating the need to grind between the posts. Bid shall include one (1) price including Aggregate, Polymer Resin, Deck Preparation (when applicable), Application, and Mobilization. All above processes and materials shall follow Wisconsin DOT Polymer Overlay specification, section 509.5100.S. 1. Polymer Overlay, Item 509.5100.S. A Description This special provision describes providing two layers of a two-component polymer overlay system to the bridge decks the plans show. B Materials B.1 General Furnish materials specifically designed for use over concrete bridge decks. Furnish polymer liquid binders from the department’s approved product list. B.2 Polymer Resin Furnish a polymer resin base and hardener composed of two-component, 100 percent solids, 100 percent reactive, thermosetting compound with the following properties: Property Requirements Test Method Gel Time[1] 15 - 45 minutes @ 73 to 75 F ASTM C881 Viscosity[1] 7 - 70 poises ASTM D2393, Brookfield RVT, Spindle No. 3, 20 rpm Shore D Hardness[2] 60-75 ASTM D2240 Absorption[2] 1% maximum at 24 hr ASTM D570 Tensile Elongation[2] 30% - 70% @ 7 days ASTM D638 Tensile Strength[2] 2000 to 5000 psi @ 7 days ASTM D638 Chloride Permeability[2] 100 coulombs @ 28 days AASHTO T277 [1] Uncured, mixed polymer binder [2] Cured, mixed polymer binder Page 3 of 9 Ensure that the polymer resin when mixed with aggregate has the following properties: Property Requirement[1] Test Method Minimum Compressive Strength 1,000 psi @ 8 hrs 5,000 psi @ 24 hrs ASTM C579 Method B, Modified[2] Thermal Compatibility No Delaminations ASTM C884 Minimum Pull-off Strength 250 psi @ 24 hrs ASTM C1583 [1] Based on samples cured or aged and tested at 75°F [2] Plastic inserts that will provide 2-inch by 2-inch cubes shall be placed in the oversized brass molds. B.3 Aggregates Furnish natural or synthetic aggregate that is non-polishing; clean; free of surface moisture; fractured or angular in shape; free from silt, clay, asphalt, or other organic materials; and conform to the following: Aggregate Properties Property Requirement Test Method Moisture Content[1] 1/2 of the measured aggregate absorption, % ASTM C566 Hardness >6.5 Mohs Scale Fractured Faces 100% with at least 1 fractured face & 80% with at least 2 fractured faces of material retained on No.16 ASTM D5821 Absorption 1% ASTM C128 [1] Sampled and tested by the department before placement. Gradation Sieve Size % Passing by Weight No. 4 100 No. 8 30 – 75 No. 16 0 – 5 No. 30 0 – 1 B.4 Approval of Bridge Deck Polymer Overlay System A minimum of 20 working days before application, submit product data sheets and specifications from the manufacturer, and a certified report of test or analysis from an independent laboratory to the engineer for approval. The department will sample and test the aggregates for gradation and moisture content before placement. If requested, supply the department with samples of the polymer for the purpose of acceptance testing. B.4.1 Product Data Sheets and Specifications Product data sheets and specifications from the manufacture consists of literature from the manufacturer showing general instructions, application recommendations/methods, product properties, general instructions, or any other applicable information. Page 4 of 9 B.4.2 Certified Report of Test or Analysis Conform to the following: Polymer Binder: Submit a certified report of test or analysis from an independent laboratory dated less than 3 years before the date of the project letting showing the polymer binder meets the requirements of section B.2. Aggregates: Submit a certified report of test or analysis from an independent laboratory dated less than 6 months before the date of the project letting showing the aggregates meet the requirements of section B.3. C Construction C.1 General Ensure that the overlay system is 1/4 inch thick or thicker. Conform to the following: Field Review: Conduct a field review of the existing deck to identify any possible surface preparation and material compatibility issues. Pre-Installation Meeting: Conduct a pre-installation meeting with the manufacturer's representative and the engineer before construction. Discuss the field review findings, verification testing of the surface preparation and establish procedures for maintaining optimum working conditions and coordination of work. Furnish the engineer a copy of the recommended procedures and apply the overlay system according to the manufacturer’s instructions. Supply for the engineer’s use for the duration of the project, a Concrete Surface Profile (CSP) chip set of 10 from the International Concrete Repair Institute (ICRI). Manufacturer’s Representative: An experienced manufacturer's representative familiar with the overlay system installation procedures shall be present at all times during surface preparation and overlay placement to provide quality assurance that the work is being performed properly. This requirement may be reduced at the engineer’s discretion. Material Storage: Store and handle materials according to the manufacturer’s recommendations. Store resin materials in their original containers in a dry area. Store all aggregates in a dry environment and protect aggregates from contaminants on the job site. C.2 Deck Preparation C.2.1 Deck Repair Remove all asphaltic patches and unsound or disintegrated areas of the concrete decks as the plans show, or as the engineer directs. Work performed to remove and repair the concrete deck will be paid for under other items. Use deck patching products that are compatible with the overlay system. Patching materials with magnesium phosphate shall not be used. Place patches after surface is prepared via shot blasting and cleaning as described in Section C.2.2 of this specification. Portland cement concrete patches shall be used for joint repairs and full depth deck repairs with a plan area larger than 4 sf, unless approved otherwise by the Structures Design Section. If rapid-set concrete is used, place patches per the manufacturer’s recommendation. If Portland cement concrete is used, place patches per standard spec 509.3.9.1. Deck patching shall be filled and properly finished prior to overlay placement. Do not place overlay less than 1 hour, or per the manufacturer’s recommendation, after placing rapid-set concrete patches in the repair areas. Do not place overlay less than 28 days after placing Portland cement concrete patches in the repair areas. C.2.2 Surface Preparation Determine an acceptable shotblasting machine operation (size of shot, flow of shot, forward speed, and/or number of passes) that provides a surface profile meeting CSP 5 (medium-heavy shotblast) according to the ICRI Technical Guideline No. 310.2. If the engineer requires additional verification of the surface preparation, test the tensile bond strength according to ASTM C1593. The surface preparation will be considered acceptable if the tensile bond strength is greater than or equal to 250 psi or the failure area at a depth of 1/4 inches or more is greater than 50 percent of the test area. Continue adjustment of the shotblasting machine and necessary testing until the surface is acceptable to the engineer or a passing test result is obtained. Prepare the entire deck using the final accepted adjustments to the shotblasting machine as determined above. Thoroughly blast clean with hand-held equipment any areas inaccessible by the shotblasting equipment. Do not perform surface preparation more than 24 hours before the application of the overlay system. Protect drains, expansion joints, access hatches, or other appurtenances on the deck from damage by the shot and sand blasting operations and from materials adhering and entering. Tape or form all construction joints to provide a clean straight edge. Before shot blasting, remove pavement markings within the treatment area using an approved mechanical or blasting method. Page 5 of 9 Prepare the vertical concrete surfaces adjacent to the deck a minimum of 2” above the overlay according to SSPC-SP 13 (free of contaminants, dust, and loose concrete) by sand blasting, using wire wheels, or other approved method. Just before overlay placement, clean all dust, debris, and concrete fines from the prepared surfaces including the vertical surfaces with compressed air. When using compressed air, the air stream must be free of oil. Any grease, oil, or other foreign matter that rests on or has absorbed into the concrete shall be removed completely. If prepared surfaces (including the first layer of the polymer overlay) are exposed to rain or dew, lightly sandblast (brush/breeze blast) the exposed surfaces. The engineer may consider alternate surface preparation methods per the overlay system manufacture’s recommendations. The engineer will approve the final surface profile and deck cleanliness before the contractor placing the polymer overlay. C.2.3 Transitional Area If the plans show, create a transitional area approaching transverse expansion joints and ends of the deck using an approved mechanical or blasting method. Remove 1/4 inch to 5/16 inch of concrete adjacent to the joint or end of deck and taper a distance of 3 feet. If the plans show, create a transitional area on the approach pavement. Prep and place the first lift 3 feet beyond the end of the deck the same width as the deck. Prep and place the second lift 6 feet beyond the end of the deck the same width as the deck. C.3 Overlay Application Perform the handling and mixing of the polymer resin and hardening agent in a safe manner to achieve the desired results according to the manufacturer’s instructions. Do not apply the overlay system if any of the following exists: 1. Ambient air temperature is below 50 F or above 100 F. 2. Deck temperature is below 50 F. 3. Moisture content in the deck exceeds 4.5 percent when measured by an electronic moisture meter or shows visible moisture after 2 hours when measured in accordance with ASTM D4263. 4. Rain is forecasted during the minimum curing periods listed under C.5. 5. Materials component temperatures below 65 F or above 99 F. 6. Concrete deck age is less than 28 days. 7. The deck temperature exceeds 100 F. 8. If the gel time is 10 minutes or less at the predicted high air temperature for the day. After the deck has been shotblasted or during the overlay curing period, only necessary surface preparation and overlay application equipment will be allowed on the deck. Provide appropriate protective measures to prevent contamination from equipment allowed on the deck during preparation and application operations. Begin overlay placement as soon as possible after surface preparation operations. The polymer overlay shall consist of a two-course application of polymer and aggregate. Each of the two courses shall consist of a layer of polymer covered with a layer of aggregate in sufficient quantity to completely cover the polymer. Apply the polymer and aggregate according to the manufacturer’s requirements. Apply the overlay using equipment designed for this purpose. The application machine shall feature positive displacement volumetric metering and be capable of storing and mixing the polymer resins at the proper mix ratio. Disperse the aggregate using a method that provides a uniform, consistent coverage of aggregate and minimizes aggregate rolling or bouncing into final position. First course applications that do not receive enough aggregate before the polymer gels shall be removed and replaced. A second course applied with insufficient aggregate may be left in place, but will require additional applications before opening to traffic. After completion of each course, cure the overlay according to the manufacturer’s instructions. Follow the minimum cure times listed under C.5 or as prescribed by the manufacturer. Remove the excess aggregate from the surface treatment by sweeping, blowing, or vacuuming without tearing or damaging the surface; the material may be re-used if approved by the engineer and manufacturer. Apply all courses of the overlay system before opening the area to traffic. Do not allow equipment or traffic on the treated area until directed by the engineer. Page 6 of 9 After the first layer of coating has cured to the point where the aggregate cannot be pulled out, apply the second layer. Before applying the second layer, broom and blow off the first layer with compressed air to remove all loose excess aggregate. Before opening to traffic, clean expansion joints and joint seals of all debris and polymer. A minimum of 3 days following opening to traffic, remove loosened aggregates from the deck, expansion joints, and approach pavement. C.4 Application Rates Apply the polymer overlay in two separate courses in accordance with the manufacturer’s instructions, but not less than the following rate of application. Course Minimum Polymer Rate[1] (GAL/100 SF) Aggregate[2] (LBS/SY) 1 2.5 10+ 2 5.0 14+ [1] The minimum total applications rate is 7.5 GAL/100 SF. [2] Application of aggregate shall be of sufficient quantity to completely cover the polymer. C.5 Minimum Curing Periods As a minimum, cure the coating as follows: Average temperature of deck, polymer and aggregate components in degrees F Course 50-54 55-59 60-64 65-69 70-74 75-79 80-84 85-99 1 6 hrs. 5 hrs. 4 hrs. 3 hrs. 2.5 hrs 2 hrs 1.5 hrs. 1 hr. 2 8 hrs. 6.5 hrs. 6.5 hrs. 5 hrs. 4 hrs. 3 hrs. 3 hrs. 3 hrs. If faster cure times are desired and achievable, submit to the engineer a certified test report from an independent laboratory showing the material is able to reach a compressive strength of 1000 psi as tested per ASTM C 579 Method B within the temperature ranges and cure times for which the product is proposed to be placed. Establish ambient air, material, and substrate temperatures from the manufacturer for field applications. Field applications will not be allowed below the documented temperatures. C.6 Repair of Polymer Overlay Repair all areas of unbonded, uncured, or damaged polymer overlay for no additional compensation. Submit repair procedures from the manufacturer to the engineer for approval. Absent a manufacturer’s repair procedures and with the approval of the engineer, complete repairs according to the following: Saw cut the limits of the area to the top of the concrete; remove the overlay by scarifying, grinding, or other approved methods; shot blast or sand blast and air blast the concrete before placement of polymer overlay; and place the polymer overlay according to section C.3. D Measurement The department will measure Polymer Overlay by the square foot, acceptably completed. E Payment The department will pay for measured quantities at the contract unit price under the following bid item: ITEM NUMBER DESCRIPTION UNIT 509.5100.S Polymer Overlay SF Payment is full compensation for preparing the surface; for tensile bond testing; for creating the transitional area; for providing the overlay; for cleanup; and for sweeping/vacuuming and disposing of excess materials. The department will pay separately for deck repairs. stp-509-030 (20200629) Page 7 of 9 Waupaca County will provide labor for traffic control. Waupaca County can provide labor for the application of the polymer resin and aggregate if requested by contractor and detailed in bid proposal form. Contractor shall provide application equipment required for mixing and dispensing polymer resin, along with spreading/placing of aggregate, and operator for equipment. Contractor shall also provide labor and equipment for material handling at the jobsites. Mobilization shall include all costs necessary to move personnel, equipment, supplies, and incidentals to Waupaca County to complete work. Deviations and exceptions from original text, terms, conditions, or specifications shall be described fully, on the bidder’s letterhead, signed, and attached to the request. The quantities shown on this request are based on estimated needs. The County reserves the right to increase or decrease quantities to meet actual needs. Deliveries shall be F.O.B destination freight prepaid and included unless otherwise specified. If any item(s) resulting from this award is a hazardous chemical, the contractor shall provide a copy of a Safety Data Sheet for each item with the shipped container. Contractor shall supply aggregate per specification. All bidders must provide a written warranty guaranteeing their product and/or services. ALL BIDDERS MUST COMPLY WITH WAUPACA COUNTY HIGHWAY INSURANCE REQUIREMENTS AND PROVIDE A CERTIFICATE OF INSURANCE ALONG WITH THEIR BID IF A CURRENT ONE IS NOT ON FILE WITH THE DEPARTMENT. Requirements can be found at: Microsoft Word - insurance requirements revised 2019.doc (revize.com) https://cms1files.revize.com/waupacacowi/Highway/insurancerequirementsrevised2019a.pdf Page 8 of 9 2024 WCHD POLYMER OVERLAY PROJECTS BID PROPOSAL FORM In accordance with your request for bids for Polymer Overlay, we are submitting the following quotation. PRICES QUOTED MUST REMAIN IN EFFECT UNTIL SEPTEMBER 27, 2024. B-68-0132 CTH C Bridge over Little Wolf River, Big Falls Quantity U/M Unit Price Total Cost 3584 SF _________ _________ B-68-0078 CTH II Bridge over Wolf River tributary, Fremont Quantity U/M Unit Price Total Cost 1397 SF _________ B-68-0135 Dayton Rd. Town of Dayton, Waupaca County Quantity U/M Unit Price Total Cost 820 SF ________ __________ B-68-0136 West Rd. over Emmons Creek Town of Dayton, Waupaca County Quantity U/M Unit Price Total Cost 808 SF ________ __________ B-68-0137 West Rd. over Radley Creek Town of Dayton, Waupaca County Quantity U/M Unit Price Total Cost 702 SF ________ __________ B-68-0145 Emmons Creek Rd. Town of Dayton, Waupaca County Quantity U/M Unit Price Total Cost 821 SF ________ __________ Page 9 of 9 Written warranty per specifications included Yes / No Contractor provides labor for application, except for traffic control Yes / No If no, provide detail of labor requested for County crews to perform __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ Bidder Name Telephone Number Bidder Address Representative Email_____________________________________