Walia International Machines is a multi divisional,vacuum de watering machine,vacuum dewatering machine,vacuum dewatering machines,vacuum de dewatering machines Address : Walia International Machines Corporation,408 Vishwadeep , District Centre, Janak Puri New Delhi- 110058,India Website : http://waliainternational.com Telefax : 011 – 25546044 ,25521275 Emails : info@waliainternational.com

1. POLYESTER POLYMER CONCRETE
Indian Roads Congress Accredited (March 2012)
DDR Global Infrastructure Pvt. Ltd.
Rajesh Oberoi, P.E. (California, USA)
WALIA INTERNATIONAL MACHINES CORPORATION
408, Vishwadeep, District Centre, Janak Puri, New Delhi – 110058
Ph # 011-25546044, 25521275, E-mail : waliaintl@yahoo.com
Website : www.waliainternational.com

2. Introduction
 DDR Global Infrastructure
Pvt. Ltd.
 RAJESH OBEROI
 P.E. (Civil) State of California, USA
 B.Tech. (Civil), 1981, IIT, Kanpur, India
 M.S. (Civil), 1985, Univ. of
Massachussetts, Amherst, MA, USA

3. Why Polyester Concrete
for Overlays in India?
 Proven technology with a track record of 30+
years
 ELIMINATES Maintenance Cost
 Provides almost 100% protection against
chloride intrusion
 Provides high skid resistance
 Quick return to service in less than 2 hrs
 Can be placed in one lift from 25mm – 300 mm
 Exceptional Bond Strength
 Used in EXTREME CLIMATIC CONDITIONS
with Altitude, Marine/Coastal, Humid,
Freeze-Thaw and Desert Environments
Polyester
Concrete
Bond line
Break line

4. What is Polyester
Concrete?
 A very durable composite material
made of hardened polyester resin,
coarse aggregate and sand.
 The polyester resin serves as the
binding agent - similar to hydrated
Portland Cement in PCC.
 Engineered Material with Consistent
Properties.
Polyester
Concrete
Bond line
Break line

5. Polyester Concrete background
 First use of current system 1983 – Thomson Creek & Beaver
Creek Bridges, Yreka, California, USA
 1985/86 Highway overlay I-80 (10 lane miles),
California, USA
 5 million m2 (55 million ft2) surface in place on
BRIDGES ALONE in 20 States in the USA equates to
approximately 1,500 km of single lane
 TODAY – An average of 2 tenders/month are
advertised in just one State (California)

6. What is Polyester Concrete?
POLYSTER POLYMER
CONCRETE (PPC 1121)
PORTLAND CEMENT
CONCRETE
WATER
POLYESTER POLYMER RESIN
(Unsaturated Isophthalic
Poly-Styrene Co-Polymer)
CEMENT
SAND
IS383
SAND
IS383
AGGREGATE
Natural,10mm Down, River Borne
AGGREGATE
Crushed, 26.5mm Down

7. Approved by FHWA in year 1988

8. AASHTO Guide Specifications - 1995

9. Indian Roads Congress Accredited - 2012

11. Polyester Concrete use in USA

12. 30+ Years of Proven Performance
Polyester Polymer Concrete
Overlay Placed in 1983
These Pictures
were taken in
July 2011

13. Polyester Concrete Properties
 Thermal coefficient of expansion – 14.6 x 10-6 deg C
 Lower modulus equals less stress
 Higher tensile and flexural strength
 High abrasion resistance
 Excellent bond strength (composite)
 Very low permeability to water and chlorides
 Fast setting – traffic in about 2 hours

14. Key Engineering Properties
Polyester Polymer
Concrete (PPC
1121)
Portland Cement
(8-Bags)
Chloride Permeability,
Coulombs
0 – 200 1,000 - 3,000
Compressive Strength 565 Kg/cm2
490 Kg/cm2
24-hr Early Strength 280 Kg/cm2
105 Kg/cm2
Flexural Strength 155 Kg/cm2
55 Kg/cm2
Modulus of Elasticity
(E)
7000 - 14000 Mpa
21000 - 35000
Mpa
Abrasion 0.25mm/year 4.0 mm/year
Open to Traffic 2 - 4 Hours 3 - 7 Days

15. PERMEABILITY

16. Signature Projects
Polyester Polymer Concrete Overlays
 San Francisco-Oakland Bay Bridge, CA- 300,000 ADT
 Richmond San Rafael Bridge, CA- 80,000 ADT
 Benicia Martinez Bridge, CA – 100,000 ADT
 Vincent Thomas Bridge, Long Beach, CA- 35,000 ADT
 South Grand Island Bridge Buffalo, NY- 40,000 ADT
 McCullough Memorial Bridge, Oregon- 20,000 ADT

17. Richmond-San Rafael Bridge
Extreme Coastal/Marine Environment
Built in 1956, 8.85 KM, Upper & Lower Decks – 3 Lanes on Each Deck
 Left Lane - Grinded
 Right Lane - Overlain by PPC
 Middle Lane - Original, Damaged,
Potholed, patched

18.  1 KM long critical link, Niagara Falls
and Buffalo, NY was overlaid with
Polyester Concrete.
 Completed: night and full weekend
closures
 Largest polyester project to date on
East Coast
 Tough winter weather conditions
 Overlay applied to newly replaced
precast deck system to protect thin
100 mm concrete deck section
South Grand Island Bridge, NY
Extreme Winter Conditions

19. San Francisco - Oakland Bay Bridge
Extreme Coastal/Marine Environment
 Built in 1936
 Total Length = 7.18 km
 Deck Surface overlaid with 25 mm Thick PPC
 Total of 110,000 Square Meters
 One of the busiest bridges in the US
 300,000+ vehicles per day
 5 lanes on the upper and lower deck

20. Polyester Concrete at Airports
Polyester Concrete has been used at airports across the
country for spall and concrete repairs:
 —San Diego International Airport
 —Southern CA Logistics Airport
 —Marine Corps Air Station Pendleton
 —Sacramento International Airport
 —Niagara Falls Guard Station Airport
 —Denver International Airport
 —Dallas Fort Worth International Airport
 —Los Angeles International Airport
—PPC 1121 - High Resistance to Jet Fuel/Aviation
Hydraulic Fluids

21. Skid Data
 Marina Viaduct
 Measured Skid Resistance in 1991
Friction Coefficient = 0.4
 Measured Skid Resistance in 2010
Measured by Towed-Trailer Skid Test
Friction Coefficient = 0.4

22. Polyester Overlay Construction:
 Step 1 (If Required): Remove/Grinding existing asphalt or concrete
overlay/coating by micro-milling
 Step 2: Find & Repair spalls or unsound concrete
 Step 3: Surface Preparation/Shotblasting
 Step 4: Apply HMWM Resin Prime Coat
 Step 5: Mix and Pave
 Step 6: Finish, Tine, sprinkle dry sand, Open to Traffic!

23. Polyester Overlay Construction:
 Step 1 (If Required): Remove existing asphalt or
concrete overlay/coating by micromilling
 Construction Keys:
 Use specialized equipment to
prevent damage to concrete deck
(Caltrans Micromill spec)
 6mm tooth spacing
 Hand removal near metal joints
 Remove slurry seals, chip seals etc.
 Potholing may be needed to
determine existing overlay thickness

24. Polyester Overlay Construction:
 Step 2: Find & Repair spalls or unsound concrete
 Construction Keys:
 Sawcut edges square
 Remove only unsound material
 May be placed during overlay
 Sandblast or shotblast, blow w/ air

25. Polyester Overlay Construction:
 Step 3: Surface Preparation/Shotblasting
 Construction Keys
 The objective is a surface free of loose
material, laitance, previous coatings or
oils.
 Utilize shotblasting machines
 Reblast if too much primer applied in
previous shift
 Remove traffic stripe or buttons prior
to shotblasting
 Should be blown off with high pressure
air after shotblasting

26. Polyester Overlay Construction:
 Step 4: Apply HMWM Resin Prime
Coat
 Construction Keys:
 Minimize puddling
 Place overlay within 15 mins of placing
primer and/or before primer gels
 Can be applied with sprayer or rollers
 Paving equipment may drive on prime
coat
 Deck surface temperature between 0 to
350C
 Dry deck surface conditions

27. Polyester Overlay Construction:
 Step 5: Mix and Pave
 Construction Keys
 Volumetric mixer ensures best product consistency
 Paver should have grade control & should consolidate overlay
 Polyester concrete should be thoroughly mixed and should be applied within 3-5
minutes of mixing

28. Polyester Overlay Construction:
 Step 6: Finish, Tine, Apply Sand, Open to
Traffic!
 Construction Keys:
 Edges should be tapered, joints/ends may
require hand finishing
 Expansion joints must be blocked out or
sawcut within 4 hours
 Sand should be applied uniformly, with
additional sand for wet or glossy looking
areas
 Tining should be applied by paving
machine or shortly after
 Paving may be opened to traffic after
Schmidt hammer reading of 24 or greater

29. Polyester Concrete Spall Repair
Step 1:
Determine
limits, sawcut
rectangular
Step 2: Chip
and remove
unsound
concrete, prep
and blow clean
Step 3: Apply
HMWM prime
coat
Step 4: Place
and finish
polyester
concrete, apply
sand

30. Summary Polymer Concrete Overlay
 30+ years of Proven performance.
 Used in EXTREME CLIMATIC CONDITIONS with Altitude, Marine/Coastal,
Humid, Freeze-Thaw and Desert Environments
 ELIMINATES almost 100% Maintenance Cost
 High Strength – Flexural, Tensile, and Compressive Strength
 100% Seals bridge deck surfaces against chloride intrusion, Extremely low
permeability to seal the deck
 Superior adhesion, Exceptional Bond Strength
 Placement temperature - 00 C to 350 C
 Performance Temperature: -500 C to +500 C
 Open to traffic quickly – in 2 hours
 Provides high skid resistance
 Thermal coefficient of expansion – compatible to PCC
 Lower modulus and higher creep equals less stress
 Excellent abrasion resistance – 16 Times Portland Cement Concrete
 Thin composite - minimizing dead load/clearance issues
 Improves ride quality and drainage
 MULTIPLE USES APPLICATION – ONE MATERIAL

31. WHAT ABOUT THE COST?
OVER A LIFE OF 30 YEARS
Polyester Polymer
Concrete
Overlay (25 mm)
Conventional Overlay on
Concrete
(Typical 65-100mm)
Rs. 4,500/Sq. m. Rs. 60,000/Sq. m.
Rs. 1.25 Cr/Km Lane Length Rs. 21 Cr/Km Lane Length