SafeLaneTM Epoxy Overlay ND 0702

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SafeLaneTM Epoxy OverlayND 07-02

• 2009 OPD Conference
• November 18 19, 2008
• Andy Mastel
• NDDOT - Materials Research Division

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SafeLaneTM Description

• SafeLaneTM is a porous aggregate that is patented
  by Cargill Inc.
• An epoxy manufactured by Unitex was used with the
  SafeLaneTM aggregate.
• This epoxy overlay system was designed to improve
  skid resistance and reduce maintenance deicing
  efforts.
• The overlay system can be used on concrete or
  asphalt pavement surfaces.

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SafeLaneTM Video
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SafeLaneTM Topics

• Purpose
• Manufacturer Expectations
• Project Locations and Design
• SafeLaneTM Cost
• SafeLaneTM Construction Process
• Manufacturer Specifications
• SafeLaneTM Evaluation

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Purpose

• Help reduce crash statistics on bridge decks.
• Reduce Frost and Black Ice formation.
• Improve surface friction.
• Observe and evaluate products according to stated
  manufacturer performance.

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SafeLaneTM Manufacturer Expectations

• Prevents ice and snow from bonding to road
  surface.
• Reduces formation of frost and black ice.
• Anti-icing and anti-skid properties.
• Provides year-round surface friction.
• Minimal aggregate loss from snow plows.
• Up to 15 year service life.

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SafeLaneTM Location and Design

• West of Williston on US Highway 2 starting at the
  Sand Creek structure.
• Bridge Deck 3640 square feet (130 linear feet)
• Roadway 7650 square Feet (300 linear feet)
• Both driving lanes in the east bound direction
  were overlaid.
• East Bound test section.
• West Bound control section.
• Beginning RP 18.303.

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Location
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SafeLaneTM Location and Design

• BNRR and Missouri Road Structure near Mandan
• Bridge Deck 7120 square feet (178 linear feet)
• Roadway 500 square Feet (20 linear feet driving
  lane)
• Both driving lanes were overlaid.
• West Bound test section.
• East Bound control section.
• Beginning RP 154.337.

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Control Section EB
Test Section WB
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SafeLaneTM Installation Costs

• The material is estimated to cost
• 2.50 to 3.00/sq. ft.
• The installed cost is estimated to be
• 9.00/sq. ft.
• Sand Creek Installation
• cost 143,710 or 12.72/ sq. ft.
• BNRR and Missouri Road
• cost 81,178 or 10.96/ sq. ft.

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Temperature Constraints

• Temperature restrictions in plan note
• The epoxy, aggregate, and pavement surface shall
  be 60 to 90 degrees Fahrenheit
• SafeLaneTM shall not be applied if the
  temperature is expected to drop below
• 55 degrees Fahrenheit within eight hours

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Construction Process

• Both projects were constructed one lane at a
  time.
• Pavement Preparation
• Mixing Epoxy
• 1st Course Application
• 1st Course Cleanup
• 2nd Course Application
• 2nd Course Cleanup

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• Pavement Preparation
• Shot blast concrete

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• Pavement Preparation
• Sand Blast Asphalt
• Sand Blast where shot blaster cannot reach

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• Pavement Preparation
• Pavement marking obliterator

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• Pavement Preparation
• Blow off with compressed air
• Tape off borders and joints
• Stage aggregate

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• Mixing Epoxy
• Pour each epoxy part into a measuring container
• Pour each part into mixing barrel

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• Mixing epoxy
• Mix two part epoxy 50/50 ratio
• Mix with variable drill that has a paddle wheel
  attached for three minutes

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• First Course Application
• Mix two part epoxy
• Pour out two part epoxy onto pavement
• Squeegee epoxy into place with notched squeegee

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• First Course Application
• Spread aggregate onto epoxy before flash time of
  the epoxy

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• 1st Course Cleanup
• Power broom excess aggregate with skid steer
  sweeper
• Blow off 1st course with compressed air
• Leaf blower was also used for cleanup
• Tape joints and overlay boundaries for second
  course

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• Second Course Application
• Same steps as first course
• Requires twice as much epoxy and aggregate
• Flat blade squeegee is used to spread epoxy

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• Second Course Cleanup
• Power broom to sweep excess aggregate
• Blow off with compressed air
• After striping overlay is ready for traffic

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BNRR and Missouri Road SafeLaneTM Installation
complete
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Sand Creek Structure SafeLaneTM Installation
complete
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Manufacturer Specifications
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SafeLaneTM Evaluation

• The sister bridge will act as the control
  structure.
• Materials and Research will evaluate this
• product with help from the District annually.
• Evaluation criteria
• 10 year evaluation period.
• Deicing capabilities.
• Crash statistics.
• Performance of binder.
• Performance of aggregate

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Questions?