Document 6E31q60JeNzwxNZDB7g1n41

UTSL Report PP-SD-100-68 PINHOLING IK GUARDKOTE 140 *>y J. E. Magee August 27, 1963 ABSTRACT A GUARDKOTE l4o application made in i960 on the Ohio Street Bridge in Chicago was observed to have pinholes and was not water-tight. A laboratory program lasting over a period of approximately nine months was conducted to determine the causes and arrive at ways to prevent the recurrence of this condition. Laboratory findings indicated that pinholing was caused by capillary action of the liquid GUARDKOTE binder when excess amounts of certain types of surfacing grits are used. Several methods for correcting this condition were found, but a second layer of GUARDKOTE binder was used to repair and seal the Ohio Street Bridge. Additional laboratory findings indicated that pinholes could be eliminated on acidetched portland cement concrete by applying GUARDKOTE 140 at a minimum of 2.5 pounds per square yard and using 12-30 and 14-2U mesh emery grit. ABS-050274 TABLE OF CONTENTS Page INTRODUCTION AND SUMMARY ......................................................................................... 1 EXPERIMENTAL .................................................................................................................... 2 UJWW Defining the Problem ..................................................................................... TABLE I - Steel-Embedded Concrete .......................................................... TABLE II - Concrete Only ............................................................................ TABLE III - Systems of GUARDKOTE 1^0 and Aggregate Applied on Glass............................................................................................................ Determining Corrective Measures ............................................................... A 5 RESULTS AND DISCUSSION .............................................................................................. 6 Defining the Problem ..................................................................................... Determining Corrective Measures ............................................................... 6 8 CONCLUSIONS AND RECOMMENDATIONS ........................................................................ 13 APPENDIX ABS-050275 -1- IETRODUCTION AND SUMMARY During the i960 paving season, a GUARDKOTE 1^0 application was made on the concrete-filled steel grating deck of the Ohio Street Bridge, Chicago, Illinois. Rust stains were observed on the GUARDKOTE applied over the steel grating soon after the newly coated deck was exposed to rainfall. This indicated that water was going through the coating. To seal the coating, it was necessary to apply another coat of GUARDKOTE 140 on the entire deck. A laboratory investigation was undertaken to determine the cause of and remedy for this condition. Preliminary laboratory investigations were intended mainly to define the parameters and obtain clues concerning the nature of this problem. At first, GUARDKOTE l4o was applied without grit, in binder rates of one to three pounds per square yard. Still varying binder rates, additives such as thickeners (Cab-O-Sil mainly) and several flow control agents were then incorporated into the binder system. In trying many combinations of these variables on glass and steel surfaces, it was con cluded that the pinholing problem involved something besides surface wetting. Soon it became obvious that pinholing was caused by capillary action of the liquid GUARDKOTE binder when excess amounts of certain types of surfacing grits are used. In the case of the Ohio Street Bridge, however, further difficulty was encountered in wetting the surfaces of the steel grating. Mention should be made that, although concrete and some steel surfaces are involved in this problem, glass surfaces were used in the preliminary work to facilitate visual evaluation of the cured systems. In addition, since glass and steel are more difficult to wet than concrete, with EPON Resin systems, it was felt that any satisfactory results obtained on these hard to wet surfaces would hold on concrete. After gathering this background information, it was discovered that various grit sizes and amounts of grit applied influenced the amount of pinholing. The addition of Cab-O-sil and the thickness of binder material also were found to be important factors. Although laboratory efforts were made to eliminate pinholing without altering the recommended grit size (8-3O mesh at the time) or the basic binder formulation, it was not possible. Grit of the recommended size, especially when applied in excess, seemed to "pull" the GUARDKOTE binder away from the surface being treated, distributing the binder unevenly and causing pinholing. At this point it was decided to approach the problem mainly with *' regard to grit size. Limited work was still done incorporating tackifiers, anti-stripping agents, and mineral fillers into the binder system, but most of the effort was devoted toward finding a suitable grit size to eliminate the problem. Grit systems of many gradation levels were investigated so that chances of arriving at several successful systems were increased. ABS-050276 -2- Summing up at this point then, we find that pinholing is partially or completely eliminated by the following techniques: 1. Use of finer aggregate 2. Application of a second binder layer 3- Application of no excess aggregate 4. Addition of Cab-O-Sil to the binder (which increases the viscosity) 5- Use of thicker layers of binder 6. Delay the application of aggregate Of all these methods^ the grit size approach still looked most attractive. Application of a second binder layer (as done on Ohio Street) was felt to be too expensive. Equipment for applying only the required amount of grit was not available at the time. The addition of Cab-O-Sil and the increase in viscosity it would bring might cause difficulties in pumping the binder from automatic dispensing equipment. The use of thicker layers of binder would make the cost prohibitive. And finally, delaying the application of grit would increase the chances of hardening before sufficient grit could be applied. . The final segment of testing took place on concrete and metal surfaces. GUARDKOTE grit layers were applied to concrete and metal surfaces. After curing, the GUARDKOTE surfaces were saturated with acid solutions. The immediate appearance of bubbling on the GUARDKOTE surfaces indicated a reaction of the acid with the concrete or metal substrate and, hence, the presence of pinholes. The results of these tests showed that on acid etched Portland cement concrete GUARDKOTE 140 and 120, applied at 2.5 pounds per square yard or greater using 12-30 mesh and 14-24 mesh emery grit, was free of pinholes. It should be pointed out that these results were obtained on, and apply only to, acid etched portland cement concrete surfaces. In addition, the information was obtained strictly on a laboratory basis and, therefore, we were limited to some extent in simulating precise field conditions. EXPERIMENTAL The experimental phases of the study were divided into two areas. The first was of a preliminary nature where the investigation was intended mainly to define the parameters, obtain background information, and gather clues regarding the fundamental aspects of this problem. In other words, what causes pinholing in GUARDKOTE 140 grit-surfaced overlays? The second phase dealt with determining corrective measure for the Ohio Street Bridge job and for future GUARDKOTE installations. - ABS-050277 Defining the Problem -3- In gathering background information on the problem, the first step was to reproduce, in the laboratory, the conditions existing on the Ohio Street Bridge. Portland cement concrete was cast in two wooden boxes. Before the concrete hardened, ten 4" x 1" x l/4" pieces of steel were embedded in the concrete so that approximately l/32" of the 4" x l/4" steel surface was exposed above the level of the concrete. The concrete was then allowed to cure for seven days. No steel was embedded in the concrete in the other box. The concrete in both boxes was etched with a 15$ solution of hydrochloric acid. Over each steel bar embedded in concrete and over the concrete in the second wooden box, various GUARDKOTE 140 or GUARDKOTE 1^0-type systems were placed at 3 pounds per square yard. The following tables summarize the systems installed on the concrete in each wooden box. The materials used in all of the subsequent studies are identified in the glossary. TABLE I Steel-Embedded Concrete System Aggregate (in excess) Remarks 1 8-20 mesh emery 2 6-12 mesh aluminum oxide 3 8-35 mesh emery 4 8-50 mesh emery 5 12-30 mesh aluminum oxide 6 8-35 mesh emery 3$ emery dust added to aggregate 7 8-35 mesh emery 5$ emery dust added to aggregate 8 8-35 mesh emery 1$ Cab-O-Sil added to binder 9 8-35 mesh emery 2$ Cab-O-Sil added to binder 10 8-35 mesh emery a) a) The resin component was 44.5 pbw EPON 828, 4.5 pbw pine oil, and 1.0 pbw phenol instead of GUARDKOTE 140A TABLE II System 1 2 3 4 Concrete Only Aggregate (in excess) 8-30 mesh emery 6-12 mesh emery 12-30 mesh aluminum oxide 30-80 mesh emery Remarks same as Ohio Street Bridge - ABS-050278 -4- After curing for 24 hours at 77F, the various resinous overlays were covered with water and kept wet during the daytime hours from Monday through Friday of each week. The test was conducted for 108 days and, during this time, any changes in appearance and any irregularities were noted. The behavior of GUARDKOTE 140 binders on various surfaces was investigated next. Although the problem of pinholing originated primarily on concrete and steel surfaces, most of the preliminary work was carried out on glass and steel surfaces. The use of glass at this point of the study was more convenient and made visual determination of irregularities much easier. GUARDKOTE 140 and similar binder systems were applied to 4" x 8" solvent-wiped steel and glass panels at rates of one and three pounds per square yard. Cab-O-Sil and various flow control agents were added to the binder systems at different concentrations. The various additives incorporated into the binder systems were as follows; Cab-O-Sil Sag 47 SR-82 Advawet 82 Beetle 2l6-8 Nuosperse 657 Advawet 10 DC-200 Antifoam A After studying the behavior of binders with various additives, GUARDKOTE l40 and similar systems, with surfacing aggregate, were applied on 4" x 8" glass panels. The binders were applied at 3 pounds per square yard, and the following table summarizes the systems investigated. TABLE III Systems of GUARDKOTE l4o and Aggregate Applied on Glass System 1 2 l I I xl II 12 13 14 15 16 17 Aggregate (in excess) Remarks 8-20 mesh emery 6-12 mesh aluminum oxide 8-35 mesh emery 8-50 mesh emery 12-30 mesh aluminum oxide 8-35 mesh emery 8-20 mesh emery 8-20 mesh emery 8-20 mesh emery 8-20 mesh emery 8-20 mesh emery 8-20 mesh emery 10-30 mesh quartz none none none none 3$ emery dust added to aggregate 5$ emery dust added to aggregate 1% Cab-O-Sil added to binder 2% Cab-O-Sil added to binder a) Emery rolled with an iron cylinder _ Emery premixed with binder 3pl>v to lpbw Binder only 0.5$ Cab-O-Sil added to binder 1$ Cab-O-Sil added to binder 2% Cab-O-Sil added to binder a7 The resin component was 44.5 pbw ETON 828, 4.5 pbw pine oil, and 1.0 pbw phenol instead of GUARDKOTE l40A ABS-050279 -5- When the overlays on glass had cured, the excess aggregate was removed and the coatings examined for pinholes and voids. Determining Corrective Measures In determining the corrective measures for pinholing, the first order of business was repairing the Ohio Street Bridge job. In order to repair the bridge, it was felt necessary to seal all of the pinholes with an overcoat of GUARDKOTE 140 binder. To penetrate these pinholes, a low viscosity system was needed and, to fill this requirement, GUARDKOTE 140 was diluted with amounts of xylene totaling 5, 10, and 20$. The three systems were tested-for viscosity, handling characteristics, cure rate, and hardness after curing. Next, attempts were made to discover ways of eliminating pinholing in future GUARDKOTE jobs. Studies were conducted on several phases of grit and binder application, the.possibility of employing heat to the system, and finally the actual quantitative determination of pinholes on GUARDKOTE surfaces. In studying grit application, various particle sizes were investigated, the amounts of grit added were varied, and time delays were incorporated between the spreading of the binder and the addition of grit. The GUARDKOTE 140 binder was modified with flow modifiers and solid fillers. Increases in binder viscosity were made by adding Cab-O-Sil. The binder was also studied over a wide range of application rates (thicknesses). The following lists give the various solid fillers and flow modifiers used in the study. Solid Fillers Wollastonite p-1 Slate Flour Suspenso Asbestos 7TF1 MCG-1 Microcel E Celite 1655 Bentone 27 Flow Modifiers Sag 47 AYAF Ethyl alcohol Furfuryl alcohol Triethylamine EPON Curing Agent V-40 n-Hexane SF-69 Triethylene glycol Antifoam A Tween 20 SR-82 Span 80 Aerosol C-6l Pluronic L-6l Antisag 7 Duomeen S Duomeen 0 Duomeen C residue Duomeen C and S residue In addition, heat was administered to the aggregate, the surfaces being treated, and the GUARDKOTE l4o binder. ABS-050280 -6- Final testing took place on concrete and steel surfaces. GUARDKOTE 120 and l4o were applied to concrete castings in wide-mouthed jars and on steel 4" x 8" panels. After the GUARDKOTE cured for 2k hours at 77F, the excess grit was removed and the GUARDKOTE was ready for testing. The testing was carried out by saturating the GUARDKOTE on both types of surface with acid solutions, 32$ hydrochloric for the concrete substrate and for the steel a solution made up of equal volumes of concentrated hydrochloric and nitric acids. The immediate appearance of bubbling on the GUARDKOTE surfaces indicated a reaction between the acid and the concrete or metal substrate and, hence, the presence of pinholes. The tests were conducted at different GUARDKOTE binder rates, with grit of various particle sizes, with and without Cah.-0-Sil, and with and without acid etching the concrete surfaces. All tests with the metal panels were conducted on solvent wiped steel RESULTS AND DISCUSSION As mentioned previously, the study was divided into two areas. One, defining the problem and obtaining background information and clues regarding the fundamentals of pinholing. The second area dealt with determining corrective measures for the Ohio Street Bridge job and for future GUARDKOTE installations. Defining the Problem The GUARDKOTE systems covered with water served to reproduce the conditions observed on the Ohio Street Bridge. When the liquid GUARDKOTE l4o binder was applied to the acid-etched concrete and steel bars in the first box, the binder was observed to "crawl" off the steel bars leaving little or no binder on the steel. The GUARDKOTE wetted the concrete in both boxes, however in the normal manner. Rust stains, similar to those observed on the Ohio Street Bridge, were seen above the steel bars coated with GUARDKOTE 140 and five different types of aggregate after 35 days. All five systems (listed below and also in Table I) were GUARDKOTE l4o, placed at three pounds per square yard using the following aggregates: System Aggregate 1 8-20 mesh emery 2 6-12 mesh aluminum oxide 3 8-35 mesh emery 6 8-35 mesh emery (3$ emery dust added to aggregate) 7 8-35 mesh emery (5$ emery dust added to aggregate) ABS-050281 -7- The three types of 8-35 mesh emery most closely simulated the 8-30 mesh emery (unavailable at the time of testing) used on Ohio Street. The grit used on the job had a higher dust content than is normally observed, but it apparently had little effect on causing or eliminating pinholes in grit surfaced GUARDKOTE since the dust-free 8-35 mesh emery coating also showed the presence of pinholes. After 108 days the rust stains still persisted over the same five overlays, but did not appear over the other systems (systems 4, 5> 8, 3, and 10). See Table I under the Experimental Section for a complete list of these systems. The 4 systems applied over acid-etched concrete (listed in Table II) and also -covered with water for 108 days showed no signs of rusting throughout the entire duration of testing. One of the four systems was GUARDKOTE 140 at 3 pounds per square yard with 8-30 mesh emery taken from the Ohio Street Bridge job site. These systems appear in Table II under the Experimental Section. In order to get closer to the individual aspects of the problem, the next step was to investigate the GUARDKOTE 140 binder separately (without aggregate). Binder systems containing 1$ Cab-O-Sil were compared to systems not containing Cab-O-Sil in regard to crawling before curing and to the formation of voids and/or pinholes while curing. The GUARDKOTE 140 was applied on solvent-wiped steel and glass surfaces at rates of 1 and 3 pounds per square yard. The tests showed that crawling occurred only with systems applied at 1 pound per square yard containing no Cab-O-Sil regardless of the type of surface treated. Systems containing 1$ Cab-O-Sil, on both surfaces, and at both rates did not crawl. After curing, voids and pinholes were evident not only where crawling occurred on the uncured binder but also on both steel and concrete surfaces, at 1 and 3 pounds per square yard, and containing Cab-O-Sil. This showed that while Cab-O-Sil eliminated crawling on steel and glass surfaces, it did not eliminate pinholes, and that their formation was probably related more to the entrapment of air beneath the surface of the binder layer. Eight different flow control agents were blended with GUARDKOTE 140 binder. All were added to the binder at levels of 0.5> I, and 2$. They are as follows: Sag 47 SR-82 Advawet 82 Beetle 216-8 Nuosperse 657 Advawet 10 DC-200 Antifoara A ABS-050282 -8- The GUARDKOTE 140 modified with the flow control agents was applied to glass and steel surfaces at 1 and 3 pounds per square yard. None of these, except for Sag 47, were satisfactory in eliminating pinholing caused by entrapped air after curing regardless of surface or rate of coverage. The Sag 47 completely eliminated this type of pinholing when used at 0.5, 1, and 2$ on steel and concrete, and at 1 and 3 pounds per square yard. Additional trials showed that on both types of surfaces and, at 3 pounds per square yard, 0.1$ and 0.2$ of Sag 47 would also eliminate pinholing in cured binder coatings. The elimination of pinholes using Sag 47 was accomplished only with GUARDKOTE 140 not surfaced with grit. It is seen in a later experiment that, even in the presence of Cab-O-Sil (later found to be helpful in eliminating pinholes). Sag 47 does not aid in eliminating pinholes in aggregate-surfaced GUARDKOTE 140. The study was next directed toward examining GUARDKOTE l4o and similar systems with different surfacing aggregates. The systems were applied on 4" x 8" glass panels at 3 pounds per square yard, and with an excess of aggregate. To test previous findings, four systems were not seeded with aggregate and, to three of these, Cab-O-Sil was added in various concentrations. A complete list of binder and aggregate systems applied on glass appears in Table III in the Experimental Section. A total of 17 systems was tested, 13 with grit and 4 without. The four panels containing GUARDKOTE l4o without grit showed the usual fine pinholes, earlier suspected of being trapped air. When examined by holding the panel between a light source and the viewer, these fine pinholes did not give evidence of transmitting light through the GUARDKOTE coating. The 13 samples containing grit, however, showed different results. When held up to the light, the viewer was able to see transmitted light through larger and more numerous pinholes, apparently caused by the addition of the surfacing aggregate. Determining Corrective Measures At the time of early investigations concerning the pinholing problem, it was necessary to arrive at a suitable way of repairing the Ohio Street Bridge job. It was decided to use a xylene-diluted GUARDKOTE 140 binder system as an overcoat on top of the original overlay. Three xylene-diluted GUARDKOTE l40 systems were investigated. The results of a preliminary study follow. Xylene concentration, $ added Viscosity, cps, at 77F Shore D, 24 hrs at 77Fa' Shore D, 24 hrs at 77F + 2 hrs at l80F 5 4l0 21-15 35-22 10 180 15-12 20 *" '' 40 9-6 30-19 liquid separation The hardness readings are the initial values and the value after 10 seconds of instrument-sample contact. ABS-050283 -9- The system to which 20$ xylene was added was chosen for the job. The very low viscosity (ho centipoises) made it an ideal candidate for penetrating and sealing the pinholes on the bridge. This composition weighed 9-15 pounds per gallon and, when applied on top of cured GUARDKOTE 14-0 out-of-doors, it cured overnight. Coverage of this out-of-doors test patch was l.l6 pounds per square yard. The system was later applied with large paint rollers to the 1800 square yard GUARDKOTE l40 overlay on the Ohio Street Bridge at a rate of 1-30 pounds per square yard. The job was completed in one day by 7 men during October, i960. Since the preliminary experiments gave a fairly strong indication that the aggregate was responsible for pinholing, this phase of the operation was studied at considerable length. First, an experiment incor porating time delays between binder spreading and grit addition was carried out. GUARDKOTE 140 was applied on A" x 8" glass panels at 3 pounds per square yard. Emery (8-20 mesh) was applied in excess after a series of time delays. The results obtained are as follows: Time of Grit Application (minutes) Result s^-) 0 pinholes 15 pinholes 30 pinholes ^5 pinholes 60 pinholes 75 pinholes SO no pinholes 120 no pinholes At some point between 75 and 90 minutes after spreading the binder (at 77F), 8-20 mesh emery can be applied in excess to a 3 pound per square yard coating of GUARDKOTE l40 without inducing pinholing. After this length of time the GUARDKOTE has advanced considerably in cure and bodied a great deal. This suggested that higher viscosity binder systems would not show pinholing when an excess of grit was added. Again, GUARDKOTE l4o was applied on 4" x 8" glass panels, but this time in a study involving a variation in the quantities of surfacing grit added. The binder was applied at 3 pounds per square yard and 8-20 mesh emery was used as the surfacing aggregate. The results of this study follow. T) In this experiment and in all subsequent determinations of this type the glass panels were held up to a source of light and visually evaluated for the presence or absence of pinholes. If any light whatsoever shone through the panel, the system was not pinhole free and, therefore, not satisfactory. ABS-050284 -10- Aggregate Applied (lb/square yard) Aggregate Retained in Binder ($) Excess Results 1.48 3.52 4.68 6.88 6.96 8.36 9-00 10.04 11.00 12.08 12.68 17-08 22.72 4o.o8 100.00 100.00 100.00 100.00 100.00 100.00 95*10 85.96 .. 85.60 85.40 85.42 65-46 51*9^ 29.89 no no pinholing no no pinholing no no pinholing no no pinholing no no pinholing no no pinholing yes pinholing yes pinholing yes pinholing yes pinholing yes pinholing yes pinholing yes pinholing yes pinholing From the results. indications are clear that as long as no excess aggregate is added, pinholing does not occur. As soon as a slight amount of excess grit was added, pinholes started to appear. This is seen at the point where aggregate was added at 9 pounds per square yard and of that quantity, 95*10$ was retained by the resinous hinder. The next step was to examine a wide range of aggregate particle sizes. Also included in the study were different types of grit applied in excess and binder systems applied at different rates of coverage. The study was carried out entirely on 4" x 8" glass panels and the results of the aggregate particle size study appear in Table IV of the appendix. Of the 302 different systems investigated, 30 produced pinhole-free GUARDKOTE l4o overlays. A summary of the mesh breakdowns of these mixtures appears in Table V. In examining these results, it can be seen that, in general, more coarse particles of aggregate can be tolerated in applications of 3 pounds per square yard than in the 2 pound applications. Aga'>n looking at Table V, it is seen that most of the aggregate in these succes al systems fall within the 20-60 mesh range. With two exceptions, however, the overall mesh range of the successful systems extends from 16 to 120. Individually, most of the synthetic aggregate mixes are quite irregular and probably would not be commercially available. The values could, however, be used as a guide in selecting similar gradation types that ar-* commercially available. System 53 shows that in spite of the presence of coarse 8 and 10 mesh particles, there is a wide enough gradation of particles in the fine range to eliminate pinholing. Another significant point is the fact that the coarsest single particle size giving a pinhole free overlay is 35 mesh (system 18). ABS-050285 -11- In studying the binder portion of the system, the first step taken was an investigation of coverage rates. GUARDKOTE l40 was applied to glass at 1, 2, 3, 4, 5, 6, and 7 pounds per square yard and surfaced with an excess of 8-20 mesh emery. Inspection of the cured overlays showed a decrease in pinholes as the rate of coverage increased, but only at 7 pounds per square yard did a pinhole-free coating result. From the experiment where the application of aggregate was delayed for various periods of time, it was felt that increasing the binder viscosity might help eliminate pinholing. Cab-O-Sil, in concen trations of 1, 1.5, 2, 2.5, 3, and 3-5$ was added to GUARDKOTE 140. The thickened binder was applied to glass at 3 pounds per square yard and surfaced with an excess of 8-20 mesh emery. Pinholes were observed at concentrations of 2$ and lower of Cab-O-Sil At 2.5$ and higher, no pinholes were seen. An attempt was made to eliminate pinholing by using a combination of Cab-O-Sil and Sag 4-7 in the GUARDKOTE 14-0 binder. Sag kj in concen trations of 0.1 and 0.5$ and Cab-O-Sil at the 1$ level were added to GUARDKOTE 14-0. The binder was spread on glass at 2 pounds per square yard and surfaced with an excess of 8-20 mesh emery. The method was not effective, however, as pinholes were seen in the cured overlay. The study of Cab-O-Sil modified GUARDKOTE l40 was taken further and, in so doing, aggregate particle sizes were varied to a greater extent. The systems studied and the results obtained appear in Table VI. Systems 8, 11, 20, 21, 22, 26, 27, 29, 30, 31, 3k, 35, 36 and 37 exhibited no pinholing. These are GUARDKOTE l40 systems containing 2$ Cab-O-Sil, applied at 2.5 pounds per square yard, and surfaced with an excess of various sizes of emery aggregate. The particle sizes of the fourteen successful systems, for the most part, were in the 20-40 mesh range. The overall range of successful systems extended from 12-60 mesh. When compared to similar mesh range values obtained with systems not containing Cab-O-Sil (20-60 mesh and 16-120 mesh overall), it is seen that the incorporation of Cab-O-Sil makes pinhole free overlays possible using coarser aggregate. Low concentrations of solid fillers were blended with the GUARDKOTE 140 binder in further attempts to eliminate pinholing. The binder was applied at 2.5 pounds per square yard after blending with the following solid fillers at the 0-5, 1, 2, and 3$ levels. Wollastonite P-1 Slate flour Suspenso Asbestos 7TF1 MCG-1 Microcel E Celite 1655 Bentone 27 ABS-050286 -12- Emery aggregate with the following per cent-by-weight mesh breakdown was applied in excess. U.S. Standard Sieve No. Mixture Aa) Mixture Bb) 12 6 Ik 2 18 16 21 25 18 23 18 20 23 15 25 15 30 13 9 7 35 3 2 Designated lk-2k mesh emery. American Abrasive Co., Westfield, Mass. h) Designated 12-30 mesh emery. American Abrasive Co., Westfield, Mass. This approach apparently has no merit since all of the 6k systems evaluated produced overlays containing pinholes. A final approach involved adding various flow modifiers and heating the GUARDKOTE l40 binder, the emery aggregate, and the glass surface, to 100F before application. In all cases the binder was applied at 2.5 pounds per square yard and aggregate having the following gradation was used. U-S- Standard Sieve No. % By Weight Retained 14 2 16 21 18 23 20 23 25 15 30 13 35 3 The systems studied and the results obtained appear in Table VII. It is readily seen that the incorporation of these materials at the given concen trations does not prevent the formation of pinholes in GUARDKOTE l40 over lays when the binder, the aggregate, and the surface are heated to 100F. Final testing, to more clearly detect the presence of pinholing in GUARDKOTE overlays, was carried out on concrete and steel surfaces using *" acid solutions. The GUARDKOTE was applied to the concrete and steel surfaces, allowed to cure for 24 hours, and then saturated with acid solutions. The appearance of bubbling indicated a reaction between the concrete and/or the steel substrate and the presence of pinholes. The results of these tests appear in Tables VIII and IX. The 36 GUARDKOTE 140 systems tested appear in ABS-050287 -13- Table VIII- The 28 GUARDKOTE 120 systems evaluated appear in Table IXIn testing most of the compositions, a total of 25 trials was run. Only six trials of a few systems were run when it immediately became obvious that the overlays contained pinholes. In order to pass the test, a system had to be perfect. All 25 trials had to show bubble-free results or they were eliminated and judged unsatisfactory. Of the 36 GUARDKOTE 140 systems tested, 10 showed no evidence of containing pinholes. Four of the ten (systems 7, 8, 9> and 10) were standard GUARDKOTE 140, applied at 3 pounds per square yard on unetched Portland cement concrete (PCC). They were surfaced with 6-12, 8-30, 12-30, and lb--2k emery aggregate supplied by American Abrasive Company, Westfield, Massachusetts. Three other pinhole-free GUARDKOTE llO systems (12, 13, and lU) applied on unetched PCC at 2.5 pounds per square yard contained 1$ Cab-O-Sil. They were surfaced with 8-30, 12-30, and 14-24 emery aggregate. Over acid-etched PCC two GUARDKOTE systems applied at 2-5 pounds per square yard and surfaced with 12-30 and lk-2k emery aggregate showed no pinholes (see systems 17 and l8). Finally, GUARDKOTE 140 (system 35) containing 2$ Cab-O-Sil, applied at 2.5 pounds per square yard on steel, and surfaced with 12-30 emery also showed no pinholes. Thirteen of 28 GUARDKOTE 120 systems showed no evidence of pinholing. System 7, GUARDKOTE 120 at 3 pounds per square yard applied on steel and surfaced with 16-40 quartz sand was pinhole free. On unetched PCC, systems applied at 2.5 and 3 pounds per square yard and surfaced with 30-100 and 16-40 quartz sand (3 pound application only) showed no pinholes. See systems 11, l4, and 15- On steel, GUARDKOTE 120 containing 2 and 3$ Cab-O-Sil, applied at 2.5 pounds per square yard and surfaced with l6-40 quartz sand, gave overlays exhibiting no pinholing. The same was true of a system surfaced with 10-30 quartz sand, applied at 2.5 pounds per square yard on steel that contained 3% Cab-O-Sil. See systems 19, 21, and 22. Systems 23 through 28, GUARDKOTE 120 applied at 2-5 pounds per square yard on steel, also showed no evidence of pinholing. Two types of aggregate (l6-l*0 and 10-30 quartz sand) and three levels of Cab-O-Sil concentration (l, 2, and 3$) were used in these six systems. CONCLUSIONS AND RECOMMENDATIONS The results of this study have shown that pinholing may be eliminated in the laboratory in six different ways. Only one of the six methods (decreasing aggregate particle size), however, appears feasible. The complete list of these techniques is as follows. , 1. Use of finer aggregate 2. Application of a second binder layer 3- Application of no excess aggregate 4. Addition of Cab-O-Sil to the binder (increase the viscosity) 5 Use of thicker layers of binder 6. Delay the application of aggregate . ABS-050288 -14- The use of finer aggregate appears to be the best method of eliminating pinholing. As seen in the work reported in Tables IV and V, pinholing decreases as the aggregate particle size decreases. To avoid jeopardizing adhesion by bond-line starvation, however, aggregate mixes containing more than 5$ of the particles passing a 40 mesh screen should not be used. Application of a second binder layer is a sure way of sealing pinholes. This method was used on the Ohio Street Bridge job in Chicago and was very successful. The method does, however, raise the cost of a GUARDKOTE job through added materials and labor. The application of only the required amount of aggregate is a promising approach. The advantages are that no aggregate will be wasted through excess quantities, and no labor would be required to sweep up excess grit after the overlay has cured. This is not feasible, however, because suitable equipment at a reasonable cost is not available. The addition of Cab-O-Sil to the GUARDKOTE binder which will increase the viscosity is another possibility. Difficulties could arise, however, as a result of using different techniques for incorporating the Cab-O-Sil in the binder. With different GUARDKOTE licensees making the material, different mixing and blending methods are likely to be used. This could possibly result in binders having viscosities too high for the automatic paving equipment to handle. Using higher binder rates (thicker overlays) would probably add too much to material cost, and therefore this method is not considered a promising one. Finally, delaying the application of grit would be a technically feasible method of eliminating pinholing. As cure advances, the viscosity increases to the point where the addition of excess aggregate will not cause pinholing. However, since rate of cure depends on many variables and is difficult to control, this seems like a dangerous approach. In judging the length of time available for grit application, one must con sider the surface temperature, the GUARDKOTE temperature, and the amount of sunlight. In addition, the possibility of breakdowns of spreading equipment and traffic jams have to be considered. Taking these factors into consideration, it seems somewhat risky to rely solely on a contractor's inexperienced superintendent or foreman to judge how long a delay in grit application would be desirable. It is, therefore, recommended that GUARDKOTE Cements be applied at a minimum of 2.5 pounds per square yard and surfaced with 12-30 mesh aggregate. ABS-050289 -15PARTICIPANTS IN WORK REPORTED P.- D. Ingerman, J. E. Magee, R. G- Roemer, C. V. Wittenwyler TECHNICAL REFERENCES Technical Records Book, Volume 1219, pages 5-^9 Written by: _J_lUi J//E Magee . Reviewed by: Approved by: C- M. Reider ABS-050290 APPENDIX Table of Contents Page Table IV The Effect of Aggregate Particle Size on Pinholing in GUARDKOTE l40 Overlays 16-30 Table V Table VI Table VII Aggregate Mixtures Producing Pinhole-Free GUARDKOTE 140 Overlays 31 The Effect of Aggregate Size and the Addition of Cab-O- Sil on Pinholing in GUARDKOTE 1^0 Overlays 32-33 The Effect of Flow Modifiers on Pinholing 3k Table VIII The Detection of Pinholing in GUARDKOTE 1^0 Overlays Using Acid Solutions Table IX The Detection of Pinholing in GUARDKOTE 120 Overlays Using Acid Solutions Glossary 35 36 37-38 ABS-050291 The E ffe c t o f A ggregate P a r t ic le S ize on P in h o lln g in GUARDKOTE 1**0 O verlays o CVJ ov 00 VO I rH 0<L1I C>(H1O) on OG nd CVJ 0 G CHfl 0-P rH tiDj orH 8 ON oc0p) CO | f0n) CL, 1 VO I 1 l/N 1 -=J- 1 OO 1 CVJ , HI VO CO LTV CO VC\ OV C-- CVJ H CVJ rH rH oO oo oo oo CO -d" CVJ CO CVJ rH CO CO ir\ CO CO CVJ CVJ CVJ H rH oo lt\ o cvj oo C---1-- CVJ CVJ rH rH rH VO CVJ co*> oc CVJ w con t0o CVJ >> w co o > c c\i ro to w N 0 CVJ >, co to w N 0 CVJ >> co to w *\ ni CVJ >, co to W V o CVJ > w CO CO tu CVJ >J CO o W -c CVJ W CO> 0to) CVJ X CO W CO <L> o o OO o Jj CO C O CO C cvj iao covo ir\-3- cocvj rH CVJ CO rH o W co c ^ ia -4 CO CVJ O CVJ co W m0 LA LA -4 LA rH LA CVJ CVJ CO rH Lf\ CO rH o on rH CO W on 0 >> (0 W on 0 VO co ICNCO rH CVJ rH rH CO CO rH LA Ov CVJ rH r- CVJ C*- OJ 5 9 7 2 CO W on 0 >> CQ W on 0 >> CO W on 0 > Key to G r it Type (a p p lie s throughout th is ta b le ) E - Emery S - S ilic a A - Alum ina BB - B la c k Beauty 16- t3 J<hD P -Q ca e<D 0o3 Q} O O 8Oto ns VO 00 O CVJ J- VO 00 O IAO IAO LTVO O O rH rH rH rH rH CVJ CVJ co cons- lev VO C--I O CVJ -P CO CO >0) f*. CO iH CO CD CO ABS-050292 Ol 1 OSlfN C-- HHH CM 00 O CM H ON w CM -17- as\ P E-CO CM i--l H -4- ON CM CM r-t w CM yes yes yes no yes yes yes yes yes no yes yes yes yes yes yes yes no no 001 CM CO H ON O n CM H CM CM H w CM t~i -ol- VO CM ON O cm irvvo VO Ol H H H f--l w CM VO I H t--C\J O CM icnvo r- C\J H r| H rl H w CM ir\\ CM CO C"l O <M CO t-- CM H rH rH r--( H w CM 77 66 87 Cent by W eight R etained on Sieves -d-l - C-- H On co tr\ LTN co CM w CM col VO CM H4NO H ro cm H w CM CM 1 CM CO H Ctu VO t-- CO (O n -S' H H w CO Hi CM CO H CO VO t-- CO CO H -4- H H w CM Ol1 ICN CM ( y f- -d OJ CO rl ri CO CO "Ovl1 UO J CM 0(0 r- -d CM CO H H CO CM po: 001i I H t-il H CO CM C-- H f-- CM CM CM CM H CM H CO CM t-- H t-- CM OJ CM CM H CM CO ro CO CM VO 1 CM O H O t-- CM CO -d- CO CO "I CM O H o CM co -d t-- CO CM -d 1 ~coll CM H CO CO rH CM CO CM rH CO CO CM H CO CO rH CM CO CM rH CO CM SCMMI[ H -d tcv -d H -d 1 Hi C-- t-- to H CM I -d -d 1 (0 g O 'O0(c03 .0a) 3 a VO 00 O W J- \D CO V *0 >> CO -p CO <>u DCO ri CO CO w CVJ cn w s CM 0) gv. H P a os U0) <d >> oto< -P r} H C M *H O PQ P in h o le s ABS-050293 TABLE IV C ontinued v0o 1 Hon! CO| Hc--| vol LA VoO\ OrHd OfHJ laoj OJ co CO rH CVJ CO CO rH nt H CM CVJ LTN i--1 NO OJ co -4rH <--i nt rH OJ CVJ LA rH VO CM CO -drH r--f fa CU oc o la co c o ta CVJ a o pa oo g o ca CVI G ITVl CO IT\ 0) | > (D rH -=t 1 CO u"v a VJ n] 'G 0) ird 1 c H d CM | -p o MV1 02 +3 <--11 A ITv 1 tH Ol LTV >> | > 4-3 ov| a a> 1 o G col QJ -dPM 1 c--I . CVJ CO -it CU CO rH rH C-- CO rH rH O h CO G CVJ co '--it CU CO rH .=}- VO U~v O ro CM CM rH rH f-- m rH rH to ta CM 0) r) o C*-- CO rH OJ O rH pa CO G -d- VO IT O noJ CM rH o [-- CO rH CM rH o o rH rH rH o o (H COMJ4- H r-- LA LA CO rH rH O CM CM ov CO la OJ OJ f>> CO pa CM OJ f o ta OJ G CO fa OJ 0) > O pa CO G rH LA -it rH OJ CM CM OJ O pa co G VOI icvl O VO Hi- rH -=t o CU CU CO rH rH \) LAH CO CO CM ^ rH rH o ta ro a o ta co G nf-l CO rH O CO CO CO CM rH rH rH o ta co G col -St <X> VO rH CU CM rH C-CO rH rH o pa co a CU 1 -it OVCO rH CU LA rH VO IAH J o pa co G rH 1 OV-drH OJ rH OV CM C1JrH rH Td 0) sP fg d 'd D CO CS CO O MD O IAO 1AO IAO O O O o Bd H rH CM CM co coj- -d- irvvo CO O CU <v *p 0) rH rH p co > CO <D >> CO H co CO CO pa CO 0) > v 0) p 0) d > CM PS CO O* 4> to rH <L) X o c+> fO XJ H H C U H H O P3 18ABS-050294 TABLE IV C ontinued LTV LmT\ LLTTVV LT\ pq OJ C0Q) OHNI LT\ LT\ LT\ LT\ -=J* pq CVJ c0>o)> CO 1 H IAOcn 1ir\^0 w OJ CO 0) MH IfUAO O m ir\ rH CO w CO a> VHO in o m o -3- H CQ w 0J a ir\i c-- CO i 4*>)h <D -4-1 H cn t-- 1 P o ml t-- 1 0) M rl Oil flj H -P i /P<y-u4* rH 1 PH ,3 1 &0 OHl i i*>o->* o\| P VO pi Q) O C0| u VO O 1/UTiO rH CVJ in I-H OOOO rl OlAH oooo rlJ-Jrl o jno tr\ o rH cvj mcvj rH O IAO IAO rH CVJ CVJ COrH o oooo rH CVJ-3- CVJ rH O OO O O rH cvi m m rH o o in in o rH cvj cvj m h O in in O O rH rH -=J- CVJ rH O inino O rH rH m m rH o in O in O 1--1 rH CVJ -4- H o oooo rH H in CVJ rH o oooo rH H m-d- H ov cvj cvj in cvj VO rH rH CO pq CVJ CQ w 0J 0) r** CQ w 0J 4) >* CO w CVJ 0) >> CO pq CVJ 0) r> CO pq CVJ >> CO pq 0J <d >> CO pq 0J aj >> CO pq 0J a> >> CO pq CVJ a> >> CO pq CVJ 0) ! CO pq CVJ OJ >> CO pq CVJ > pq o mc *d 0J p. .Q cd a TJ 3 to C a 00 CVJ o o o o o o a cd "1 CVJ mvo co o OJ p 0) rH p cn > to 0) > CQ H m D CO v OJ -P <d 0) a) > Ph 05 to O' OJ 0-H u 10 rH J "v, O p > JC H C rH C J-i H *H O PH ABS-050295 o1 SI IAI>AH ImA4O IA W CO CM 0) >> IA IA IA O IA rH j- m W CO CM > CO>|1 IT\ COM OUACOM UA W CQ CM OJ >> cHh IfMrMTMTv O HW4 H W CO CM > vo I LT\ O IAO O rH m J- r-H CO W CM Q> >> LT\| IAIAIAIAO H mmh W CO CM a; > H1 - IAO O IAO rH4 m r-1 CO W CM <D >> mi ON IAiO--i -I4AOmOi--i CO w CM a> OJ 1 ON IAIi--A1 OLf\ COM Oi--1 CO w CM >> iH j <*1 OlAOOlA i-< m ir\ w CO CM <D S| O IAO O IA i--1 CM Mj w CM yes l Or-| Or-l ImA-O4 IA w CO CM a> >i 000011 O O O IAIA r-l r-l mj- w to CM OJ ;>> C--lI O O IAO IA CO r-l i--1 CM IfN w CM a> >> VO l1 OrH pCM ICAM LmAOr-l CO w CM <D S ltnl) OrlrIlAWO 4IAOrl w CO CM 0) >> -c=ot |1 Or-l IrHAOm ImAOr-l CO w CM >> CM l1 OrH OH ImAImAOrH w (0 CM 0) >> rHl| ir\ ooia m>Mo to w CM <L) CO SO> 'd 0) u d XaI d 3 cs cd -p V CO >I) CO rH D CO Or-H OrHJ COM O00O4 Oin. ID -p r) IQD| a f>, to J>5 fc-H kID o' (D CO r-| o -Prl J-i TJ aH X3 rH ,C GH O FQ ABS-050296 TABLE IV C ontinued ChoM I Or-Nl|l r-l| 00 1 H (--1 1 r-l rH-l I VO 1 H HI MOl CO Hi ><D HI H H-l H Hi oG cn| rH I Q) r*H | C H 03 evil pH <D HI K P Hi H Hi H 0) | H >3 HI P P Ov| |c O 0) rH o G 00 1 (I) o Pm Hi r-l o hI vol o rH 1 mo| o rH | H-l q rH 1 rH 1 cm| rH I rH 1 o rH | UMr-Ti UmAoIjAOcj IAIrHAOCM O -4 COM mo uo mo uo o H CM ro CM mo uo o O o H CO CO CM ino ITIO O H CO no CM uo oH oIT\ uo H CoM IA' "OH -OS' ICAM OCM IAO O IAO H CM -4 CM IAO O IAO H no CO CM AO O O A H UO CM rH AOOO A H -3* CO rH AOOO A H CM in H uo o lt\ uo uo H CM .4 rH ino lAinin H CO CO rH AO AO O H CM UO rH AO O AO H 104- H MO O AO O H MO CM H MO O O MO O H VO H H A AO O O H VO H H M0 o MO MO MO H CM MO 0) u a? S *G D CO G S CM O O O O B (0 H CM C04 M0 P CO H CO D CO CO W CM <v >3 to W CM d) >3 to W CM <D >3 CO W CM <D >3 CO CM 0) >3 CO W CM 0) >3 CO W CM 0) >3 CO W CM <L> CO W CM 0) >3 <0 W CM <D >3 CO W CM 0) >> CO w CM 0) >3 CO w CM 0) >3 CO w CM QJ >3 CO w CM 3 CO w CM Q) >3 to H CM <D >3 CO W CM d) >3 CO W CM QJ >3 CO W CM <L> >3 v <D P O HU wH 0HOO)) oG uoHnnIi HoH"ni| Tc(UJ oonn| h| -0p) OoJnI 05 hI JC<HajDC hon|. Hi rQt>> ohm|| +o<a3u cOrHuN\I <D Ph COhJ0|I OchJ-|I VOhDJ lI OHuJni1| JOh-J1I 5OTJ I h| OOrHJJ|| OHJ 1 rH | LA -Oa- LoAn O oj LA Oca LmA Om 1AO cm clAnO^t LA LHA OonOir\ la IHAIoAj Oon o1Aj LT\ HlOOOJ JIA- IrAH IA IHrtOOl UonMOTJv LA HUMHAJO OIAl Lf\ OH OIAJ JO- OoJ LA OH OLJA IoAn IA oj LA OH un oj Oon Oon LA O h oLjALojALoAn LA HOOOJ O-d- IOAJ LA o h ooi mon oon LA oH co\i oon uonn LA OH IHAOU-\OOJ LA OH LHAJLALOAJ LA HO un h jO- Oon LA OH HLALoAn LoAn LA HLT\-O4- OOJ OOJ to CB0PO) CO Ucd CccPOd DCO 0OJ) OrHJ VrH) Ooi OonOj OLON W OJ CO >0)i W OJ C<OD >> w OJ 0C>O) W OJ 0CO) s W OJ C0>O)> w OI CO 0) W OI C0O> w OJ C<>Ou> W OJ CO a> W OJ C0>O)> W OJ >CaO>> w OJ >aCO)> w OJ a>CO> w OJ C0O) i w OJ CVO >> w OJ ta>o;> w OJ 4C>O >> w OJ Ca>O;> w OJ t<>ou> w OJ CO V J OJ -Hp ou -0c<p5dU pa> 'dGH CQ >> o(D* Hjo ,rOGCaHcHO; 22' ABS-050298 TABLE IV C o n tin u e d Ol VO r-II OLTN\I| r~ 1 cUonl| r~ oL~T\| r~" VuOn| r-- CQ Ucr\\\l <u iH CO un| rH C O on uni -CPQ CO !> CO 1H) CO D CO c^ aa ro cu cOu 1oAnc1uAOcvj WO OOJ CUJMrAo OHO4O4 OH O1--1 OOon Ocvj O l/VO IA H on on cvj 'OrH OonOonOon O un 0 un rH cvj on on OrH OCVJ OonO.4 un 0 0 un on on cvj rH CuVnJ CuVnJ cuun CuVnJ cOu OmOmOcvj cOu uonn un oj c0u Q O UMA cu cu cu on un un un un rH On on rH urHn O 3- cuun c0u ruHn cuun 0on 0m uHn 0 OJ un CU J0 un -u4n -u4n un IAO O IA IA on H VI-OH C0U Oon-O4 Oun CD Pd CU 0) >> CQ Pd CU 4) >> CQ W CU 0) >* CQ Pd CU 0) >> Pd OJ CQ 0) >4 CQ w cu a; >> CQ Pd cu 0) >i CO Pd cu >> CQ Pd cu 0 >i CQ Pd cu Q) >> CO W cu a; >> CQ Pd cu Q> >> CQ Pd cu a; > CQ Pd cu a> >> CQ Pd cu >> CQ Pd cu a; >> CQ Pd cu <D >> Pd cu CQ 0) >> (0 Pd cu 0) n a> p TJ <U Gj ft PC CQ I? p <U p -o O' 0) --m^ rH O ,q H P lHc rH 1H3 O CD 23 ABS-050299 TABLE IV C ontinued oI co H| ONI t" Hl 001 H H1 irv irv irv irv CM vo ITV ITV l/V ICV co irv LTV LTV IT\ ITV -d" c-l H 11 LTV o o in rH cj vo VO I H r--1 1 O ir\ ir\ o HHWlA LTNl to H 03 HI > 3 th-- I -p o\| c 113 VHD i O P C0| 03 VO Ph Hi M VO Hi vol VO hI O IAO 1A H H OJ I/O O 0-0 o ,-H iH -d- -d- oo oo rl H COlA O O iaja rl H OJ IA in in in in H 00-3- IA1AO O HOIA LT\ LT\ IT\ O i-J CVJ vo UVO IAO rl COlA ino iao H CVJ vo oopo -3 CO CU rH irvl VO Hi J-l VO HI col VO h| IAOOIA 00 cr> CVJ rH O I/O LTV p CO CVJ OJ CJ irv LTV LTV LTV CVJ CVJ CVJ CVJ OJ I VO Hi H1 vo rH | 'd 4p033 03 S -1P0 6? TdanJ) CO CO D SsD 03 C>0HO3 ITV U"\ LTV m CVJ CO CVJ rH inp ino CVJ CO CO H OoJ orojo- ou"\ CO w cvj 4> CO w CVJ CO w CVJ a> s CO w CVJ 4> >> CO w CVJ 4> >> CO w CVI 4) >> a w CVJ 4) CO w CVJ 4) >> CO w CVJ 4) >> CO w CVJ 4J > CO w CVJ 4) >> to w CVJ 4) >> CO w CVJ 4) >> CO w CVJ 4) >> CO w CVJ 4) > CO w OJ CO w OJ (D >> 03 4) dp & p. 0-4 p CO O* 4) CO rH 03 o -p tH p Tl a rH rH S CH p P3 P. 2kABS-050300 TABLE IV C ontinued Oo 11 o H oo mvo cj| CM ON o LTV LT\ H i--1 c-- HI CO 1 O--N11 LTN IT\ O LPv J- M O^N1 Lf\ LT\ O J- LTV NO 1 ON HI to LTNl ON to rH | > to t-1 -=H CO ON rH 1 a U ml TJ ON to H| ar_ni cd OJI -P ON to H I a: +> HI ON 00 H| H to O1 ON >S H | rQ +5 OM CO 0) H) o COI to CO -HI tH CO HI VOl ChO I ITN O LT\ m\o tr\ lf\ o H CO 3000 H C\l W IA oooo rH oj m jO L"lO IA i--i i--i OJ tcv O iaiaO H H W 1A O IA1AO H H m-aoooo i--1 H OJ VO OOOO rH H m LTV OOOO H H J- -dIAO IAO H OJ VO ITkl CO HI H-1 CO Hi ml co hI OJ 1 CO Hi rH) CO HI 1AO O IA H m ia 1AOO IA H -d- LP> Lf\ UA LTV m irv tfV lOv l/V Uf\ L/N IAIA LTV cr\ m u tJ CO a> >i CO H CO 13 CO 20 u-\ o o O oj mj- uv to w OJ to w Ol ttoo w OJ ttoo to w CVJ 0) to w Ol a> to w OJ 0) to w OJ 0) >> to w OJ 0) to w OJ to >> w OJ ttoo > to w Ol to >* to w OJ to >-> to w OJ to > to w OJ to >> w w OJ to t>> to w OJ to >> to OJ to > to w OJ to >> to w OJ to >> w w OJ to >> OJ -p TJ > o' ttoo ra rH a> o -P <d ,Q A H p 3 H H GH o pq p* 25 ABS-05030I TABLE IV C ontinued 8 CM 0\| f--11 Oil COl 'CHM 11 M rH CMl mo| r-<l CM| <1u0 lf\| rH CM| > -aHt J | co r-t cm! oC ro| o rH acHt CM| cd CM | -0p) rH cm| K iHMtCPtt rH | H cu | o| rH I cm| c pI 0t cm! o p CO | Pati o CM | M o cm| mo| o cm| to) o CM | J| O cm| CO| Pcm| CMl o cmI H1 P LO JLO OLT\ to to o I-H CO io to O r-l to to IAO iA -l J J IAO tO H MIA IAO 1A rH CM VO ' ooo i-H MO CO O IAIA rH J J OOO H COMO O IAIA HHtumaO mo CO IO IO O J lO IAO 1A COMO IO IO Q rH CO to to o rH to CO to o to rH J J to O to H CO to to o to rH CM MO o oo rH MO CO O to to rH J J p d 0) P a) E 3 to S C C3 s 8 JAOOO cm raj- to o P at -P CO > to at >> CO CP S3 CO to W CM <D >> w W CM 0) >> CQ w CM a> >> CQ w CM (D ^5 CQ w CM 4> CQ w CM OJ >> CQ w CM > CQ w CM <D CO w CM > CQ w CM (!) S CQ H CM > CQ w CM d> > CQ M CM & >* CO W CM a; to W CM (V CQ W CM (D > CQ W CM 0) > CO M CM v > CO M CM 0) at P t3 fl) cd > Pi K to >B> >i tol)' Ha> at o P T3 43 J3 H a rH C op inH tP-i( 26ABS-050302 TABLE IV C ontinued l cm| ONl CO cm| col CO cm| c--| CCMO | NO 1 CO CM | i/n| C0O1 CO CM | > <D tHo -d1 CO CM 1 oc col T<Gu) CO CM | rt -cCpdD CcMo 1 CM | 05 P Hi CO bO cm| H D0C) Ol >--1 CO CM | .Q -P ONl G CD CM CM | O p CD 1 CD CP CM CM | C1 CM CM | VO I CM CM| LTnI CM cm| -d 1 CM cm| COl CM CMl cmi CM cm| pH I CM CM | Tl p tcJd co G 5 cd 0) p -p CO co 6 CO D & 8 O lt\ lC\ O CO CM CM CM COm mino O CM CM -d H l/N UMT\ ICN CM CM CM CM ITN O LTN O CM CM _d H .,CCN ICMfMTN CM Hd H OOOO CM CO CM CO pOOO CM CM IC\ rH 8 83 8 pooo CM CM CO CO ON uo On CD H H CO o r-- cm on CM rH -d CM CO O O CM r-t LTN H ITN LfN O H ITN CO UNO 1A H -d -d UNO UN rH CO LTN O ICN ITN H -d -d OOO H COMO LTN LTN O NO CO 1AOOOOO CM CO J- MONO CO co w CM <D >> co w CM CD > CO w CM CD >5 CO w CM CD > w cm a) !>> CO w CM 0) >> CO w CM CD !>> co w CM a; CO H CM 0) > CO W CM 01 >> CO w CM 0) CO w CM CD SO CO w CM 4) > CO w CM 0) > CO w CM 0) CO w CM 0) >> CO w CM 0) >> CO w CM 0) >> CO w CM 0) >> o w CM C CD -P ga) 0c5d idlo co cd 0) p 0)' co . roH -P Td XX JHh ch G H O CQ (P 27ABS-050303 TABLE IV C ontinued 20 oI VoOil o\| LTV CVJ | CO I Lf\| Oil t--1 Cla\il VO I elvail LTVl 10 <D OLTVil > 0) H J-l CO la CVJ | oc ml IA CD Oil G H cd CVJ I -p Q) O(Ail cc p H| U3 OLAf| O| LA >> OJ | ,0 -p OV| G 0) Oil o p col <y Ph -=r CVJ | tH 1 Oil vo| -O3-il ir\ irs o o CVJ OJ -=f i-H LT\ LTN LT\ LT\ OJ OJ OJ CVJ oO O O oj m oj m oooo cvj c\j ir\ r-i ooo OJ CVJ j- oooo cvj Cvj mm -On ltn ON CO O Ov hhm r--1 o r~-oj On CVJ OJ rH J- rH oOJ CO o OJ H IAH OmoLAj cQu u\0 rH f-H LA IA O LT\ ITS OJ Ol OJ rH rH LA O O O ir\ OJ OJ OJ CVJ H LA LA O ITS lf\ OI H J" i-H oooOO OJ OJ rH rH ooooo CVJ OJ CVJ CVJ CVJ LA| OJtil| OIAIAOO CVJ r-t -=t jH rH Oil LA O O O ITS H OJ OJ OJ CVJ ml OJ I CVJ I -4- oj| Hi Oil UMAO LT\ LT\ rH rH rH rH ir\o iao o HH rH CVJ ooooo HOJ J CVJ rH Jh OJ P cd e D o oW G 85 VAO O O S CD oj m_a- LfNVO CO d> P OJ -tPo CO :<>u CO H Dm U"\ CO w 0) CVJ >> LT\ CQ w 0) CVJ > w LTN (0 0) CVJ LTN cq w CVJ IT\ CO w 0) CVJ w Lf\ CO a> OJ >> w U"\ to a; OJ LT\ CO w > w LTV (0 OJ CVJ >* CQ W CVJ 0) >> CQ w CVJ <L> r>> CO w CVJ (D >> CO w CVJ 0) CO w CVJ 0) >> CQ w CVJ 0) >4 CQ w OJ 0) > (0 w CVJ a> >> CO w CVJ a> >> 0)CQ w CVJ >> CO w OJ Q) >> 0) <CuL| -apJ 05 'd >> CQ u* 0) oCO rH dJ s,'s. -p H p C H rO rH ,q a H o PQ Oh ABS-050304 Cent by W eight R etained on Sieves o1 cOoil o ovco vo CO OJ H H rH rH rH On| OMJ 1 col CCMH1 VO Is- r*- t-- c^vo H H H H rH rH m-d- vo co Ov 8 H rH H rH rH tH CM | NO | cm| o cm irvco r-l -3rl rl rl rH CM CM O la m CM 8 irv O rH rH PI cmI LT\ a CM CM 8 ITS LA rH rH J-1 c-- OJ mi OtHJ | ja o 8 o LA CM CM CM rH Aa CM rH O -d* LA LA rH 20 20 20 20 20 OJ I Moj| O oo -d~ rH rH Pi or| 88 o| t--I CM 1 o\| VcOm| oa CM i-H ltn -d- oo rH rH ltn o rH CM 20 20 LA CM COl VO J CM 1 A LTN rH rH O -d* LA LA rH rH M VCOM 1 lT\ o rH rH A -=t o8 rH 10 20 20 20 20 10 vO 1 VO CMI IT\| VCOM | J-1 VCOM | O -d* oo mm o CM O ITS mCM A CM ml vp OJ CM | VO CM r-l| VcOm| oo m cm Oo CO CM LTV LTV CM CM o -d* O rH LPi LT\ LA CM CM CM CM G 0) U <0 S G CO GK AO AO Ao o d cm m m^i- j- LAND <L) P 0) P CO > 01 >> CO m CO LTN CO w > IA CO w 0) CM >i LA CO w d CM LA CO w <D CM LA CO w 0) CM LA CO w 0) CM >> LA CO Hd CM LA CO w d CM LA CO wd CM A CO w *d CM A CO wd CM >> A CO M *d CM A CO W 0) CM A CO wd CM A CO w * 0) CM >> A CO w OJ CM >> A CO w d CM >5 A CO w * 0) CM >> A CO w d CM >> V <D P f`G V d >> P< PM s CO 0) G (0 rH 0) ^ o +3 T* ,G H G H cj H o PL, 29ABS-050305 C8V\J]1 ma> >Oa3J CCt--VOJ Ka0Hp)) 4 LO. CCVOJ CCVOJ "o<SL> ro CO CVJ u0) PM CVJ CCVOJ CCO\l mm-n4 rroo pmq OJ (00) >* ' oo rH pq 0)CO CVJ r^i oo rH ppqq OJ 0CO) >> oo ppqq OJ 0CO) rH -4 H CO iO CVJ O OJ CVJ rH rH rH rH W ir\ C0O) CVJ >i cotf ON CO VO -4 rH rH rH rH ro rH W ir\ OJ C0O) s C c--VO t-- -- t--VO rH rH rH rH rH rH W i/\ oc OJ co 4 VO CO ON O rH rH rH rH rH CVJ w ITS OJ C0O) >> o LT\ tr\CVJ CO rH -4 w 0)rH H H rH CVJ OJ CO r i o-4 H CO LTV OJ OJ OJ rH rH rH rH LT\ CO w QJ CVJ CaO +<3D CO C>O cud ccd -CpO CO D ,ap0s3o<) 0) >0H) CO Oi--tVfO--l CLVTJ NCOO L^O JLT-V iO/~\ o1 CO 0) 4H-3 T0CJ) co roH OU *H H PH 30 TABLE IV C ontinued ABS-050306 A ggregate M ix tu re s P roducing P in h o le -F re e GUARDKOTE l4 o O ve rla ys on G loss ( V is u a lly Observed) o r-- CM 31- CVJ o c-- o rH rH SI CO rH 1 OJ OJ O o rH -d OJ ON CO LT\ C-- rH rH rH 00 o rH O rH CM 00 CM CM rH rH CVJ CVJ CO G\ on m irv ir\ Ol o VO I 0J o uv| ir\ CM O O CM rH rH O rH rH O ON CO rH CM P rH CM UN O mo UN VO CO rH CO CO (--1 rH r-- r-- cvj rH UNCO 00 UNO CVJ Q rH rH rH OJ CVJ CM cm rH u 01 1 a iS OJ > UNl <D CO H co O Ti co| a 'S uv cv I 0) -p CQ tel CO *31 rH o o rH Owd CM CM CM CM MO H C-- rH rH CO OJ O UN C-- rH rH CM VO rH rl CO t-- CM rH rH CD t-- UN HHH t'rH UN CM On O UN t-- rH CO NO rH rH O O rH CM O ON CM CM rH VO rH rH irv CM NO t--CO NO -d OJ rH O rH VO rH rH rH OJ OJ CM rH rH rH rH CO CM CM rH rH ITN rH O rH VO LTN lr\ rH H H H rH rH CM -d CM NO rH rH O rH UN CM CO UN CM ON rH CM CM CM -d -d ro rH rH rH CO NO C--00 CO on on rH CM m m CO P CO rH CM CM CM 31 -d CM 31 CVJI SI 001 O ON <-H -d CM -d CO UN CM U\ CM -d COd- CM MO -d Q) -P >1 05 o' u0an) 10 & rH rH CQ ITN CMCMCMCMCMCUCMCMCMCMCMCMCM CO CO CO CO CO CO CO CO CO CO CO CO CO CO CO CO CO 0) a) d P &! C aJ * b u- u > h > cj bo a) 4) 0) 3 0)<ua)0)0)0)0)0) H 0) H 0) ^ 0) ^ 0) s 3 0) 0) g) U gj 111 OJ h, S EH EESBSS-'" B B S _B rH EB Hb> w w < cq (3 W W W WWWW CO CO W W W BB WW w W ( w bC < 8 CJ -P (0 CM 00 C__O____C_T_v__O__ ___O_ __M__O___0_0_ o,, CO CO-d UN UN UN VO f-- f--t -d r- CM CO CM CO HH COM dCM OroCdM drod_ddundvodC--CJO ucnouunNitn~OunNmpo ' CM CM CO ABS-050307 The E ffe c t o f Aggregate P a rtic le Size and th e A d d itio n o f C a b -O -S il on P in h o lT n g in GUARDKOTE 140 O verlays 10 10 5 9 7 2 o LT\ t-- ON rH fOIAt-n UA o c\j rH rH rH rH CVJ w CVJ G CVJ oxi r--i ua o rH O UNO UNO rl H Cy H rt O IPs rH w UA CD CVJ a; CVJ >> CO l/\ o O O O O UN UA UA UA CD H rH i--1 i--1 r--1 1--1 <--1 rH rH ca CVJ <D CVJ >> h- lTV ua O O O O un IP\ O UA CO iH r~i r-i i~-t i--1 rH CU w OJ Q) OJ >> VO rH uaI CO rH 0) > <D H CO rH c u rol rH 0> c H cd OJ p rH 0) cc p rH XX rH bD (1) rs lf\ r-- CO O rH M4- VO VO rH rH rH rl rH rH ua o rH IAO O UNO rH OJ OJ rH rH UA - - UA UA UN UN UN UN UN UA rH rH rH rH rH rH ir\ o rH O O UN UN UN rH rH rH rH rH Q CVJ UA LPv O O UN UN O rH rH H rH CVJ O OJ UA t- ON rH OO UN C~- PA rH i--! i--1 r--1 0J UA O O p O UN CO rOCU rH UA CO w CVJ a> CVJ >* UA to w OJ 0) CVJ s UA CO w CVJ 0) OJ rt UA CO w CVJ 0) CVJ UA CD w CVJ 0) OJ >> UA o w CVJ a 0J IP\ CD w CVJ u CVJ >> -p c On > UA o w CVJ G CVJ tVO ir\ ua o rH UN IfN UN UN UN rH rH rl H CVJ Lf\ o rH O UN UN P UN H rl rl OJ CVJ UA 00 H4 J-O UV rH rH rH CVJ OJ UA CD H CVJ 0) CVi >> CeD UA CD w W CVJ OJ CVJ >> ii w UA CD W OJ 0J CVJ >5 O J- o rH UA CD w 0J OJ >> O ro o rH VO CO uncO OJ rH 0J rH rH cvj H m ro un m m rH 0J 0J CVJ rH rH UA CD w OJ 0) o oCVJ >> 4-> IPX CD w OJ Q) tl CVJ >> CD d) CO -H D CO s (D -P cd (D cd >> rH (X H > W cr co >rH a> \0 > O -P H3 1 ,C H G H P^.C G H C3 -H O PQ U Oh -32ABS-050308 -33- TABLE V I C ontinued c-- I CO VO 1 CO CO LA 1 QJ > 0) H CO -=f 1 m a o m1 Q) m c ctf P<D jx CVJ | ro1 p rP ofc m 1 *ri <V & o >> m P P ON O CO cd CoD >VH CD O LA LA LA LA LA LA r--i ri i--l i--1 (--l i-H IAO LA LA LA O O rl rl rl rlW W LA O O LA LA O LA ri H H H W CD LAXO PH4 rH rH rH CM CM CO m ON LA O LA CM CM rH rH rH LA LA Q O O O rH CM CM CM CM LA LA LA O O LA rH rH CM CM CM LA O LA p O O H rH CM CM CO la o la On mao rH rH rH CM CM LAOOIAPIAOOLA rH rH rH CM rH rl rH LA O O O O O LA LA LA rHrHrHrHrHrHrHrH LA LA O P P O LALAO rl H H rH rH rl CJ la r-- co o rH mj-vovo rH rH rH rH rH rH LA O LA O O LA O LA rH rl CM CM rl rH LA lA IA LA LA LA LA LA rH rH rH rH rH rH LAO O O LA LA LA O rH rH rH rH rH rH CM LA LA O O LA LA O O rH rH rH rH CM CM VOO LAO LA O LA O Q rH cm CM m roj- LA'S W LTV CVJ CM Ofi LTV O w CVJ CM a ir\ o w CM c cu ir\ o w CM a oo LT\ CD w CM QJ OJ VfN 01 w CM Hi OJ >a w t/N CVJ CM Ofl tr\ o w CM OJ LT\ O w OJ CM tr\ W w OJ CM 0) O ir\ o w CVJ CM LT\ o w CM OJ LT\ O w CM OJ U\ 01 w CM CVJ > ITN 0] w CVJ CM 0) >a ITS O w CVJ CM w LT\ CM Ofl 0J 0) p T) *L 4) cd P< D3 -p -rH Ji to > o' c0 >r-t P co) jP-\oi & J03 H C H XI ^ C OVi *H ocd *PiHh >S Jh (1) a w ii w 0) P H o o p ;>> <D ABS-050309 TABLE VII The Effect of Flow Modifiers on Pinholing"^ Flow Modifier Added to GUARDKOTE lAo Rone - Control Thixcin E age/ayaf - 95/5 age/ayaf - 90/10 .. age/ayaf - 85/15 age/ayaf - 75/25 Ethyl Alcohol Furfuryl Alcohol Triethylamine EPON Curing Agent V-AO N-Hexane SF-09 . Antifoam A. Triethylene Glycol Tween 20 SR-82 Span 80 Aerosol C-6l Anti-Sag 7 Duomeen S Duomeen 0 Duomeen C Residue Duomeen C and S Residue Per Cent by Weight Added 1, 2, 3, A, 5, and 6 2, A, and 6 A and 6 2, A, and 6 2, A, and 6 1 and 3 1 and 3 0.2, 0.5, 1, and 3 0.2, 0.5, 1, and 3 0.2, 0.5, 1, and 3 0.2 and 1 0.2 and 1 0.2 and 1 0.2 and 1 0.2 and 1 0.2 and 1 0.2 and 1 0.2 and 1 0.3 and 1 0.3 and 1 0.3 and 1 0-3 and 1 Pinholes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes 17 The GUARDKOTE lAo binder, the aggregate, and the glass surface were heated to 100F before application ABS-050310 -35- TABLE VIII The Detection of Pinholing in GUARDKOTE l40 Overlays Using Acid Solutions Binder Rate , System lb/sq yd Emery Aggregate, mesh Surface^ Cab-O-Sil, Pinhole-Free $w Trials^) 11 21 6-12 14-24 Unetched PCC Unetched PCC - 3 of 6 2 of 6 3 2-5 6-12 Unetched PCC - 1 of 6 4 2.5 5 2-5 8-30 12-30 Unetched PCC Unetched PCC - 5 of 6 4 of 6 6 2-5 14-24 Unetched PCC - 4 of 6 73 6-12 Unetched PCC - 25 of 25 8 3' 8-30 Unetched PCC - 25 of 25 93 12-30 Unetched PCC - 25 of 25 10 3 14-24 Unetched PCC - 25 of 25 11 2-5 6-12 Unetched PCC 1 18 of 25 12 2-5 8-30 Unetched PCC 1 25 of 25 13 2-5 12-30 Unetched PCC 1 25 of 25 14 2-5 14-24 Unetched PCC 1 25 of 25 15 2-5 6-12 Etched PCC - 23 of 25 16 2.5 8-30 Etched PCC - 21 of 25 17 2-5 18 2-5 19 1 20 1 12-30 14-24 6-12 14-24 Etched PCC Etched FCC Steel Steel - 25 of 25 25 of 25 15 of 25 0 of 25 21 2.5 22 2.5 23 2-5 24 2.5 25 3 26 3 27 3 28 3 6-12 8-30 12-30 14-24 6-12 8-30 12-30 14-24 Steel Steel Steel Steel Steel Steel Steel Steel - - 15 of 25 - 10 of 25 - 20 of 25 - 0 of 25 - 20 of 25 - 20 of 25 - 12 of 25 - 12 of 25 29 2.5 30 2-5 6-12 8-30 Steel Steel 1 0 of 25 1 8 of 25 31 2-5 32 2-5 12-30 14-24 Steel Steel 1 0 of 25 1 5 of 25 33 2-5 6-12 Steel 2 8 of 25 34 2.5 8-30 Steel 2 0 of 25 35 2-5 36 2.5 12-30 14-24 Steel Steel 2 25 of 25 2 8 of 25 1) Portland cement concrete (PCC) surfaces that were etched were treated with 16$ solutions of hydrochloric acid 2) The results show the number of pinhole-free overlays obtained out of the indicated number of test trials ABS-050311 -36- TABLE IX The Detection of Plnholing in GUARDKOTE 120 Overlays Using Acid Solutions Binder Rate, Quartz Aggregate, System lb/sq yd mesh Surface^-) Cab-O-Sil, Pinhole-Free #w Trials^) 11 30-100 Steel 0 of 25 21 10-30 Steel - 8 of 25 3 2-5 30-100 Steel - 0 of 25 4 2.5 - l6-4o Steel - 5 of 25 5 2.5 63 73 10-30 30-100 l6-4o Steel Steel Steel - 8 of 25 - 0 of 25 - 25 of 25 83 10-30 Steel - 8 of 25 91 30-100 Unetched PCC - 0 of 25 10 1 10-30 Unetched FCC - 0 of 25 11 2-5 30-100 Unetched PCC - 25 of 25 12 2.5 16-40 Unetched PCC - 20 of 25 13 2.5 10-30 Unetched PCC - 20 of 25 14 3 30-100 Unetched PCC - 25 of 25 15 3 16-40 Unetched PCC - 25 of 25 16 3 10-30 Unetched PCC - 15 of 25 17 2-5 l6-4o Steel 1 17 of 25 18 2-5 10-30 Steel 1 17 of 25 19 2-5 16-40 Steel 2 25 of 25 20 2-5 10-30 Steel 2 20 of 25 21 2-5 16-40 Steel 3 25 of 25 22 2-5 10-30 Steel 3 25 of 25 23 2-5 l6-4o Unetched PCC l 25 of 25 2k 2.5 10-30 Unetched PCC l 25 of 25 25 2.5 16-40 Unetched PCC 2 25 of 25 26 2-5 10-30 Unetched PCC 2 25 of 25 27 2.5 16-40 Unetched PCC 3 25 of 25 28 2-5 10-30 Unetched PCC 3 25 of 25 IT) PCC = Portland cement concrete 2) The results show the number of pinhole-free overlays obtained out of the indicated number of trials ABS-050312 Advawet 10 Advawet 82 Aerosol C-6l AGE Alumina '" Antifoam A Asbestos 7TF1 AYAF Beetle 2l6-8 Bentone 27 Black Beauty Aggregate Cab-O-Sil Celite 1655 DC-200 Duomeen C Residue Duomeen C and S Residue Duomeen 0 Duomeen S Emery MCG-1 Microcel E -37- GLOSSARY Wetting agent. Advance Solvents and Chemical Company Wetting agent. Advance Solvents and Chemical Company Surface active agent, American Cyanamid Co. Allyl glycidyl ether Synthetic aluminum oxide Defoaming agent, Dow Corning Corporation Johns-Manville Corporation Vinyl resin. Union Carbide Corporation Urea-formaldehyde resin, American Cyanamid Co. Gelling agent. National Lead Company Boiler slag aggregate, H- B- Reed and Company Colloidal silica thixotropic agent, Godfrey L. Cabot, Inc. Diatomaceous silica filler, Johns-Manville Corp Silicone oil, Dow Corning Corporation Alkyldiamine bottoms, Armour Chemical Division Mixture of alkyldiamine bottoms, Armour Chemical Division Alkyldiamine, Armour Chemical Division Alkyldiamine, Armour Chemical Division Naturally occurring crude aluminum oxide Mineral filler, Nopco Chemical Corporation Calcium silicate extender, Johns-Manville Corp. ABS-050313 Nuosperse 657 Pluronic L-6l Sag kj SF-69 Slate Flour Span 80 SR-82 Suspenso Thixcin E . Tween 20 Wollastonite P-1 -- GLOSSARY Continued -38- Surface active agent, Nuodex Products Co. Surface active agent, Wyandotte Chemicals Corp. Defoaming agent. Union Carbide Corporation Silicone resin. General Electric Company Mineral filler, Whittakei} Clark and Daniels, Inc. Wetting agent. Atlas Powder Company Silicone resin, General Electric Company Calcium carbonate filler. Diamond Alkali Co. Thixotropic agent. Baker Castor Oil Company Wetting agent. Atlas Powder Company Solid mineral filler, Godfrey L. Cabot, Inc. ABS-050314