Standard Specification for

Epoxy Protective Coatings

AASHTO Designation: M 200-73 (2007)

1. SCOPE

1.1. This specification covers two-component epoxy resin adhesive for use as protective and or skid
resistant overlays on portland cement concrete surfaces and bridge decks. Two classes of epoxy
resin adhesive are provided.

1.2. Classes:

1.2.1. Class I, bitumen modified coating is for use in protective coatings for skid resistant and/or
protective overlays for cement concrete bridge decks and surfaces. It includes a recommended
practice for the preparation of the concrete surface and for the application of the epoxy prime coat
when required, epoxy top coat, glass fabric when required, and cover material. Each system may
be used as a wearing course or as a protective coating beneath an asphalt concrete pavement.

1.2.2. Class II, oil modified coating is for use, with suitable aggregate, in mortar overlays 9.5 to 12.7 mm
(3/8 to 1/2 in.) thick as skid resistant and/or protective overlays for cement concrete bridge decks
and surfaces. It is also suitable for application in a thin layer under asphaltic concrete as described
for Class I material. It is not generally recommended as a wearing course in thin layers.

1.3. The values stated in SI units are to be regarded as the standard.

1.4. This standard does not purport to address all of the safety concerns, if any, associated with its use.
It is the responsibility of the user of this standard to establish appropriate safety and health
practices and determine the applicability of regulatory limitations prior to use.

2. REFERENCED DOCUMENTS

2.1. AASHTO Standard:

 T 55, Water in Petroleum Products and Bituminous Materials by Distillation

2.2. ASTM Standards:

 D 154, Testing Varnishes
 D 412, Vulcanized Rubber and Thermoplastic Rubbers and Thermoplastic Elastomers-
Tension
 D 482, Ash from Petroleum Products
 D 570, Water Absorption of Plastics
 D 638, Tensile Properties of Plastics
 D 664, Acid Number of Petroleum Products by Potentiometric Titration
 D 1078, Distillation Range of Volatile Organic Liquids
 D 1084, Viscosity of Adhesives

TS-4c M 200-1 AASHTO

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  D 1652, Epoxy Content of Epoxy Resins
 D 1668, Glass Fabrics (Woven and Treated) for Roofing and Waterproofing
 D 2240, Rubber Property—Durometer Hardness

2.3. Other Standard:

 FSS HH-C-466, Cloth, Glass, Coated (For Membrane Waterproofing and Built-Up Roofing)
Also refer to ASTM D 1668 as noted above.

CLASS I—BITUMEN-MODIFIED EPOXY RESIN MIXTURE

3. MATERIALS

3.1. Epoxy Resin Mixture shall be furnished in two components for combining in equal volumes
immediately before use in accordance with the written instructions of the manufacturer.

3.2. Top Coat:

3.2.1. Component A (Modified-Epoxy Resin)—Top coat shall consist of a condensation product of

epichlorohydrin with bisphenol A, shall contain no reactive diluents, no insolubles, and shall
conform to the requirements of Table 1.

Table 1—Requirements for Component A

Property Top Coat
Epoxide equivalenta 225 to 275
Viscosity, Pa·s (poises), 25˚C (77˚F) (Spindle No. 3, 20 r/min) 0.8 to 1.6 (8 to 16)
Ash, mass, percent, max 0.2
Volatile loss (to 177˚C (350˚F)) cm3, max 3.00
Specific gravity, 25/25˚C (77/77˚F) 1.10 to 1.25

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a
Grams of material containing one gram equivalent of epoxide.

Note 1—When the slope of the concrete surface exceeds about three percent, a thixotropic
agent approved by the engineer may be added to Component A by the formulator to either or both
coats. If a thixotropic agent is used, the requirement for ash, viscosity, and epoxide equivalent will
not apply.

3.2.2. Component B (Modified-Amine Hardening Agent)—Top coat shall be the hardening agent
for Component A Top Coat and shall be composed of a bitumen which has been especially treated
with a modified aliphatic polyamine. It shall contain no contaminants, reactive diluents, or
insolubles and shall conform to the requirements of Table 2.
Table 2—Requirements for Component B
Property Top Coat
Viscosity, Pa·s (poises), 25˚C (77˚F) (Spindle No. 2, 20 r/min) 0.2 to 0.8 (2 to 8)
Ash, mass, percent, max 0.5
Volatile loss (to 177˚C (350˚F)) cm3, max 3.00
Specific gravity, 25/25˚C (77/77˚F) 1.10 to 1.25
Water, mass, percent, max 2.0
Alkalinity, equivalent/100 g 0.19 to 0.27

TS-4c M 200-2 AASHTO

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 3.3. Prime Coat:

3.3.1. When a prime coat is ordered, the prime coat shall consist of a mixture of Component A and
Component B to which has been added toluene or 2-nitro propane not in excess of 10 percent of
the total volume.

3.3.2. Component A Primer shall be composed of Component A Top Coat to which has been added
toluene to produce a mixture of flowing consistency. In areas subject to air pollution control
regulations forbidding the use of toluene, 2-nitro propane shall be used.

3.3.3. Component B Primer shall be composed of Component B Top Coat to which has been added
toluene to produce a mixture of flowing consistency while maintaining a 1:1 ratio with
Component A Primer. In areas subject to air pollution control regulations forbidding the use of
toluene, 2-nitro propane shall be used.

3.4. Physical Requirements of Cured Epoxy Resin System—When components A Top Coat and
Component B Top Coat are combined on an equal basis the mixture shall conform to the
requirements of Table 3.

Table 3—Physical Properties of the Cured System

Property Top Coat
Water absorption, mass, percent, max 0.3
Tensile strength, min Pa (psi) 2758 (400)
Elongation, percent, min 35
Gel time, minutes 25–50
Shore D hardness, 25˚C (77˚F) 35–65
Bond strength, direct tension, min, Pa (psi) 621 (90)
Flexural creep, min:
24 hours, in. (mm) 0.010 (0.2540)
7 days, in. (mm) 0.015 (0.3810)

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3.5. Thixotropic Agent (Mineral Filler):

3.5.1. When mineral fillers are specified or permitted, they shall be inert and nonsettling or readily
dispersible. The filler shall have a fineness such that at least 99 percent shall pass the 0.045-mm
(No. 325) sieve and 100 percent shall pass the 0.150-mm (No. 100) sieve.

3.6. Aggregates:

3.6.1. Surface Application—The aggregate for surface application shall be nonfriable, nonpolishing,
clean, and free from surface moisture. It shall be durable and sound and shall have a proven record
of performance in applications of this type. Known suitable aggregates include aluminum oxide,
emery, silica sand, garnet, and blast-furnace slag. The grading of the aggregate shall conform to
the requirements given in Table 4.

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 Table 4—Aggregate Gradation
Sieve Designation Mass, Percent, Passing
mm No. Grade A Grade B
4.75 4 ― 100
2.36 8 100 0–5
0.600 30 0–3 ―
0.075 200 0–1 0–1

3.6.2. Aggregate, which will be exposed to traffic, shall have a minimum Mohs’ scale of hardness of 7.

3.7. Waterproofing Fabric:

3.7.1. Waterproofing fabric shall be woven glass fabric conforming to FSS HH-C-466 or to
ASTM D 1668, except that the requirement for minimum mass of coating shall be waived.
Note 2—Grade A Aggregate is recommended when the Coal-Tar Coating is to be used as a
Wearing Course. Grade B aggregate is recommended when the Coal-Tar Epoxy Coating is to be
followed by an asphaltic concrete Wearing Course.

4. PACKAGING

4.1. Packaging—The two components of the epoxy resin system furnished under this
specification shall be supplied in separate containers that are nonreactive with the materials
contained therein.

4.2. Marking—Each container of the two components shall be labeled with the name of the mixture,
the component type, the name of the manufacturer, the lot or batch number, the date of packaging,
and the quantity contained therein. The proper component type shall also be placed on each lid and
shall show whether it is formulated for use as a primer or as a top coat. Each label shall include
essentially the following text for Directions for Use:

DIRECTIONS FOR USE

The contents of the separate packages containing Components A and B must be thoroughly stirred
before use to redisperse any mineral filler used. Do not use the same paddle to stir Component A
as is used to stir Component B. To mix the adhesive, blend one part by volume of Component A
with one part by volume of Component B and stir thoroughly. Do not mix more material than can
be used before it hardens.
Equipment and tools must be cleaned with toluene before the adhesive has set. Components A
and B should be stored at a temperature between 24 and 27ºC (75 and 80ºF) for several hours
before use.
Warning—This material will cause severe dermatitis if proper precautions are not followed. Do
not let it come in contact with the skin or eyes. Use gloves and protective creams on the hands. If
contact with the skin occurs, wash thoroughly with soap and water. If any gets in the eyes, flush
for 10 minutes with water and secure immediate medical attention. Do not attempt to remove this
material from the skin with solvents.

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 5. CERTIFICATION

5.1. At the request of the purchaser, the manufacturer of the epoxy resin system shall certify that
Components A and B meet the requirements of this specification. Such certification shall consist
of either a copy of the manufacturer’s test report or a statement by the manufacturer, accompanied
by a copy of the test results, that the Components A and B have been sampled and tested. Such
certification shall indicate the date of testing and shall be signed by an authorized agent of the
formulator or manufacturer.

5.2. At the request of the purchaser, the formulator shall certify that the mineral filler used in either
component meets the following:

5.2.1. The filler shall be inert and nonsettling or readily dispersible. It shall have a fineness such that at
least 99 percent shall pass the 0.045-mm (No. 325) sieve and 100 percent shall pass the 0.150-mm
(No. 100) sieve.

6. METHOD OF TESTING

6.1. Tests shall be conducted in accordance with the following methods:

6.1.1. Epoxide Equivalent—ASTM D 1652.

6.1.2. Viscosity—ASTM D 1084, Viscosity of Adhesives, Method B. Using Spindle No. 3 at 20 r/min
for Component A and Spindle No. 2 at 20 r/min for Component B, except that the temperature
shall be 25.0 ± 0.5ºC (77 ± 1ºF).

6.1.3. Ash—ASTM D 482.

6.1.4. Volatile Loss—ASTM D 1078, except that a 10 mL graduated cylinder with 0.1 mL subdivisions
shall be used as a receiver and the distillation shall be discontinued when the temperature reaches
177ºC (350ºF). Record the volume of the distillate in the receiver as volatile loss.

6.1.5. Specific Gravity—ASTM D 154.

6.1.6. Water Content—AASHTO T 55.

6.1.7. Alkalinity—ASTM D 664, titrated to the first end-point, which will occur at a pH of about 6.3.
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6.1.8. Water Absorption—ASTM D 570, 0.5-hour boiling water immersion after seven-day cure at 25ºC
(77ºF).

6.1.9. Tensile Strength and Elongation—ASTM D 638. The speed of testing shall be 5.1 mm (0.20 in.)
per minute ±25 percent (Speed B) using specimens cut from a laboratory cast sheet 3.2 min
(1/8 in.) thick. The cast shall be allowed to harden for 18 hours at 25ºC (77ºF) plus five hours at
70ºC (158ºF) and allowed to return to room temperature before cutting and testing. The test
specimens shall be cut using Die C of ASTM D 412, having a gauge length of 25.4 mm (1 in.) and
a width of 12.7 mm (0.500 in.), or by use of a die similar to that shown in Figure 1.

TS-4c M 200-5 AASHTO

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 Metric Equivalents
mm in.
50.8 2
38.1 1 1 /2
34.92 1 3 /8
31.75 1 1 /4
25.40 1
3
19.05 /4
1
12.7 /2
3
9.52 /8
1
6.35 /4
5
0.13 /1000
0.9 20 gauge

Note: Cutting edge is of 0.9 mm spring steel and is

held between three metal blocks machined to
conform to the above dimensions.

Figure 1—Cutting Die for Tensile Test

6.1.10. Gel Time—The following procedure shall be used to determine gel time. Measure 30 mL (1 oz) of
Component A and 30 mL (1 oz) of Component B each at 25ºC (77ºF) into an unwaxed paper cup
and record the time. Immediately, the two components shall be mixed by stirring for three minutes
with a wooden tongue depressor, periodically scraping the walls and the bottom of the cup. The
mixture shall be poured into a 240 mL (8 oz) unwaxed paper cup placed on a wooden bench top.
Starting 20 minutes from the time recorded above the mixture shall be probed every two minutes
with a small stick, until a small ball forms in the center of the container. The total time, including
mixing, required for the ball to form shall be recorded as gel time. The test shall be performed in a
room or enclosed area maintained at 25 ± 2ºC (77 ± 3.6ºF) and 50 ± 5 percent relative humidity.

6.1.11. Shore Hardness—ASTM D 2240, except that the specimen for testing shall be prepared and cured
using the following procedure. Measure 30 mL (1 oz) of Component A and 30 mL (1 oz) of
Component B at 25 ± 2ºC (77 ± 3.6ºF) into an unwaxed paper cup. The two components shall be
mixed by stirring for three minutes with a wooden tongue depressor, periodically scraping the
walls and bottom of the cup. The mixture shall be poured into an unwaxed paper container with a
diameter not less than 60 mm (2.36 in.) placed on a wooden bench top. The mixture shall be
allowed to harden without being disturbed, 24 hours in a room or enclosed area maintained at
25 ± 2ºC (77 ± 3.6ºF) and 50 ± 5 percent relative humidity before testing.

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M 200-6 AASHTO
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 6.1.12. Bond Strength—The cured epoxy mixture shall develop a bond strength that is equal to or greater
than the cohesive strength of the concrete when tested for adhesion as specified in the report of
A.C.I. Committee 403 title No. 59-43. This test comprises bonding a standard 51-mm (2-in.) pipe
cap to the concrete surface and measuring the tensile force required to bring about separation.

6.1.13. Low Temperature Creep—California Test Method 419A.

7. RECOMMENDED CONSTRUCTION PRACTICE

7.1. Preparation of Surfaces—Surfaces of concrete to be treated shall be sandblasted before applying

tar-epoxy mixture.

7.1.1. When the mixture is to be applied to old surfaces having heavy local deposits of oil, grease, and
other adherent foreign materials, which will interfere with proper cleaning, these deposits shall be
completely removed using any suitable means. Possible methods include solvents, such as
trichloroethylene or xylene, heavy-duty detergents and/or mechanical means such as scraping.
Where the concrete surface has deteriorated, it shall be cleaned down to sound material and
patched, if necessary.
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7.1.2. New concrete shall be aged at least 14 days before any coating is applied.

7.1.3. Both old and new concrete shall then be cleaned by sandblasting. Sandblasting shall be
accomplished in such a manner as to insure the removal of all laitance or any other substance that
would prevent good adhesion of the epoxy. Suitable traps shall be installed in sandblasting
equipment to prevent water or oil from being deposited on the bridge surface. After sandblasting,
the surface shall be swept, vacuumed, hosed, or blown free of all dust and grit. The surface of the
concrete shall be dry when the epoxy coating is applied.

7.1.4. Unless specifically permitted, bitumen modified epoxy mixture shall be applied only when the air
temperature is above 10ºC (50ºF).

7.2. Preparation of Mixtures—Equal parts, by volume, of the two components shall be mixed
mechanically batchwise, or continuously in automatic paving equipment which provides
continuous metering, mixing, and application at a controlled rate. Caution shall be exercised to
make certain that Component A Primer, is mixed with Component B Primer, and that
Component A Top Coat, is mixed with Component B Top Coat.

7.2.1. If the components are to be mixed batchwise, mixing shall be performed with a propeller-type
stirrer, or other power agitator attached to a 12.7 mm (1/2 in.) heavy-duty drill. Care must be
exercised to incorporate thoroughly mixed material at the sides and bottom of the mixing
container. Mixing time shall be not less than five minutes at 15 to 27ºC (60 to 80ºF) or three
minutes at 27 to 38ºC (80 to 100ºF).

7.2.2. The mixed material will set quickly if allowed to remain in a large mass such as in the mixing
container. The pot life is approximately as follows:

Air Temperature Pot Life (Measured from Beginning of Mixing)

15°C–21°C (60°F–70°F) 18 min
21°C–27°C (70°F–80°F) 12 min
27°C–32°C (80°F–90°F) 10 min
32°C–38°C (90°F–100°F) 8 min

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 7.3. Application of Primer—The resinous material for the prime coat shall be distributed evenly
over the entire area to be surfaced at a minimum thickness of 0.38 mm (15 mils) 0.4 kg/m2
(0.75 pounds per square yard approximately). The prime coat shall be applied uniformly to all
areas to be subsequently given a second coat and so that no gray areas remain. Care shall be taken
to treat the curbs on each side to a height of at least 50 mm (2 in.). The prime coat shall be spread
with rollers or approved mechanical equipment touched up by hand.

7.4. Application of Top Coat—After the prime coat has set sufficiently to walk on or to operate
equipment over (and in any case within 24 hours), the top coat mixture shall be distributed evenly
over the entire area to be surfaced at the rate specified in Section 7.4.1. If binder is mixed
batchwise, it shall be leveled with lutes, brooms, paint rollers, or screeds.

7.4.1. The exact rate of application of the top coat mixture shall be determined by the engineer. As a
check on the rate of application, measured volumes of the mixture shall be applied to measured
areas of the surface. The top coat shall be applied at a rate such that the total application for the
two coats will give a thickness of 1.5 mm (60 mil) (0.66 m2/L (27 sq ft/gal)) or 1.6 kg/m2
(3 lb/sq yd) approximately. One liter has a mass of approximately 1.15 kg (one gallon has a mass
of approximately 9.6 pounds).

7.5. Application of Fabric—When fabric is to be incorporated to form an impervious membrane

beneath an asphaltic wearing course, the fabric shall be immediately embedded in the epoxy top
coat. To provide a watertight seal at the curb and deck joint, it is recommended that a glass fabric
tape approximately 200 mm (8 in.) wide be applied to the deck and 50 mm (2 in.) of the curb
before applying the full width of fabric to the flat surface of the deck. All fabric shall be lapped at
least 50 mm (2 in.) transversely and longitudinally.

7.6. Application of Aggregate—While the epoxy mixture is still liquid, the surfacing aggregate shall be
dropped into the epoxy in excess of the rate necessary to cover the surface. The aggregate must be
sprinkled or dropped vertically in such a manner that the level of the epoxy mixture is not
disturbed. The aggregate shall be applied within five minutes after the application of the epoxy,
except at temperatures below 21ºC (70ºF) when a maximum of 10 minutes is allowable.

7.7. After the aggregate is spread, all vehicular and foot traffic shall be prohibited in the area until the
epoxy cement is hardened and the embedded aggregate cannot be removed. When the epoxy has
completely hardened, excess aggregate shall be swept up for recovery or disposal.

CLASS II—OIL-MODIFIED EPOXY RESIN MIXTURE

8. MATERIALS

8.1. The oil modified epoxy resin mixture shall be furnished in two components to be combined
in equal volumes immediately prior to use in accordance with the written instructions of
the manufacturer.

8.1.1. Component A (Transparent Modified Epoxy Resin) shall be based on a liquid epoxy resin, a
condensation product of hisphenol A and epichlorohydrin. The component shall be homogeneous
and shall conform to the requirements of Table 5.

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M 200-8 AASHTO
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 Table 5—Requirements for Component A
Property Specific Value
Epoxide equivalent 275 to 300
Viscosity, Pa·s (Poises) 25˚C (77˚F), spindle No. 3, r/min 2.5 (25) max
Water content, mass, percent 0.2 max
Volatile loss, mL to 121˚C (250˚F), at 1.3 kPa (10 mm) absolute pressure 2.0 max

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8.1.2. Component B (Transparent Modified Amine Curing Agent) shall be the curing agent for use
with Component A and shall be composed of a polyamine modified with petroleum oils,
flexibilizers, and accelerators. It shall contain no contaminants or insolubles and shall conform to
the requirements of Table 6.

Table 6—Requirements for Component B

Property Specific Value
Alkalinity, ep./100 g 0.21 to 0.25
Viscosity, Pa·s (Poises) 25˚C (77˚F), spindle No. 1, 20 r/min 1.5 max
Water content, mass, percent 0.2 max
Volatile loss, mL to 177˚C (350˚F) 1.0 max

8.1.3. When Components A and B are combined on an equal basis by volume, the mixture shall conform
to the requirements of Table 7.

Table 7—Physical Properties of the Cured System

Property Specific Value
Water absorption, mass, percent 0.5 max
Tensile strength, kPa (psi), 25 ± 1˚C (77 ± 2˚F) 6205 (900) min
Elongation at max load, percent 25 ± 1˚C (77 ± 2˚F) 40 min
Gel time, minutes, 25 ± 1˚C (77 ± 2˚F) 30 to 60
Shore hardness, 25 ± 1˚C (77 ± 2˚F) 35 to 65

9. METHODS OF TESTING

9.1. For tests to be performed on cured material, the curing schedule shall be a minimum of 24 hours at
24 to 27ºC (75 to 80ºF) followed by 20 ± 2 hours at 57 ± 3ºC (135 ± 5ºF).

9.1.1. Epoxide Equivalent—ASTM D 1652.

9.1.2. Viscosity—Brookfield.

9.1.3. Water Content—AASHTO T 55.

9.1.4. Volatile Loss, Component A—ASTM D 1189, and Component B—ASTM D 1079.

9.1.5. Alkalinity—ASTM D 664. Titrated to the first end point which will occur at a pH of about 6.3.

9.1.6. Water Absorption—ASTM D 570, 0.5 hour in boiling water.

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 9.1.7. Tensile Strength and Elongation, ASTM D 638—Individual specimens shall be cast to conform to
dimensions for Type I. Thickness shall be 33 ± 5 mm (0.13 ± 0.02 in.). Speed of testing shall be
5.1 mm per min (0.20 in. per minute) ± 25 percent (Speed B).

9.1.8. Gel Time—The gel time shall be determined by weighing into a 240 mL (8 ounce) unwaxed paper
cup sufficient amounts of each component, in the proper ratio for the particular material being
tested, to make a total mass of 60.0 ± 0.2 g. The time shall be recorded and the two components
mixed together by stirring for three minutes with a wooden tongue depressor or small spatula,
periodically scraping the walls and bottom of the cup. The cup shall then be set on a wooden block
and probed every two minutes with a small glass rod starting 20 minutes from the initiation of
mixing. The time at which a semi-solid gel is formed shall be recorded as the gel time.

9.1.9. Shore D Hardness—ASTM D 2240 as modified in Section 7.1.11.

10. PACKAGING

10.1. Components shall be packaged and marked as set forth under “Packaging” in Sections 4.1 and 4.2.
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