Appendix 1600/2

Acrylic elastomeric coating

Appendix 1600/2 Acrylic elastomeric coating

The System :

It comprises water based (solvent free), conforming to code and specifications, acrylic
polymer modified with selected mineral fillers applied over the prepared surface to form
an elastic elastomeric protective membrane. The coating should have anti carbonation
and water vapor diffusion property and should be resistant to action of UV radiation. It
should be waterproof and capable of bridging crazings and cracks. The coating protects
exposed faces of the superstructure and the substructure of concrete bridges from the
aggressive action of industrially polluted and marine / saline environment. The shelf life for
such coatings shall not be more than 6 months.

It is necessary that the system should be capable of protecting the pre-stressed and
reinforced concrete from all deleterious elements such as chlorides and sulphates.
The protective treatment should allow excess water vapor in the concrete to evaporate out
(breathing) without rupturing itself due to vapor pressure. The protective system itself
should not deteriorate from exposure to UV rays and weathering.

The Acrylic Elastomeric coating system shall satisfy the following requirements given in
Table 6.6:
Table No. 6.6
Sl. Parameter Requirement Reference
No.
1. Specific Gravity 1.35 to 1.45 IS – 354
2. Solid contents 70 + 3% IS – 354
3. UV resistance No colour change ASTM-G-53/
DIN.EN-1S0-105
4. IR – Spectrum As per Acrylic Polymer IR – Spectro
meter standards
5. Adhesion with concrete 1.5 N/mm2 ASTM-D-4541-
02/DIN500014
6. Dry film thickness 200-225 Microns
(for minimum 2 coats)
7. Coverage 400-450 gm / m2 (2 coats)
8. Physical properties Equivalent air layer DIN 53122
Diffusion resistance thickness Part -I
against Carbon dioxide SDCO2 shall be >50m
9. Diffusion resistance Equivalent air layer DIN 52615
against water vapor thickness SD H2O < 4 m
10. Water proofing Percentage reduction in
characteristics flux should be > 50%
11. Recoatability Min. 2 h to 72 h or as per
manufacturers specification
with the approval of the
Engineer in charge.

2
Acrylic elastomeric coating Appendix 1600/2

The primer shall satisfy the following requirements :

(i) System - Single component universal polymer primer
(ii) Base - Acrylic Resin dispersion
(iii) Curing – Air Curing
(iv) Colour - Milk white, transparent application
(v) Shelf life - 6 months from date of manufacturing in tightly sealed container.
(vi) Coverage – 75 – 100 gms/ m2 (depending upon smoothness and absorption of
concrete surface)

Quality Assurance

The Acrylic elastomeric material should be tested in Government of India accredited

laboratories where such laboratories are available, otherwise in other standard laboratories
where similar facilities exist for properties specified above. Approval of the material can
be decided on the basis of these test results for each parameter initially. On the basis of
test results approval of the material can be decided by Engineer-in-Charge. Random
samples during execution should be taken from consignments brought to site to verify that
the test results match with the earlier certificates produced before approval of the product.
Both the test results (prior to approval and during execution), shall conform to the
requirements as per Table 6.6, failing which the consignment shall be rejected. It should
be made mandatory that the stock register for the materials should be maintained at site
and signed by the Engineer-in-charge periodically.

Surface Preparation :

The concrete surface shall be free from all adhesion inhibiting substances such as oil,
grease release agents as well as laitance and dust. The surface shall be cleaned by wire
brushing, mechanical scraping and any loose material shall be removed by chiseling with
small hammer and washed with clean water. The sub-strata shall be structurally sound for
effective bonding of the acrylic polymer with the concrete surface. All pin holes shall be
filled with non-shrink polymer modified fine repair mortar.

Application :

After preparing the surface and filling the pin holes, primer coat (75- 100 gm/ sqm.) shall
be applied with brush / lambskin roller / spray gun and shall be cured for 60 minutes or as
specified by the manufacturer.

Subsequently, 1st and 2nd coats of polymer coating shall be applied with brush / spray gun/
roller keeping the time between coats not less than 2 h and not more than 72 h. Consumption
per coat shall be 200 – 225 gms / m2. The total dry film thickness of the protective coating
for all coats shall be in the range of 200 – 225 microns. It is recommended that wet film
thickness may be measured at a number of selected locations at the time of application

3
Appendix 1600/2 Acrylic elastomeric coating

with painting gauges. For measuring the dry film thickness, suitably located painting gauge
shall be used. At least one gauge shall be located on each face of superstructure in each
span but not less than one gauge / 100 Sqm. For the given solid content in the application,
the dry film thickness to wet film thickness ratio should be established by prior testing in
the laboratory using appropriate panels like glass plates, flat concrete slabs, steel plates
(300 x 300mm) with similar coatings. Alternatively, the dry film thickness may be calculated
from the measured wet film thickness by multiplying with the solid contents per unit volume.

These specifications could be applied to new bridge works immediately after completion
as also to old existing bridges after suitably repairing / rehabilitating the concrete surface.

Performance Guarantee

This type of protective coating should be executed only through authorized technical
applicators of standard manufacturers who have requisite work experience for having
carried out similar type coating works. However, the Employer / department may take
performance guarantee from the agency responsible for the execution of the work for a
period of 5 years or so, which is the minimum time for defects due to corrosion of embedded
steel to start becoming apparent.