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Flexolith Overlay: Experimental Feature WA 84-02, Post Construction Report


This report describes the installation and post-construction evaluation of a thin, lightweight epoxy concrete bridge deck overlay. This subject "Flexolith" epoxy concrete system was installed by Dural International Corporation on a bridge located on I-82 near Ellensburg, Washington.

The application of the overlay was unique in both the use of a special machine which mixed the epoxy components with the aggregates and the use of a vibratory screed to distribute and level the epoxy concrete to the desired depth. A small segment of the overlay, however, was placed using the more common broom and seed method of installation.

Post-construction testing showed that the overlay has adequate bond strength, extremely high friction resistance, and is performing adequately as a waterproof membrane. The only deficiencies noted were a non-uniform surface texture and profile. A recommendation was made to not allow the use of the vibratory screed method until improvements are made to insure that the final product will have a surface texture and profile equivalent to overlays placed with the broom and seed method.


  • Date Published: February, 1987
  • Publication Number: WA-RD 107.1
  • Last Modified: August 24, 2007
  • Author: Keith W. Anderson.
  • Originator: Washington (State). Dept. of Transportation.
  • # of Pages: 60 p., 1,845 KB (PDF)
  • Subject: Bond strength (Materials), Bridges, Epoxy coatings, Evaluation, Floors, Friction, Maintenance, Overlays (Pavements), Pavements.
  • Keywords: Epoxy, concrete, lightweight, bridge decks, overlays, Thrall Road Overcrossing Bridge No. 82/105, I-82, Ellensburg (Wash.)
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This abstract was last modified April 29, 2008