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.