CCS Binder, Bridge Deck

Low Modulus Epoxy Binder for Protective Overlays

 CCS Binder, Bridge Deck is a low viscosity, low modulus, two-component epoxy binder specifically designed for protective overlay applications on concrete and steel decks. It serves as the bonding medium in mortar, slurry, and chip seal systems that shield structural surfaces from wear and chemical intrusion.

·      Base Binder: CCS Binder, Bridge Deck (2:1 mix ratio by volume of Part A resin and Part B hardener)

·      Aggregate (varies by application):

o      Overlay/repair mortars: kiln-dried, graded sand (#12 or 16 with #70 or 90 mesh; or #20/30 for single fraction)

o      Slurry coats: 3/8" thickness using aggregate broadcast (#6 x 12 to 20 x 40 mesh)

o      Broadcast systems: multiple layers using aggregate sized according to final desired thickness

o      Polish-resistant aggregates (e.g., aluminum oxide, silicon carbide) for vehicular traffic

·      Protective overlays on bridge decks and similar infrastructure

·      Repair mortars for concrete surface spalls and defects

·      Slurry coats and multiple-layer chip seal systems for high-wear environments

·      Surface Preparation: Clean, dry, sound substrate free of contaminants. Prepare per ASTM D 4259 or ACI 503R.

·      Priming: Prime substrate with mixed binder at 8–10 mils thickness (160–200 sq ft/gal).

·      Overlay Mortar: Applied over tacky primer using trowel methods.

·      Slurry Coat: Mix 1 part binder with 2–2.5 parts aggregate, apply 3/8” thick, broadcast 10–14 lb/sq yd aggregate.

·      Broadcast System: First coat at 45 sq ft/gal, second at 30 sq ft/gal, each followed by aggregate broadcast (8–14 lb/sq yd).

·      Tool Cleaning: Use acetone or epoxy strippers before curing.

·      Pot Life: Approx. 18 minutes for 1 quart mix

·      Dry Time: Thin film hard dry in ~5 hours

·      Full Cure: Varies by application, generally within 6–8 hours per layer for broadcast systems

·      Temperature Limits: Minimum application and cure temperature is 50°F (10°C)

·      Humidity: Substrates must be dry; no damp/wet applications

·      UV Resistance: Not specified; primarily used in protected overlay systems

·      Thickness Limits: Max thickness ~1 inch per lift

·      Coverage Rates:

o      Primer: 160–200 sq ft/gal

o      First broadcast coat: ~45 sq ft/gal

o      Second broadcast coat: ~30 sq ft/gal

·      Shelf Life: Minimum 3 years in original, unopened containers stored at 60–90°F