EMSEAL BEJS Bridge Expansion Joint Systems NS Chezzetcook Bridge

Emcrete

Rapid setting, self-leveling, impact absorbing elastomeric concrete

Impact resistant premium nosing and patching material for bridges, roadways and decks.

Emcrete is a greater flexibility, durable, high-impact elastomeric concrete material. It is a bio-based, non-hazardous, extremely-low VOC product primarily used as a component of an expansion joint assembly either to fill blockouts on each side of a expansion joint gap, to repair a damaged expansion joint gap edges, as an impact-absorbing backfill nosing, or as a fast-curing patching material for potholes, or spalls on concrete roadways and bridges.

Emcrete is comprised of a two-component polyurethane resin mixed with lower ratio of chopped fiberglass and silica-free aggregates. The aggregate imparts compressive strength. The fiber provides cross-linked reinforcement while, in combination with the silica-free aggregate, adds body to the polyurethane resin.

Emcrete cures rapidly. This means you can usually install BEJS into an Emcrete joint header after about 45-minutes. You can turn traffic to Emcrete used either as patch or as an expansion joint header in 2-3 hours (see “Emcrete FAQ” below).

Emcrete

Rapid setting, self-leveling, impact absorbing elastomeric concrete

Features

  • Impact absorbing
  • Resists cracking
  • Durable under snowplowing
  • Low odor, Low VOC
  • Flowable
  • Fast curing
  • Pre-kitted
  • Mixes easily
  • Chopped fiber-glass and silica-free aggregate reinforced
  • Lowest aggregate to resin ratio

Color

Black

Uses

Repair and Rebuild Joint Edges
To repair spalled concrete expansion joint slab edges. The spalled concrete must be cut out using industry standards for concrete repair. Once the gap edge has been cut and cleaned, and reinforcing bar added per the engineers design, the self-leveling Emcrete can be poured to form an impact-absorbing header is more resistant to spalling and cracking than cementitious patching materials.

Patch Potholes and Spalls in Concrete
Quickly and easily repair, and reopen to traffic, spalls and potholes in concrete bridge and road surfaces.

Q: How soon after pouring Emcrete can I install the BEJS expansion joint against Emcrete?

A: About 45 minutes.  It takes about 45 minutes for Emcrete to reach a hardness at which you can remove your forms. If the forms come away cleanly (nothing stuck to the Emcrete) you can solvent-wipe and proceed directly to installation of the BEJS.  If the forms stick to the Emcrete, blast or grind any residual form material from the Emcrete joint faces, solvent wipe and install the BEJS.

Q: How soon after pouring Emcrete as a patch, or as an expansion joint header, can we turn traffic over it?

A: About 3 hours. Emcrete cures hard fast. Depending on the ambient temperature it can handle traffic in between 2 to 3 hours. This rapid cure time allows you to retrofit an entire joint usually in a single day by redirecting traffic across lanes as you complete them.

IMPORTANT: When comparing elastomeric concrete materials it is vital
to compare the data of the fully mixed material. Resin-only data is
irrelevant as the material is not used without aggregate. Aggregate
increases compressive strength at the expense of flexibility and
brittleness. Heavy aggregate loading, while it reduces cost, is
detrimental to performance of the material as an impact-absorbing
nosing and patching material. The following are properties of Emcrete
(resins, sand, and chopped fiberglass) at as-supplied ratios.

AGGREGATE RATIO
Ratio of Resin to Aggregate by Weight does not exceed 1:2

ADHESION: Pull Off Strength
Concrete (abraded, wiped, primed) exceeds 490 psi
Steel (abraded, wiped, primed) exceeds 485 psi
Galvanzied Steel (wiped, primed) exceeds 535 psi

IMPACT: Ball Drop Test
1-pound steel ball dropped onto 3/8” thick (8mm) x 2.75” diameter
(70mm) disk from 17 feet:
At room temperature (69°F; 20°C) no cracks
At -4°(F); -20°C no cracks

HARDNESS
ASTM D 2240 at 77°F (25°C)
98 Shore A
57 Shore D

The following is a summary. Complete installation instructions can be found in the Emcrete Installation Data Sheet.

Substrates must be thoroughly dry and the temperature must be at least 45°F (8°C) and rising to install Emcrete. The bonding surface should be in sound and good condition before prepping. The entire bonding surface is to be blasted, or wire brushed and fully cleaned leaving no contaminants such as dirt, dust, oils, or other residue on any surface.

The area where the Emcrete will be poured should be fully prepped and formed. The substrate is then primed with the Emprime primer that is included with units of Emcrete and allowed to dry for 30 minutes. The Emcrete is then mixed in accordance with the complete Installation Instructions in the pre-measured amounts provided. The Emcrete is then poured into the forms where it will self-level and cure exothermically. It can be lightly trowelled to ensure a consistent surface. The working time of Emcrete is less than 10-minutes after mixing. Working time, and cure time, is longer in cool weather and shorter in hot weather.

Packaging
Emcrete Elastomeric Concrete is sold by the unit. Each unit is comprised of pre-measured containers which hold the liquids (Parts A & B), a mixing pail, and Sand and Fiber.

Yield
1 Unit: 9,766 cubic cm (596 cubic inches)
*account for a 5% waste factor