Appendix DD - Expedient Spall Repair Material.pdf

Appendix DD Expedient Spall Repair Material

1. Introduction. Under the ADR Modernization Program, spall repair material is utilized within the spall repair kit. Spall repair material is used to repair pavement damage that is < 5-ft in diameter and does not penetrate in the soil below. Because the pavement damage is relatively small and scattered, the material is packaged in 5-gal buckets to allow mixing in close proximity to the spall.

2. Spall Repair Material.

2.1. The Engineering Research and Development Center (ERDC), Vicksburg, MS, is the Department of Defense’s lead pavement research facility for roadways, permanent airfields, contingency airfields, and railroads. ERDC is the approving agency for all Air Force ADR related repair materials. Due to the critical nature of performing emergency airfield repairs, presumably after an act of war, and the requirement to support heavy aircraft loads, materials must be pre-qualified for procurement and use. Failure of the materials to meet performance metrics could result in failure to restore flight operations, failure in contingency operations plans, damage to or loss of individual aircraft, material and personnel. Currently, nine products meet the spall repair performance specifications.

Although, contractor must verify intended product approval and compliance with AFCEC/CXXM per task order.

2.2. Feasibility:

2.2.1. The minimum packing requirements are:

2.2.1.1.Product must be packed in a 5-gal Bucket; the bucket must allow for the addition of water and mixing operation.

2.2.1.2. Buckets will be shipped palletized and shrink wrapped.

2.2.2. Shelf Life –The minimum shelf life requirements for the material are:

2.2.2.1.Outside Covered – minimum 18 months.

2.2.2.2.ISO Container Stored – minimum 36 months.

2.2.3. Safety/Hazardous Chemical Issues – The material’s SDS will be evaluated against that of standard cementitious material. If additional precautions are required, the effect to the spall repair process will be evaluated and if deemed unacceptable, the material will be rejected.

3. Tri-Service Spall Repair Certification Requirements

Test Description Testing Specifics Criteria

Compressive Strength ASTM C39

≥ 3000 psi @ 2-hr ≥ 5000 psi @ 1 day ≥ 5000 psi @ 7 day ≥ 5000 psi @ 28 days

Flexural Strength ASTM C78

≥ 350 psi @ 2-hr ≥ 600 psi @ 7 days ≥ 600 psi @ 28 days

Bond Strength ASTM C882 Repair Material to Repair Material ≥ 1000 psi @ 1 day

Repair Material to Ordinary PCC ≥ 1000 psi @ 1 day

Modulus of Elasticity ASTM C469 2 ≤ x ≤ 6 Mpsi @ 2-hr 2 ≤ x ≤ 6 Mpsi @ 28 day

Time of Set ASTM C191 Initial Set: ≥ 15-min Final Set: 25 - 35-min

Slump ASTM C143 Within 5-min of added water ≥ 3 inch

Length Change ASTM C157 Stored in air - 0.04% ≤ x ≤ +0.03%

@ 28 day Stored in water Coeff. of Thermal Expansion

ASTM C 531

Begin test @ 7 days ≤ 12∙10‐6 °F‐1

Shrinkage Potential ASTM C1581 ≤ 40 με @ 14 days

No cracking @ 28 days