New Jersey Route 46 Over Saddle River
Case Study
Location:
Lodi, New Jersey
Owner:
New Jersey Department of Transportation
Project Completion:
2011, Inspected 2023
Product:
PPC 1121 Polyester Polymer
Concrete
Project Details
The Route 46 Westbound bridge over the Saddle River was part of a construction project to reconstruct a segment of roadway in Lodi, NJ. During the deck placement, the beams exhibited more camber reduction than anticipated, resulting in a deviation from proposed grade at the bridge’s center. To rectify this, a variable thickness overlay was deemed necessary, and Kwik Bond Polymers’ PPC 1121 Polyester Polymer Concrete was chosen to perform this grade correction while safeguarding the substrate deck from moisture and chloride ingress.
Project Background
As an integral component of a larger construction project, the job involved the placement of a new bridge deck. Grade issues surfaced after casting the deck, necessitating a variable thickness overlay to establish the riding surface at the proposed grade. This involved milling out the deck’s boundaries to facilitate a minimum 1-inch placement, leaving the majority of the deck intact.
Major advantages to PPC 1121 and not offered by any other systems:
A proven performance history
Impermeability for complete substate preservation
Abrasive resistance in this high-traffic area
Permanent adhesion, integrated into substrate
Kwik Bond polyester concrete overlays provide a 30 year proven solution, unequaled preservation and a two hour traffic return in a variety of conditions.
The Solution
Given the DOT’s preference for a low-maintenance and long-lasting overlay, Kwik Bond PPC emerged as the optimal solution. The integrated strengthening of the substrate through the High Molecular Weight Methacrylate (HMWM) primer component ensured a permanent bond, surpassing mere longevity. Furthermore, PPC effectively sealed the new deck against future moisture and chloride intrusion, maintaining the structure in a condition not initially planned during the design phase. The overlay, placed by a contractor unfamiliar with the material, showcased the versatility of Kwik Bond PPC, with the entire process executed over a single weekend in near freezing temperatures.
After twelve years in service, the PPC 1121 overlay remains in near-new condition, exhibiting no signs of distress. Kwik Bond Polymers’ PPC 1121 has proven to be a pioneering solution, safeguarding structures of the future by delivering unprecedented protection and durability. This successful project exemplifies Kwik Bond Polymers’ commitment to innovative, long-lasting infrastructure solutions.
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