ARIZONA
TRANSPORTATION
RESEARCH
CENTER
THORITE AND
ROADPATCH
206 S. 17th Avenue
Maildrop 075 R
Phoenix. Arizona 85007
The contents of this report reflect the views of the
authors who are responsible for the facts and the
accuracy of the data presented herein. The contents
do not necessarily reflect the official views or policies
of the Arizona Department of Transportation or the
Federal Highway Administration. This report does not
constitute a standard, specification, or regulation.
Trade or manufacturer's names which may appear
herein are cited only because they are considered
essential to the objectives of the report. The U. S.
Government and the State of Arizona do not endorse
products or manufacturers.
PRODUCT EVALUATION
34-oe.
THORD FRCILIUCT DEMONSTRATION
PREPAF:EP PY:
STEVEN L. TRITSCH
TIYCITHY F. WlllLFE
TECHNIC& REPORT DOCUMENTATION PAGE
I. REPORT NO. 12. GOVERNMENT ACCESSION NO. 1 3. RECIPIENT'S CATALOG NO.
84-08
4. TITLE AN0 SUBTITLE
PRODUCT EVALUATION
THORO PRODUCT DEMONSTRATION
ARIZONA TRANSPORTATION RESEARCH CENTER
206 South 17th Avenue
5. REPORT DATE
J u l y 18, 1986
6. PERFORMING ORGANIZATION CODE
ATRC
% AUTHOR(S)
STEVEN L. TRITSCH
II. CONTRACT OR GRANT NO.
8. PEREORMING ORGANIZATION REPORT NI
Phoenix, Arizona 85007
I3.MPE OF REPORT 8 PERIOO COVEREC
'2. SPONSORING AGENCY NAME AN0 ADDRESS FINAL REFORT
3. PERFORMING ORGANIZATION NAME AN0 ADDRESS 10. WORK UNIT NO.
(SAME AS ABOVE)
DECEMBER, 1984 - JULY, 1986
14. SPONSORING AGENCY CODE
NONE
This r e p o r t contains a product evaluation of Thoro System's "Roadpatch"
and "Thorite."
Roadpatch is a cement base, f a s t - s e t t i n g patchin2 m a t e r i a l . The material
is f o r t i f i e d with s p e c i a l a l k a l i r e s i s t a n t g l a s s f i b e r s . I t is designed t o
r e p a i r potholes i n portland cement concrete.
Roadpatch was demonstrated i n Arizona on a s e c t i o n of concrete pavement.
In a two-year evaluation, the product performed well. A l l of t h e p a t c h e s h e l d
up under heavy t r a f f i c . The Arizona Transportation Research Center recommends
t h a t t h i s material be considered f o r use on maintenance p r o j e c t s .
T h o r i t e is another Thoro System product. It is a f a s t - s e t t i n g , non-s
h r i n k m a t e r i a l f o r p a t c h i n g c u r b s .
The Thorite material cracked and f a i l e d within one year. The patch did
not bond well t o t h e o r i g i n a l concrete o r t o t h e o t h e r patches. Based on
its poor performance, t h e Arizona Transportation Research Center has recom-mended
n o t using it on f u r t h e r curb patching p r o j e c t s .
17. KEI WORDS 1 18. DISTRIBUTION STATEMENT
PAVEMENT, CONCRETE. PATCH, JOINT,
SEALANT, hlAINTENANCE, ROADPATCH,
TllORITE
I
9. SECURITY CUSSIF. (of this report)
NONE
20. SECURITY CLASSIF. (of this page ) 22. PRICE
NONE
21. NO. OF FAGES
18
INDEX
PAGE
INTRODUCTION . . . . . . . . . . . . . 1
LOCATION OF TEST SECTIONS . . . . . . . . . 2
TEST CONDITIONS AND PROCEDURES . . . . . . . 4
CONSTRUCTION ANALYSIS . . . . . . . . . . 8
EVALUATION . . . . . . . . . . . . . . 11
RECOMMENDATIONS . . . . . . . . 14
APPENDIX
MAP OF LOCATION . . . . . . . . . A1
MATERIAL INFORMATION . . . . . . . B1
I. INTRODUCTION:
Joint breakouts in concrete pavement are becoming an ever
increasing problem along the Black Canyon Freeway (1-17). As the
joints begin to deteriorate potholes form in the pavement. To
repair these potholes, a 6-7 man maintenance crew is usually
required. Their effective work time is limited to the hours
be.tw een 9:00 a.m. and 2:30 p.m. to avoid rush hour traffic.
Previous repair work has utilized Set 45 and Cono-crete 149. The
Set 45 repairs failed within one year but the Cono-crete 149
seems to perform satisfactorily.
Another form of spalling which has received a great deal of
attention from the District Maintenance Section is curb spalling
along the off ramps at intersections. The concrete curbs along
these intersections are severely cracked and deteriorated due to
truck traffic. These curbs are usually repaired by patching but
most have deteriorated so severely that they may have to be
removed and replaced.
Thoro System Products has introduced two products which deal
with pothole patching and curb spalling problems. Thoro's
"Roadpatch" is a cement base, fast-setting patching material. The
material is fortified with special alkali resistant glass fibers.
The glass fibers improve the impact, flexural and tensile
strengths of this high compression strength mix to resist
cracking and abrasion resistance. With Roadpatch, traffic
bearing patches can be put back into service in two hours.
Thoro System Products has also developed "Thorite" to patch
old or deteriorated concrete curbs. Thorite is a fast-setting,
nonshrink patching material especially prepared to repair
1
concrete. Thorite can be used to rehabilitate disintegrated
areas without the need for formwork. It can also be used on
spalling bridge decks.
11. CONSTRUCTION REPORT
Thoro System Products demonstrated its products on December
6, 1984 at two locations in the Phoenix area. In attendance were
Larry Foppe and Bill Briscoe of ADOT, Ian Barberton of Thoro, and
Don Sobczak of Builders Specialty Supply. A pothole was patched
on 1-17 at Van Buren Street using Roadpatch, and a deteriorated
curb section at Beardsley Road and 1-17 was repaired using
Thorite patching material. An evaluation of these products was
performed over an eighteen month period. Arizona Transportation
Research Center was contacted to aid in the evaluation and
document the test sites.
A. LOCATION OF TEST SECTIONS
1) Roadpatch
The Roadpatch material was placed in a pothole located on
1-17 ~ u s t south of Van Buren Street (Figure 1). The pothole is
located in the southbound travel lane at Station 137-45.
2 ) Thorite
The Thorite test site is located on Beardsley Road at the
1-17 northbound on-ramp intersection (Figure 2 ) . The northwest
corner curb was reconstructed using Thorite and was marked with
white spray paint (Figure 3). Points "a" to "b" represent the
area patched with Thorite and "b" to "c" represent the area
patched with Thorite and pea gravel. The second section ("b" to
"c") was completed one week after the original section.
VAN BUREN
STREET
FIGURE 1 - LOCATION OF ROADPATCH TEST SECTION
- ---
------ - -
WB I ---
I n 1 'TEST SITE
BEARDSLEY
ROAD
FIGURE 2 - LOCATION OF THORITE TEST SITE
AT BEARDSLEY ROAD AND 1-17
-
EB
--
--.
- - - - - -
t l - NB - - - - -
1-17
- - - - - - -
-
SB - - - - - - I-.;
1-
STA. 137.~45
BEARDSLEY
ROAD
TEST SITE
I
FIGURE 3 - MARKINGS ON THDRITE TEST SITE
111. TEST CONDITIONS AN11 PROCEDURES
a ) Roadpatch
The 1-70 Raadpatch teet site was placed a t about l l : 3 C i a.m.
The ambient a i r temperature was appro:.:imately 70-F. Klistrir+ I
maintenance provided t r a f f i c c o n t r o l and perfoi-med t h e pothule
p r e p a r a t o r y work. The p r e p a r a t o r y work c o n s i s t e d of removing
d r t e l - i c ~ l - a t e d concl-etc, ( F i g u r e 4! brocaminy t h e d e b r i s , and a i r
b l a d i n g t h e c a v i t y . The prepared c a v i t y measured 16"x3?":.:2"
( F i g u r e 51.
Rr- b- 1- e z e n t a t i v e s fi-om Tti8=rcb F r o d u c t s p l a c e d t h e patchi:-,g
ma t e r i a l . F i r s t , a s l u r r y c o a t of t h e Roadpatch war ~ ~ I - u E ~CJ. ~EL .. ~
( F i g u r e 6) and then t h e patch m i : : was placed nver t h e sluri-y c c ~ a t
: F i g u r e 7). The p a t c h mi:.: was p r e p a r e d by mi::ing Roadpatmzti v i t t ~3
l i q u i d coiht-aining 1 p a r t Acryl-60 t o 3 p a r t s c l e a n water. M~:.:lng
dampened and coated with a slush coat of Thorite, making sure all
pores and voids were filled (Figure 10). Consecutive layers of
Thorite were applied in 1-2 inch lifts (Figure 11). The surfaces
were scratched before addition of successive lifts. No form work
was used to construct the curb. The finished curb is shown in
Figure 12.
The materials incorporated into the patch consisted of a
white liquid mix (Acryl 60) added to water and the Thorite patch
mix. The Acryl 60 bonding agent was used because of the large
size of the patch and because no gravel was utilized in the
patch. One and one-half cans were used at a cost of $21.00 per
can. Each can contained about 60 pounds of material.
Only half of the curb was finished during the demonstration.
To save time and material, the remainder of the curb was
reconstructed a week later by Thoro Products personnel using pea
gravel mix. The beginning and ends of both test sites were
marked with white spray paint.
IV. ANALYSIS
a) Roadpatch
The Roadpatch repair was completed in about 10 minutes with
no problems. This system would seem to have potential due to its
short maintenance time and quick setting time. Although two
hours is recommended for setting, the Thoro representative stated
that at higher temperatures, 3/4 - 1 hour would be sufficient.
The shorter setting time could be advantageous in emergency
situations. Another advantage of roadpatch is that the patch can
be placed flush with the pavement surface because there is very
little densification. Finally, from an aesthetic standpoint white
patches are desirable over black patches on concrete.
b) Thorite
The Thorite patch was completed in approximately 75 minutes.
This long period of time was due to the number of thin layers
used in reconstructing the curb. Normally, pea gravel would be
used in the mix so that larger lifts could be formed. This
patching system is advantageous in that no formwork is required
and the set-time is quick.
V. EVALUATION
a) Roadpatch
On February 12, 1985. the first inspection of the "roadpatch"
section was made by the ATRC. The product was holding up well
with no sign of fatigue.
A final evaluation was performed on April 2, 1986. The patch
was still performing well (Figure 13) with no sign of spalling or
cracking. The patch appeared the same as in the original
construction photos.
b) Thorite
On February 12, 1985, the first evaluation was made by the
research center. Shrinkage cracks were apparent throughout the
curb. The section was again evaluated on June 20, 1985. The
condition of the curb can be seen in Figures 14 and 15. Several
stress cracks had developed due to the contact between vehicle
tires and the curb. The stress caused by the vehicle tire had
begun to spa11 the ends of the curb.
On April 2, 1986 a final evaluation was performed by
Research. The curb patch had completely failed. Figure 16 shows a
photo of the curb and piece that had been knocked out by traffic.
VI. RECOMMENDATIONS
The Roadpatch product is performing well. It appears to be a
viable product for repair of PCCP spalls based on its limited use
per the above mentioned test section. The ATRC recommends that
maintenance consider the use of Roadpatch for the repair of PCCP
spalls in their maintenance operations.
Economically, Roadpatch compares favorably with other
conventional concrete patching materials from the standpoint of
initial costs, i. e., materials costs, required equipment,
manpower, and time constraints are similar to those of
Econo-crete. Long term performance will many times determine
true cost of the product. Insufficient data is available at the
writing of this report (August 86) to ascertain true life costs
of the Roadpatch material. Initial performance looks promising.
The Thorite product did not perform as well. Within one year
the patch had failed. Based on its poor performance at the
Beardsley Road T. I., the ATRC recommends that the product not be
considered for use of PCCP repair by ADOT maintenance forces.
APPENDIX
setting patching material
for concrete bridge
decks, expressways.
DESCRlPTlON feather edge patches, either cut or
chip to a depth of approximately 318"
A cement-base, fast-setting patching to 112 (.95 to 1.27 cm) around edge
material that develops high of patch.
compressive strengths and will allow
traffic bearing patches to be put back
in service in 2 hours from time of
placement. Roadpatch is fortified with
MIXING
special alkali resistant glass fibers that Thoroughly mix Roadpatch with a
improve appreciably the impact. mixing liquid consisting of 1 part Acryl
flexural and tensile strengths. The use 60 to 3 parts clean, potable water.
of these special fibers contributes Mix until material has been thoroughly
substantially to the ability Of the blended and has ach~evedc ement
product to resist cracking and the mortar conscstency (2-3 [5-7.6 Cm]
abrasion resistance. These improved slump).Thiscan be achieved in
properties, the high compression approximately 1-2 minutes if blending
strength, and the overall capabilities by hand. In a mixer approximately 60
make Roadpatch a superior patching seconds is sufficient.
material for highway departments, When mixing in rotary mixer. rubber tip
municipalities, and industry blades are desirable. Add dry material
throughout the world. to mixing liquid for better blending.
Note: 25 lbs. (11.3 kg) of 1/4 to 3/8"
USES (6.3-9.5 mmj or less of dry, clean
To patch bridge decks, curbs, aggregate, stone or pea gravei may be
expressways and other areas where added to 50 lbs. (22.7 kg) of Roadpatch
partial depth patching is required. for patches in excess of 1" (2.5 cmj.
Small amount of Roadpatch may be
ADVANTAGES mixed by hand: just maintain same
consistency as described above.
Excellent impact resistance.
High compressive strength.
Very resistant to cracking.
Excellent flexural and
tensile strengths.
APPLICATION
Freeze-thaw resistant.
Before applying Roadpatch, dampen
area with water. Leave no standing
Fast-setting. water. Then apply Roadpatch, forcing
Traffic bearing 2 hours. the material against the sides and
Can be applied to a bottom of the patch area. Trowel
damp surface. material level, allow to take initial set.
Longer working time. Roadpatch can be troweled or broom
Contains no calcium chloride. finished. Preferred curing of
Good storage stability. Roadpatch is at 7O0F., 50' relative
Will not burn itself out. humidity and air cured.
SURFACE PREPARATION LIMITATIONS
Area to be patched must be clean. Do not re-temper Roadpatch.
structurally sound and free of all Do not apply on frozen or frost-filled
loose, dirty, oily and scaly material surfaces or if the temperature is below
before applying Roadpatch. Do not 40°F (4.4" C).
PROPERTIES
Set - approximately 10 - 15 minutes at normal
temperatures.
Heat of hydration - Minimum heat of hydration
Percentage of calcium chloride - NONE
Bondability - Bonds to all clean and sound
concrete, masonry and stone.
PACKAGING
50 lb. (22.7 kg) bags
COVERAGE
50 lbs. (22.7 kg) will cover approximately 12 sq. fl.(1 .1
m2) @ l/2" (1.27 cm) thick.
TEST DATA
All tests were conducted by Pittsburgh Testing Laboratory
following ASTM procedures.
Compressive Strength (psi) - ASTM C109-80
3 Hours 1 Day 7 Days 28Days@70"F-50%RH
1060 2210 5000 6080
Flexural Strength (psi) - ASTM C-348-80
7 Days 28 Days @ 70" F - 50% R.H.
720 1320
:
Tens~leS trength (psi) - ASTM C-190-77
1 Day 7 Days 28 Days @ 70°F- 50% R H
. ,209 304 361
Shrinkage (psi) - ASTM C-490-77/C 596-75 1
. 7 Days ,!: - - 28 Days @ 70'F - 50% R.H.
' , , -0.04%. , . . .,
' : -0.07% ,;. . .
THORO
Centerville, IN Bristol, PA Newark, CA Mol, Belgium
Office: 7800 NW 38th Street, Miami, Florida 33166
Telephone: (305) 592-2081
A Unit oiBcacn~eC hem>cal. Diva,on of Baalric~F ood* Co
1. 1983. Thoro System Prmucls Printed ~n US4 9183
Technical Bulk , No. 20-H
Fast-setting, non-shrink
patching material for
new and old concrete
and masonry.
DESCRIPTION
A fast-setting, non-shrink patching material
specially prepared for patching new and old
concrete and masonry. Disintegrated areas
can be rehabilitated with Thorite without the
need of expensive form work.
USES
Patching and filling spalled concrete where
reinforcing rods are exposed and corroded.
Patching honeycomb and construction faults
in concrete. Restoring disintegrated 1 ~irst remove at1 loose, spalid concrete.
surfaces of old concrete and brick masonry. Clean rantarclng rms, Inen avpty slrrsn coatol
Repairing cracked and broken stucco. Thorlte over rods and concrsls to be patched.
Patchinq concrete pipe and setting stubs.
patching precast concrete.
ADVANTAGES
Quick-setting.
Prepared ready to use when mixed with
water.
Does not contain waxes, metallics, tars, or
emulsions of any type.
Does not contain calcium chloride.
Non-shrink qualities and freedom from
oxidation make a durable patch.
Workman can complete work in one
'nr-n.. ~r-a..t-in., 'n
Saves labor, forming, excessive 2. ~i monte to mamar consistancv and force
ima area to be patched. Aner Thome has set.
scaffolding. shape to conform to sunounding areas.
Does not slump from edge of patch.
High structural strength.
APPLICATION
TO PATCH SPALLED CONCRETE:
Concrete-found to be cracked, spalled or
otherwise showing evidence of
disintegration or structural failure should be
cut out to Sound surface. All surfaces to be
patched must be structurally sound. Loose
c.o.n crete and rust on steel rods should be ~ -~~
removed by sandblasting, chisel and
hammer or wire brush. Heavy particles of
concrete should be removed by air or electric . . . . ..-..- .... .....-..-
hammer. Wash clean with waier from hose
before filling with Thorite. Mix Thorite to 3. N w appiy a finish coat of moroseal overthe
~ a t c k dar ea. Thlsarea lwu iiks new, a Mt he batter consistency and apply by brush over building has beso gtven new 1018. out&. easy.
reinforcing rods and concrete within B COM~ ~ C- BanId duiabb.
patching area. Slush mix under rods,
between steel rods and over old concrete
surface. All previously embedded stee, should be
thoroughly covered and slushed with brush coal before
filling patch with heavier, trowel coat of Thorite. Thorite
must be in place and leveled within five to ten minutes
after mixing water is added. No forms are necessary.
Apply in successive '/2' (1.27 cm) to 1" (2.5 cm) layers.
Scratch first layer, cool with water and apply second
layerwithin 15 to 20 minutes. If patch gets hot and turns
light gray. cool by wetting. Keep patch damp 20 to 30
minutes after fillingto complete curing. Several patches
may be made during one stage of scaffolding and work
completed without comeback or additional moving.
Apply coat of Thoroseal over Thorite immediately after
completion of patch.
TO PATCH CONCRETE FLOORS AND CURBS: Edge
of disintegrated surface to be patched should be cut or
chiseled at rlght angle with surrounding surface, or
undercut if possible. Thoroughly clean area removing all
loose panicles. Dampen surface and apply heavy brush
or slush coat of Thorite, making sureall poresand voids
are filled. Follow this with trowel coat of Thorite, forcing
material against edge of patch, all the way around, and
work toward center. If area to be patched is greaterthan
1" (2.5 cm) in depth. material should be applied in 1" (2.5
cm) layers, scratched, then applied in successive 1" (2.5
cm) coats until patch is filled. Dampen first application
with water before making second. Screed off and steel
trowel Thorite patch to level of floor. Affer material has
hardened, so it is not soff or tacky, place either burlap
bags or construction paper over patched area. If burlap
is used, saturate with clean water and keep wet for 45
minutes to 1 hour. Thorite generates considerable heat
if used in quantities, and it is advisable to keep material
cooled with water until heat has been dissipated, after
LIMITATIONS
Do not retemper; Thorite that has been retempered will
never get hard. Do not add other material. Do not stir
constantly, just enough to mix water through batch. Do
not permit Thorite to get hot in place; sprinkle with cold
water after placing. Fog spray from hose or dash on
water with brush. Do not apply Thorite on frozen or
frost-covered masonry or over frosted steel rods; frost
must be removed by heating with blowtorch before
making application. Do not apply in large quantities.
Thorite is best applied in '/2" (1.27 cm) to 1" (2.5 cm)
layers; scratch and apply successivecoats until patch is
filled. Cool first application with water before making
second application. Do not neglect to apply coat of
Thoroseal over finished patch immediately to assure
secure bond for later applications of Thoroseal. Do not
apply over dry, dusty surface.
COVERAGE
1 lb. (.45 kg) fills 17 cubic inches (278 cm3)
PACKAGING
12 lb. (5.4 kg) can; 50 lb. (22.7 kg) sack; 60 lb. (27.2 kg)
steel nail.
TEST DATA
1 COMPRESSIVE STRENGTH PSI (kaicm2)
which area can be covered with construction paper after
final wetting down. Light traffic can be used over
p.~a t..c hed area after 1 hour, but the longer it is cured the
Due to exceptional fast-setting qualities of Thorite, and
to increase the length of setting timeduring hot weather,
Centerville, IN Bristol, PA Newark, CA Mol, Belgium
Office: 7800 NW 38th Street, Miami, Florida 33166
Telephone: (305) 592-2081
. - --- , - .
Conducted by Arnbric Testing 8 Engineering-Laboratory
No. 14576
we recommend the following:
Q1983. Thoro System Produar
24 HRS. 7. DAYS
I. Use cold mixing water.
2. Keep material in cool place.
Printed in USA 4/64
28 DAYS
AUTOCLAVE TEST.. . 0.0285% EXPANSION
Conducted by Pinsburgh Testing Laboratory No. 460020
812 3910. I 5743 1
3. Cool surface to which material is'to be applied with
clean, cold water.
4. Mix small batches and use quickly.
During cool weather, keep material warm and use
lukewarm mixing water to speed set.
