Using traditional methods to repair potholes in reinforced concrete (RC) bridge decks is time-consuming and requires significant manpower and equipment. However, commercially available epoxies and similar materials provide a repair option that does not require saw cutting the deck around the pothole, concrete removal, and replacement. Researchers laboratory tested three epoxies to identify which is best for pothole repairs. Based on assessments of substrate penetration times and set times for epoxy and epoxy mortar, as well as compressive strength gain over time for epoxy mortar, researchers selected Sikadur 52 for static and dynamic bending tests using small-scale beams with simulated potholes and as well as field testing. Static tests evaluated (1) the performance of repair patches on specimens with varying pothole surface roughness, (2) the use of crushed concrete to fill the pothole, and (3) the addition of pea gravel as the primary aggregate of the epoxy mortar. Dynamic tests were carried out for different epoxy mortar cure times to determine the minimum amount of time lanes should be closed to traffic while the material cures. Field testing evaluated the use of epoxy to repair potholes on the decks of four bridges in KYTC Districts 06, 07 and 08. At ambient temperatures ≥ 70°F, the material set up rapidly and affected traffic lanes were reopened to traffic within two hours. The repair method is more effective and economical for potholes where the cracked concrete material is still in place. Sikadur 52 is a useful material for patching potholes in side-by-side box beam bridges, where traditional methods of repair may not be feasible. Fewer personnel and less equipment are needed to apply epoxy than a typical cement-based repair mortar application. Subsequent field inspections of the deck repairs found no distress on the epoxy repair patches.

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The supplemental file is a pamphlet that describes procedures for using Sikadur 52 to repair potholes on bridge decks. The pamphlet includes QR codes that link to instructional videos which demonstrate repair processes.