Waterproofing for Concrete Bridges and Viaducts
Elastomastic™ TFN, 20 kg
MBC-VT 116 – термоустойчива епоксидна смола / 30 кг
Bridge deck waterproofing is a continuous protective layer between the structural deck and the road surfacing. It limits water and dissolved salts reaching the concrete and reinforcement and works together with drainage, joints and asphalt layers. For concrete bridges and viaducts beneath asphalt, the ELASTOMASTIC TFN system combines MBC-VT 116 epoxy primer, an epoxy-polyurethane waterproofing layer and quartz broadcasts. MBC-VT 116 primer is also suitable for early-age concrete from 7 days of age. Before applying ELASTOMASTIC TFN, the substrate must be checked separately against the requirements for the next layer.
This collection contains the two main products: MBC-VT 116, 30 kg for priming the concrete substrate and Elastomastic™ TFN, 20 kg for the tough-elastic coating. Quartz grades, consumption and details are selected for the complete system build-up.
System layers · Technical performance · Application · Consumption · Price and selection
Concrete bridge deck waterproofing beneath asphalt
Water can reach the bridge deck through road surfacing, cracks and connections around kerbs and drainage outlets. Asphalt and waterproofing therefore perform different functions: the surfacing carries traffic, while the waterproofing system protects the substrate against water ingress. Bonding between layers also matters under braking, acceleration and temperature changes.
A liquid-applied coating forms a continuous layer following the prepared deck geometry. It can be used in new construction and refurbishment where the structure, substrate and project detail specify this system. Refurbishment starts with assessing the existing layers, the concrete condition and the cause of leakage.
System build-up and layer sequence
For the concrete deck beneath asphalt, the layers run from bottom to top:
- Sound, prepared reinforced-concrete deck with completed falls and repaired defects.
- MBC-VT 116 epoxy primer to bond to the concrete substrate.
- Quartz broadcast with a particle size of 0.4–0.8 mm.
- Two-component ELASTOMASTIC TFN epoxy-polyurethane layer with a dry film thickness of at least 2 mm.
- Quartz broadcast with a particle size of 1.0–3.0 mm to provide the surface profile for the following layer.
- Asphalt concrete surfacing of the type and thickness specified by the road design.
This is a specific build-up for a concrete road deck. Primer substitutions, changes to aggregate grading or adding filler to the resin require a project-specific technical decision. Waterproofing thickness is checked separately from the height of the quartz broadcast.
What does each product do?
MBC-VT 116 — epoxy primer for the concrete deck
MBC-VT 116 by MC-Bauchemie is a two-component, red-transparent, heat-resistant epoxy resin. It serves as the primer in this build-up. Separate applications include sealing and scratch coating, each with its own application sequence and consumption. Priming prepares the bond to the substrate; it does not provide the entire waterproofing layer.
Elastomastic™ TFN — epoxy-polyurethane coating
Elastomastic™ TFN by Sherwin-Williams forms a tough-elastic, mechanically resistant coating. It is a two-component, solvent-free material, approximately RAL 7037. Within the bridge system it provides the continuous protective layer, while the selected quartz materials help form the surface profile and interlayer bond.
System technical performance
The technical performance for the specified build-up on concrete is:
- Dry waterproofing layer thickness: ≥ 2 mm.
- Tensile bond strength: ≥ 1 N/mm².
- Shear strength with asphalt concrete: ≥ 0.4 N/mm².
- Water absorption: ≤ 2%.
- Dynamic water loading: passes the test.
- Crack bridging: maintains watertightness after testing at a temperature ≤ −10°C.
The bond strength of the applied system and the tensile strength of the concrete surface are different properties. Crack-bridging performance does not replace an expansion-joint detail designed to accommodate structural movement.
Concrete substrate requirements
The substrate must be sound, dry and clean, with an open-textured surface. Remove cement laitance, weak material, dust, oil and remnants of previous coatings. Repair voids, irregularities and damaged edges before applying the system.
Concrete requirements for ELASTOMASTIC TFN include a minimum compressive strength of 25 N/mm², an average surface tensile strength of at least 1.5 N/mm² and residual moisture not exceeding 4% by the CM method. Concrete moisture and relative air humidity are measured separately.
Falls and drainage must direct water towards the intended outlets. The waterproofing layer follows the prepared surface; it should not be used arbitrarily to compensate for major defects or incorrect falls.
Bridge waterproofing application sequence
- Assessment and preparation. Inspect the concrete, falls, cracks, kerbs, joints and drainage outlets. Prepare mechanically to a sound, textured substrate and remove dust. After wet preparation, allow drying and measure the residual moisture.
- Local repairs. Repair defects and form transitions using compatible materials. Select concrete repair mortars for the depth and function of the repair.
- Priming. Mix MBC-VT 116 at a base-to-hardener ratio of 3:1 by weight. Distribute evenly without pooling and apply the specified quartz broadcast.
- Preparing the coating. Mix ELASTOMASTIC TFN at A:B = 40:60 by weight for at least 3 minutes. Transfer to a clean container and briefly mix again. Do not thin the material.
- Application and broadcasting. Spread with a trowel, serrated trowel or squeegee, use a spiked roller and broadcast within the application window. Remove unbound aggregate after curing.
- Checks before asphalt. Verify continuity, thickness, adhesion, details and surface condition. Start subsequent work when the system has reached the required readiness.
Temperature, working time and curing
MBC-VT 116 requires air and substrate temperatures of +8 to +30°C, relative humidity no higher than 75%, and a substrate at least 3°C above the dew point. Working time is approximately 35 minutes at +20°C and 50% relative humidity.
ELASTOMASTIC TFN requires a substrate temperature of +10 to +40°C, at least 3°C above the dew point, material temperature above +20°C and relative air humidity below 85%. Pot life is approximately 1 hour at +20°C. Check the conditions separately for each application stage.
At +20°C, the indicative walkable time for ELASTOMASTIC TFN is 12 hours for a 4–10 mm layer. Final cure is approximately 1 week, depending on thickness and temperature. These timings do not automatically define when asphalt can be laid over the bridge system with a 2 mm layer. That decision depends on the application procedure, site conditions and checks before the next layer.
Material consumption and quantities
MBC-VT 116 consumption as a primer is approximately 0.4–0.5 kg/m². Concrete absorption and texture affect the actual quantity. Sealing and scratch coating require different quantities and must not be treated as a single priming coat.
ELASTOMASTIC TFN quantities depend on the design thickness, exact build-up and its consumption rate. Calculate resin, any filler mixed into it and surface broadcast separately. The starting calculation is area × consumption for each layer, allowing separately for details, irregularities and application losses.
Primer-only example: 100 m² at 0.4–0.5 kg/m² requires a theoretical 40–50 kg before application losses. With a 30 kg pack size, this means two packs. The calculation excludes the waterproofing coating, quartz and substrate repairs.
Kerbs, drains, joints and critical details
The coating needs continuous transitions to drainage elements and termination areas. Connections at kerbs, outlets, edges and work interruptions require particular attention. Outlets must drain from the intended level without leaving pockets of standing water.
Assess active cracks and expansion joints according to their movement. Select joint waterproofing solutions as separate details compatible with the bridge system. Checks include complete coverage, thickness, even broadcasting, adhesion, and the absence of blisters, missed areas and contamination.
Concrete deck, steel bridge or exposed coating?
This page describes a concrete bridge deck with asphalt concrete surfacing. ELASTOMASTIC TFN also has applications on steel, inspection sidewalks, pedestrian and cycle areas, and ballast troughs. Their preparation, primer, thickness and aggregate grading may differ.
Steel substrates require corrosion protection and the corresponding metal preparation. Directly trafficked coatings have requirements for wear and slip resistance. Bituminous bridge membranes use a different application method and their own details. Selection begins with the structure and intended use, rather than the resin type alone.
Bridge waterproofing price and technical selection
Price per m² depends on area, substrate preparation, repairs, design thickness, quartz materials and the number of complex details. A pack price for primer or coating is different from the cost of the complete waterproofing system. Compare options using the same build-up and scope of work.
To determine products and quantities, provide the area, substrate type and condition, design build-up, falls and drainage, joint details and planned surfacing. Send a technical enquiry for bridge waterproofing.
Products and technical information
Bridge waterproofing questions
What does the ELASTOMASTIC TFN system for concrete bridges include?
The build-up includes a prepared concrete deck, MBC-VT 116 epoxy primer, a 0.4–0.8 mm quartz broadcast, ELASTOMASTIC TFN with a dry film thickness of at least 2 mm, and a 1.0–3.0 mm quartz broadcast. Asphalt concrete surfacing is then installed as specified by the road design.
What is the difference between MBC-VT 116 and Elastomastic™ TFN?
MBC-VT 116 is the epoxy resin used to prime the concrete. Elastomastic™ TFN is the epoxy-polyurethane coating forming the tough-elastic waterproofing layer. The products perform different, consecutive functions within the described system.
Can bridge waterproofing be applied to damp concrete?
ELASTOMASTIC TFN requires a dry substrate with residual moisture not exceeding 4% by the CM method. This is different from relative air humidity. After wet deck preparation, allow drying and measure the conditions; visual inspection alone is insufficient.
How are material quantities for a bridge deck calculated?
Multiply the area by the consumption for each individual layer. MBC-VT 116 used as a primer has an indicative consumption of 0.4–0.5 kg/m². Calculate ELASTOMASTIC TFN, fillers and broadcasts for the exact build-up and thickness, accounting separately for details and application losses.
When can asphalt be laid over bridge waterproofing?
Once the system has reached the required readiness and thickness, adhesion, continuity and details have been checked. Walkable time does not automatically mean readiness for asphalt. Temperature, asphalt type and sequence must follow the project application procedure.
Can the same system be used on a steel bridge?
The MBC-VT 116 build-up described here is for a concrete deck beneath asphalt. ELASTOMASTIC TFN also has steel applications, using the appropriate preparation, anticorrosive primer and layers. The concrete build-up must not be transferred automatically to a steel substrate.
How are cracks and expansion joints treated?
Cracks are assessed for their cause and movement, and defects are repaired before waterproofing. Expansion joints need a separate compatible detail. The coating’s crack-bridging capability does not mean that it can replace a bridge expansion joint.
What affects the price of bridge waterproofing per m²?
Area, concrete condition and preparation, repairs, coating thickness, quartz materials and detail complexity all affect cost. Product selection and quantities require the system build-up, area and information about the planned surfacing.