Pennsylvania Turnpike Bridge Case Study: A Proven Solution for Concrete Restoration & Preservation

By Frank Jad

In the mid-90s, the Pennsylvania Turnpike faced a critical challenge: bridge deterioration and rebar corrosion. To address these issues, SURTREAT™ surface-applied technology was tested on Turnpike Bridge EB-526 over Sandy Hill Road. The results? Enhanced durability, reduced permeability, and increased concrete strength, proving that SURTREAT™ is a game-changer in infrastructure preservation.

The Challenge: Bridge Deterioration

The bridge deck, constructed with reinforced concrete under an asphalt surface, showed signs of rebar corrosion and surface wear.

Exposure to deicing salts, moisture, and environmental stressors accelerated deterioration.

The goal was to extend the life of the structure without costly reconstruction.

The SURTREAT™ Solution

SURTREAT™ is an advanced, water-based, environmentally friendly technology that:

✅ Inhibits rebar corrosion by forming a stable protective layer.

✅ Reduces porosity and strengthens concrete, making it more resistant to environmental stress.

✅ Seals pores and micro-cracks, preventing salt, water, and contaminants from penetrating.

✅ Controls pH levels, maintaining high alkalinity and acid resistance.

✅ Increases compressive, flexural, and tensile strength, making concrete more durable.

Scope of Work: Application Process

1️Surface Preparation:

The asphalt overlay was removed and the deck surface was milled.

12,000 SF of concrete was cleaned using a pressure washer.

2️⃣ SURTREAT™ Treatment Application:

TPS II was applied twice, allowing penetration and curing for 24 hours.

SURTREAT™ REPEL applied, decreasing water permeability by 97% and extending service life by 20 years.

Cracks filled with moisture-curing urethane elastomer.

3️⃣ Final Protective Coatings:

After two days of curing, an asphalt tack coat was applied.

Permaquick hot liquid rubber membrane was installed for additional protection.

Joints and curb interface sealed with reinforced hot rubber.

Project Results: Measurable Improvements

 Concrete Strength Enhancement

Pull-out force increased by 10.5 KN, raising compressive strength from 3,215 psi to 5,038 psi.

Demonstrated significant structural improvements, reinforcing concrete durability.

 Water Permeability Reduction

Before SURTREAT™: 2.5 cc/min water penetration.

After SURTREAT™: 0.05 cc/min (98% reduction).

 Chloride Reduction & pH Improvement

Total chloride content remained low, ensuring minimal risk of corrosion.

pH levels increased from 8-9 to 11.5, reversing carbonation effects.

Corrosion Protection

Measured embedded rebar corrosion potential using silver chloride half-cell testing.

Corrosion activity was significantly reduced, transitioning rebars from a corrosive to a non-corrosive state.

Acid & Water Resistance

Pre-application: Acid etched and foamed on the concrete surface.

Post-application: No reaction—concrete remained unaffected.

Water repellency was visibly demonstrated, with treated surfaces preventing water absorption.

Why Choose SURTREAT™?

🔹 Proven to extend the life of concrete structures—reducing maintenance costs.

🔹 Environmentally friendly, non-invasive application—no need for disruptive repairs.

🔹 Ideal for bridges, roads, retaining walls, and hardscape elements.

Join the Movement in Sustainable Infrastructure Preservation!