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Magnesium phosphate cements (MPCs) have been used in proprietary products for pavement repairs for over 30 years. However, these products generally are intended for small repair sections less than 0.5 ft3 due to high heat generations and short working times. The objective of this research was to develop optimal mixture proportions of MPCs for use in pavement applications. Materials used in this research included three types of magnesium oxide (MgO), one phosphate salt, two types of fly ash, a retarder, two course aggregate gradations, and one sand. From these materials, 24 mixture proportions were batched with variations including water content, retarder, and fly ash to determine the effects on physical and mechanical properties. Laboratory testing at various scales was conducted on a mixture consisting of a dead-burned MgO, potassium dihydrogen phosphate, Class C fly ash, boric acid, and local aggregates. Four variations were developed and commercially blended in bulk super sacks. These concrete mixtures met the workability, setting time, and strength requirements. A volumetric mixer was used to batch 2 yd3 field placements in test sections 8.5 ft wide x 8.5 ft long x 8 in. deep. This was noteworthy because no literature was discovered for MPC concrete placements at this large volume. DISCLAIMER: The contents of this report are not to be used for advertising, publication, or promotional purposes. Citation of trade names does not constitute an official endorsement or approval of the use of such commercial products. All product names and trademarks cited are the property of their respective owners. The findings of this report are not to be construed as an official Department of the Army position unless so designated by other authorized documents. DESTROY THIS REPORT WHEN NO LONGER NEEDED. DO NOT RETURN IT TO THE ORIGINATOR. ERDC/GSL TR-20-04 iii

Development of magnesium phosphate cement (MPC) concrete mixture proportioning for airfield pavements : laboratory and field validation MPC test report