CONCRETE REPAIR MATERIALS- A PROGRESS REPORT

December 7 985 Engineering and Research Center

Department of the Interior Bureau of Reclamation

Division of Research and Laboratory Services

Concrete and Structural Branch

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14. SPONSORING A G E N C Y C O D E

DlBR

9. P E R F O R M I N G O R G A N I Z A T I O N N A M E A N D ADDRESS

Bureau of Reclamation Engineering and Research Center PO Box 25007 Denver CO 80225

12. S P O N S O R I N G A G E N C Y N A M E A N D ADDRESS

Same

15. S U P P L E M E N T A R Y N O T E S

Microfiche and/or hard copy available at the Engineering and Research Center, Denver, Colorado.

7 . AUTHOR^)

Fred E. Causey

10. WORK U N I T NO.

1 1 . CONTRACT OR G R A N T NO.

13. T Y P E O F R E P O R T A N D P E R I O D C O V E R E D

Editor:RNW(c) 16. A B S T R A C T

D-1510

8. P E R F O R M I N G O R G A N I Z A T I O N REPORT NO.

GR-84-2

The Bureau of Reclamation's investigations of concrete repair materials were divided into four tasks or phases: (I) epoxy injection study, (11) screening of repair materials for concrete repair, (Ill) comprehensive laboratory testing and development of testing methods, and (IV) field testing. Three epoxy resins were injected into cracked or sawed concrete specimens to study the resin's effectiveness at various temperatures and moisture conditions. Repair materials were screened for concrete repair, and promising materials were then selected for further testing. Both the epoxy concretes and polymer concretes had higher strengths than portland cement concrete, but may develop problems when used as concrete repair materials due to thermal incompatibility when there are large temperature gradients. The acrylic and latex emulsions had strengths in the range of portland cement concrete, but their freezing and thawing resistance was less than that of good air-entrained portland cement concrete.

17. K E Y WORDS A N D D O C U M E N T A N A L Y S I S

DESCRIPTORS-- concrete mixes/concrete tests/concrete technology/research and develop- ment/polymerization/durability/acrylic portland cement concretes/latex portland cement concretes/epoxy concretes/polymer concretes/magnesium phosphate cement concretes/ aluminum and copper sulfate portland cement concretes/epoxy resins/polymers/emulsions/ resins/structural concrete/concrete properties/concrete products/abrasion-erosion of concrete

b. I D E N T I F I E R S - - *concrete repair materials/epoxy concrete/concrete-polymer materials/ acrylic and latex emulsion concrete/concrete additives/latex/acrylics

c . C O S A T I F i e l d / G r o u p 13C COWRR: 1303 SRIM: 18. D l S T R l B U T l O N S T A T E M E N T 19. S E C U R I T Y C L A S S

( T H I S REPORT)

U N C L A S S I F I E D 20. S E C U R I T Y CLASS

( T H I S PAGE)

2 1 . NO. O F P A G E S

5 4 2 2 . P R I C E

CONCRETE REPAIR MATERIALS - A PROGRESS REPORT

by Fred E. Causey

Concrete and Structural Branch Division of Research and Laboratory Services

Engineering and Research Center Denver, Colorado

December 1985

UNITED STATES DEPARTMENT OF THE INTERIOR .k BUREAU OF RECLAMATION

As the Nation's principal conservation agency, the Department of theInterior has responsibility for most of our nationally owned publiclands and natural resources. This includes fostering the wisest use ofour land and water resources, protecting our fish and wildlife, preserv-ing the environmental and cultural values of our national parks andhistorical places, and providing for the enjoyment of life through out-door recreation. The Department assesses our energy and mineralresources and works to assure that their development is in the bestinterests of all our people. The Department also has a major respon-sibility for American Indian reservation communities and for peoplewho live in Island Territories under U.S. Administration.

The research covered by this report was funded under theBureau of Reclamation Press (Program Related Engineeringand Scientific Studies) allocation No. DR-380, "Concrete Re-pair Materials."

The information contained in this report regarding commercial prod-ucts or firms may not be used for advertising or promotional purposesand is not to be construed as an endorsement of any product or firmby the Bureau of Reclamation.

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CONTENTS

Introduction. . . . . . . . . . . . . . . . . . . . . .. . . .. . . . ... . . . .. . . . . ... . . . .. . . . ."'"

. .""

. . . . . . . . . . . . .. . . . . . . . .. . . . . . . . ... . . . .. . . . . .. . . . .'"

. . . .

Conclusions """""""""""""""""""'"Epoxy injection materials..........................................................................................................Repair materials ..

Discussion of Results...................................................................................................................Phase I - Epoxy injection study................................................................................................Phase \I - Initial laboratory screening of repair materials.............................................................Phase 11\- Comprehensive laboratory testing and development of testing methods......................

Compressive tests...............................................................................................................Tensile tests........................................................................................................................Bond tests ..Double shear tests...............................................................................................................Abrasion-erosion tests.........................................................................................................Thermal tests......................................................................................................................Freeze-thaw tests................................................................................................................

Phase IV - Field tests..............................................................................................................

Bibliography.."""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""

Appendix A - Reports describing the selection and use of repair materials......................................

Table

Figure

TABLES

23456789

10111213

Flexural tests of bond strength at various temperatures and moisture conditions for repairswith injected epoxy....................................................................................................

Mix design of repair materials..........................................................................................Summary of first series of screening tests.......................................................................Summary of second series of screening tests...................................................................Repair materials selected for comprehensive tests............................................................Summary of repair material relative performance...............................................................Mix design of concrete repair materials, comprehensive testing

"""""""""""""""""""'"Compressive strength and elastic properties....................................................................Tensile strength and elastic properties.

""'" """" """" """"""""""""""""""'"""""

Bond tests.....................................................................................................................Double shear tests.........................................................................................................Abrasion-erosion tests....................................................................................................Coefficient of thermal expansion, and freezing and thawing tests

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FIGURES

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Modulus of rupture of repaired beams (broken beams) ......................................................Modulus of rupture of repaired beams as a percentage of the beam's original modulus of

rupture .Modulus of rupture of repaired beams (saw cut beams)......................................................

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INTRODUCTION

The Bureau of Reclamation has many concrete structures which are subject to deterioration from

abrasion, erosion, freezing and thawing, chemical attack, or a combination of these agents. Ma-

terials which will resist these types of deterioration are needed to repair such structures. There

are many new materials that can be applied satisfactorily under dry, warm conditions, but few

can be applied satisfactorily under the cold, wet conditions often present on Bureau water-con-

veyance systems needing such repairs.

The research program, DR-380, Concrete Repair Materials, was divided into four phases:

Phase I - Study of epoxy injection materials

Phase II - Initial laboratory screening of repair materials

Phase III - Comprehensive laboratory testing of promising materials and development of test

methods

Phase IV - Field trial application of repair materials that perform well in laboratory tests

This report describes the progress made, from January 1979 to June 1983, in evaluating com-

mercial products for repairing concrete.

The repair systems currently used by the Bureau are generally