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Polymer emulsions improve bond, increase strength and resist chemical attack
ynthetic latexes are made by dispersing polymer particles in water to form a polymer emulsion. When these emulsions are added to portland cement conc re t e, the spheres of polymer will coalesce or come together to form a film that coats the aggregate particles and the hydrating cement grains and seals off voids. The resulting mixture develops higher strength, bonds better to existing concrete, has a higher resistance to chloride penetration and is more resistant to chemical attack than plain concrete. The three basic polymers used as latex modifiers for concrete or mortar are acrylics, styrene-butadiene rubbers (SBR) and polyvinyl acetates (PVA). PVAs are not generally recommended for use in wet environments because some types may hyd ro l y ze or break down chemically. Defoamers are incorporated into the polymer emulsions when they are manufactured to inhibit formation of excessive air that would be caused by foam generated during mixing of the mortar or concrete. Unlike conventional concrete, entrained air is not required for freezethaw durability of latex-modified concrete. Howe ve r, some air is entrained by the latex during the mixing process so it is common for a specification to include a maximum air content, say 6.5 percent, but not a minimum. The 28-day compressive strength of latex-modified concrete typically ranges between 3500 and 6000 psi and
Used primarily for bridge decks, parking ramps and other large expanses of concrete exposed to extreme weather, latex-modified concrete is resistant to freeze-thaw damage and to the harmful effects of deicing salts.
the shear bond strength at the same age will generally be between 325 and 450 psi. Flexural strengths at 28 days are between 900 and 1400 psi. The modulus of elasticity is somewhat lower than that of conventional concrete, with a typical value of 3,600,000 psi for a 6000 psi compressive strength mix.
coarse aggregate by weight. The water-cement ratio (including water in the latex) should be 0.30 to 0.40 and the latex solids-cement ratio 0.10 to 0.20, both by weight. With these pro p o rt i o n s, the slump is normally 4 to 6 inches. Because the concentration of latex solids in commercial products va ri e s, the dosage in gallons of latex per
coat is brushed or broomed onto the prepared concrete surface. This bond coat can be the mixture used for the overlay or patch, or may be made by mixing undiluted latex with portland cement. The surface is first thoroughly wetted with clean water for not less than 1 hour prior to placement. After removing all free water but with the surface still damp, sufficient mixed material to coat all bonding surfaces is then placed and vigorously broomed to assure maximum contact with the old concrete. The rate of application of bonding material should be limited so that the bond coat doesnt dry before being covered with repair mortar or concrete needed to bring the repair to the required elevation.
To enhance bond, latex-modified concrete is broomed into the prepared and dampened surface just ahead of the placing operation. An alternative method is to use a bond coat mixture of undiluted latex and portland cement prepared in a separate mixer.
100 pounds of cement will vary with the brand of latex. To determine the amount of a particular latex to be used, obtain the concentration or solids content from the label or manufacturers literature. This will be given either as pounds of polymer per gallon or as percent solids and weight per gallon. Calculate the gallons of the particular latex required to obtain the desired latex solids-cement ratio. For instance, assume that you want a mix with 16 percent latex solids by weight and a maximum water-cement ratio of 0.40. The emulsion to be used weighs 8.4 pounds per gallon and the latex solids comprise 48 percent of the total emulsion. To get 16 percent latex solids by weight of the cement the calculated quantities would be: 0.16 x 100 = 16 pounds of latex solids per 100 pounds of cement 0.48 x 8.4 = 4.0 pounds of latex solids per gallon of latex (the rest is 4.4 pounds of water) 16 / 4.0=4.0 gallons of latex per 100 pounds of cement Weight of water in 4 gallons of latex=4x4.4=17.6 pounds. If the water-cement ratio is not to exceed 0.4, then the maximum amount of additional water that should be used is 4017.6 = 22.4 pounds per 100 pounds of cement.
A curing cover of wet burlap and polyethylene sheet prevents shrinkage before latex in the concrete coalesces to form a polymer film. The cover is removed after 24 hours and the surface is permitted to air cure.
Bond coat
To obtain a high bond between the latex concrete overlay or mortar patch and the base concrete, a bond
minimum speed (16 to 18 rpm), aggregate and cement are next introduced, followed by the remainder of the mixing water needed to achieve the desired consistency. Total mixing time shouldnt exceed 4 minutes at slow speed, longer mixing times may incorporate excess air in the mix. For large areas such as bridge decks requiring more than 4 cubic yards of mixed material, mobile batcher mixers are recommended. Because of the relatively short working life for latex-modified mixes, the amount mixed will be limited by the placing and finishing timeabout 20 minutes. If the mortar or concrete is manipulated after the latex has coalesced, cracking may occur on drying. Due to the short working time, steel trowel finishes are difficult if not impossible to produce without surface cracking.
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