Epoxy Adhesives in Civil Engineering

SpecialChem | Edward M Petrie - Jun 18, 2008

There are many applications for epoxy adhesives in civil engineering applications. This week's
editorial takes a broad look at the reasons why epoxies are highly valued in these projects and
where the development of these materials may take us.
Epoxy adhesives have been used considerably in the last several decades for the construction,
repair, and rehabilitation of our transportation infrastructures. Epoxy systems are highly valued
in these projects because they can be formulated to set outdoors in a relatively short period of
time, they have good adhesion to a number of materials of construction, and they provide
relatively good weathering properties and durability.
Table 1 lists several applications for epoxy adhesives in civil engineering projects. Epoxy
adhesives are generally considered to be the "workhorse" of the industry. In the construction or
repair of roads and bridges, epoxy adhesives have primarily been used for bonding concrete
and for bonding stiffening members or repair structures to degrading concrete facilities.
Airfield runways and aprons
Highway and bridge joints
Bridge abutments
Concrete lined canals,
traverse and longitudinal
joints
Multilevel parking lot joints
Underground tunnel construction
joints and sections
Attaching metal studs in concrete
Bonding pancake lighting systems on
airport runways, parking lots, etc.
Bonding traffic markers on roadways
and road dividers
Table 1 : Common Applications and Polymeric Resins Used in the Construction and Repair of
the Transportation Infrastructure
Epoxies are high priced, but they have better chemical resistance and durability than other
adhesives, and they have dominated the market in outdoor applications. Significant advantages
of the epoxy based adhesives are that they have no solvents and, therefore, exhibit little
shrinkage. They cure relatively fast and are not as exposed to inclement weather as are slower
curing systems. Their physical properties do not change significantly on aging in the field.
One problem with early epoxy formulations is that they cured to a relatively brittle material. By
using reactive flexibilizers, such as polysulfides, epoxy adhesive formulators have obtained the
flexibility required for many applications in this industry. Polyamides and even coal tars have
also been used to provide flexibility to epoxy base resins.
Another problem is that many two-component, room temperature curing epoxies cure with a
high exotherm. This can cause the mixed uncured epoxy to get very hot. Excessive heat of
exotherm provides a safety hazard and significantly shortens the working life of the mixed
adhesive. This problem is generally solved by mixing small batches or using continuous mixing
equipment.
Cured concrete may be bonded to cured concrete, as in the installation of precast buttons to a
highway surface. Steel bridge railings may be bonded to the concrete surface of a bridge
sidewalk. In the case of deteriorated concrete, the adhesive can be used to rebuild the structure
to its former line and grade. Epoxy adhesives are also commonly used on other roadway
materials, such as asphalt and brick; however, the predominant application is concrete
substrates. The most frequent combinations of substrates that are bonded with adhesives in this
market segment are:
Cured concrete to cured concrete
Cured concrete to other materials
New concrete to cured concrete, and
New concrete to other materials.
In the bonding of cured concrete to cured concrete, the adhesive is applied directly to the
substrates. In the case of new concrete, a bonding agent may be incorporated into the concrete
formulation or the adhesive may be applied to the non-concrete surface.
There are many applications for bonding cured concrete to another material. These include
bonding of plastic reflectors to road surfaces or dividers, attachment of railings or metal
structures, and bonding of floor covering materials.
For applying new concrete over old concrete, such as in the case of a patch, epoxy is often the
best solution as a replacement for the new concrete. In these formulations an epoxy mortar is
made using aggregate similar to the aggregate used in concrete mixtures. Adhesion is excellent
and the epoxy mortar has generally better properties than the concrete; however, it is a
relatively high cost solution. The old concrete surface should be cleaned and sandblasted down
to sound concrete.
n the future, the use of adhesives in this market is expected to grow significantly due to the
aging infrastructures. An interesting application that has received much attention because of the
aging road infrastructure in many regions is the repair and strengthening of existing concrete
structures. Concrete beams can be strengthened by attaching steel plates and composites.
The use of epoxy adhesive systems with fiber reinforcement is expected to increase
significantly. Such adhesives will be applied to bridge piers, beams, and other elements
requiring repair. These adhesives can be used to not only repair deteriorating structures but
they will also provide added strength to new structures.
1,2

References
1. Meier, U., "Composite Material in Bridge Repair", Applied Composite Materials, vol. 7,
2000, pp. 75-94.
2. Field Test Increases Viability of Composites in Bridge Repair", Engineering News
Record, vol. 237, no. 12, September 16, 1996, p. 22.