INSTITUTE OF ROAD AND TRANSPORT TECHNOLOGY

ERODE

GROUP- III
EPOXY RESIN AS A BONDING COMPOUND IN
CONCRETE REPAIR
BY

E.Anbazagan
K.Vignesh
Second year Civil

E-MAIL ID : anbusaran007@gmail.com

PHONE NO : 9994382237

CONTACT ADDRESS :
E.Anbazagan,
Second year,
Civil Engineering,
IRTT hostel, E-45
Erode – 638 316.
ABSTRACT

Almost all the structures in our country are constructed using Reinforced
Cement Concrete (RCC). The main problem faced is the repair and rehabilitation of such
structures which are not cent percent effective owing mainly due to poor quality control
and aggressive atmospheric conditions prevailing in our country. Many compounds are
being used to bind the old concrete with new concrete during repair works, each of them
having their own merits and demerits. Epoxy resins are added to concrete during mixing
as an aqueous emulsion or in dispersed form to improve the tensile strength, extensibility,
impact and abrasion resistance of concrete. The demand for epoxies has been increasing
steadily due to their good mechanical strength, chemical resistance and ease of working.
Epoxies are being extensively used in construction/civil engineering
applications such as structural adhesives, repairing of cracks, reducing water leakages,
corrosion resistant linings etc.A large number of cost-effective polymers and epoxy
formulations are available commercially, but the proper choice of the resin and its
formulations with other modifiers is essential for obtaining the optimum performance in
practical situations.
INTRODUCTION:

Concrete and in particular reinforced concrete is the most commonly used

in our country for construction. But poor control on water per cement ratio, quality of
water used, carbonation, aggressive environment and other detrimental factors adversely
affect the RCC structural members, which have to be either replaced or repaired. Since
replacement is uneconomical and time consuming, repairing the damaged portion alone is
preferred. Repairing involves the laying of fresh concretes over hardened old concrete
and binding them together. Earlier emphasis was on a long term durability of repaired
structures. But, now the structural effectiveness of repairs to concrete members has
gained importance. Researches have also highlighted the potential importance of property
mismatch between patch repaired materials and the reinforced concrete structure and
found that the modulus value of the repaired material is of great importance and
recommended that it should not differ significantly.

METHOD OF PATCH REPAIR:

For patch repair, concretes surrounding the affected reinforcement are

removed exposing the reinforcement. Bonding material is then applied on the treated
surface and fresh concrete is laid over it. The conventional bonding material used was
cement slurry/cement based materials. However, the performance of these materials was
not satisfactory owing to property mismatch or improper repair techniques. Thus alternate
materials such as Epoxy Resin, polymer emulsion, acrylic latex, polyvinyl acetate, etc.
have been tried. Few have been found to be effective through experiments. But most of
the tests were confirmed to beam repairs on tension side.
THE STUDY:
The following is a study on the effectiveness of Epoxy Resin as a
bonding material for a fresh and hardened concrete tension and compression zone as well
as at construction joint. The results are compared with results for cement slurry as
bonding material and full cast beam.
TEST SPECIMEN:

The dimensions of beams usually adopted in reinforced concrete buildings

provide guidelines for the selection of dimensions for the test specimen. For geometrical
similarity between the prototype and the test specimen, it is necessary that all linear
dimensions of the test specimen should be scaled down from the corresponding
dimensions of the prototype by a constant ratio.However,practical limitations prevent the
scaling of fine aggregate, cement particles and steel surface deformation is impossible
fortunately deviations do not pose serious problems.
The beam span in building frames often varies from 3.5 to 12m.In this
experimental investigation, reinforced beams of square cross section 150x150mm and
span of 1000mm is selected.
All eleven specimens of the reinforced beams were provided with 2 bars
of 8mm dia.high yield strength deformed steel on tension side and 2 bars of 6mm
dia.plain mild steel on compression side with 6mm dia.plain mild steel two legged
stirrups at 75mm spacing making the beam under reinforced as well as safe in shear.
These beams were tested on roller supports with effective span of 900mm under four-
point loading.
Strength Properties of Reinforcement
Material Diameter Yield strength Ultimate Strength
(mm) (MPa) (MPa)
HSD Bars 8 470 595
MS Bars 6 275 340
Dimensions, detailing and loading arrangements of a specimen beam are shown in fig.1
In the first case, the flexural test with vertical bond plane under four point
loading was conducted and the bond plane was contained in constant moment zone .
In the second case, tension side and in the third case compression side
reinforcements were kept exposed surface was treated and concrete was cast and tested
under four point loading (fig.2).These tests were conducted to check the effectiveness of
the repair material in flexure.
All dimensions are in mm
Fig-1

All dimensions are in mm

Fig-2
EPOXY RESINS:

These are organic compounds which when activated with

suitable hardening agents form strong chemically resistant structures having excellent
adhesive properties. They have used as binders or adhesives to bond new concrete
patches to existing surfaces or bond together cracked portions. Once hardened this
compound will not melt, flow or bleed. Care should taken to place the Epoxy within the
pot life period after mixing.

The specimen were taken for the test.Then the slabs were allowed to set.After
one day the slabs were tested for their behaviour under the same loading condition and
position.The slabs were loaded uniformly till cracks developed and treated with epoxy
resin.Once again the slabs were loaded as previously.And surprisingly,we found that new
cracks in slabs were entirely different even though they were loaded at the same point
and they were broken in new lines and load applied was withstood by the bonding show
in fig.a
 Some of the slabs were loaded for its ultimate strength so that they
were broken in to pieces.These specimens were taken for the test.the cempatch
primer/epoxy resin is comprised of a base and a hardener. The base and a hardener were
taken in a ratio 1:2 and mixed well in a container. Then the mix was applied on the
broken edges of the two broken pieces of the slab with a brush. Mix was applied
uniformly and thoroughly on the edge surface for better bonding. Then the slabs were
allowed to set. After one day the slab were tested for their behavior under the same
ultimate load. The square slabs treated with cempatch primer is shown.
 The growing demand for epoxy resins has been due to their good
mechanical strength, chemical resistance and ease of working. The best known
applications in civil engineering/construction are high performance coatings, floorings,
grouting, adhesives or injection system etc.

Epoxy Grouts, morts and coatings:

These are used

∗ To bond plastic concrete to hardened concrete
∗ To bond rigid materials to each other
∗ For patching work
∗ For coating over concrete to give color, resistance to chemicals, water penetration,
abrasion etc. Epoxy coatings are available for marine under water and moisture
resistance conditions.

Epoxy resins for structural repairs and rehabilitations:

Among the synthetic resins such as epoxy, polyester, acrylic,

polyurethane, etc. epoxy resins possess very high mechanical and adhesive strength
properties a most desirable for Civil Engineering applications.
Epoxy resins when cured with different hardness offer a wide range of properties:

1. High adhesive strength to almost all materials

2. Low shrinkage during curing
3. Exceptional dimensional stability
4. Natural gap filling
5. Thermosetting (Does not melt)
6. Resistance to most chemicals and environment.
Epoxy for crack repairs:
The most important method of crack repair depends on whether there is
still actively moving or not. Active may be due to inadequate provision of a movement
joints in the structure. The repair process involves converting the crack into a movement
joint, by the use of a suitable sealant. The injection of a low viscosity epoxy is a possible
repair method for cracks between 0.02mm to 6mm in width. There are wide variations in
the properties of different low-viscosity epoxy systems and it is therefore necessary to
choose carefully to match the individual job requirements in relation to such matters as
temperature of application, capability of bonding to moist concrete, shrinkage, thermal
and elastic properties of the hardened resin. For epoxy injection to be effective the cracks
must be free of dirt, grease, etc. Before injection can begin, the crack, where it appears on
the surface of the member, must be sealed, so that the liquid resin does not leak and flow
out of the crack before it begin to get and cure.
Epoxy mortar and concrete:
Epoxy resins are used with aggregate (silica sand) to produce epoxy
mortar or epoxy concrete which is used for repairs of flooring, foundation grouting, roads
and bridges, industrial pavings, etc. They are not normally used where rapid curing can
be obtained. The repair of pot holes and spalled joints on Portland-cement concrete
highways and bridge decks is a good example for the use to epoxy mortar especially
where a lane can not be closed to traffic for long hours.
The rate of curing of the epoxy mortar is directly dependent on the
ambient temperature. In cold weather, small patches of mortar can be easily heated
artificially to provide a rapid cure. Clean, dried, specially-graded silica sand is used as
filler with resin- hardener mixture. Addition of sand helps in reducing shrinkage
improves abrasion, thermal shock resistance and lowers the thermal coefficient of
expansion making it nearer to concrete.

EPOXY COATINGS FOR REINFORCEMENT:

Extensive experimental investigations reveal that epoxy coatings when

properly applied could be expected to adequately protect reinforcing steel bars from
corrosion. However, powder based epoxies performed better than the liquid epoxies.
Epoxy resins find used in grouting, bonding of old to new concrete, repairs of eroded
concrete, coatings for reinforcements, etc. a judicious use of epoxies is called for in the
light of their very high cost.

Epoxies are also used for bonding of steel plats to the external faces of
structural members like beams, etc., which have suffered damage revealed by cracks in
the flexural, shear modes. The technique consists of in-situ strengtherining of failed
concrete elements by boundary steel plats to concrete surface with epoxy resins resins.
A large amount of experimental work done all over the world, including in
India show that the repaired and externally reinforced beams exhibit a 24% increase in
strength over the original RCC beams in flexure and shear.
 Other important admixtures include shrinkage compensating admixtures
that can be used for filling of grouts cracks etc and accelerators for guniting and shot
creating works.

Bonding with epoxies:

Cracks in concrete may be bonded by the injection of epoxy bonding

compounds under pressure. Usual practice is to drill into cracks from the face to the
concrete at several locations. Water or a solvent is injected to flush out the dirt and
foreign mater and allowed to get cleaned through this process. The surface is then
allowed to dry. The epoxy is injected into the drilled holes until it flows out through the
other holes.
Epoxy grouting works:
Preparing arrangements by making coffer dam and water diversion.
• Scaffolding.
• Cleaning along the cracks by high pressure water jet for proper visibility of cracks.
• Thorough surface preparation along the cracks.
• Cutting V groove along the cracks.
• Providing entry port holes along the cracks.
• Fixing nozzles.
• Sealing the cracks by epoxy putty and holes by epoxy concrete.
• Leakage of epoxy sealant by compressed air.
• Grouting with medium violosity, water insensitive and high bond strength epoxy.
• Sealing the nozzles after grouting.
• Cutting the extended portion go the nozzles.

Epoxy mortar plaster treatment:

Preparatory arrangement of cofferdam and water diversion.

• Through dewatering.
• Cleaning the surface through high pressure water jet.
• Thorough surface preparation by various methods.
• Drying of the surface by compressed air, hot air blowing.
• Provision of one coat of epoxy primer.
• Preparation of mortar plaster of 6-8mm thick.
• Providing two coats of seal cote.
MAJOR HYDRO ELECTRIC PROJECTS WHERE EPOXY
RESINS HAVE BEEN USED:

APPROXIMATE
QUAITY OF
EPOXY
SL.NO PROJECT(LOCATION) APPLICATION
CONSUMED, kg

1. Koyna Dam, Maharashtra Grouting of cracks 3000

2. Bhandaradasa Dam, Maharashtra Grouting of cracks 1850

Kundha Hydro electric project, Repair of water

3. 250
Kundha, Tamil Nadu carrying tunnel
4. Kodayar Hydro electric project,
Repair of water 1000
Papanasam, Tamil Nadu
carrying tunnel

5. Bonding of old to
Barvi Dam, Maharashtra 2500
guniting concrete
layer
Grouting of cracks in
Pench Hydro- electric project,
6 bus shaft and water
Maharashtra
proof coating. 2000

Filling of cavities in
7 Panshet Dam, Maharashtra concrete by grouting
700
8. Hirakud Dam, Orissa Repair of cracks 2000

Repair of beams and

9. Rihand Dam, Uttar Pradesh columns in power
house 1000
 Epoxy resins and systems are being increasingly used in the
construction / civil engineering applications such as structural adhesives, repairing of
cracks, reducing water leakages, corrosion resistant linings etc. A large number of costs
– effective epoxy resin formulations are readily available commercially. The proper
choice of resins and its formulations with other modifiers is essential for obtaining the
optimum performance in actual – use conditions. The advances in epoxy resin systems,
application developmental studies and field experience have evolved considerable
information as to the capability and limitations in the usage of these materials.

CONCLUSION
From the above discussions, it is clear that epoxy resin is the more
suitable compound for repairing the beams as well as at the construction joint than the
cement slurry with the same or lower W/c ratio as in concrete. The separation of new and
old concrete on tension side indicates that cement slurry is not suitable for treating or
repairing the beam on tension side. Crushing of new concrete on the compression side of
the beam at the junction of old and new concrete on the compression side of the beam at
the junction of old and new concrete suggests that richer grade of concrete may be
required up to certain length of beam from joint or the repair zone. However this may
depend on the age of old concrete, span of the beam, loading condition, support
condition, etc., for which further study is required. Also these tests have been done for
only one grade of concrete and one bonding compound with different loading and support
Conditions.

BIBLIOGRAPHY
Hand book of concrete mixes ,BIS ,New Delhi 1982.
Causes,evoluation and repair of cracks in concrete structures,ACIJ 1984.