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AICSGE 6, Structural Engineering Dept.

, Faculty of Engineering, Alexandria University

15-17April 2007

SELECTION OF APPROPRIATE FIXING AGENT IN CONCRETE REPAIRS


A. AYOUB, A. KURDI, A. ABDO
* Structural Engineering Department, Faculty of Engineering, Alexandria University-Egypt

A. JAHIN
Civil Engineer

ABSTRACT: Some mechanical properties of commercial fixing agents were investigated to update and complement existing data on these materials. Epoxy and polyester adhesives are the most common adhesives that used to fix steel reinforcement into hardened concrete. Results obtained in these tests indicated that cured epoxy adhesives posses five to eight times higher tensile strength and shear strength than Portland cement mortar and much reduces young's, shear and flexure modulus. Cured polyester adhesives also posses four to seven times higher tensile strength and shear strength than Portland cement mortar and much reduces young's, shear and flexure modulus. This paper presents an experimental study to select the appropriate fixing agent in concrete repair. Compressive strength and flexural strength were carried out on epoxy and polyester fixing agents, steel reinforcement pull-out test were carried out on concrete specimens with steel reinforcement fixed into it by epoxy and polyester adhesives, also by cement slurry to compare between materials. Compressive strength is carried out according to ASTM C 109, flexural strength is carried out according to BS 6319 Part 3 and steel fixing tests is carried out according to BS 5080 Part 1/ 1993 and BS 5080 Part 2/1986. Five candidate commercial epoxy resins and three candidate commercial polyester resins that are produced by five local companies were selected and tested. Cement mortar containing sand cement ratio 3:1 and water cement ratio 0.4 is used as a control material in compressive and flexural strength tests, cement slurry containing equal weights of cement and water is used as a control material in steel fixing test. Results suggest that most specimens of epoxy and polyester fixing materials resist approximately the same pull-out loads of specimens that have steel reinforcement fixed into fresh concrete, and about 20% greater than the loads of specimens that have steel reinforcement fixed into concrete by cement slurry. Some other epoxies show a reduction in tension loads about 10% of that when steel bars were fixed by cement slurry.

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REINFORCEMENT FIXING MATERIALS Reinforcement fixing materials or anchorage materials are the materials used to fix new bars of steel into old concretes that have to repair, the steel bars are installed into holes drilled into concrete, this system is called post installed system as described in ACI 546 R /1996 and ACI 355.1 R /1991. There are two types of bonded anchors: grouted anchors and chemical anchors. In the first type, the steel bars are bonded in place with cement grout. In the second type; the steel bars are bonded in place with two-part chemical compounds of polyesters, vinyl esters, or epoxies. The chemicals are available in four forms: glass capsules, plastic cartridges, tubes, or bulk (ACI 355.1 R/ 1991). Glass capsules are inserted into the drilled hole, and then broken by the anchor rod when it is rotated and hammered into place, thereby mixing two components to cause a chemical reaction. The plastic cartridges are used with a dispenser and a mixing nozzle, which mixes the two parts, initiating a chemical reaction while installing the compound into the drilled hole. The anchor rod is then inserted into the hole completing the installation. The setting time is dependent on temperature, varying from a few minutes up to several hours. The tube type contains two components which were mixed and then placed into the hole, and finally, inserting the anchor rod into the hole. The bulk systems use epoxies, which are either premixed in a pot and used immediately, or pumped through a mixer and injected, into the hole. The anchor is installed immediately afterward. Epoxies can be formulated to set up quickly or slowly (ACI 355.1 R /1991). Cement Slurry and Mortar: Cement slurry containing equal amount of cement and water is the most cost-effective bonding agent. Cement mortar with 3:1 sand cement ratio and 0.4 water cement ratio is the most cost- effective repairing mortar. Epoxy Adhesives: Epoxy resins are gradually becoming some of the most important and versatile polymers in modern civil engineering. Because epoxy have some unique properties, such as toughness, versatility of viscosity and curing conditions, low shrinkage compared to most other thermo- setting resins and concrete, high adhesive strength and resistance to chemicals. Epoxies are generally composed of two components: epoxy resin ( the base) and hardener ( the reactor), and some times inorganic filler. These compounds cure by chemical reaction between the resin and the hardener. They are the most common used polymer adhesives. Polyester adhesives Polyester adhesives are less sensitive to inaccuracies in proportioning than epoxies. They posses a number of desirable qualities such as good resistance to MT-90

a wide range of chemicals, high resistance to abrasion and water penetration and high bond strength with most building materials. The amount of heat involved during curing is greater than with epoxies. Shrinkage of polyesters during curing is more than with epoxies, it ranged between 4% and 8% by volume and may continue over a long time (Jack Vinson/1975). Most polyester do not bond well to damp surfaces like epoxies, they have little resistance to fire. COMPRESSIVE STRENGTH TEST ASTM C l09/1980 specified the compressive strength test method. 50mm cubes were prepared from epoxy and polyester adhesives and tested, the control specimens were made of cement mortar with the same dimensions, such specimens were cured 7 days in fresh water, stored in the laboratory temperature for 28 days then tested. FLEXURAL STRENGTH TEST Flexural strength test has been carried out according to BS 6319 Part 3/1990 to determine the flexural strength of specimens of polymer-based mortars and cement based mortars. The principle of the flexural strength test is the subjection of a test specimen of a defined geometry and in the form of a simple beam to four points loading until failure. Measurement of the apparent surface stresses in bending is carried out to determine flexural strength. The dimensions of the specimens and the four points loading test as specified in BS 6319 Part 3/ 1990 are shown in Fig. 1

Fig.1. Dimensions of the four points loading test.

A deflection transducer or a dial gauge - capable of continuously monitoring the central deflection of the beam to an accuracy of 0.01 mm- was used. Four specimens were tested at a time from each batch, the test specimens was maintained at the test temperature for not less than 16 hours before testing. The test was carried out at 20C. When testing specimens, the two moulded faces was placed to be perpendicular to the upper face that contact with the metal rollers. The flexural strength f (in N/mm2) of each specimen is calculated using the following equation: MT-91

f =FL/BD2 where F is the maximum load recorded prior to fracture in Newton. L is the span of the specimen in mm B is the breadth of the specimen at its point of fracture in mm D is the depth of the specimen at its point of fracture in mm The mean flexural strength obtained for a minimum of four specimens originating from the same batch was calculated and expressed to the nearest o.2 N/mm. STRUCTURAL FIXINGS TEST BS 5080 Part 1/1993 and BS 5080 Part 2/1986 specify a method for conducting tests under tensile and shear forces respectively on structural fixings installed in concrete used in civil engineering, the tests apply to the bonded fixings held in drilled holes by grouts or other bonding materials. The distinct situation in which the test can be applied is for comparative purposes, to compare fixings installed in drilled holes using bonding agents with fixings cast in concrete or to compare between different bonding agents. The specimens size is based on a characteristic dimension A that is equal to the maximum diameter of the fixing or of the embedded length, whichever is greater. The minimum distance of 12A between the center of any fixing and a free edge, and the minimum depth of 4A below the maximum depth of the fixing or of the hole into which it is inserted (BS 5080). The dimensions shown in Fig. 2 were used.

Fig.2. Dimensions of structural fixings specimens .

Concrete specimens was cast, compacted by mechanical vibration and cured at least 7 days in water before drilling and the fixing was located in the specimen on any cast face, i.e. not on the top, trowel led face as shown in Fig. 3. The reinforcement in the standard specimen shall be so positioned as to offer no additional strength in the zone of interaction between the concrete and the fixings. BS 5080 Part 1/1993 and BS 5080 Part 2/1986 state that the diameter of the drill bit used shall be specified either by the supplier of the fixing materials or by the user. In this study it was chosen (16mm), the hole shall be normal MT-92

to the surface of concrete, the fixing shall be secured so that the axis of the threaded portion remains normal to the surface of the concrete.

Fig.3. Structural fixing test specimens.

Tension and shear forces were applied as shown in Fig.4 using the universal testing machine.

Fig.4. Tension and shear forces

Five samples of each patch of fixing materials were tested using pull out test, also five samples of control specimens (SC) were tested. The steel bars of control specimens are stitched into the mould before casting fresh concrete using a wooden tie as can be seen in Fig. 5.

Fig. 5. The wooden tie for control specimens.

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Fig.6. Steel shear test machine.

EXPERIMENTAL PROGRAMME Compressive strength test was carried out on three specimens prepared from each of the fives selected epoxy adhesives and the three selected polyester adhesives and three specimens prepared from cement mortar. The specimens were cubes of 50 mm side length. Flexural strength test was carried on four specimens prepared from each of the fives selected epoxy adhesives and the three selected polyester adhesives and four specimens prepared from cement mortar. The specimens were prisms of 2525320 mm dimensions. Pull-out test and steel shear test were carried out on steel fixed into concrete by the five selected epoxy adhesives, the three selected polyester adhesives and cement slurry (SS). Five samples of each patch of fixing materials were tested, also five samples of control specimens were tested (SC). Materials and Mix Proportions Five epoxy adhesives and three polyesters commercially available in the Egyptian market were examined throughout the program. List of the chemical products and some of their characteristics are given in Table 1. Coded keys are assigned to the products, such coded keys are EA, EB, EC, ED, EF, PB, PC, and PF, the first litter is referred to the product epoxy or polyester, the second litter is referred to the company. Portland cement Type 1 (Amerria) meets BS 12/1989 requirements was used in the tests, the physical properties of cement are given in Table 2. MT-94

Table 1 Description of the adhesives Coded name Description and density of contents content Three components. Filler Base Hardener After mixing Three components Filler Base Hardener After mixing Three components Filler Base Hardener After mixing Two components Base Hardener After mixing Three components Filler Base Hardener After mixing Two components Comp. 1 Comp. 2 After mixing Two components Comp. 1 Comp. 2 After mixing Two components Comp. 1 Comp. 2 After mixing Description White with yellow grains Yellow liquid Light brown liquid Easy workable light brown dough Gray fine cementitious powder Light green liquid Yellow liquid Very viscose, bad workable black dough White powder Heavy white liquid Black dough Very viscose, bad workable gray dough White heavy liquid Opaque gray dough Heavy light gray slurry Gray fine powder Light amber yellow liquid Amber yellow liquid Light brown dough Light green powder Heavy pink liquid Light green dough Fine green powder Heavy pink liquid Dark green dough Light pink powder Dark pink liquid Pink dough Density gm/cm 1.82 1.3 1.1 1.25 2.03 1.15 1.0 2.0 2.2 1.25 1.45 1.75 1.7 1.8 1.8 1.84 1.3 1.15 1.6 1.7 1.03 2.04 1.95 1.23 2.04 1.78 1.26 1.96 Epoxy bonding agent Polymer concrete PC Base: hardener 2:1 Filler: base: hardener 70 : 7 : 2 Polymer concrete PC Filler: base: hardener 21 : 4 : 3 Polymer concrete PC Classification Mixing ratio By weight Filler: base: hardener 17 : 2 : 1 Filler: base: hardener 40 : 7 : 2

EA

EB

Polymer concrete PC

EC

ED

EF

PB

Polyester polymer concrete PC Polyester polymer concrete PC Polyester polymer concrete PC

3:1

PC

3:1

PF

3:1

Natural siliceous sand from (Katatba) has been used as fine aggregate in all mixes. This natural sand has a fineness modulus about 2.5, Sieve analysis test results of fine sand according to ASTM C33/2003 are given in Table 3. " N.M.S. crushed pink limestone delivered from sixty kilometer, Alexandria Cairo desert road has been used as coarse aggregate in producing concrete prisms for structural fixing test. The results of sieve analysis test for coarse aggregate are given in Table 4. Tap water was used for mixing and curing concrete and one type of admixtures was used in producing concrete; it was super-plasticizer. The quantities of concrete constituents were designed to achieve 28 days cube compressive strength more than 500 Kg/cm. The mix design for 1m of

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concrete is as follows: P.L.S. coarse aggregate = 1140 Kg, sand = 664 Kg, cement = 450 Kg, water = 157 liters and super-plasticizer = 6 liters 28 days cube compressive strength was 550 kg/cm
Table 2 Physical properties of ordinary Portland cement (Amerria)

Description of Test Percentage of water required to give a paste of standard consistency Setting time (Vicat test) Initial Final Soundness of cement ( Le Chatelier test) Fineness of cement % Retained on B.S. sieve No.(170) by weight Compressive strength of mortar cube (50mm) ( 3 sand: 1cement) 3 days, N/mm 7 days, N/mm

Specification Limit BS 12/1989

Test Data

Not less than 45 min Not more than 10 hours Not more than 10mm Not more than 10%

25% hr : min 1 : 30 2 : 40 7.7 mm 4%

Not less than 18 Not less than 27

19.73 29.24

Table 3 Sieve analysis of fine aggregate (sand) Sieve No. ASTM C 33- Upper limits Limits Lower limits % Passing " 100 100 100 No.4 100 95 99 No.8 100 80 96 No.16 85 50 84 No.30 60 25 56 No.50 10 0 10 No.100 10 0 4

Table 4 Sieve analysis of coarse aggregate (pink lime stone). Sieve No. ASTM C33 - Upper limits Limits Lower limits % Passing 1" 100 100 100 " 100 95 96 " 77 55 55 " 55 20 30 No. 4 10 0 6 No. 8 5 0 0

TEST RESULTS AND DISCUSSION Cube compressive strength Fig. 7 shows the cube compressive strength results of the epoxy and polyester adhesives and the percentage increase of the compressive strength of cement mortar. Polyester adhesives have greater compressive strength than epoxy adhesives and cement mortar, the compressive strength of polyester adhesives is 125% greater than that of cement mortar, the compressive strength of epoxy adhesives is ranged between 30% and 120% greater than that of cement mortar according to the kind of epoxy used.

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Fig . 7. Compressive strength of adhesives and cement mortar

Flexural Strength

Fig. 8. Flexural strength of adhesives and cement mortar

Fig. 8 represents the flexural strength results of the epoxy and polyester adhesives and the percentage increase of the flexure strength of cement mortar. Polyester and epoxy adhesives have greater flexural strength than cement mortar, the flexural strength of polyester adhesives is ranged between 109% and 370% greater than that of cement mortar according to the type of polyester used, the flexural strength of epoxy adhesives is ranged between 165% and 375% greater than that of cement mortar according to the kind of epoxy used. Pull out test Fig. 9 illustrates the test results of the pull out test of steel fixed into concrete by adhesives and cement slurry SS together with the control SC (steel bars fixed into fresh concrete). Most specimens of epoxy and polyester fixing materials resist approximately the same pull-out loads of specimens that have steel reinforcement fixed into fresh concrete SC and about 20% greater than the loads of specimens that have steel reinforcement fixed into concrete by cement slurry SS while EA and ED MT-97

resist approximately the same loads of SS and show a reduction in tension loads about 10% of SC load.

Fig. 9. Steel tension failure loads.

The maximum value of pull out loads is attained by polyester adhesives, it is about 24% greater than the loads attained by cement slurry. Fig.10 shows the pull-out test modes of failure. SC specimens follow concrete cone failure CF. SS, EA and ED specimens follow bond slip failure BF, while the other specimens follow the three modes of failure.

Fig. 10. Pull-out test modes of failure. Shear test Fig. 11 illustrates the test results of the shear test of steel fixed into concrete by adhesives and cement slurry SS together with the control SC.

Fig.11. Steel shear test results.

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Most Epoxy and polyester fixing materials resist approximately the same loads of SC and about 10% greater than the loads of SS while EA and ED resist approximately the same loads of SS and show a reduction in shear loads about 10% of SC load. Taking to consideration that the price of epoxy or polyester steel fixing agents is approximately forty times the price of the same weight of cement slurry, it can deduced that the cement slurry is a good choice for fixing steel into concrete. Fig. 12 shows the shear test modes of failure. SS, EA and ED specimens follow concrete sliding failure CF, while the other specimens follow steel shear failure SF.

Fig.12. Shear test modes of failure.

CONCLUSIONS Five candidate commercial epoxy resins and three candidate commercial polyester resins that are produced by five local companies were selected and tested. Compressive strength and flexural strength were carried out on epoxy and polyester fixing agents, steel reinforcement pull-out test were carried out on concrete specimens with steel reinforcement fixed into it by epoxy and polyester adhesives, also by cement slurry to compare between these different materials and the control SC (steel bars are stitched into the mould before casting fresh concrete).. Polyester adhesives have greater compressive strength than epoxy adhesives and cement mortar, the compressive strength of polyester adhesives is 125% greater than that of cement mortar. The compressive strength of epoxy adhesives is ranged between 30% and 120% greater than that of cement mortar according to the kind of epoxy used. Polyester and epoxy adhesives have greater flexural strength than cement mortar. The flexural strength of polyester adhesives is ranged between 109% and 365% greater than that of cement mortar according to the kind of polyester used, the flexural strength of epoxy adhesives is ranged between 165% and 375% greater than that of cement mortar according to the kind of epoxy used. Most specimens of epoxy and polyester fixing materials resist approximately the same pull-out loads of control specimens (that have steel reinforcement fixed into fresh concrete), and about 20% greater than the loads of specimens that have steel reinforcement fixed into concrete by cement slurry. While some specimens with steel reinforcement fixed by some epoxies resist MT-99

approximately the same pull-out loads of specimens that have steel reinforcement fixed into fresh concrete and show a reduction in loads about 10% of specimens fixed by cement slurry load. Most specimens of epoxy and polyester fixing materials resist approximately the same shear loads of control specimens (that have steel reinforcement fixed into fresh concrete), and about 10% greater than the loads of specimens that have steel reinforcement fixed into concrete by cement slurry. While some specimens with steel reinforcement fixed by some epoxies resist approximately the same shear loads of specimens that have steel reinforcement fixed into fresh concrete and show a reduction in shear loads about 10% of specimens fixed by cement slurry load. The maximum value of pull out loads is attained by polyester adhesive, it is about 24% greater than the loads attained by cement slurry. Taking into consideration that the price of epoxy or polyester steel fixing agents is approximately forty times the price of the same weight of cement slurry, it can deduced that the cement slurry is a good choice for fixing steel into concrete. Compression and flexural strengths that the usual data specified in data sheets introduced by the producing companies are less important data than that must be specified in the function of steel fixing agents, the most important data are the pull-out test and shear test loads sustained by each material. Acknowledgement The work presented in this paper was carried out at the material laboratories of the Faculty of Engineering of Alexandria University. Thanks are due to the director of the material laboratories. Thanks are also due to the material stuff. REFERENCE [1] [2] [3] ACI Committee 355.1R 91 State of the art report on anchorage to concrete. ACI Manual of Concrete Practice, Farmington Hills, Michigan. ACI Committee 548 .1 R 97 Guide for use of polymers in concrete . ACI Manual of Concrete Practice, Farmington Hills, Michigan. ASTM C 109 80 Standard Test Method for Compressive Strength of Hydraulic Cement Mortars (Using 2-in Cube Specimens) Annual Book of ASTM Standers, American Society for Testing and materials. ASTM C 881 90 Standard Specification for Epoxy Resin Base Bonding systems For Concrete Annual Book of ASTM Standards, American Society for Testing and Materials. ASTM E 488 - 96 Standard test method for strength and anchors in concrete and masonry elements Annual Book of ASTM Standards, American Society for Testing and Materials. ASTM C33-03 Standard Specification for Concrete Aggregates, Annual Book of ASTM Standards, American Society for Testing and Materials

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British Standard Institution BS 5080 part 1 Structural fixings in concrete and masonry method of test for tensile loading . British Standard Institution BS 6319 part 3, Testing of resin and polymer / cement compositions for use in construction, methods for measurement of modulus of elasticity in flexural and flexural strength Lee How son and George C.S. Yuen Building maintenance technology Building department, Ngee a polytechnic, Singapore. N. Jackson Civil engineering materials English language book society Neville, A.M. Properties of concrete. Pitman, London (1983). Y.L. Mo, Member, ASCE and J. Chan Bond and slip of plain Re-bars in Concrete Journal of Materials in Civil engineering November 1996. ASTM E 1512-01 Standard test method for testing bond performance of bonded Anchors Annual Book of ASTM Standards, American Society for Testing and Materials. ACI Committee 546 R -96 Concrete repair guide . ACI Manual of Concrete Practice, Farmington Hills, Michigan. ASTM C136-04 Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates, Annual Book of ASTM Standards, American Society for Testing and Materials. Jack R. Vinson, Tsu Wei Chou Composite materials and their use in structure London 1975. Alaa El-Din M.Jahien, .New Repairing Materials And its Applications" M.Sc thesis, Structural Engineering Department, Faculty of Engineering, Alexandria University, 2004. Tawfic Ayoub, Adel el Kurdi, A. Ali Abdo, and Alaa El-Din Jahien, "Selection of Optimum Bonding Properties in Concrete Repairing Work" under submission to ASCE 6, 2007.

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