ORI GI NAL ARTI CLE

Effects of polymercement ratio and accelerated curing

on exural behavior of hardener-free epoxy-modied
mortar panels
Muhammad Aamer Raque Bhutta
Received: 5 June 2009 / Accepted: 7 December 2009 / Published online: 18 December 2009
RILEM 2009
Abstract This experimental study reports the appli-
cability of hardener-free epoxy-modied mortar pan-
els to permanent forms as precast concrete products.
Hardener-free epoxy-modied mortars are mixed
using a Bisphenoal A-type epoxy resin without any
hardener with various polymercement ratios and
steel ber reinforcement, and subjected to different
curings. Hardener-free epoxy-modied mortar panels
are prepared with same polymercement ratios and
steel ber reinforcement on trial, and tested for
exural behavior under four-point (third-point) load-
ing. The effects of polymercement ratios and
curings on strength properties of hardener-free
epoxy-modied mortars, and on the exural strength,
exural stress-extreme tension ber strain relation,
exural loaddeection relation of hardener-free
epoxy-modied mortar panels were examined. The
adhesion in tension (to placed concrete) of the
hardener-free epoxy-modied mortar panels was also
tested. As a result, the hardener-free epoxy-modied
mortar panels develop a high exural strength, large
extensibility and good adhesion to the placed con-
crete. The epoxy-modied mortar panels are more
ductile and have high load-bearing capacity than
unmodied mortar panels and can be used as precast
concrete permanent forms in practical applications.
Keywords Epoxy resin Hardener-free epoxy
modied mortar Permanent form Polymercement
ratio Flexural behavior Adhesion
1 Introduction
Japan lays great emphasis on the issue of global
environment protection, therefore, environment-con-
scious construction materials have been used, and
sustainable concretepolymer composites have been
vigorously developed. Recently, the construction
industry has seen the development and use of such
sustainable concretepolymer composites which are
permeable polymer-modied concretes, repairing
systems using polymer-modied mortars for rein-
forced concrete structures, polymer-modied cemen-
titious waterproong systems and so on, particularly,
epoxy-modied mortars and concretes without any
hardeners are newcomers in the construction indus-
try. A lot of work has been done in the research and
development of epoxy-modied mortars and con-
cretes in Japan and it has been reported that epoxy
resin without any hardener in epoxy-modied mortars
and concretes can harden in the presence of alkalis
or hydroxide ions (OH
-
) from calcium hydroxide
[Ca(OH)
2
] as one of cement hydrates [1, 2]. Like
M. A. R. Bhutta (&)
Department of Structures and Materials Faculty of Civil
Engineering, Universiti Teknologi Malaysia, Skudai,
Johor, Malaysia
e-mail: maraque@utm.my
Materials and Structures (2010) 43:429439
DOI 10.1617/s11527-009-9578-8
polymer-modied mortars and concretes, epoxy-mod-
ied mortars and concretes are also superior in
properties [35]. They have excellent chemical resis-
tance, high strength development, abrasion resistance,
freezethaw resistance and water-tightness compared
to conventional cement mortar and concrete. In Japan,
polymer-impregnated mortar permanent forms have
been employed only in the limited applications, giving
a good costperformance balance for them, for the past
30 years [69]. Only one company currently produces
the polymer-impregnated mortar permanent forms as
commercial products to order in Japan. The manufac-
turing process and material cost of polymer-impreg-
nated mortar permanent form is relatively high. The
purpose of this experimental study is to examine the
applicability of epoxy-modied mortar panels to
permanent forms as precast concrete products as
alternate of polymer-impregnated mortar permanent
forms. In the present paper, hardener-free epoxy-
modied mortars using a bisphenol A-type epoxy resin
without any hardener, with polymercement ratios of
0, 10,15 and 20% (epoxy-cement ratios) and with steel
ber reinforcement [steel ber content of 1.2%
(volume fraction)] were prepared and subjected to
different curing conditions, and tested for strength
properties. The effects of polymercement ratios and
curings on strength properties of hardener-free epoxy-
modied mortars are examined. Hardener-free epoxy-
modied mortar panel specimens sized 450 9 900 9
30 mm were also manufactured using same polymer
cement ratios and same steel ber reinforcement
content. Based on previous research work results
reported by Ohama et al. [4] and present study, the
panel specimens were subjected to optimum curing
condition [1-d moist [20C, 90% (RH)] ? 1-d steam
(90C) ? 1-d heat (120C)]. The cured hardener-free
epoxy-modied mortar panel specimens are tested for
exural behavior under four-point (third-point)
loading. The exural strength, exural stress-extreme
tension ber strain relation, exural loaddeection
relation were investigated. The effects of polymer
cement ratio and accelerated curing on exural
behavior of hardener-free epoxy-modied mortar
panel specimens are observed. To examine the adhe-
sion in tension of epoxy-modied mortar panels to
placed concrete, fresh concrete is placed on the epoxy-
modied mortar panels attached to molds (450 9
900 9 30 mm), and subjected to a 28-d dry [20C,
60%(RH)] curing. The effect of polymercement ratio
on the adhesion or bond strength of hardener-free
epoxy-modied mortars to placed concrete was also
discussed. Consequently, the hardener-free epoxy-
modied mortar panels develop a high exural
strength, large extensibility and good adhesion to the
placed concrete. The hardener-free epoxy-modied
mortar panels are more ductile and have high load-
bearing capacity than unmodied mortar panels and
can be used as precast concrete permanent forms in
practical applications.
2 Materials
2.1 Cement
Ordinary Portland cement as specied in JIS (Japa-
nese Industrial Standard) R 5210 (Portland cement)
was used. The physical properties and chemical
compositions of the cement are given in Table 1.
2.2 Aggregate
Crushed aggregate and two types of crushed sands
were used as coarse and ne aggregates. Table 2
gives the properties of the aggregates.
Table 1 Physical properties and chemical compositions of cement
Density
(g/cm
3
)
Blaine specic
surface
Setting time (h-min) Compressive strength of mortar (MPa)
Initial set Final set 3d 7d 28d
3.16 3370 210 330 28.8 43.6 61.2
Chemical compositions (%)
MgO SO
3
ig. loss
1.48 2.12 1.90
430 Materials and Structures (2010) 43:429439
2.3 Epoxy resin
Diglycidyl ether of bisphenol A was used as an epoxy
resin or hardener-free epoxy resin. The constitutional
formula of the epoxy resin is expressed in Fig. 1. The
properties of the epoxy resin are shown in Table 3.
2.4 Steel ber reinforcement
Commercially available steel bers were used as
reinforcement. The properties of steel bers are
shown in Table 4.
3 Test program
3.1 Mixing of hardener-free epoxy-modied
mortars
According to JIS A 1171 (Test methods for polymer-
modied mortar), all hardener-free epoxy-modied
mortars were mixed using mix proportions as shown
in Table 5 with polymercement ratios (P/C) of 0, 10,
15 and 20%, steel ber content of 1.2% (volume
fraction) and a superplasticizer.
3.2 Preparation of hardener-free epoxy-modied
mortar specimens for strength tests
Beams specimens 40 9 40 9 160 mm for exural
and compressive strength tests and cylindrical spec-
imens U50 9 100 mm for tensile strength test were
molded using hardener-free epoxy-modied mortars,
and subjected to the following curings:
(1) Steam curing: [1-d moist (20C, 90%(RH)] ?
2-d steam(90C)]
(2) Autoclave ? heat curing: [1-d moist (20C,
90%(RH) ? autoclave (120C, 3 h) ? 1-d heat
(120C)]
(3) Steam ? heat curing: [1-d moist [20C, 90%
(RH)] ? 1-d steam (90C) ? 1-d heat (120C)]
Table 2 Properties of aggregates
Type of aggregate Size (mm) Fineness modulus Bulk density (kg/l) Density (g/cm
3
) Water absorption (%)
Fine
a
0.152.5 3.29 1.48 2.62 0.94
2.55 4.83 1.64 2.63 0.58
Coarse
b
520 6.61 1.66 2.63 0.54
a
Aggregate for epoxy-modied mortar panels,
b
aggregate for placed concrete
CH2 CH CH2
CH3
CH3
C O O
O
CH2 CH2 CH
CH3
CH3
C O
O
CH2 CH CH2
OH
O
n*
*n= 0.1 0.2
Fig. 1 Constitutional
formula of diglycidyl ether
of bisphenol A
Table 3 Properties of bisphenol A epoxy resin
Epoxy equivalent Molecular weight Density (g/cm
3
, 20C) Viscosity (mPa s, 20C) Flash point (C)
184 380 1.16 38000 264
Table 4 Properties of steel ber
Size (mm) Tensile strength (MPa) Elastic modulus (GPa) Elongation (%)
/ 0.3 9 0.4 9 15 585 200 50
Materials and Structures (2010) 43:429439 431
3.3 Preparation of hardener-free epoxy-modied
mortar panel specimens for exural behavior
For exural behavior, mortar panel specimens
450 9 900 9 30 mm were molded and subjected to
optimum curing condition [1-d moist [20C, 90%
(RH)] ? 1-d steam (90C) ? 1-d heat (120C)]. The
manufacturing process of hardener-free epoxy-mod-
ied mortar panel specimens and their view after
demolding are shown in Figs. 2 and 3, respectively.
3.4 Preparation of specimens for adhesion test
in tension
Preparation of specimens for adhesion in tension,
ready-mixed concrete with specied design compres-
sive strength of 30 MPa is placed on the epoxy-
modied mortar panels attached to molds (450 9
900 9 300 mm) as shown in Fig. 4, and subjected to
a 28-d dry [20C, 60% (RH)] curing. Ready-mixed
concrete having slump of 80 mm and air content of
Table 5 Mix proportions of hardener-free epoxy-modied mortars
w/c (%) s/a (%) P/C (%) Mix proportions (kg/m
3
)
Water Cement Sand Steel bre Admixture
a
0.152.5 mm 2.55 mm
35.0 58.0 0 175 500 958 715 95 3.5
34.8 10 174 500 958 715 95 3.5
34.6 15 173 500 958 715 95 3.5
34.4 20 172 500 958 715 95 3.5
a
Superplasticizer
Fig. 2 Manufacturing of hardener-free epoxy-modied mortar panel specimens
Fig. 3 A view of hardener-free epoxy-modied mortar panel specimen
432 Materials and Structures (2010) 43:429439
4.5% was used. The mix proportions of ready-mixed
concrete is given in Table 6. The hardener-free
epoxy-modied mortar panel specimens have rough
surface on back for mechanical interlocking or
bonding to placed concrete.
4 Testing procedures
4.1 Strength tests for hardener-free epoxy-
modied mortar specimens
Beams specimens were tested for exural and
compressive strengths in accordance with JIS A
1171. According to JIS A 1185, splitting tensile
strength of specimens was done.
4.2 Flexural test for hardener-free epoxy-
modied mortar panel specimens
The hardener-free epoxy-modied mortar panel spec-
imens were tested for exural behavior under four-
point (or third-point) loading with a span of 750 mm
and a loading rate of 50 N/s by using the Amsler-type
universal testing machine. Figure 5 illustrates the
setup of exural test for the steel ber reinforced
epoxy-modied mortar specimen. At the same time,
the central (or midspan) deection of the specimens
was measured by a sensitive LVDT (linear variable
differential transformer), and their extreme tension
ber strain was measured by the three 30-mm-long
paperback electrical strain gages installed on the
extreme tension ber at the midspan. Their exural
toughness was calculated as an area under a exural
loaddeection curve up to a deection at the
maximum exural load (at failure load). Their exural
strength was calculated using the following Eq. 1
r
f

P
bh
2
1
where r
f
is exural strength (MPa), P is maximum
exural load (N), is span (mm), b is width (mm) of
specimen, and h is thickness (mm) of specimen. Their
exural modulus of elasticity was calculated by the
following Eq. 2
E
f

23P
3
54bh
3
d
2
where E
f
is exural modulus of elasticity (10
-3
GPa),
P is exural load (N), d is central (midspan)
deection (mm), is span (mm), b is width (mm)
of specimen, and h is thickness (mm) of specimen.
4.3 Adhesion test in tension
According to JIS 6909, the cured specimens were
tested for adhesion in tension by using manually
operated jack pull-gage. A set up for adhesion test in
tension is shown in Figs. 6 and 7.
5 Test results and discussion
5.1 Effects of polymercement ratio and
accelerated curings on strength properties
of hardener-free epoxy-modied mortars
Figure 8 illustrates the polymercement ratio versus
compressive, exural and tensile strengths of
Fig. 4 (1) Installation of
hardener-free epoxy-
modied mortar panel
specimens. (2) Placement of
concrete on hardener-free
epoxy-modied mortar
panel specimens
Table 6 Mix proportions of placed concrete for adhesion test
w/c
(%)
s/a
(%)
Mix proportions (kg/m
3
)
Water Cement Sand Aggregate Admixture
a
48.5 44.1 160 330 800 1016 3.30
a
Water-reducing agent
Materials and Structures (2010) 43:429439 433
accelerated-cured hardener-free epoxy-modied mor-
tars with steel ber reinforcement. The effects of
polymercement ratio and accelerated curing
conditions on the strengths of hardener-free epoxy-
modied mortars are considerable. The strengths of
hardener-free epoxy modied mortars with polymer
Fig. 5 Setup of exural
test for hardener-free
epoxy-modied panel
specimen
Fig. 6 Adhesion of steel plates to hardener-free epoxy-modied mortar panel specimens
P
Load cell
Central hole jack
Continuous thread stud
Steel stand
Steel plate
Epoxy-modified mortar
panel specimen
Fig. 7 A set up for
adhesion test in tension
434 Materials and Structures (2010) 43:429439
cement ratios of 10, 15 and 20% are signicantly
increased compared to unmodied mortars (with a
polymercement ratio of 0%). Except for steam cured
[1-d moist (20C, 90% (RH)] ? 2-d steam (90C)]
hardener-free epoxy-modied mortars, the compres-
sive, exural and tensile strengths of auto-
clave ? heat cured and steam ? heat cured
hardener-free epoxy-modied mortars are increased
with increasing polymercement ratio. The compres-
sive, exural and tensile strengths of steam cured
hardener-free epoxy-modied mortars increased with
increasing polymercement ratio, and reached its
maximum at polymercement ratios of 10 to 20%.
The reason for this is that the strength development of
steam cured hardener-free epoxy modied mortars
with high polymercement ratios needs mature
hardening reaction to get higher degree of hardening
of the hardener-free epoxy resin [4, 5]. The strengths
of hardener-free epoxy-modied mortars are remark-
able due to maximum hardening reaction during
autoclave ? heat curing and steam ? heat curing.
The compressive, exural and tensile strengths of the
steam ? heat cured hardener-free epoxy-modied
mortars are somewhat higher than those of the
autoclave ? heat cured ones. The application of heat
curing to the autoclave- or steam-cured hardener-free
epoxy-modied mortars, the hardener-free epoxy
resin in the mortars can harden completely by the
acceleration of its hardener reaction due to the heat
curing in the presence of alkalis or hydroxide ions
(OH
-
) produced by the hydration of cement in the
mortars, and contributes to the strength development
of the mortars. It is evident from the results of SEM
observation of microstructures and disappearance of
epoxy group in hardened epoxy resin in Infrared
spectroscopy reported by Ohama et al. [3]. The
hardening reaction of the hardener-free epoxy resin in
the presence of the hydroxide ions in the mortars can
be expressed by the following formula [2, 10]:
The signicant increase in strengths of hardener-
free epoxy-modied mortars is a result of a strong
adhesion between comatrixes (cement hydrates ?
epoxy resin) and ne aggregates and steel bers due
to steam ? heat curing. This can be attributed to the
good timing of the interaction between the cement
hydration and hardening of the hardener-free epoxy
resin, and then the development of strong bond
between comatrixes (cement hydrates ? epoxy resin)
and ne aggregates and steel bers.
Fig. 8 Polymercement ratio versus compressive, exural and
tensile strengths of accelerated-cured hardener-free epoxy
modied mortars
OH
Hardened epoxy resin
O CH
2
CH CH
2
n
O CH
2
CH CH
2
O
Epoxy resin
CH
2
CH CH
2
O CH
2
CH CH
2
O
H O
O
n from cement
hydration
OH
O
n
OH
Materials and Structures (2010) 43:429439 435
5.2 Flexural behavior of hardener-free
epoxy-modied mortar panel specimens
Figures 9, 10, 11, 12 represent the exural stress-
extreme tension ber strain curves for hardener-free
epoxy-modied mortar panel specimens with poly-
mercement ratios of 0, 10, 15 and 20% and steel
ber reinforcement. The exural stress-extreme ten-
sion ber strain relationship of hardener-free epoxy-
modied mortar panel specimens with polymer
cement ratios of 10, 15 and 20% is much higher
than that of mortar panel specimens with polymer
cement of ratio of 0%. The maximum exural stress
of the hardener-free epoxy-modied mortar panel
specimens is gradually increased with increasing
polymercement ratio and remarkably improved at
polymercement ratio of 20%.
Table 7 and Fig. 13 show the exural behavior of
hardener-free epoxy-modied mortar panel speci-
mens with polymercement ratios of 0, 10, 15 and
20% and steel ber reinforcement. The deections of
mortar panel specimens with polymercement ratio
of 0% are found to increase linearly with maximum
exural load until almost failure, but the deections
of hardener-free epoxy-modied mortar panel spec-
imens with polymercement ratios of 10, 15 and 20%
are increased almost linearly with increasing exural
load until the maximum exural load giving a brittle
failure. At this point, the difference in exural
behavior due to hardener-free epoxy resin modica-
tion to mortar panel specimens with polymercement
ratios of 10, 15 and 20% and mortar panel specimens
with polymercement ratios of 0% is clear. The
maximum deections, exural toughness, exural
Fig. 9 Flexural stress-extreme tension ber strain curves for
mortar panel specimens with polymercement ratio of 0%
Fig. 10 Flexural stress-extreme tension ber strain curves for
hardener-free epoxy-modied mortar panel specimens with
polymercement ratio of 10%
Fig. 11 Flexural stress-extreme tension ber strain curves for
hardener-free epoxy-modied mortar panel specimens for
polymercement ratio of 15%
Fig. 12 Flexural stress-extreme tension ber strain curves for
hardener-free epoxy-modied mortar panel specimens for
polymercement ratio of 20%
436 Materials and Structures (2010) 43:429439
strengths and exural moduli of elasticity of the
hardener-free epoxy-modied mortar panel speci-
mens are signicantly increased by increasing poly-
mercement ratio. The exural strength, exural
toughness and maximum deections of hardener-free
epoxy-modied mortar panel specimens are more
than twice than that of mortar panel specimens with
polymercement ratio of 0%. The exural moduli of
elasticity of hardener-free epoxy-modied mortar
panel specimens is also somewhat improved with
increasing polymercement ratio. The hardener-free
epoxy resin modication and the application of heat
curing to the steam-cured hardener-free epoxy-mod-
ied mortar panel specimens is proved to be effective
to improve the strength properties. The steam curing
may provide an induction period for epoxy resin
hardening reaction in the hardener-free epoxy-mod-
ied mortars, and then an application of heat curing
to the steam-cured hardener-free epoxy-modied
mortars may cause the acceleration of the epoxy
resin hardening reaction in the presence of hydroxide
ions, and the evaporation of water in the mortars.
This contributes to the high-strength development in
the exural behavior of hardener-free epoxy-modied
mortar panel specimens with polymercement ratios
of 10, 15 and 20%. From the above exural behavior
trend, it is obvious that hardener-free epoxy-modied
mortar panel specimens are more ductile. This means
that hardener-free epoxy-modied mortar panel spec-
imens with polymercement ratios of 10, 15 and 20%
have a high load-bearing capacity and large extensi-
bility compared to mortar panel specimens with
polymercement ratio of 0% as permanent form
application.
5.3 Adhesion test in tension of hardener-free
epoxy-modied mortar panel specimens to
placed concrete
Figure 14 exhibits the adhesion test in tension of
hardener-free epoxy-modied mortar panel speci-
mens to placed concrete. As mentioned in the
preparation of specimens for adhesion in tension,
the hardener-free epoxy-modied mortar panel spec-
imens have rough surface on back for mechanical
bonding to placed concrete. Therefore, the effect of
polymercement ratio on the adhesion test in tension
was not clearly observed. All specimens showed
cohesive failure in placed concrete substrate. The
hardener-free epoxy-modied mortar panel speci-
mens with polymercement ratio of 15% gave higher
adhesion in tension of 2.6 MPa to placed concrete
which is higher than that of 1.8 MPa of polymer-
impregnated permanent forms or panels to placed
concrete [8].
6 Conclusions
Based on the above test results the following
conclusions may be drawn:
Fig. 13 A exural load-deection curves for hardener-free
epoxy-modied mortar panel specimens
Table 7 Flexural behavior of hardener-free epoxy-modied mortar panel specimens
Polymercement ratio
(P/C)
Flexural behavior
Max. extreme tension
ber strain (910
-6
)
Max. deection
(mm)
Flexural
toughness (kN mm)
Flexural
strength (MPa)
Flexural modulus
of elasticity (GPa)
0 395 1.42 3.9 8.9 23.0
5 606 3.29 14.6 16.2 26.7
10 779 3.40 16.8 18.0 24.1
20 798 3.52 19.5 20.2 26.5
Materials and Structures (2010) 43:429439 437
1. The effects of polymercement ratio and accel-
erated curing on the strengths of hardener-free
epoxy-modied mortars are signicantly marked.
The strengths of accelerated-cured hardener-free
epoxy-modied mortars are increased with
increasing polymercement ratio. The applica-
tion of heat curing to autoclave- or steam-cured
hardener-free epoxy modied mortars causes a
signicant improvement in their strengths
because of the acceleration of epoxy resin
hardening reaction in the presence of alkalis or
hydroxide ions and the elimination of water in
the mortars.
2. The maximum exural stress of the hardener-free
epoxy-modied mortar panel specimens is grad-
ually increased with increasing polymercement
ratio and remarkably improved at polymer
cement ratio of 20%.
3. Modication of hardener-free epoxy resin to
mortar panel specimens increases the deection
characteristics of all epoxy-modied mortar panel
specimens regarding to polymercement ratio.
The exural strength, exural toughness and
maximum deections of hardener-free epoxy-
modied mortar panel specimens are more than
twice than that of mortar panel specimens with
polymercement ratio of 0%. The exural moduli
of elasticity is also somewhat increased with
increasing polymercement ratio of hardener-free
epoxy-modied mortar panel specimens.
4. The effect of polymercement ratio on the
adhesion test in tension is not evident. All
specimens showed cohesive failure in concrete
substrate. The concrete with polymercement
ratio of 15% gives higher adhesion in tension of
2.6 N/mm
2
to placed concrete.
5. The hardener-free epoxy-modied mortar panels
are more ductile and have high load-bearing
capacity than unmodied mortar panels and can
be used as precast concrete permanent forms in
practical applications.
Acknowledgements The authors wishtoexpress their gratitude
and sincere appreciation to Research and Development Center,
Takamura Holdings Co., Ltd., for nancingthis researchworkand
conducting experiments in its laboratory.
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