Polymers for Repair

Manu Santhanam

Chapter Outline
Basics of polymers
Polymer structures
Mechanical characteristics
Thermal behaviour
Polymers for repair
Polymer modified cementitious systems
Resin repair mortars
Bonding aids
Crack injection resins
Polymer impregnation

Basics of polymers
Polymer = many mers

Covalent chain configurations and strength:

Direction of increasing strength

Types of polymers
Homopolymer (-A-A-A-A-A-)n
Copolymer
- Random (-A-A-B-A-B-A-A-A-B-)n
- Alternating (-A-B-A-B-A-B-)n
- Block (-A-A-B-B-A-A-B-B-)n

Polymer characteristics
Molecular weight, Mw: Mass of a mole of chains.

Tensile strength (TS):

--often increases with Mw.
--Why? Longer chains are entangled (anchored) better.

% Crystallinity: % of material that is crystalline.

--TS and E often increase
with % crystallinity.
--Annealing causes
crystalline regions
to grow. % crystallinity
increases.

crystalline
region
amorphous
region

Molecular weight
Function of chain length
Number average and weight average
defined
Degree of polymerization defined as the
total number of units

Mechanical characteristics
Influenced by rate of deformation,
temperature, and presence of water, oxygen,
organic solvents etc.
Three types of responses Brittle, plastic,
and elastomeric

Tensile response

Brittle behaviour common at low temperatures and high strain rates

Elastomeric case

Compare to responses of other polymers:

--brittle response (aligned, cross linked & networked case)
--plastic response (semi-crystalline case)

Thermoplastic Vs. Thermosetting

Thermoplastics:
--little cross linking
--ductile
--soften w/heating
--polyethylene (#2)
polypropylene (#5)
polycarbonate
polystyrene (#6)

T
viscous
liquid

mobile
liquid

Thermosets:
--large cross linking
(10 to 50% of mers)
--hard and brittle
--do NOT soften w/heating
--vulcanized rubber, epoxies,
polyester resin, phenolic resin

crystalline
solid

Callister,
rubber
Fig. 16.9
tough
plastic
partially
crystalline
solid

Molecular weight

Tm

Tg

Viscoelasticity

Stress relaxation test:

--strain to o and hold.
--observe decrease in
stress with time.

Relaxation modulus:
(t )
Er (t )
o

Data: Large drop in Er

for T > Tg.

(amorphous
polystyrene)

Sample Tg(C) values:

PE (low Mw)
PE (high Mw)
PVC
PS
PC

-110
- 90
+ 87
+100
+150

Additives for polymers

Fillers improve strength, hardness, dimensional
and thermal stability; e.g. fine sawdust, silica
flour, sand, glass, clay etc.
Plasticizers Improve ductility and toughness
(also flexibility), and reduce hardness and
stiffness; generally liquids with low vapour
pressure and low molecular weights; act as
lubricants, especially for lowering brittleness
(used in thin sheets, tubing, etc.)

..contd.
Stabilizers Improve resistance to environment,
especially light, UV radiation and oxidation (in
other words, aging)
Colourants Dyes (that dissolve in the polymer)
and pigments (that remain as a separate phase)
Flame retardants Interfere with combustion
process, or cause cooling of the burning region

Polymer modified cementitious

systems

Polymer based chemical admixtures

Lignosulphonate
Both Ca and Na-Lig used
Avg MW 20000 - 30000

Sulphonated naphthalene
formaldehyde
Higher MW more effective

Complex interactions with cement

Polycarboxylic ether
Bulky side chain causes
steric hindrance improved
dispersion, lasts longer

Mainly physical interactions

Method of action

http://www.carolinapumping.com/education/elementary/admixtures.html

Styrene-butadiene latex concrete

Combination of styrene and
butadiene
Solids content of latex ~ 40
50%
Polymer film forms along with
the hydrating cement, resulting
in a monolithic matrix
Causes improved pasteaggregate bond, resistance to
crack propagation, and
watertightness of concrete

Structure of SBR latex

Properties of SBR latexes

Milky white dispersion in water (sometimes used as partial
replacement of mix water)
Same level of alkaline passivation protection offered to
steel as conventional cementitious materials
Sometimes, repair products sold as 2 part material
powder (mortar) and liquid (SBR latex); mixed on site;
spray dried polymer also available directly mixed with the
powder only water to be added at site
Other latexes in use PVA, PVDC, acrylics and modified
acrylics

Polymer modified cement mortars

Mainly used for repair of reinforced
concrete, for replacement of cover, between
12 and 30 mm thick
Also for re-fixing external claddings

Resin Repair Mortars

For smaller covers (< 12 mm) and
small areas

Materials
Based on reactive resins filled with
carefully graded aggregates
Epoxy, polyester, and acrylic resins used
thermosetting materials
Generally, supplied as 2/3 component
systems: resin, hardener, and fillers

Epoxy resins
Material with reactive hooks along with a
hardener with reactive eyes
Hook

Exothermic
reaction

2 eyes

Curing is an exothermic
reaction leads to
hardening
Rate of cure increases with
temperature

Volume change due to

thermal contraction to be
accounted for

Unsaturated reactive polyester resins

Liquid resin contains both hooks and eyes
in the right proportion
Hardener is based on organic peroxide
causes unblocking of hooks
Maximum heat evolution occurs after
setting of resin this causes significant
thermal contraction

Unsaturated acrylic resin

Based on monomers of very low viscosity or
blends of monomers
Methyl methacrylate most commonly used
Mortars exhibit lesser shrinkage than unsaturated
polyester resins
Also lower modulus, implying that stresses due to
inherent shrinkage will be absorbed without
causing bond failure with the concrete substrate

Selection of resin
Epoxy resin most widely used
Grading of fillers important to provide
stability to the resin
Polymer based repair material is bonded
directly to concrete
Important to be aware of the distinction in
physical and mechanical properties of the
resin and concrete

Polymer Bonding Aids

Polymer bonding aids

To enhance bond between repair concrete
and substrate
Open time should be carefully chosen
Spray dried factory blended polymer
bonding aids now available
Sometimes, the epoxy bonding aid also
serves as impermeable barrier

Crack injection resins

For cracks greater than 0.3 mm
Cause of cracking should be ascertained
Low viscosity resins chosen either
applied as such or pressure injected
For large cracks (1 2 mm) resin may
simply drain away; here, thixotropic resins
should be used

Polymer impregnation
For filling up the voids on the concrete
surface, in order to improve abrasion
resistance
Based on acrylic resins such as methyl
methacrylate

Summary
Construction materials are getting more and more
diverse!
Range of polymeric materials available for
concrete repair
Essential to be aware of differences in physical
and mechanical properties of polymer and
concrete; also, one should be aware of the
environmental resistance of the polymer before
selecting for a specific application