ACI 503.

5R-92
(Reapproved 2003)

Guide for the Selection of Polymer Adhesives with Concrete

Reported by ACI Committee 503
Raymond J. Schutz Chairman Robert W. Gaul* Subcommittee Chairman Milton D. Anderson* Roger W. Black John P. Cook Floyd E. Dimmick Wolfgang D. Eisenhut Jack J. Fontana*
*

Myles A. Murray Secretary Joseph A. McElroy* Paul F. McHale Peter Mendis* Richard Montani Joseph M. Plecnik

Paul R. Hollenbach David P. Hu T. Michael Jackson Troy D. Madeley Albert Mayer

Hamid Saadatmanesh W. Glenn Smoak Joe Solomon Michael M. Sprinkel Douglas G. Walters*

Members of Subcommittee who prepared this report.

This guide provides the engineer, contractor, and architect with a description of the various types of polymer adhesives (epoxy, polyester, acrylic, polyurethane, polysulfide, silicone, vinyl acetate, and styrene butadiene) most frequently used for adhesive bonding of fresh concrete to cured concrete, repair of cracks in concrete, bonding concrete to other materials, and adhesive grouting of bolts and other inserts into concrete. The guide emphasizes the factors that should be considered when selecting a structural adhesive, including characteristics during installation and in service. The benefits and limitations of adhesive bonding are discussed for each application. Keywords: acrylic resins; adhesives; bolts; bonding; epoxy resins; fire resistance; fresh concrete; grouting; latex; loads (forces); methacrylate; plastics, polymers, and resins; polyester; polysulfide; polyurethane; repairs; sealing; serviceability; silicone resins; styrene-butadiene resins; toxicity; vinyl acetate; water-borne adhesives.

CONTENTS Chapter 1General, p. 503.5R-2 1.1Organization of the guide 1.2Caution 1.3Advantages/disadvantages of adhesive bonding 1.4Glossary of terms Chapter 2Solvent-free adhesives, p. 503.5R-4 2.1Application characteristics 2.2Properties during cure 2.3Properties of cured adhesive 2.4Distinguishing characteristics Chapter 3Water-borne adhesives (latex and latex powder adhesives), p. 503.5R-8 3.1Application characteristics 3.2Properties of cured adhesive 3.3Distinguishing characteristics Chapter 4Adhesive selection criteria, p. 503.5R-10 4.1Type and magnitude of loads 4.2Conditions during application
Copyright 1992, American Concrete Institute. All rights reserved including rights of reproduction and use in any form or by any means, including the making of copies by any photo process, or by electronic or mechanical device, printed, written, or oral, or recording for sound or visual reproduction or for use in any knowledge or retrieval system or device, unless permission in writing is obtained from the copyright proprietors.

ACI Committee Reports, Guides, Manuals, Standard Practices, and Commentaries are intended for guidance in planning, designing, executing, and inspecting construction. This document is intended for the use of individuals who are competent to evaluate the significance and limitations of its content and recommendations and who will accept responsibility for the application of the material it contains. The American Concrete Institute disclaims any and all responsibility for the stated principles. The Institute shall not be liable for any loss or damage arising therefrom. Reference to this document shall not be made in contract documents. If items found in this document are desired by the Architect/Engineer to be a part of the contract documents, they shall be restated in mandatory language for incorporation by the Architect/Engineer.

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Chapter 5Adhesive for bonding of hardened concrete to hardened concrete, p. 503.5R-10 5.1Important application characteristics 5.2Important bond-strength considerations Chapter 6Adhesives for bonding of plastic concrete to hardened concrete, p. 503.5R-11 6.1Important application characteristics 6.2Important bond-strength considerations Chapter 7Adhesives for repair of cracks in concrete, p. 503.5R-11 7.1Important application considerations 7.2Important strength considerations Chapter 8Adhesives for bonding inserts into concrete, p. 503.5R-12 8.1Important application considerations 8.2Important strength considerations Chapter 9Adhesives for bonding concrete and other materials, p. 503.5R-12 9.1Important application considerations Chapter 10Quick reference guide, p. 503.5R-14 Chapter 11References, p. 503.5R-14 11.1Specified and/or recommended references 11.2Cited references 11.3Additional references CHAPTER 1GENERAL This guide is intended to aid the engineer, contractor, and architect in choosing a proper polymer adhesive for adhesive bonding applications encountered in joining concrete members in construction, repair, and rehabilitation of concrete structures. 1.1Organization of the guide Sections 2 and 3 of the guide describe the properties of the two major classes of polymer adhesives in use (solvent-free adhesives and water-borne adhesives) and identifies the distinguishing features of the specific polymers (e.g., epoxy, acrylic, and polyvinyl acetate) within each class. Section 4 lists the basic criteria that should be used in all adhesive selections. Sections 5 through 9 provide additional guidance specific to the selection of adhesives for bonding fresh or hardened concrete to hardened concrete, repairing cracked concrete, bonding other materials to concrete, and bonding inserts into concrete. Section 10 is a quick reference guide to help narrow the search for a proper adhesive. This guide includes more data and information on epoxy adhesives than on other types because epoxy adhesives are the most versatile and by far the most widely used with concrete. Information on other types is included where there is a choice. 1.2Caution This guide presents data on the various polymer and copolymer types (epoxy, polyester, acrylic, polyurethane,

silicones, vinyl acetate, and styrene-butadiene) either as typical values, as a range of values, or as relative values. Because of the ease of tailoring polymer products by formulation, some very special products within a group may possess values for a particular characteristic that differ widely from the typical value or fall outside of the range. To include all extremes would lead to a less accurate perception of the true nature of these groups of products as they are commonly used. The cited characteristics of classes of polymer adhesives are only a guide to help narrow the field in a search for an appropriate adhesive. When using an adhesive, the manufacturers literature should always be reviewed. Manufacturers recommendations should be followed because the adhesive may differ from other adhesives in its class. Many adhesives contain hazardous ingredients. Material Safety Data Sheets (MSDS) and labels should always be consulted before using the adhesive. 1.3Advantages/disadvantages of adhesive bonding The major advantage of adhesive bonding is that it allows distribution of an applied load over much larger areas compared to other methods of fastening, thus reducing the unit stress on the elements that are bonded. It allows attachment without having to alter the shape or deface the elements to be attached. The adhesive bond line can also act as a moisture barrier.1,2 The major disadvantage of adhesive bonding is that the bonded elements cannot be disturbed after being joined, because the adhesive cures for hours or days, depending on the cure rate of the adhesive used and the temperature of the elements being bonded. Thus, work progress may be slowed down if the other work tasks cannot be scheduled to accommodate the adhesive cure time. 1.4Glossary of terms This glossary gives definitions of some terms that are used in adhesive bonding in the concrete industry. Other terms may be found in ASTM D 907. acceleratora material that increases the rate of a chemical reaction. acrylicone of a group of resins formed by polymerizing the esters or amides of acrylic acid. adhesivesthe group of materials used to join or bond similar or dissimilar materials; for example, in concrete work, the epoxy resins. age hardeningthe progressive change in the chemical and physical properties of an adhesive, leading to embrittlement. bond linethe interface between two surfaces bonded together with an adhesive. catalysta substance whose presence increases the rate of a chemical reaction. In some cases, the catalyst is consumed and regenerated; in other cases, the catalyst seems not to enter into the reaction, but functions by virtue of some other characteristic.

SELECTIONOF OFPOLYMER POLYMER ADHESIVES WITH CONCRETE SELECTION ADHESIVES WITH CONCRETE
cohesivethe type of molecular attraction that holds adhesives and other materials together. cohesive failurea failure by separation within the adhesive itself, or within the substrate, rather than in the adhesives bond to the substrate. copolymerizationpolymerization of two or more dissimilar monomers. crosslinking agenta substance that increases the molecular weight of a polymer by chemically linking and bridging the polymer chains. cureto change the properties of a chemical (usually a polymer) by increasing its molecular weight by polymerization or crosslinking, usually accomplished by the action of heat, catalyst, crosslinking agent, curing agent, or any combination, with or without pressure. curing agenta substance that accelerates or participates in the curing of chemicals, sometimes referred to as a hardener. elastomericpertaining to a substance that has rubberlike properties. emulsiona two-phase liquid system in which small droplets of one liquid (the internal phase) are immiscible in, and dispersed uniformly throughout, a second continuous liquid phase (the external phase). epoxy resinsa class of organic chemical bonding systems used in the preparation of special coatings or adhesives for concrete or as binders in epoxy resin mortars and concretes. exothermicpertaining to a chemical reaction that occurs with the evolution of heat. flexibilizera substance that is mixed with a more brittle material to make the latter more ductile. gela colloid in which the dispersed phase has combined with the continuous phase to produce a viscous jelly-like material. glass transition temperaturethe temperature or range of temperature at which polymeric materials change from a rigid, glass-like state to an elastomeric-like state. heat deflection temperature (HDT)the temperature at which a plastic material reaches an arbitrary deflection when subjected to an arbitrary load and test condition. It can be an indication of the glass transition temperature, although these two temperatures are not necessarily equal. initiatora substance that causes a chemical reaction (such as polymerization or curing) to start. The term usually applies to free-radical polymerization-type reactions. latexa dispersion of organic polymer particles in water. minimum film-forming temperature (MFFT)the lowest temperature at which the polymer particles of a latex have sufficient mobility and flexibility to coalesce into a continuous film. monomeran organic liquid, of relatively low molecular weight, that creates a solid polymer by reacting with itself or other compounds of low molecular weight, or both. plasticizera substance added to polymer or copolymer to reduce its minimum film-forming temperature and/or its glass transition temperature. polyesterone of a large group of synthetic resins, mainly produced by reaction of unsaturated dibasic acids

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with dihydroxy alcohols; commonly prepared for application by mixing with a vinyl-group monomer and free-radical catalysts at ambient temperatures and used as binders for resin mortars and concretes, fiber laminates (mainly glass), adhesives, and the like. polymerthe product of polymerization; more commonly a rubber or resin consisting of large molecules formed by polymerization. polymerizationthe reaction in which two or more molecules of the same substance (monomer) combine to form a compound containing the same elements, but of high molecular weight. polyola polyhydric alcohol, i.e., one containing two or more hydroxyl groups. polysulfidesynthetic polymers obtained by the reaction of sodium polysulfide with organic dichlorides. polyurethanereaction product of an isocyanate with anyone of a wide variety of other compounds containing an active hydrogen group; used to formulate tough, abrasionresistant coatings. polyvinyl acetatecolorless, permanently thermoplastic resin; usually supplied as an emulsion or water-dispersible powder characterized by flexibility, stability toward light, transparency to ultraviolet rays, high dielectric strength, toughness, and hardness; the higher the degree of polymerization, the higher the softening temperature; may be used in paints for concrete. promotersubstances that, when added in small quantities, increase the activity of catalysts, as well as increase or promote polymerization activity. pseudoplasticoften referred to as thixotropic, a substance whose viscosity decreases with increasing shear. rheologythe science dealing with the flow of materials. siliconea resin in which the main polymer chain consists of alternating silicon and oxygen atoms, with carbon containing side groups; silicones may be used in caulking or coating compounds, admixtures for concrete, or as adhesives. substratea material upon the surface of which an adhesive is spread for the purpose of bonding. surface-active agenta substance that markedly affects the interfacial or surface tension of solutions even when present in very low concentrations. surface energythe interfacial free energy per unit area of the boundary between the surface of a substrate and the air above it. surface tensiona measure of surface energy, arising from molecular forces at the surface of a liquid, that tend to contain the volume to a minimum surface area. surfactanta contraction of the term surface-active agent. thermoplasticbecoming soft when heated and hard when cooled. thermosettingbecoming rigid by chemical reaction and not remeltable. thixotroping agentsa substance incorporated into an adhesive to impart thixotropy. thixotropythe property of a material that enables it to stiffen in a short period of time on standing, but to acquire a

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lower viscosity on mechanical agitation, the process being reversible; a material having this property is termed thixotropic or shear thinning (see rheology). vinyl esterone of a group of synthetic resins produced by the reaction of acrylic with epoxy resin or Bisphenol A, and commonly prepared for application by mixing with a vinyl group monomer and free-radical catalysts at ambient temperatures, and used as binders for resin mortars and concretes, and fiber laminates (mainly glass) adhesives. viscositythe property of a material that resists change in shape or arrangement of its elements during flow, and the measure thereofspecifically, the ratio of the shear stress existing between laminae of moving fluid and the rate of shear between these laminae. working lifethe period of time when an adhesive, after mixing with a curing agent or other ingredient, remains sufficiently workable to permit spreading and application. CHAPTER 2SOLVENT-FREE ADHESIVES Solvent-free adhesives cure by polymerization of monomeric resins. Section 2.1 describes the characteristics of polymeric adhesives prior to curing that are important in applying or installing the adhesive. Section 2.2 describes properties of these materials during and after curing that affect their suitability in achieving and maintaining an adhesive bond. Section 2.3 describes the features that distinguish each of the polymeric adhesives. 2.1Application characteristics 2.1.1 Working lifeWorking life can vary from as little as 2 minutes to as long as 8 hours from one adhesive to another within each type of solvent-free adhesive. In general, the longer the working life, the longer the curing time. Automatic metering and mixing equipment makes practical the use of adhesives with a very short working life.3 The temperatures of the adhesive components, the ambient temperature, and the substrates also influence working time. High temperatures shorten working time and low temperatures lengthen working time.4 The polymerization reaction is exothermic. Holding a mixed adhesive in a mass in a mixing container increases the temperature of the adhesive because the beat cannot dissipate efficiently. This significantly shortens the working life. Applying the adhesive to the substrate immediately after mixing lengthens the working life because most of the exothermic heat can be dissipated into the substrate without raising the temperature of the adhesive. 2.1.2 CuringThere are two mechanisms for curing adhesives. Epoxies and two-component polyurethanes cure by the chemical reaction of the base resin and a curing agent. Polyesters, one-component polyurethanes, methacrylates, polysulfides, and silicones cure by the addition of a catalyst or release of a catalyst included in the formulation.5 The curing reaction of a monomer/curing agent is very temperature-dependent.6 Lower temperatures extend the curing time and higher temperatures shorten the curing time. Although special adhesives are available that will cure at temperatures down to 0 F (18 C), most adhesives will not

effectively cure in a practical time at temperatures below 40 F (4 C). Catalytic curing is less temperature-dependent than the monomer/curing agent reaction, and the cure rate can be increased by the addition of an accelerator.7 The adhesive must cure quickly enough to obtain strength levels that can resist stresses that develop from removal of support of the bonded composite, or from temperature changes in the bonded composite; and from exposure to moisture due to precipitation, tides, or other sources that could cause degradation. 2.1.3 ViscosityPolymeric adhesives are available with viscosities ranging from 15 centipoise (cps) to a paste-like consistency. The viscosity of the adhesive depends on the inherent viscosity of the base monomers and curing agents, fillers, and thixotroping agents. The viscosity of any adhesive can be lowered by raising its temperature. This can be achieved either by heating the adhesive itself or by heating the substrate. 2.1.4 ThixotropyVery viscous adhesives are not necessarily thixotropic. When thixotropic properties of an adhesive are desired, an adhesive must be chosen that has been manufactured to include thixotroping agents. Generally, high temperatures will lower the thixotropic characteristic of the adhesive and lower temperatures will increase the thixotropy, but is not affected to the same extent as viscosity by temperature.8 Adhesives are available that will stand in a bond line as thick as 1/4 in. (6.4 mm) without external containment. 2.1.5 Toxicity and safetyMost components of solventfree adhesives prior to curing have some degree of toxicity and some are flammable. Toxicity and hazard potentials vary widely from product to product. The manufacturers literature and Material Safety Data Sheet (MSDS) for each product should be consulted, and all cautions should be observed. In general, adhesives require the use of protective clothing, good ventilation, good housekeeping, and personal cleanliness. 2.2Properties during cure 2.2.1 GelCure of an adhesive is accompanied by an increase in viscosity and formation of a gel state before full cure. In the gel state, the adhesive does not possess the physical or chemical properties it will ultimately achieve. If the adhesive is stressed during curing, irreversible damage can be done to the bond with the substrate or the adhesive itself, resulting in lower strength.9,10 2.2.2 Exothermic reactionThe chemical reaction of curing is exothermic and can accelerate cure rate, resulting in the adhesive reaching the gel state at an elevated temperature. If this happens, internal stresses are induced in the bond when the adhesive cools to normal temperature. On a practical level, this condition occurs only in bond lines greater than 1/8 in. (3.2 mm) in thickness, because in narrow bond lines the heat dissipates into the substrates. 2.2.3 ShrinkageAll adhesives shrink when they cure. The addition of fillers to an adhesive system will reduce volumetric shrinkage but the inherent characteristics of a particular polymer system have by far the greatest influence

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Table 1Polymer materials: typical physical properties (from Reference 26)
Acrylic Tensile strength, psi (ASTM D 638) Tensile elongation, % (ASTM D 638) Compressive strength, psi (ASTM D 695) Compressive modulus at 73 F, 103 psi (ASTM D 695) Heat deflection temperature, F (ASTM D 648) Coefficient of thermal expansion, 10 /in./in./C (ASTM D 696)
Note: NR: not reported.
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Epoxy 4000 to 13,000 3 to 6

Polyester 600 to 13,000 2 to 6

Polyurethane 175 to 10,000 100 to 1000 20,000 10 to 100 NR 100 to 200

Silicone 350 to 1000 20 to 700 NR NR NR 300 to 800

Styrene-butadiene 100 to 9350 20 to 1350 NR 3.6 to 120 <0 to 170 67 to 140

5000 to 9000 20 to 70

4000 to 14,000 15,000 to 25,000 13,000 to 30,000 290 to 370 165 to 209 48 to 80 NR 115 to 550 45 to 65 300 to 400 140 to 400 55 to 100

on shrinkage.11 Volumetric shrinkage from the uncured to the cured state varies from as low as 2% for filled epoxy systems to over 20% for some unfilled polyester systems. Shrinkage works against good adhesion. It reduces the intimate contact between adhesive and substrate that is important for mechanical interlock and attraction of the adhesive molecules to the substrate surface; it also builds internal stress in the bond line.12 2.3Properties of cured adhesive 2.3.1 Bond strengthThe strength of an adhesive bond depends on: a. Adhesion of the adhesive to the substrate materials. b. Cohesive strength of the adhesive. c. Cohesive strength of the substrate materials. The bonded joint is only as strong as the weakest of these three strengths.13,14 In all bonding/repair applications, the surface of the hardened concrete must be sound and clean. Grease and oil-type contaminants will interface with the formation of a sound bond. The condition and strength of concrete at the surface is particularly important. If the larger aggregate is not exposed, the surface layer is considerably weaker than the concrete below the surface. The application of low-viscosity primers improves adhesion of solvent-free adhesives that are more viscous or that have relatively poor molecular attraction to concrete. The low-viscosity primer can provide more intimate contact with the substrate, resulting in better adhesion. Adhesive strengths with concrete are usually measured in tension as a pulloff, in flexure in a bond line parallel with the direction of the applied load, or in shear. The slant-shear test described in ASTM C 882 is the most useful and commonly used test. See Table 1 for typical adhesive bond strengths. The pipe cap pulloff test described in ACI 503R-80, Appendix A, is useful for field testing adhesive bonds. 2.3.2 Tensile strength and elongationBecause of the higher tensile strength of polymers relative to concrete, the tensile strength of an adhesive material itself is seldom a controlling factor. Tensile strength of adhesives is most commonly measured by ASTM D 638. Tensile elongation as measured in ASTM D 638 is an indication of the relative stiffness of the adhesive. The numerical value determined in the test method for percentage of elongation should not be taken as the elongation that will take place in an adhesive joint. The elongation in the

test specimen is measured over a length of 1 in. (25 mm) with an initial cross section of 1/2 x 1/8 in. (12.7 x 3.2 mm) or less. As the test specimen is loaded, the cross section can become smaller without any external constraints. In an actual adhesive joint loaded in tension, the length of the adhesive in the direction of the tensile load can vary from a few thousandths to a tenth of an inch. The cross section perpendicular to the tensile force can be literally thousands of square inches. Because the adhesive is bonded to the substrates it is not free to change its cross section by necking down. Thus, its ability to elongate is severely restricted and the elongation achieved in the adhesive joint is not the same as in the test specimen. In fact, at most it can only be a small fraction of the elongation measured in ASTM D 638.15 2.3.3 Shear strengthShear strength is the most important property of adhesive materials commonly used to bond concrete. Shear strength is usually the only strength property for short-time loads that may be exceeded without the bonded concrete substrate failing first. If the shear forces in the bond line can be calculated, shear strength data can be used to determine if the adhesive has the strength required. 2.3.4 Flexural strengthAs with tensile strength, adhesive materials have high flexural strength relative to concrete. Flexural strength of an adhesive is seldom a critical factor in adhesive bonding of concrete. 2.3.5 Modulus of elasticityThe stiffness of polymer adhesives varies from rubber-like with some silicones and polyurethanes to glass-like with some methacrylate and polyesters (refer to Table 1). However, the modulus of all polymer adhesives is affected by temperature, especially near or above the heat-deflection temperature (HDT). Below the HDT, the change in modulus with temperature is modest (Fig. 1). Although the modulus of elasticity of polymeric adhesives used with concrete ranges from about 2% to no more than 20% of the modulus of elasticity of concrete, this difference has an insignificant effect on transfer of load because of the very small volume of adhesive per unit area of bond line. 2.3.6 Heat-deflection temperature (HDT)Each polymer adhesive formulation has a specific HDT. Frequently, manufacturers literature and technical references report physical properties at only one temperature. When this is so, it is important to know the HDT to be able to anticipate if the physical properties at actual service temperatures will be

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Fig. 1Modulus of amine-cured epoxy (from Reference 38). substantially different from those strengths reported in the published literature. Modulus of elasticity, adhesive strength, bond strength, creep resistance, and chemical and radiation resistance all begin to change at about 18 F (10 C) below the HDT and begin to fall off rapidly in a region beginning about 18 F (10 C) above the HDT16-18 (also see Fig. 1). Heat-deflection temperature is determined by ASTM D 648. 2.3.7 Creep resistancePolymer adhesives have a much higher tendency to creep than inorganic materials such as concrete. Sustained loads at temperatures more than 18 F (10 C) above the HDT can result in creep to failure.19 Creep resistance can always be improved by reducing bond-line thickness, by increasing filler content of the adhesive as supplied by the manufacturer, or by adding aggregate in the field. The amount of aggregate that can be added is limited by the degree that workability is reduced and/or air voids result from too high an aggregate-to-adhesive ratio. Physical testing is required to quantify the effect of filler addition for each specific adhesive. 2.3.8 Coefficient of thermal expansionPolymer adhesives have coefficients of thermal expansion two to ten times that of concrete (refer to Table 1). When the adhesive is confined in a narrow [1/8 in. (3.2 mm) or less] bond line between two concrete elements or between concrete and steel, this difference bas not proven to be a problem. However, when placed in thicker sections or used to bond materials with a greater thermal expansion and contraction than that of concrete, the difference can cause failure in the concrete if the bonded elements are subjected to low temperatures (below 30 F). Problems caused by the differences in thermal expansion of the adhesive and concrete can always be lessened by reducing bond-line thickness. Choosing an adhesive with a lower modulus of elasticity also helps to minimize stress caused by differences in thermal expansion but increases the danger of creep failure if the bond line is subjected to sustained loads.

2.3.9 Fire resistancePolymers are combustible, as are most organic materials. Incorporation of special fire-retardant additives and inorganic fillers allows the formulation of adhesives with fire resistance acceptable for some applications. The performance of a bonded concrete structure or of an assembly of concrete adhesively bonded to other materials will depend on the insulation value and thermal conductivity of each of the bonded materials, as well as the temperature level (see Section 2.3.6), duration of exposure, and the magnitude and direction of stress on the bond line. An analysis should be performed to estimate the actual temperature that may be reached, and consideration should be given to the possibility that some of the bonded material may be consumed or removed by the fire. Through appropriate design, including plaster coating of the concrete member to prevent burnout of the adhesive, the fire resistance of adhesively bonded concrete structures can be maintained within desired levels. Test data for a specific application and configuration should be required when a fire rating is required.20,21 2.3.10 Age hardeningMost polymer adhesives develop over 90% of their strength at normal ambient temperature, 68 to 100 F (20 to 38 C), within 7 days after placement. However, curing continues and results in higher strength accompanied by higher modulus, or by hardening.22 Age hardening is undesirable with flexible, low-modulus adhesives that are expected to maintain their flexibility over a long period of time. Adhesives are available for which long-term test data are available. Accelerated aging data using elevated temperature aging for several days is often used as an indication of susceptibility to aging. However, a precise correlation between long-term tests at the expected service temperature and accelerated tests can be established only by conducting both tests. 2.3.11 Chemical resistanceThe degree of chemical resistance varies greatly, not only between polymer groups, but also from formulation to formulation within a polymer group; refer to Table 2 for comparison of the polymer groups. Chemical resistance of an adhesive in a bond line is often better than chemical resistance tables would indicate because only a very small surface area (the edges of the bond line) of the entire mass of adhesive is exposed to the chemical environment. 2.3.12 Water resistanceCured polymer adhesives have generally good water resistance. As with chemical resistance, there can be a wide variation both between polymer groups and within a polymer group for resistance to water. Relative water resistance can be measured by water absorption tests such as ASTM D 570. However, water resistance in service also depends on the degree of exposure of the adhesive to water, either through the substrates or at the edge of the bond line (Table 2 gives a comparison of polymer groups). 2.3.13 Radiation resistancePolymer materials are much more susceptible to radiation than inorganic materials such as concrete. Within a polymer type formulation, variations can greatly influence radiation resistance. Refer to Fig. 2 for relative radiation resistance for polymer type groups.23-26

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Table 2Chemical and water resistance: polymer materials*
Acrylic 25 C Nonoxidizing acids Oxidizing acids Aqueous salt solution Aqueous alkalies Polar solvents Nonpolar solvents Water
*

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Epoxy 25 C S U S S S S S 65 C S U S S S Q S Q U S Q Q U S

Polyester 25 C Q U S U Q U S 65 C Q U S U U U Q

Polyurethane 25 C Q U S Q U Q S 65 C U U S U U U S Q U S S S Q S

Silicone 25 C 65 C Q U S Q S U S

Styrene-butadiene 25 C S U S S S U S 65 C S U S S S U S

65 C

S U S S S U S

Source: Reference 37. Notes: S = satisfactory; Q = questionable; U = unsatisfactory.

Fig. 2Radiation resistance of polymer materials (from Reference 23). 2.4Distinguishing characteristics 2.4.1 Epoxy adhesivesEpoxy adhesives are generally composed of an epoxy resin, an amine or polyamid curing agent, reactive diluents, and, in some cases, inorganic fillers and thixotroping agents. They are the most commonly used polymeric adhesives. Epoxy adhesives generally have excellent adhesion because of relatively low curing shrinkage, with low surface tension and molecular properties that enhance their attraction to a wide variety of substrates. They are very tolerant of the alkalinity of concrete. Epoxy adhesives can be formulated to cure at temperatures as low as 0 F (18 C) or to have a working life allowing use at 100 F (38 C). Most epoxy adhesives have very low ratios of resin to curing agent, which allows proper metering and mixing within the tolerances of available automatic equipment. Epoxy adhesives conforming to ASTM C 881 will bond to concrete substrates and some will cure and bond underwater.27 Since resin systems (resin/curing agent) are available with viscosities lower than 100 cps and are in semi-solid form, they can be formulated into adhesive products that pour and penetrate but require containment in a bond line or into products that can fill gaps without being contained. Epoxies can be formulated with HDTs as low as 10 F (12 C) or as high as 180 F (82 C) after curing at normal ambient temperatures. This means that they can be tailored to a wide variety of strength and modulus requirements for a broad range of service temperatures. Water and chemical resistance of epoxy adhesives after cure, as a class, is second only to polyester adhesives. 2.4.2 Polymer adhesivesUnsaturated polyester resins are generally dissolved in styrene monomer. They are cured

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with initiators, usually an organic peroxide such as methyl ethyl ketone peroxide or benzoyl peroxide. Typically, promoters or accelerators are used to activate the decomposition of the initiator at room temperature, thus enabling rapid low-temperature curing. Because of their relatively high shrinkage while curing, polyesters have found only limited use as adhesives.28 Epoxy or modified-urethane primers may be used to improve the overall bond strengths to concrete substrates if the primers are compatible with the polyester resin prior to use. Resistance to bond failure can also be increased by increasing the flexibility of the polyesters, thus providing some local stress relief during the application of external forces. Most polyesters do not bond well to damp or wet substrates and should not be used when these conditions exist.28 However, recent research has shown that some vinyl esters, a type of polyester, can bond under such conditions. Curing of polyesters can be accelerated by the addition of an accelerator component, which can provide full cure in approximately 2 minutes. The use of accelerators that provide very short cure times requires mixing with automatic equipment. The accelerator is usually added at a very high ratio of resin/accelerator (100/1 to 100/10). Since the accelerator does not become an integral part of the polymer system, intimate mixing with the monomer resin at a precise proportion is not required to achieve full cure. Generally, polyesters have excellent resistance to acid environments. Some polyesters have relatively poor resistance to alkalis and solvents. Although water resistance of the polymer itself is good, most polyester adhesive bonds to concrete deteriorate under constant wet conditions. Polyesters, in general, are considered flammable, with flash points below 100 F (38 C). However, products with flash points over 100 F (38 C) are available. The peroxides used as initiators, when in the pure state, may decompose rapidly at elevated temperatures over 90 F (32 C) and may even cause fire or explosion. Powder peroxides, such as benzoyl peroxide, are extended with inert fillers or are supplied as emulsions, or in paste form in combination with water or inert organic liquids, thus minimizing the explosion hazard. In any event, prolonged storage of the initiators at elevated temperatures should be avoided to avoid decomposition of the peroxide. 2.4.3 Acrylic adhesivesMethyl methacrylate and highmolecular-weight methacrylate monomers of the acrylic family are used as solvent-free adhesives for concrete. These adhesives generally share the same characteristics as polyester adhesives. They are most commonly used by mixing with fine aggregate to form an easily flowable adhesive mortar. The flowability of the mortar can be controlled by the amount of aggregate added. The mortar can be used as an adhesive to fill wide bond lines and provide a cure adequate for service in 30 minutes to 2 hours. In almost all cases, a primer composed of the methacrylate monomer cured with an organic peroxide is used to provide an improved bond to concrete. 2.4.4 Polysulfide adhesivesPolysulfides are most frequently used as flexibilizers in epoxy resin formulations. These formulations are sometimes referred to as polysulfide

adhesives, but they fit properly into the epoxy adhesive category. Polysulfide materials that are primarily joint sealants can be used to bond glass to concrete.29 2.4.5 Polyurethane adhesivesPolyurethane adhesives are available as both rigid and flexible materials. When combined with an aromatic amine, the urethane forms a rigid polymer similar to epoxy adhesives. When combined with a polyol, they form an elastomer. They have limited use with concrete because of their low bond strength. The flexible types have been used in membrane systems and for bonding ceramic tile to concrete where impact resistance is required. 2.4.6 Silicone adhesivesSilicones that have the ability to cure in a wide temperature range are almost exclusively used as flexible joint sealants.29 However, they can be used to bond elements such as windows to concrete where a highly flexible adhesive is required to minimize concentration of stresses. Silicone should not be used in applications requiring resistance to sustained loads. CHAPTER 3WATER-BORNE ADHESIVES (LATEX AND LATEX-POWDER ADHESIVES) The only water-borne adhesives currently used to bond concrete are latex and latex-powder adhesives. There are two types of latex and latex-powder adhesives:30 Type I, which is designed to be used without further formulation, and Type II, which is designed to be used in slurry form with a hydraulic cement, usually portland cement. For Type II adhesives, the ratio of latex to cement is about one part latex solids to four parts of cement by weight. Both types of adhesives are generally used for bonding fresh, unhardened concrete to hardened concrete. However, Type II adhesives have occasionally been used for bonding hardened concrete to hardened concrete. Latexes and latex powders are generally made by emulsion polymerization techniques, which have been described in the literature.31 The types in use today include the following: Polyvinyl acetate (PVA) Vinyl acetate copolymers (VAC) Polyacrytic esters (PAE) Styrene-butadiene copolymers (SB) Type I latex and latex-powder adhesives are generally made using a polyvinyl alcohol (PVOH) surfactant system. This type of adhesive gives a dried film that is redispersible upon application of water. This category includes most polyvinyl acetate and vinyl acetate copolymers. The more common comonomers are ethylene, butyl acrylate, and the vinyl ester of versatic acid. Type II latex adhesives are usually made with non-ionic surfactant systems such as alkyl phenols reacted with various levels of ethylene oxide. Often, low levels of anionic surfactants are incorporated to assist in polymerization or to result in specific latex properties. This type of latex gives a dried film that is not redispersible. Polyacrylic esters and styrene-butadiene copolymers are included in this category. 3.1Application characteristics 3.1.1 Surface preparationFor both Type I and II adhesives, the surface should be damp, but without any standing water.

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This damp condition is conducive to penetration by the polymer particles of the adhesives into the hardened concrete. 3.1.2 Working lifeType I latex adhesives have a virtually unlimited working life because of their redispersible characteristic. The adhesive is usually applied by brush or roller, and the fresh, unhardened concrete can be applied whether the latex is still wet or has dried. In the latter occurrence, water from the fresh, unhardened concrete causes redispersion of the latex polymer. Although it is recommended that the fresh, unhardened concrete be placed within 24 hours of applying the latex, satisfactory bonds have been obtained when the fresh, unhardened concrete was placed up to 7 days after latex application. Note that the dried film of the Type I latex adhesive must be kept clean from dust and other contaminants between the times of film forming and the application of the fresh concrete. Type II adhesives have a limited working life, the length of which will depend on the type of latex, the type of hydraulic cement, and the environmental conditions. Typically, the working life of the slurry, in a relatively closed container, will be from one to several hours; however, in an open environment, drying can occur quickly and shorten working life to less than 30 minutes. It is important that the fresh concrete be placed while the latex-cement slurry is still wet. If the slurry has dried, it may act as a bond breaker rather than an adhesive. 3.1.3 CuringCuring of Type I adhesives depends on the cure of the fresh concrete because Type I adhesives cure by drying. The drying occurs as water is removed either by evaporation or by hydration of the cement in the fresh concrete. Curing of Type II adhesives depends on the rate of hydration of the cement in the slurry and also on evaporation of the water. 3.1.4 Methods of applicationType I and Type II adhesives are usually applied by brush or roller, although other techniques such as spraying and troweling have also been used. It is essential that the surface being coated be thoroughly damp, and that the application technique be such that the adhesive completely wets the surface. 3.1.5 Application conditionsIt is essential that the latex adhesive, whether Type I or II, coalesces to form a polymer film. Consequently, application temperatures must either be above the minimum film-forming temperature (MFFT) or above 50 F (10 C), whichever is higher, when the adhesive and the fresh concrete are placed. Although the surface must be thoroughly damp when the latex adhesive is applied, the adhesive and fresh concrete should not be placed during wet environmental conditions, such as in rain or snow. 3.2Properties of cured adhesive 3.2.1 Bond strengthThe bond strength of Type I and Type II latex adhesives will depend on the latex, the type of cement, the quality of the hardened surface, and the quality of the fresh concrete. When tested by ASTM C 1042 method, Type I adhesives usually give bond strengths in excess of 300 psi (2.1 MPa), while Type II adhesives give strengths usually in excess of 1200 psi (8.3 MPa).32 3.2.2 ShrinkageThere is virtually no shrinkage associated with Type I and Type II latex adhesives because these

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materials, when properly applied, completely migrate into the hardened surface and the fresh concrete. Consequently, any shrinkage that occurs is caused by shrinkage of the fresh concrete. 3.2.3 Water resistanceThe water resistance of Type I latex adhesives has always been considered suspect because the latex film is redispersible and vinyl acetate hydrolyzes in the presence of moisture and high pH values to give watersoluble products (vinyl alcohol and a metallic acetate). However, this type of adhesive has been successfully used without apparent problems in areas exposed to moisture. It is postulated that the function of the adhesive is to insure that the fresh concrete wets out the hardened concrete surface. The resulting bond is obtained from the penetration of the cement paste of the fresh concrete into the surface. If this postulation is correct, it explains why moisture failures of Type I adhesives have not occurred where expected. Type II latex adhesives (slurries of latex and hydraulic cement) have excellent water resistance. In fact, such slurries are used for waterproofing swimming pools and for corrosion protection of steel members.33 3.3Distinguishing characteristics 3.3.1 Polyvinyl acetatePolyvinyl acetate latexes are Type I adhesives and are usually formulated with a plasticizer such as dibutyl phthalate or dipropyl glycol dibenzoate. The plasticizers are added to decrease the minimum film-forming temperature (MFFT). This type of adhesive is usually made in a polyvinyl alcohol surfactant system and is available both in the latex form and as a redispersible powder. Water resistance of such adhesives is suspect because of hydrolysis of the polyvinyl acetate. Films of the latex are redispersible. 3.3.2 Vinyl acetate copolymersCopolymers of vinyl acetate with such materials as butyl acrylate, ethylene, and the vinyl ester of versatic acid are Type I adhesives but can also be used as Type II adhesives. They are generally made in polyvinyl alcohol surfactant systems and are available in latex and redispersible powder forms. Their water resistance is much better than that of polyvinyl acetate, both because the comonomer reduces the hydrolysis of the vinyl acetate grouping, and because the resultant product is not as water soluble as polyvinyl alcohol. The water resistance of such polymers will depend on the type and ratio of comonomer to vinyl acetate. The comonomer also causes a reduction in the minimum film-forming temperature, which eliminates the need for the addition of plasticizers. When used as Type II adhesives, bond strengths (ASTM C 1042) usually exceed 1000 psi (6.9 MPa). This value is slightly lower than most other Type II latex adhesives. It has been postulated32 that these lower values may be caused by the larger particle size of such latexes. 3.3.3 Polyacrylic esters and acrylic copolymersPolyacrylic ester latexes, such as polyethyl acrylate, and acrylic copolymer latexes, are Type II latex adhesives. They are generally made using primarily a nonionic surfactant system. They could be used as Type I adhesives, but this is not recommended because the dried films are usually not redispersible. If the latex dries before placement of the fresh

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concrete, the dried film can act as a bond breaker rather than as an adhesive. Glass transition temperatures for such latexes are normally less than 18 F (10 C). Low levels (less than 2%) of reactive groups, such as vinyl carboxylic acids, may be incorporated in the polymerization of these polymer latexes. These groups can improve adhesion by ionic reaction with metallic radicals in the surface of the fresh concrete. However, it has been observed that such groups may retard the initial hydration of the hydraulic cement. 3.3.4 Styrene-butadiene copolymersStyrene-butadiene copolymer latexes are Type II adhesives. They could be used as Type I adhesives but are not recommended for this category because their films are not redispersible. In addition, their surfactant system is primarily of the nonionic type. Small levels of reactive groups, such as vinyl carboxylic acids, can be incorporated in the polymerization. Such groups can improve adhesion and latex stability, but may also retard the initial hydration of the hydraulic cement. CHAPTER 4ADHESIVE SELECTION CRITERIA This chapter describes the factors that can be important in choosing an adhesive for a specific application. 4.1Type and magnitude of loads For permanent adhesive bonds, the adhesive should be able to transfer loads to the same degree as the structural elements that are bonded together. For each load, a determination should be made of: Direction (tension, compression, shear, flexure) Rate (static, dynamic) Duration Frequency Most often data are available only for a single load rate while information on creep, fatigue, or dynamic loading is not available. For very critical adhesive applications, if adequate test data are not available, a test program should be conducted that simulates the load conditions expected. Alternately, field experience of an adhesive under similar service and environmental conditions can indicate the suitability of a polymer adhesive for a particular use. 4.2Conditions during application Equally as important as the strength characteristics of the adhesive is whether it can be installed to provide the strengths that are achieved in controlled laboratory tests. Factors that affect the installation and that the adhesive must be able to tolerate are described in the following sections. 4.2.1 Surface contaminationThe presence of oils, greases, chemicals, dirt, dust, or any other foreign materials can interfere with achieving a good bond. If a foreign substance cannot be completely removed, the adhesive chosen must be able to tolerate its presence. This tolerance can be demonstrated only by testing under the specific applications and service conditions expected.13,14 4.2.2 Temperature of the contact surfacesThe temperature of the contact surfaces and of the adhesive, when it is applied during the curing period of the adhesive, will affect the rate of bond strength development. Low temperatures may make

the adhesive too viscous to apply properly. High temperatures may cause the adhesive to gel before it can be properly placed and the substrates joined. 4.2.3 Wetness of the substratesThe presence of water can seriously affect the ability of adhesives to bond to concrete or other construction materials. If there is any chance that the surfaces to be bonded together will be damp, have residual water on them, or be submerged, the adhesive specified must be compatible with moisture to achieve the required bond strength. 4.2.4 Surface accessibilityThe accessibility of the surfaces to be bonded may dictate an adhesive with a long working time. The length of time that external supports for bonded elements may be in place during the curing of the adhesive can also influence the selection of the adhesive. CHAPTER 5ADHESIVES FOR BONDING OF HARDENED CONCRETE TO HARDENED CONCRETE Polymer adhesives are frequently used in segmental construction to bond together broken concrete, and to attach elements such as facades to concrete structures. In most critical situations, the adhesive bond is used in conjunction with mechanical attachments, with reinforcing steel, or with tendons that cross the bond line. 5.1Important application characteristics 5.1.1 Viscosity and thixotropyAn adhesive for bonding hardened concrete to hardened concrete must be viscous and thixotropic enough not to run out of the bond line prior to forming a gel. It must also be applied in a thickness that will completely fill any irregularities that exist between the surfaces to be bonded. Except for match cast segments, the bond line between concrete elements is seldom uniform. 5.1.2 Working lifeThe working life should be adequate to allow placing, positioning, and aligning the concrete elements to be bonded. In bonding large segments, especially where several segments are assembled at one time, a working life of many hours is necessary. Once the working life has expired but before cure has taken place, the concrete elements cannot be realigned or adjusted without significantly reducing the bond strength that would be realized on full cure. 5.1.3 Cure timeWhen choosing an adhesive for its curing time, the working life requirements described in Section 5.1.2 must be considered since cure time and working life for polymer adhesives are related. 5.1.4 Bond-line thicknessRecommended bond-line thickness requirements vary from one adhesive to another. In general, however, the strength of unreinforced joints decreases as the bond line thickness increases. 5.2Important bond-strength considerations Although the published bond strengths for polymer adhesives may appear to be adequate for a specific hardened concrete to hardened concrete application, the effects of high ambient temperatures (Sections 2.3.6 and 2.3.7) must be considered, especially if reinforcement does not pass through the adhesive joint.

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CHAPTER 6ADHESIVES FOR BONDING PLASTIC CONCRETE TO HARDENED CONCRETE Polymer adhesives provide a better bond of plastic concrete to hardened concrete than can be obtained by relying on the cement itself or on a cement slurry, because polymer adhesives shrink less than cement paste upon curing, and because they tolerate a wider range of moisture conditions in the plastic concrete and the hardened substrate. The primary use of all types of water-borne adhesives with concrete is to bond plastic concrete to hardened concrete. The only solvent-free adhesives used for bonding plastic concrete to hardened concrete are epoxy adhesives because, unlike other solvent-free adhesives, they can be readily formulated to cure and bond in the presence of water. 6.1Important application considerations 6.1.1 Viscosity and thixotropyMost applications of bonding fresh concrete to existing concrete are on relatively large areas. To place the adhesive economically, it is desirable to use an adhesive that is sufficiently low in viscosity to be sprayed or applied by a roller or squeegee. However, if the surface is rough, as it would be from only rough trowelling or chipping, the adhesive must have enough thixotropy to maintain a uniform bond-line thickness without draining away from the high spots and into the low spots. For vertical surfaces, the adhesive must be able to stand without running off. 6.1.2 Working lifeThe working life of an adhesive used for bonding fresh concrete must be long enough to allow workers time to place the concrete before the adhesive gels. This is especially important in large concrete placements, or when the adhesively bonded concrete must be placed in forms. 6.1.3 Cure timeWith solvent-free adhesives, there must be a proper balance between adhesive curing time and concrete curing time. If the adhesive cures before the shrinkage in the curing concrete takes place, the concrete at the interface can be weakened enough to result in immediate bond failure, even without external loads. If the adhesive cures too slowly, it may not have the strength in its uncured state to resist curling caused by curing shrinkage of large thin section concrete placements that are unrestrained. A modified ASTM Test Method C 882 can provide assurance that the proper balance of cure rates exist. It is vital, of course, that the specific adhesive and concrete mixture to be used in the field application rather than the mortar mix specified for use in ASTM C 882 be used in the laboratory tests. Additionally, the 3 x 6 in. cylinder size specified in ASTM C 882 may have to be increased to provide a cylinder diameter to large aggregate ratio greater than three to one as prescribed in ASTM C 192. For general construction, epoxy adhesives conforming to ASTM C 881 have been found to be adequate. 6.1.4 Bond-line thicknessThere are wide variations in the recommendation of manufacturers regarding application rate which in turn determines bond-line thickness. Rough surfaces actually have greater true surface areas than smooth surfaces of the same dimensions. For epoxy adhesives, application rates should be between 25 and 100 ft2/gal. (0.61 and 2.45 m2/L), depending upon the surface profile. The

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maximum bond-line thickness for water-borne adhesives is limited by their viscosity. 6.1.5 Water sensitivityBy the very nature of the process of bonding fresh concrete, the adhesive must tolerate water prior to cure of the adhesive. There are wide variations in the sensitivity to water from one adhesive to another, even among those used to bond fresh concrete. There are also great differences in the amount of water present in different concrete mixtures. The only way to be absolutely sure of bond strength capability is to conduct one test, such as a modified ASTM C 882, using the specific adhesive and concrete mixture (see Section 6.1.3). For general construction applications, materials conforming to ASTM C 881 or ASTM C 1059 have proven to be satisfactory. 6.2Important bond-strength considerations Epoxy adhesives provide higher bond strengths than water-borne adhesives. In thicker bond lines, epoxy adhesives, as opposed to water-borne adhesives, can bond to a greater surface area of the larger aggregate. As an example, ASTM C 881 requires a minimum slant-shear strength of 1500 psi (10.3 MPa) for an epoxy adhesive, whereas ASTM C 1059 requires a minimum of 400 psi (2.8 MPa) for Type I and 1250 psi (8.6 MPa) for Type II water-borne adhesives. CHAPTER 7ADHESIVES FOR REPAIR OF CRACKS IN CONCRETE Epoxy adhesives are the most common adhesives used for crack repair. They are usually introduced into cracks by injection. High-molecular-weight methacrylates are also used on some flat-surface applications by flooding the surface with adhesive, and they have been used occasionally to inject into fine cracks because of their low viscosity. Polyesters and latex-cement slurries have been used very infrequently with either application method.18,21 7.1Important application considerations 7.1.1 Viscosity and thixotropyLow viscosity is required for adhesives to penetrate cracks without using high injection pressure. Typical viscosities for liquid epoxy injection adhesives range from 100 to 500 cps at 77 F (25 C). Highmolecular-weight methacrylates have viscosities in the range of 15 to 20 cps at 77 F (25 C). However, if injection adhesives with viscosities lower than 100 cps are used, the adhesive can penetrate into the concrete so far that it leaves a starved bond line. In this case, there must be a continual reservoir of adhesive available to the crack until the adhesive gels to fill the bond line. Liquid adhesives without thixotropic properties will also drain out of a crack, even into subgrades, if all faces of the crack are not sealed prior to filling the crack. For cracks where all faces cannot be sealed, a thixotropic or psuedoplastic adhesive should be used which will stay in the crack without constraint. 7.1.2 Water sensitivity during cureAll cracks in concrete that is outdoors should be assumed to have water in them unless there is evidence to the contrary. An adhesive that will bond in the presence of water should be used whenever water is present in the crack.

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Conformance with ASTM C 881 Type IV or ASTM C 1059 will assure that a satisfactory adhesive is chosen. For adhesive injection into cracks underwater, no standard tests exist. Special laboratory or field tests should be conducted to qualify an adhesive for underwater injection. ASTM C 882 has been used for this purpose by fabricating the test specimens underwater. 7.1.3 Concrete temperatureCracks in concrete open and close as the temperature of the concrete changes. If a crack cannot be injected while it is in its widest position, an injection adhesive should be chosen that cures fast enough to resist the tensile forces that result when the crack widens from temperature change. 7.2Important strength considerations 7.2.1 LimitationsAdhesive bonding of cracked concrete may not be permanent if the original cause of the crack is not eliminated. For example, if overloads continue to exist or if foundations continue to settle, the concrete structure will probably crack again in the vicinity of the original crack. Factors such as these should be considered before repairing the original cracks. 7.2.2 FlexibilityThe use of a low-modulus flexible adhesive in a crack will not allow any significant movement of the concrete structure for the reasons cited in Section 2.3.2. The effective modulus of elasticity of a flexible adhesive in a crack is substantially the same as that of a rigid adhesive.15 7.2.3 Creep resistanceFrequently the adhesive in a bonded crack will be subjected to sustained loads. These loads may be external or they may be caused by restraints on a structure that is undergoing cyclic temperature changes. Unless it can be determined that the adhesive in a crack will not be subject to sustained loads, an adhesive conforming to ASTM C 881 Type IV should be used. CHAPTER 8ADHESIVES FOR BONDING INSERTS INTO CONCRETE Solvent-free polymer adhesives have been widely used to bond or grout anchorages and reinforcing steel into concrete. This procedure avoids the difficulties of maintaining the location of an insert during a concrete placement, and allows placement when the location has not been decided prior to the concrete setting of the concrete. Glass capsules containing both the resin and the initiator or curing agent have been widely used to bond anchors in concrete. The two components are separated in the capsule as supplied by the manufacturer. The capsule is placed in the hole in the concrete; as the anchor is inserted and twisted, the capsule breaks and the adhesive is mixed. 8.1Important application considerations 8.1.1 Viscosity and thixotropyFor vertical holes with the opening upward, a liquid adhesive can be used. A liquid adhesive requires less time to place than a paste or thixotropic or psuedoplastic adhesive, and it is much less likely to trap air in the bond line. For vertical overhead and horizontal holes, a thixotropic or psuedoplastic paste adhesive is more suitable because it will not require containment to keep it from running out of the hole. However, it must be capable of

being pumped from the bottom (back) of the hole toward the front of the hole to avoid trapping air bubbles in the bond line. Air bubbles would reduce contact area and result in a weakened bond. 8.1.2 Hole diameterHole diameters normally used are 1/8 to 1/2 in. (3.2 to 12.7 mm) greater than the bolt, dowel, or insert diameter. In all cases, the smaller the annulus between the insert diameter and the hole diameter, the lower the possibility of creep failure. As the annulus dimension increases, the potential for creep failure under constant load increases. (Refer to Section 2.3.7.) 8.1.3 Hole depth and spacingTo develop the full strength of a steel anchor or a reinforcing bar, as opposed to inducing a failure in the concrete, the steel should generally be embedded to a minimum depth of ten times its diameter. Anchor spacing should allow a sufficient quantity of anchors to transfer the desired loads from the attached members without development of excessive stress interaction through the concrete between the anchors. For specific guidelines for hole depth and spacing for steel anchorages, see ACI 349, Code Requirements for Nuclear Safety Related Concrete Structures, Appendix B, Steel Embedments.30,34 8.2Important strength considerations 8.2.1 Pullout strengthPullout strength is generally determined by applying an axial tensile load to the anchorage until tensile failure occurs. The ability of the concreteanchor system to develop full pullout strength of the anchor as determined by ASTM E 488 depends mostly on the bond strength of the adhesive and the cleanliness of the hole. This test evaluates the ability of the adhesive to bond and cure under the conditions of moisture and surface preparation actually encountered in application. 8.2.2 Creep resistanceMany inserts that are bonded into concrete are put under a constant load. Examples are fixtures being hung from anchorages and torqued anchor bolts. Therefore, creep resistance should be carefully considered (see Section 2.3.7). For critical applications, pre-testing of a mockup is recommended because no standard test methods are currently available. CHAPTER 9ADHESIVES FOR BONDING CONCRETE AND OTHER MATERIALS Epoxy and some polyester adhesives are commonly used for bonding steel in the form of inserts (see Section 8), external28,29,35 or internal36 reinforcement, and protection plates. For other construction materials such as aluminum, wood, glass, rubber, and plastics, a wider variety of adhesives is required because of the very different characteristics of each of these materials. 9.1Important application considerations There are innumerable combinations of types of adhesive and types of construction materials that can be bonded to concrete. Which application conditions are important depends on which combination is used. Since each application is unique, there is little information available except in the manufacturers literature. Standard test methods do not exist.

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For critical applications, special tests must be designed unless field experience for the exact combination of adhesive and material to be bonded to concrete can be demonstrated for the same service conditions. Some of the more common factors to consider are listed in the following paragraphs for the general classes of construction materials. 9.1.1 SteelIf it is necessary to hold a steel plate in place while the adhesive cures, care must be taken not to stress the steel with the application of clamps that will be removed once the adhesive cures. Because of the much higher modulus of elasticity of the steel compared to the polymer adhesive, the steel can exert stresses on the bond line that exceed the strength of the adhesive. Even if the adhesive does not fail immediately upon removal of the clamps, constant stresses will be built into the bond line, which can cause creep failure at a later time. Because of its high heat capacity, changes in steel temperature can lag behind changes in atmospheric temperature and cause condensation of water vapor on the surface of the steel. Particular attention should be paid to providing a dry surface. If a dry surface cannot be assured, an adhesive should be chosen that will bond to wet steel. Steel that is exposed to the sun may reach temperatures as high as 170 F (77 C). The working life of an adhesive applied to a steel surface may be much shorter than would be expected if the ambient temperature or the adhesive temperature in the mixing container is used to predict working life. 9.1.2 WoodThe wide variety of chemical, density, and grain characteristics of the many woods used in construction makes it impossible to generalize on the suitability of a type of polymer adhesive for bonding wood. The particular adhesive and wood combination should be tested at the wood moisture content that is expected when the adhesive is applied. Changes in moisture content that cause the wood to shrink or swell after the adhesive has cured will stress the bond line and can cause failure of the wood fibers.

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Standard laboratory tests are not available either for bonding wood to concrete or for the effect of changes in the moisture content of wood. 9.1.3 GlassThe brittle nature of glass requires that an adhesive be used that will minimize stresses at the bond line caused by temperature changes or external forces. For this reason, only silicone and polysulfide materials are usually used for bonding glass to concrete. Particular attention should be paid to the surface condition of the glass, because any film of oil or other foreign substance that may not be visible can interfere with the bond. 9.1.4 Plastics, reinforced plastics, and rubberThere is wide variation in chemical and physical properties among the different rubber and plastic materials. Because the surface energy of most rubber and plastics is much lower than that of steel or concrete, they are much more difficult to bond with polymer adhesives. In many cases, the surface must be oxidized or otherwise chemically treated to provide a bondable surface. In the bond of a flexible plastic or rubber to concrete, the adhesive can be subjected to peel forces when the plastic or rubber substrate is loaded in a manner that tends to deform the substrate at the bond line. For this reason, only silicone, polyurethane, and very low-modulus epoxy adhesives are usually used to bond flexible plastics or rubber to concrete. Some rubber and plastic materials contain nonreactive plasticizers used to enhance their physical properties. The presence of the plasticizer on the surface can prevent a good bond from being achieved. Migration of the plasticizer to the bond line after the adhesive is cured and bonded can cause deterioration of the adhesive bond. 9.1.5 AluminumBecause of the rapid formation of oxide on a freshly abraded aluminum surface, aluminum is usually prepared for adhesive bonding by treatment with a chromicsulfuric acid mixture or by anodizing if a long lasting corrosionresistant bond is desired. In either case, an adhesive primer is used if maximum corrosion resistance is required.

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CHAPTER 10QUICK REFERENCE GUIDE

Performance requirements of adhesives Bond strength (ASTM C 882) Conditions for use of adhesives Plastic concrete to cured concrete Cured concrete to cured concrete Cracked concrete Cured concrete to other materials with similar CTE and EM Cured concrete to other materials with dissimilar CTE and EM Anchoring bolts Above 2000 psi (13.8 MPa) E E, P, M E, P, M E, P, M E, PP E, P, M Below 2000 psi (13.8 MPa) Water resistance Moisture Submerged E E, P, M, PP E, P, M E, M E, PP E, P, M Temperature resistance Below 32 F (0 C) Above 120 F (49 C) E, A, SB, PA E, P, M, PP, S E, P, M E, P, M E, PP E, P, M E, A, SB, PA E E E, P, M E, PP E, P, M

E, SB, PVA, PAE, E, PAE, SB, VAE VAC E, P, M, PP, S E, P, M, SB, PAE E, P, M, PP, S E, PP, S E, P, M E, P, M, PP E, P, M E, P, M E, PP E, P, M

Water resistance Conditions for use of adhesives Plastic concrete to cured concrete Cured concrete to cured concrete Cracked concrete Cured concrete to other materials with similar CTE and EM Cured concrete to other materials with dissimilar CTE and EM Anchoring bolts
ABBREVIATIONS: E: epoxy P: polyester M: methylmethacrylate monomer PP: polysulfide and polyurethane S: silicone PAE: acrylic latex SB: styrene-butadiene latex PVA: polyvinyl acetate latex CTE: coefficient of thermal expansion EM: elastic modulus VAC: vinyl acetate copolymer latexes

Application requirements of adhesives Temperature E E E E, PP E E, M E, M E, M E, PP E, M E, P, M E, P, M E, P, M E, PP E, P, M

Moist substrate E, PAE, SB, PVA, VAC E E, SB, PAE E E E

Submerged substrate Below 32 F (0 C) Above 100 F (38 C)

Ability to flow into narrow voids E, P, M E, P, M

CAUTION: The listing of a particular type of adhesive as suitable for an adhesive requirement indicates that many adhesive products of that type meet the requirement. It does not mean that all adhesives of that type meet the application or performance requirement. The purpose of the chart is to guide the designer to a generally appropriate adhesive type but the designer must verify that the specified adhesive product meets the performance and application requirement for each particular project.

CHAPTER 11REFERENCES 11.1Specified and/or recommended references The documents of the various standards-producing organizations referred to in this document are listed with their serial designation, including year of adoption or revision. The documents listed were the latest effort at the time this document was revised. Since some of these documents are revised frequently, generally in minor detail only, the user of this document should check directly with the sponsoring group if it is desired to refer to the latest revision. American Concrete Institute 224.1R-84 Causes, Evaluation, and Repair of Cracks in Concrete Structures 503R-80 Use of Epoxy Compounds with Concrete 503.1-79(86) Standard Specification for Bonding Hardened Concrete, Steel, Wood, Brick and Other Materials to Hardened Concrete with a MultiComponent Epoxy Adhesive 503.2-79(86) Standard Specification for Bonding Plastic Concrete to Hardened Concrete with a MultiComponent Epoxy Adhesive

ASTM C 192-88

Specification for Making and Curing Concrete Test Specimens C 881-87 Specification for Epoxy Resin-Base Bonding Systems for Concrete C 882-87 Test Method for Bond Strength of Epoxy Resin Systems Used with Concrete C 1042-85 Test Method for Bond Strength of Latex Systems Used with Concrete C 1059-86 Specification for Latex Agents for Binding Fresh to Hardened Concrete D 570-81 Test Method for Water Absorption of Plastics D 638-89 Test Method for Tensile Properties of Plastics D 648-82(88)Test Method for Deflection Temperature of Plastics Under Flexural Load D 695-89 Test Method for Compressive Properties of Rigid Plastics D 696 Standard Test Method for Coefficient of Linear Thermal Expansion of Plastics Between 30 C and 30 C With a Vitreous Silica Dilatometer D 907 Standard Terminology of Adhesives

SELECTIONOF OFPOLYMER POLYMER ADHESIVES WITH CONCRETE SELECTION ADHESIVES WITH CONCRETE
E 488-88 Test Method for Strength of Anchors in Concrete and Masonry Units

503.5R-15

879

The publications may be obtained from the following organizations: American Concrete Institute PO Box 9094 Farmington Hills MI 48333-9094 ASTM International 100 Barr Harbor Dr West Conshohocken PA 19428-2959 11.2Cited references 1. Adams, R. D., and Wake, W. C., Structural Adhesive Joints in Engineering, Elsevier Applied Science Publishers, Essex, 1984, pp. 8-13. 2. Skeist, I., Handbook of Adhesives, 2nd Edition, Van Nostrand Reinhold Co., New York, 1977, pp. 3-4. 3. Lee, H., and Neville, K., Handbook of Epoxy Resins, McGraw-Hill Book Co., New York, 1967, pp. 25-7 to 25-11. 4. Skeist, I., Handbook of Adhesives, 2nd Edition, Van Nostrand Reinhold Co., New York, 1977, pp. 6-3 to 6-4. 5. Modern Plastics Encyclopedia, McGraw-Hill, New York, 1989, pp. 129-132, 134-135. 6. Kinloch, A. J., Structural AdhesivesDevelopments in Resins and Primers, Curing Properties of Thermosetting Polymers, by J. K. Gillham, Elsevier Applied Sciences Publishers, London and New York, 1986, pp. 1-6. 7. Rodriguez, F., Principles of Polymer Systems, McGrawHill, New York, 1970, pp. 53-55, 62-65. 8. Eirich, F. R., Rheology Theory and Applications, Academic Press, New York and London, 1960, pp. 205-215. 9. Rodriguez, F., Principles of Polymer Systems, McGraw-Hill, New York, 1970, pp. 53-55, 62-65. 10. Skeist, I., Handbook of Adhesives, Introduction to Adhesives, Chapter 6, by F. A. Lewis and R. Saxon, 2nd Edition, Van Nostrand Reinhold Co., New York, 1977, pp. 400-403. 11. Lee, H., and Neville, K., Handbook of Epoxy Resins, McGraw-Hill Book Co., New York, 1967, pp. 6-29 to 6-30, 21-28 to 21-30. 12. Wake, W. C., Adhesion and the Formulation of Adhesives, Applied Science Publishers, London and New York, 1982, pp. 46, 122-124. 13. Murray, M. A., Surface Preparation for Adhesives, Concrete International, V. 11, No. 9, Sept. 1988, p. 69. 14. Gaul, R. W., Preparing Concrete Surfaces for Coatings, Concrete International, V. 6, No. 7, July 1984, pp. 17-22. 15. Adams, R. D., and Wake, W. C., Structural Adhesive Joints in Engineering, Elsevier Applied Science Publishers, Essex, 1984, pp. 121-125. 16. May, C. A., and Tanaka, Y., Epoxy Resins, Chemistry and Technology, Marcel Dekker, Inc., New York, 1973, pp. 400-407.

17. Lee, H., and Neville, K., Handbook of Epoxy Resins, McGraw-Hill Book Co., New York, 1967, pp. 6-25 to 6-27. 18. Gaul, R. W., State-of-the Art Adhesives for Concrete Construction, Construction Canada, V. 30, No. 3, May 1988, pp. 15-20. 19. Adams, R. D., and Wake, W. C., Structural Adhesive Joints in Engineering, Elsevier Applied Science Publishers, Essex, 1984, pp. 160-162. 20. Plecnik, J. M.; Plecnik, J.; Parra, V.; and Diba, A., Fire Testing Epoxies, Concrete International, V. 8, No. 4, Apr. 1984, p. 29. 21. Plecnik, J. M.; Plecnik, J.; Diba, A.; Howard, J.; and Hiremagular, J., Fire Research on Seismically Damaged Concrete Beams Repaired with Epoxy Adhesives, Final Report, Contract No. PFR-7927222, National Science Foundation, Washington, DC, Aug. 18, 1983. 22. Struk, L. C. E., Physical Aging in Amorphous Polymers and Other Materials, Elsevier Scientific Publishing Co., Amsterdam, 1978, pp. 1-46. 23. Schonbacher, H., How Plastics Perform Under Nuclear Radiation, Modern Plastics, Dec. 1985, pp. 64-68. 24. Van de Voorde, M., and Restat, C., Selecting Guide to Organic Materials for Nuclear Engineering, Organisation Europeenne pour la Recherche Nucleaire, Geneva, 1972. 25. How Radiation Affects Polymers, Rubber and Plastic Processing, May-June 1963, pp. 23-24. 26. Modern Plastics Encyclopedia 89, McGraw-Hill, New York, V. 65, No. 11, Oct. 1988, pp. 576-619. 27. Encyclopedia of Chemical Technology, V. I, John Wiley & Sons, New York, 1978, p. 503. 28. Mays, O. C., Structural Applications of Adhesives in Civil Engineering, Materials Science and Technology, V. 1, Nov. 1985, pp. 937-942. 29. Albrecht, P.; Sahli, A.; Crute, D.; Albrecht, P.; and Evans, B., Application of Adhesives to Steel Bridges, FHWA/RD 87/037, Federal Highway Administration, U.S. Dept. of Transportation, Nov. 1984. 30. ASTM C 1059, Standard Specification for Latex Agents for Bonding Fresh to Hardened Concrete, ASTM International, West Conshohocken, Pa., 1999, 2 pp. 31. Walters, D. G., What are Latexes? Concrete International, V. 9, No. 12, Dec. 1987, pp. 44-47. 32. Walters, D. G., Latex Adhesives for Bonding Concrete, paper presented at the American Concrete Institutes Fall Convention, Houston, TX, Nov. 3, 1988. 33. Ohama, Y., Polymer-Modified Mortars and Concretes, Concrete Admixtures Handbook, V. S. Ramachandran, ed., Noyes Publications, Chapter 7, 1984. 34. Cannon, R. W.; Godfrey, D. A.; and Moreadith, F. C., Guide to the Design of Anchor Bolts and Other Steel Embedments, Concrete International, V. 3, No. 7, July 1981, pp. 28-41. 35. Jones, R.; Swamy. R. N.; Blorham, J.; and Beuderbalah, A., Composite Behavior of Concrete Beams with Epoxy Bonded External Reinforcements, International Journal of Cement Composites, V. 2, No. 2, May 1980. 36. Stratton, W. F., and Crumpton, C. F., Kansas Bridges Renovated by Post Reinforcement and Thin Bonded

880 503.5R-16

ACI COMMITTEE REPORT CONCRETE REPAIR MANUAL

Concrete Overlay, Concrete Construction, Aug. 1984, pp. 705-709. 37. Seymor, R. B., Plastics Versus Corrosives, John Wiley & Sons, New York, 1982, pp. 147-262. 38. May, C. A., and Tanaka, Y., Epoxy Resins, Chemistry and Technology, Marcel Dekker, Inc., New York, 1973, p. 347. 11.3Additional references Calder, A. J. J., Exposure Tests on Externally Reinforced Concrete BeamsFirst Two Years, Supplementary Report 529, Transport and Road Research Laboratory, Crowthorne, 1979. Cook, J. P., and Panek, J. R., Construction Sealants and Adhesives, 2nd Edition, John Wiley & Sons, New York, 1984, pp. 295-297.

Hugenschmidt, F., Epoxy Adhesives for Concrete and Steel, Proceedings, First International Congress on Polymer Concretes, London, May 1975. Luke, P. C. C., Strength and Behavior of Rebar Dowels Epoxy-Bonded in Hardened Concrete, thesis, Graduate School of Engineering, University of Texas at Austin, 1984. Plecnik, J. M.; Gaul, R. W.; Pham, M.; Cousins, T.; and Howard, J., Epoxy Penetration, Concrete International, V. 8, No. 2, Feb. 1986, pp. 46-50. Tilmans, A., and Krokosky, E. M., Effect of Radiation on Some Mechanical Properties of an Epoxy System, Journal of Materials, JMCSA, V. 6, No. 2, June 1971, pp. 465-481.
ACI 503.5R-92 was submitted to letter ballot of the committee and approved in accordance with ACI standardization procedures.