DURABILITY PERFORMANCE OF POLYUREA BASED SYSTEMS FOR

CONCRETE MEMBER REHABILITATION

Matthew E. Beyer

Prof. John J. Myers

Undergraduate Research Assistant

CIES / Department of Civil, Arch., & Env. Engineering
Missouri University of Science and Technology
Rolla, MO 65409, USA

Associate Professor
CIES / Department of Civil, Arch., & Env. Engineering
Missouri University of Science and Technology
Rolla, MO 65409, USA
jmyers@mst.edu

KEYWORDS: Polyurea Durability Performance; Fiber-Reinforced Polymers (FRPs); Concrete Member

Rehabilitation.
ABSTRACT
Over the past decade, polyurea based systems have been researched as a means to retrofit columns and
other structural components for increased ductility. During extreme dynamic events such as a seismic or
blast event, ductility in these structural components could help minimize damage to the structure and
save lives. Including the polyurea is being looked at as a potential alternative to steel jacketing in
column repairs. However, little is known about the long-term durability of polyurea systems exposed to
environmental conditioning. The following study was designed as preliminary look at the effects of
freeze/thaw and deicing on polyurea confined concrete. The study compares the compressive strength
and ductility of a sprayed on polyurea system to concrete cylinders subjected to acclerated aggressive
environmental conditioning to controlled specimens with and without polyurea confinement in
laboratory conditions. Findings of the work indicated that the polyurea system investigated to have
good durability performance when subjected to both freeze-thaw and deicing environments.
INTRODUCTION
With the advent of polymers, researchers have aggressively studied how fiber reinforced polymers
(FRP) can replace conventional construction materials or methods. The use of FRP jacketing systems is
just one of many applications researchers have studied. In fact, several physical and analytical studies
have already been conducted to understand and provide information on the benefits of FRP (Mirmiran et
al., 1997; Pessiki et al., 2001). One application researchers are considering is the revitalization of
deteriorating reinforced concrete (RC) members with FRP. Additionally, retrofit for seismic and
explosive blasts have become a major concern, which FRP systems can mitigate. Studies have proven
how FRP can be used effectively to strengthen walls to improve the ductility of the walls during extreme
events such as blast (Carney et al., 2005; Myers et al., 2004; Muszynski et al., 2003; Porter et al., 2002).
In Muszynskis research, a control wall and a wall with an FRP backing was subjected to a blast. The
FRP backed masonry wall was successful in holding up to the blast whereas the control wall failed.
Muszynskis research is just one of the many research experiments showing the value of FRP material
for improved performance. Presently, steel jacketing systems are a conventional choice for designers
when it comes to reinforcing concrete members. FRP jacketing systems are being considered for
replacement of steel jacketing systems for several reasons.
Steel is an isotropic material, which diminishes its full potential in multiple axis for some applications.
A multi-directional material like steel has identical properties running opposite to the load; these
properties may not be required for some applications. FPR material can be designed to be unidirectional, which places the full material requirements in the direction of the load. Another concern
with steel is its corrosiveness over long-term duration, which FRP materials do not experience. In
reference to the methods of construction, FRP systems have several advantages over steel jacketing
systems: less labor hours to construct, less skilled labor is needed, and the FRP is a lighter material to
transport (Mirmiran et al., 1997). FRP jacketing systems include wrapped, wet lay-up, and epoxy
sprayed show great promise from this perspective.

Over the past few decades, polyurea has been heavily researched as a means to retrofit columns and
other structural elements (see Fig. 1) for increased ductility in the system. By retrofitting columns,
polyurea usage could be essential in saving lives by preventing progressive collapse and reducing
structural damage during seismic and blast events. However, little is known about the long-term
durability of polyurea in environmental conditions. The following study was designed as preliminary
look at the effects of freeze/thaw and deicing on polyurea confined concrete. The study examines the
compressive strength, stiffness and ductility of polyurea sprayed concrete cylinders subjected to
acclerated environmental conditioning against control specimens with and without polyurea
confinement in laboratory conditions. The study includes varying concrete design mixes to represent
varying concrete types to investigate their effect on the conditioning of the FRP jacketing system. The
concrete design mixes that were selected for this study included: High-Strength Lightweight Concrete
(LWC), High-Strength/High Performance Concrete (HSC), and Normal Strength Concrete (NSC).

(a)

(b)

(c)

Fig. 1 Sprayed poly-urea [Courtesy of Hrynyk and Myers 2007b].

(a) Primer application, (b) Poly-urea application, (c) Backing (optional process, which increases strength)
EXPERIMENTAL PROGRAM
The experimental program consists of conditioning polyurea jacketed concrete cylinders through freezethaw and deicing attacks followed by axial compressive testing to investigate the durability of the
conditioned polyurea jacketing system based on the compressive strength at failure and the loaddeformation response of the specimens. Further, the investigation includes variables of design mix and
duration of conditioning. The unconditioned cylinders with and without the jacketing system were tested
to evaluate the effectiveness of the jacketing system.
(1) Materials
Three design mixes were evaluated: High-Strength Lightweight Concrete (LWC), High-Strength/High
Performance Concrete (HSC), and Normal Strength Concrete (NSC) with specific densities of 120.54
lb/ft3 (1,931 kg/m3), 156.14 lb/ft3 (2,501 kg/m3), and 149 lb/ft3 (2,398 kg/m3), respectively. The
compressive strength of the mix designs at testing were as follows: LWC-9,410psi (64.88 MPa), HSC13,970psi (96.32 MPa), NSC-8,470psi (58.40 MPa).
Each mix is composed of sixteen 4 in. (102 mm) diameter by 8 in. (204 mm) height specimens, which
were divided into four categories: Concrete Control (un-jacketed and unconditioned), Polyurea Jacketed
Concrete Control (jacketed and unconditioned), Polyurea Jacketed Concrete (2-week conditioning), and
Polyurea Jacketed Concrete (4-week conditioning). Hereon the conditioning will be abbreviated as
shown in Table 1. Control specimens were kept at room temperature under laboratory conditions.

Table 1 Experimental program matrix.

Type of Mix
Design

Conditioning
Control (C)

Conventional
Concrete

Control with Poly-urea

confinement (PC)
Poly-urea confinement 2-week
Freeze/Thaw Cycle (PSD)
Poly-urea confinement 4-week
Freeze/Thaw Cycle (PLD)
Control (C)

High
Strength/
High
Performance
Concrete

Control with Poly-urea

Confinement (PC)
Poly-urea confinement 2-week
Freeze/Thaw Cycle (PSD)
Poly-urea confinement 4-week
Freeze/Thaw Cycle (PLD)
Control (C)

High
Strength
Lightweight
Concrete

Control with Poly-urea

Confinement (PC)
Poly-urea confinement 2-week
Freeze/Thaw Cycle (PSD)
Poly-urea confinement 4-week
Freeze/Thaw Cycle (PLD)

Specimen ID
ConditionMix DesignSpecimen #

# of
Specimens

CNSC1 through 4

PCNSC1 through 4

PSDNSC1 through 4

PLDNSC1 through 4

CHSC1 through 4

PCHSC1 through 4

PSDHSC1 through 4

PLDHSC1 through 4

CLWC1 through 4

PCLWC1 through 4

PSDLWC1 through 4

PLDLWC1 through 4

The specimens with the jacketing system received a 1/16 in. (1.6 mm) coat of an epoxy-based polyurea.
The spary-on coating was applied by a technitian experienced with polyurea application systems. The
mechanical property testing of the polyurea was reported by Hrynyk and Myers (2007b). Coupon level
samples are illustrated in Fig. 2. Uni-axial tension testing was preformed on four coupons of polyurea
having a gage length of 5 in. (12.7 mm). From these coupons, the stress-strain relationships were
determined and are summarized in Table 2.

Fig. 2: Polyurea coupon specimens.

Courtesy of Hrynyk and Myers (2007a)

Table 2 Polyurea Average Property Values (Reported by Hrynyk and Myers, 2007b).
Stress at Full Yield

Modulus of Elasticity

ksi (MPa)

ksi (GPa)

0.58 (4.00)

12.1 (0.083)

Strain at Full Yield

Ultimate Stress
ksi (MPa)

0.145

> 1.0 (6.89)

(2) Exposure Conditioning

The conditioned specimens were subjected to environmental conditions of freeze-thaw cycles and
deicing to investigate their affect on the polyurea system. These specimens were chosen to either
undergo two or four weeks of acclerated environmental conditioning as illustrated in Fig. 3.
Temperature ( Deg. Fahrenheit)

C = (5/9) x (F-32)

80
70
60
50
40
30
20
10
0
-10

75 F
One Cycle

After a
week of
cycles

40 F
Cycle repeated for
per week
(28 cycles total)

-1 F
0

4
6
Time (hours)

10

Fig. 3 Freeze-thaw cycle.

Specimens were exposed to cycles of increasing and decreasing temperature similar to the standard
ASTM C 666 freeze-thaw (F-T) temperature profile where specimens are cycled between a maximum
temperature of 40F (4C) and a minimum temperature of -1F (-18C). At peak temperatures, for both
maximum and minimum the chamber was stabilized at those temperatures for a period to ensure the
concrete from surface to center core stabilized at these values (see Fig. 3). In total, the two week cycle
included a total of 56 F-T cycles whereas the four week cycle included a total of 112 F-T cycles.
The second environmental mechanism subjected to the conditioned specimens was deicing. A salt
solution at 7.5% by weight was sprayed on the specimens three times a week to saturate the surface of
the cylinders. The saline solution simulates the effects of deicing on bridges or marine environments.
During the freeze-thaw cycles, the salt solution may affect the strength of the concrete as well as the
bond between the concrete and polyurea wrap.
In Rolla, Missouri, USA the total number of days annually below 32 F (0o C) is 104 per year on
average, which is based on data collected over 106 years. In order for a freeze-thaw cycle to be
detrimental to the concrete, the concrete must reach a stabalized internal temperature of at least 23 F (5o C) and exceed a critical saturation threshold of 91.7% during the time period. An internal concrete
temperature of 23 F (-5o C) is equivalent to an ambient air temperature of 15 F (-9o C). Of the average
104 F-T cycles in Central Missouri annually approximately 5 per year result in moist freeze-thaw cycles
that satisfy these previously noted criteria and similar to the conditions simulated via the cycling
described above. These cycles would represent approximately two decades of field exposure in Central
Missouri, USA when compared to the acclerated 4 week exposure cycle.
(3) Experimental Test Set-up

Twelve conditions with four specimens representing each condition were fabricated (Refer to Table 1).
For each condition, the first specimen was subjected to axial compression to failure. The remaining
three specimens were loaded to 50% of the ultimate compressive strength of the first specimen and then
unloaded with a compressometer twice to determine the modulus of elasticity (MOE). Two cycles were
preformed on each MOE specimen. The compressometer was mounted on these cylinders to measure the
axial strain and calculate the MOE. After removal of the compressometer the specimens were loaded for
a third time to failure. Strain gages were attached and used to record the axial and hoop strain
relationships for each condition set as illustrated in Table 3. Placement of strain gages and
compressometer are illustrated in Fig. 7. The loading rate for all tests was 450 lb/sec (204 kg/sec).
Table 3 Loading information for each condition.
Specimen in
each Condition
#1
#2

#3

#4

Type of Loadings

1st Loading- Taken to Failure (Max. strength recorded)

1st Loading- Taken to 50% Max.
2nd Loading-Taken to 50% Max.
3rd Loading- Taken to Failure
1st Loading- Taken to 50% Max.
2nd Loading-Taken to 50% Max.
3rd Loading- Taken to Failure
1st Loading- Taken to 50% Max.
2nd Loading-Taken to 50% Max.
3rd Loading- Taken to Failure

X
X
X
X
X
X

X
X
X

X
X
X
X
X
X

Note: C- Compressometer, A- Axial Strain Gage, and H- Hoop Strain Gage. X states which
sensors where use for each loading.

(a)

(b)

(c)

Fig. 7 Compression testing set-up.

(a) Compressometer, (b) Axial and Hoop Strain Gage, (c) Axial Strain Gage

EXPERIMENTAL RESULTS
(1) Modulus of Elasticity

The polyurea wrap increased the modulus of elasticity (MOE) of the jacketed specimen modestly by
2.8%, 13.2% and 8.8%, for the NSC, LWC, and HSC respectively (see Fig. 9 Fig. 11) without
conditioning. The polyurea wrap increased the MOE in greater magnitude for the higher strength
concretes respectively. Interestingly, the preconceived thought was the wrap would not affect the MOE
to the level observed irrespective of concrete composition, but rather primarily only increase the
ductility of the system due to its low relative stiffness and high strain capability. As reported earlier in
Table 2, the polyurea material has a tested modulus of elasticity of 12.1 ksi (83.4 kPa), which is very
low as compared to the MOE for any of the concrete types used in this work. In coupon testing the
polyurea behaved as almost a bi-linear material with a linear-elastic region and a plastic region as
illustrated in Fig. 8. In all of the tests performed on the polyurea coupons, the extensometer was
removed after reaching the apparent yield of the material, but prior to ultimate, to prevent damaging the
testing machine. It should also be noted that the tensile testing machine reached its displacement limit
prior to rupturing the polyurea material. In all four tests performed, the limiting displacement of the
testing machine corresponded to a cross-head displacement greater than three times the original gage
length.
0.80
0.70

Stress (ksi)

0.60
0.50
0.40
Test A
Test B
Test C
Test D

0.30
0.20
0.10
0.00
0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0.40

Strain (in./in.)

Note: X indicates the point at which the extensometer was removed

Conversions: 1 ksi = 6.895 MPa; 1 in./in. = 1 mm/mm

Fig. 8. Stress-Strain Behavior of Polyurea (Hrynyk and Myers, 2007b)

The polyurea provided additional confinement to the concrete similar to a steel jacket or spiral steel ties,
except it is comparably weaker in tension, but able to develop a higher strain level under direct tension.
Similar to mild steel the polyurea has a level where the polyurea transforms from a material that has the
ability to take on load with little deformation to a material that becomes plastic. The polyurea wrap
created an elastic confinement on the concrete which modestly affected the cylinder stiffness. At high
strain levels the polyurea performed in a plastic nature, as exhibited when the concrete failed and
displaced under concrete crushing (Refer to Fig. 17).
Fig. 9 Fig. 11 illustrate the MOE for each concrete type and conditioning. In general, prolonged
conditioning appeared to reduce the MOE of the concrete system although part of this may be attributed
to the trend of reduced compressive strength subjected to conditioning. Four weeks of conditioning
appeared to be more detrimental than two weeks of conditioning although it must be stated that the
variance on testing was high in many grouping and more testing is warranted to confirm this behavior.
(2) Axial Compressive Strength
The inclusion of the polyurea wrap on the concrete cylinder did not improve the axial compressive
strength as illustrated in Fig. 12 Fig. 14. In fact, a slight decrease of strength was incurred with the
utilization of the wrap. However, this loss of strength was within the normal variance for the concrete
tested. It is unclear if this trend was associated with simply the variation of testing or if it may have been
related to the polyureas affinity for moisture that may have impacted the concrete strength gain.

Normally, a primer is applied to the application area to restrict the polyurea from absorbing moisture out
of the material. In the experimental study, the concrete cylinders were not primed to serve as a worst
cases bond scenario. The cylinders were sprayed with the polyurea coating after approximately 21-days
of initial curing. Though unlikely, the polyurea may have affected the curing of the concrete to some
degree, which led to lower strength values. More work to examine the interaction of concrete curing
and polyurea jacket is warranted.
10000
high

Elastic Modulus (ksi)

Elastic Modulus (ksi)

10000
9000
average

8000

low

7000
6000
5000

9000
8000
7000
6000
5000
4000

4000
C

PC

PSD

PLD

1 ksi = 6.89 Mpa

9000
8000
7000
6000
5000
4000
PSD

10000
9000
8000
7000
6000
5000
C

PLD

PC

PSD

PLD

Condition

Condition

1 ksi = 6.89 MPa

Fig. 11 Modulus of elasticity for HSC.

Fig. 12 Axial compressive strength for NSC.

11000

Compressive Strength (psi)

1 ksi = 6.89 Mpa

Compressive Strength (psi)

PLD

Fig. 10 Modulus of elasticity for LWC.

Compressive Strength (psi)

Elastic Modulus (ksi)

10000

PC

PSD

1 ksi = 6.89 MPa

Fig. 9 Modulus of elasticity for NSC.

PC

Condition

Condition

10000
9000
8000
7000
6000
C

PC

PSD

PLD

Condition

1 ksi = 6.89 Mpa

Fig. 13 Axial compressive strength for LWC.

15000
14000
13000
12000
11000
10000
C

PC

PSD

PLD

Condition

1 ksi = 6.89 MPa

Fig. 14 Axial compressive strength for HSC.

In the long-term conditioned specimens (PLD), a significant loss in strength was observed as shown in
Fig. 12 and Fig. 13 for the NSC and LWC specimens. Before testing the NSC/LWC cylinders subjected

to the PLD conditioning, it was observed the concrete inside the polyurea jacket showed some signs of
freeze-thaw distress. Based on this observation, the concrete was concluded as the potential weak link
for the drop in compressive strength rather than the jacketing material per say for the NSC/LWC
specimens. In support of this, the compressive strengths found in Fig. 14 for the HSC specimens with no
signs of F-T distress varied minutely between each condition.
(3) Hoop Strain
A strain gage parallel to the circumference was placed on one cylinder for conditioned specimens PC,
PSD, and PLD for each mix design. The inclusion of the polyurea jacket demonstrated very high levels
ductility in the hoop direction. The polyurea system was only comprimized at very high strain levels
well beyond the strain limit of the concrete. Only very minimal decreases (less than 5%) with duration
under environmental exposure was noted in the polyurea in terms of stress-strain ductility behavior of
the jacketed system. A significant loss in hoop ductility for the PLD conditioned specimen was noted
due to the poor freeze-thaw resistance of the NSC and LWC mixes rather than the polyurea coating.
(4) Bond Retension
The polyurea wrap was cut down the length of a representative cylinder after testing; core concrete was
removed and then laid out to inspect the bond retension. The polyurea wrap proved to have good bond
adherence to the concrete, even after testing as represented in Fig. 15. The bond of the polyurea wrap
appeared unaffected by the environmental conditioning.

Fig. 15 Polyurea bond to concrete after failure.

Upon failure of the concrete core, the polyurea wrap would contain the fragmented concrete core as
illustrated in Fig. 16. The wraps ability to hold in or confine the concrete fragments/debris when it fails
in a very ductile fashion under high compressive stress exhibits the positive attributes that the wrap can
contain the debris and fragmentation under high sudden stress levels. However, the polyurea wrap at
times did fracture with the HSC mix (see Fig. 17). This only occurred with HSC, due to the more violent
release of energy under failure. The amount of cases the polyurea fractured was evenly distributed
among all conditions for the HSC mix: PC, PSD, and PLD.

Fig.16 Ductility of polyurea wrap

confining concrete.

Fig. 17 Failure of polyurea wrap.

CONCLUSIONS
The purpose of this study was to observe the effects of aggressive environmental agents and freeze-thaw
cycles on the performance of polyurea wrapped concrete. The data resulting from this study shows the
polyurea system studied to have good durability to both freeze-thaw and deicing. The polyurea wrap
created an elastic confinement on the concrete which resulted in enhanced ductility, modest stiffness
increases, but did not affect the axial compressive strength of the cylinder. On observation during
testing, the polyurea wrap did not engage or rupture until after failure of the concrete; it performed well
containing and confining the concrete as it failed in a brittle crushing fashion under high stress levels.
As represented in the polyurea wraps ability to contain the concrete, a more ductile member could be
constructed to mitigate collapse and/or fragmentation during seismic and blast events. Two of the
selected mix designs did exhibit some signs of F-T/deicing distress under the most severe cycling.
Further research is warrented on full-scale columns to more accurately understand how the wrap affects
the ductility of reinforced concrete members with representative aspect ratios. The 4-in. x 8-in. (102 mm
x 204 mm) cylinders used in the experimental study were not subjected to realistic deflections normally
found on full-scale columns. The smaller deflections experienced with 4-in. x 8-in. (102 mm x 204 mm)
cylinder used little of the ductility performance the polyurea wrap could have delivered in a full-scale
column.
ACKNOWLEDGEMENTS
This study was funded by the National Science Foundation OURE Program at the Missouri University
of Science and Technology (formally the University of Missouri-Rolla). The authors would also like to
recognize Mr. Trevor Hrynyk, Mr. Jared Brewe, Mr. Jason Cox and Mr. Travis Hernandez from the
Center for Infrastructure Engineering Studies (CIES) at Missouri S&T for their assistance in this
research study.
REFERENCES

Carney, P., Myers, J.J. (2005) Static and Blast Resistance of Unreinforced Masonry Wall
Connections Strengthened with Fiber Reinforced Polymers, American Concrete Institute Special
Publication-230, FRPRC7-Editors C. Shield, J. Busel, S. Walkup, D. Gremel, November 2005, pp.
229-248.

Hrynyk, T., Myers, J.J. (2007a) Comparative Study on the Out-Of-Plane Behavior of Retrofitted
Masonry Wall Systems with Arching Action, Proceedings for the 10th North American Masonry
Society, St. Louis, Missouri June, 2007, Published on CD-ROM, 12 pages.
Hrynyk, T., Myers, J.J. (2007b) Static Evaluation of the Out-of-Plane Behavior of URM Infill
Walls Utilizing Modern Blast Retrofit Systems, Report Number 07-75, May, 2007.
Micelli, F., Myers, J.J., Murthy, S. (2002) Performance of FRP Confined Concrete Subjected To
Accelerated Environmental Conditioning, Proceedings of the Second International Conference
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