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11R-12
Guide for the Application of Epoxy and Latex Adhesives for Bonding
Freshly Mixed and Hardened Concretes
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1
2 APPLICATION OF EPOXY AND LATEX ADHESIVES FOR BONDING (ACI 548.11R-12)
Chapter 7Use of latex adhesives, p. 3 necessary to clear the reinforcing steel (VDOT 2007). This
7.1Selection of latex adhesive saw cutting delineates the repair area and reduces edge
7.2Application of latex adhesive spalling and weakness introduced by outlining the area using
other methods. Saw cutting also provides a shoulder against
Chapter 8References, p. 4 which the repair materials can be placed and finished,
resulting in a neater appearance. The saw-cut line should
CHAPTER 1SCOPE be located outside of the determined limits of the defect to
This guide provides information, requirements, and ensure that all defective concrete is removed and that the
procedures for bonding freshly mixed and hardened concretes fresh material is bonded to sound concrete.
by using epoxy or latex adhesives. This information will be Several types of systems are available to remove unsound
of particular use to contractors. concrete.
This guide consists of: a) Scabblers or bush hammers are tools with several points
a) Evaluation of hardened concrete to determine proper that remove concrete by pulverizing or fracturing the surface
preparation and surface conditioning before application of b) Scarifiers have wheels with several points that are
adhesives tipped with carbide, tungsten, or diamonds. This equipment
b) Selection of suitable epoxy or latex adhesive depending removes concrete by scraping or impacting the surface
on the expected performance and environmental conditions c) Water blasting (hydrodemolition) removes concrete by
(ACI 503.5R) projecting jets of potable water
c) Application methods d) Jackhammers remove concrete by impacting the surface
is adequate, but the concrete quality may not be adequate. working time. Elevated temperatures reduce the viscosity
In this case, an additional evaluation in accordance with of the epoxy. This makes it easier to mix and apply and
Chapter 3 may be necessary. shortens the working time in the container. Less open time
before early polymerization affects the bonding ability
CHAPTER 6USE OF EPOXY ADHESIVES of the epoxy compound. Cooler temperatures increase
To ensure adequate bonding using epoxy adhesives, the the viscosity of the epoxy. This makes thorough mixing
following requirements should be met. difficult, lengthens the working time in the container,
a) The concrete surface should be strong, dense, and sound and extends the open time before concrete placement.
as determined by the methods in Chapter 5. The quantity of adhesive to be mixed should not exceed
b) The concrete surface should be clean and free from the amount that can be readily applied within the pot life
contaminants and prepared as described in Chapter 5. or working time of the specific adhesive.
c) In addition to other considerations, the selection of For best results, condition the components from 65 to
epoxy adhesive should consider the anticipated ambient and 85F (18 to 29C) or as recommended by the manufacturer.
concrete temperatures. The ease of use and final properties of Before mixing, premix each component separately.
epoxy application are influenced by the surface temperature. Mechanical mixing of the two components is necessary,
Refer to ASTM C881/C881M for a list of epoxies for use at except for mixing volumes of less than 1 qt (1 L). A
different temperatures. mixing container should have a flat bottom and a capacity
d) Surface moisture and vapor can interfere with the approximately two times the batch size. Dry, clean, plastic
bond of the adhesive. Surface moisture and vapor leaving pails are suitable because the sides can be scraped during
the concrete surface should be recognized as potential mixing, allowing for easy clean up. A cage or propeller-type
impediments to proper bond. Efforts should be made mixing paddle driven by a low-speed electric or air-powered
to dry the surface. Moisture vapor transmission may be drill is recommended for mixing. Mixing may take 3 to
detected by covering the surface tightly with a 4 x 4 ft (1.2 5 minutes. Thorough mixing of both components provides
x 1.2 m) transparent plastic film, following the procedure optimum results.
in ASTM D4263. If moisture has not accumulated under Preportioned or prepackaged units are usually supplied by
the film after 6 to 8 hours, or within the time required the manufacturer so that the entire contents of both containers
for the adhesive to cure and the concrete to set, capillary are mixed together. If smaller quantities are required, the
moisture or out-gassing vapors are insufficient to specific proportioning ratio should be accurately measured
adversely affect the bond. The exposure time should be by mass or volume.
extended 50 percent under the film if temperatures are For large volumes of mixed adhesive, automatic
below 40F (4C) or if the site is under cloud cover. metering and mixing equipment that dispense the properly
proportioned and mixed material is recommended. Such mixers
6.1Selection of epoxy adhesive are available commercially. Mixed adhesive is applied to the
The epoxy adhesive should meet the requirements of repair area through a spray gun or extruding nozzle.
ASTM C881/C881M, Type II and V, Grade 2 and 3, Class A,
B, or C. In addition, unless otherwise recommended by 6.3Application of epoxy adhesive
the adhesive manufacturer, apply sufficient adhesive The adhesive can be applied to the properly prepared
to cover the entire prepared surface without leaving surface using brushes, rollers, squeegees, or spray
excessive adhesive in the low areas. Apply adhesive equipment. Use stiff bristle brushes in a scrubbing
to horizontal, vertical, and overhead surfaces prior to motion to ensure all surface irregularities and pores are
placing the freshly mixed concrete. Type II adhesives are coated. Epoxy adhesive provides satisfactory adhesion if
used in non-load-bearing applications, whereas Type V are the freshly mixed concrete is placed 5 to 10 minutes after
for load-bearing uses. Grade 1 materials are low viscosity. applying the adhesive. This is to allow the adhesive to
Grade 2 materials are medium viscosity. Grade 3 materials wet the existing surface before contact with the freshly
have a nonsagging consistency. Class A materials are used mixed concrete. The freshly mixed concrete should be
when temperatures are below 40F (4C), Class B materials placed while the adhesive is tacky. If the epoxy bond
are used when temperatures are typically between 40 and coat has reached a tack-free stage before placement of
60F (4 and 16C), and Class C materials are used when the freshly mixed concrete, a second coat of the bonding
temperatures are above 60F (16C) with upper limits set epoxy should be applied before placement of the freshly
by the manufacturer. mixed concrete. If more than 5 hours elapse, the semi-
cured or cured epoxy should be brush blasted to provide
6.2Mixing of epoxy adhesive a bondable surface for the second coat of epoxy.
Epoxy adhesives are supplied as two-part systems. One
part contains the epoxy resin and the other part contains the CHAPTER 7USE OF LATEX ADHESIVES
hardener or curing agent. To ensure adequate bonding using latex adhesives, the
Epoxy and substrate temperatures directly affect the following requirements should be met.
performance of the epoxy compound. The quantity and a) The concrete surface should be strong, dense, and sound
temperature of the adhesive at time of mixing influence the as determined by methods in Chapter 3.
American Concrete Institute Copyrighted Materialwww.concrete.org
4 APPLICATION OF EPOXY AND LATEX ADHESIVES FOR BONDING (ACI 548.11R-12)
b) The concrete surface should be clean and free from CHAPTER 8REFERENCES
such contaminants as described in Chapter 5.
c) Latex adhesives need to be applied to a damp surface 8.1Referenced standards and reports
to ensure adequate wetting. The moisture content should Committee documents are listed first by document number
be such that newspaper should become damp when placed and year of publication followed by authored documents.
on the surface. The newspaper should be removed before
placing the latex adhesive. American Concrete Institute
ACI 201.1R-08Guide for Conducting a Visual Inspection
7.1Selection of latex adhesive of Concrete in Service
Type I latex adhesives are redispersible, one-component ACI 228.1R-03In-Place Methods to Estimate
systems used as supplied. They are restricted for interior work Concrete Strength
not subject to water immersion or relative humidity greater ACI 364.1R-07Guide for Evaluation of Concrete
than 90 percent. Typically, Type I latex adhesives are vinyl Structures before Rehabilitation
acetate homopolymers or copolymers, with the comonomer ACI 503.5R-92Guide for the Selection of Polymer
being ethylene or an acrylic ester. The vinyl acetate Adhesives with Concrete (Reapproved 2003)
homopolymers may be plasticized.
Type II latex adhesives are nonredispersible and may ASTM International
be mixed with hydraulic cements. They are suitable for ASTM C823/C823M-12Standard Practice for Examination
interior and exterior work and may be used in areas subject and Sampling of Hardened Concrete in Constructions
to water immersion or high humidity. Typically, they are ASTM C881/C881M-10Standard Specification for
styrene-butadiene copolymers or acrylic ester copolymers Epoxy-Resin-Base Bonding Systems for Concrete
with a solids content of approximately 50 percent by weight. ASTM C1059/C1059M-99(2008)Standard Specification
Latex-to-cement ratios are typically one-to-one by for Latex Agents for Bonding Fresh to Hardened Concrete
volume or one-to-two by mass. The pot life of two-part ASTM C1583/C1583-04Standard Test Method for
adhesives is 10 to 120 minutes. Pot life depends on the Tensile Strength of Concrete Surfaces and the Bond
type of hydraulic cement and environmental conditions Strength or Tensile Strength of Concrete Repair and
such as temperature and relative humidity. For Overlay Materials by Direct Tension (Pull-off Method)
information on Type I and Type II latex adhesives, refer ASTM D4258-05(2012)Standard Practice for Surface
to ASTM C1059/C1059M. Cleaning Concrete for Coating
ASTM D4259-88(2012)Standard Practice for Abrading
7.2Application of latex adhesive Concrete
Type I latex adhesives, stabilized with polyvinyl ASTM D4263-83(2012)Standard Test Method for
alcohol, are not suited for spray application and should Indicating Moisture in Concrete by the Plastic Sheet Method
be applied by brush or roller. Type II latex adhesives are ASTM E965-95(2006)Standard Test Method for
applied by brushing, rolling, or spraying. Measuring Pavement Macrotexture Depth Using a
The prepared surface of the hardened concrete should Volumetric Technique
be dampened before application of the adhesive to ensure
good contact. International Concrete Repair Institute
Typical rates of application are 200 ft2/gal. (5 m2/L) 310.1R-1997Guide for Surface Preparation for the
for Type I adhesives and 55 ft2/gal. (1.4 m2/L) for Type II Repair of Deteriorated Concrete Resulting from Reinforcing
adhesives. Follow the manufacturers recommendations Steel Corrosion (formerly No. 03730)
for rate of application. 310.2R-1997Selecting and Specifying Concrete Surface
For Type II adhesives, it is essential that the freshly mixed Preparation for Sealers, Coatings, and Polymer Overlays
concrete is applied before the adhesive has dried or set up. If (formerly No. 03732)
the Type II adhesive has dried or set up, the adhesive should 310.3R-2004Guide for the Preparation of Concrete
be removed and the surface should be prepared to meet the Surfaces Using Hydrodemolition Methods
conditions described in Chapter 7 (a, b, and c). Because
Type I adhesives are redispersible, timing the application of USACE, 1995, Evaluation and Repair of Concrete
the freshly mixed concrete is not critical, but it should be Structures, EM 1110-2-2002, United States Army Corps of
placed before the adhesive becomes contaminated. If such Engineers, Washington, DC, 185 pp.
contamination occurs, the surface should be cleaned by wet VDOT, 2007, Road and Bridge Specifications, Section
brushing or water spray and the Type I adhesive reapplied. 412.03, Virginia Department of Transportation, Richmond, VA.
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