Proceedings of the Conference on Engineering Research, Innovation and Education 2010 CERIE 2010, 11-13 January, Sylhet, angladesh

Studies on polymer modified mortar and concrete using epoxy resin

Md. Mostafizur Rahman1* and Mainuddin Ahmed3

1,3

!ousing and uilding Research Institute "! RI#, $arus-sala%, &ir'ur, $ha(a-121), angladesh* +el, "02# -000.20, /a0, "02# .0)0113

Md. Akhtarul Islam

2

$e'art%ent of Che%ical Engineering and Poly%er Science, Shah2alal 3niversity of Science and +echnology "S3S+#, Sylhet- 3114, angladesh

+he %ain o52ective of the study is to i%'rove the %echanical 'ro'erties of conventional %ortar and concrete using e'o0y resin as a 5inding %aterial* +he author has conducted a series of tests on e'o0y resin %odified %ortar and concrete 6ith vie6 to co%'are their 'erfor%ance 6ith conventional Portland ce%ent %ortar and concrete* 7aturally occurring local fine aggregate o5tained fro% Sylhet and local hard roc( collected fro% &adha'ara have 5een used as fine aggregate and coarse aggregate res'ectively in the investigation* 8ll aggregates and 5inding %aterials have 5een characteri9ed in this study* $ifferent 'ro'erties of 5oth e'o0y %odified and un%odified %ortar and concrete s'eci%ens have 5een %easured* +hese 'ro'erties include %echanical strength, density and 'orosity* +he %easured 'ro'erties of e'o0y %odified %ortar and concrete co%'ared 6ith that of nor%al conventional %ortar and concrete* It is found that de'ending on the co%'osition of the 'oly%eric %aterial, so%e targeted 'ro'erty of concrete and %ortar has 5een i%'roved several folds as co%'ared to those 're'ared fro% conventional ce%ent-sand-aggregate co%'osition* It is finally o5served that the variation of concentration of the 'oly%er %aterials is very (ey factor, the 'ro'erties of %ortar and concrete can 5e varied as 'er re:uire%ent in a 6ide range %a(ing the Poly%er %odified concrete "P&C# very versatile in a''lications even as a re'air %aterials* +he effects of other varia5les on the 'ro'erties of e'o0y %odified %ortar and concrete s'eci%ens have 5een discussed* $ue to have e0ce'tionally higher early strength 'ro'erties, e'o0y resin %odified %ortar and concrete can 5e used in re'airing 6or(s* It is also a candidate %aterial for /erro ce%ent a''lications* It is concluded that the e'o0y resin %odified %ortar and concrete has high 'ers'ective in angladesh* !ey"ords# Poly%er; concrete; &ortar; &echanical Strength; Porosity %a(ing various structural and non-structural 'recast 'roduct, re'air of structural %e%5ers, 6ater 1. I$%R&'()%I&$ 'roofing and decorative finishes, <verlay of 'ave%ents, 5ridge and industrial floors "&ehta In %odern concrete construction and re'air 6or(s the and &onteiro,1--3#* role of 'oly%ers is increasing day 5y day* Poly%ers are either incor'orated as a co-5inder 6ith Portland ce%ent or used as a single 5inder* +he co%'osites %ade 5y using 'oly%er along 6ith ce%ent and 8 nu%5ers of ther%o'lastic and ther%o setting aggregates are called 'oly%er ce%ent %ortar "PC&# 'oly%ers are used in %odifying %ortars and or 'oly%er ce%ent concrete "PCC#, 6hile co%'osites concrete since 1-=0>s "$i(eou, 1-1.#* +he %ade 6ith 'oly%er and aggregates are called 'oly%er choice of 'oly%ers de'ends u'on the intended %ortar "P&# or 'oly%er concrete "PC#* <ha%a, 1-.1, use and re:uire%ent of 'erfor%ances "8CI and &ir9a et al*, 2002, found that the incor'oration of =4.*3R--=, 2000#* &any researchers around the 'oly%ers greatly i%'roves strength, adhesion, 6orld used e'o0y 5ased 'oly%er as a 5inder in resilience, i%'er%ea5ility, che%ical resistance and %ortar and concrete and found i%'roved dura5ility 'ro'erties of %ortar and concrete* +hese %echanical 'ro'erties since 1-.- "?i'ulanandan 'ro'erties %a(e PC& and PCC a suita5le %aterial for
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Proceedings of the Conference on Engineering Research, Innovation and Education 2010 CERIE 2010, 11-13 January, Sylhet, angladesh
and $har%ara2an, 1-.-#* &ost of the researchers used locally availa5le aggregates as filling %aterials in the study* In vie6 of this, this is the first ti%e in angladesh, an e0'eri%ental study has 5een underta(en to develo' e'o0y 5ased different ty'es of 'oly%er %odified %ortar and concrete using locally availa5le aggregates as filling %aterials* +he %aterials are characteri9ed and co%'ared 6ith those of un%odified %ortar and concrete* 2*3) %% 1*1. %% 0*)0 %% 0*30 %% 0*1= %% )*12=*13 3.*32 22*01 =*11 )*131*-2 10*24 -2*2= -1*-)

+he 'article si9e distri5ution curve of coarse aggregate is sho6n in /ig*1*

. MA%*RIA+S and M*%,&'

.1 Materials E'o0y e%ulsion used in the e0'eri%ent 6as 're'ared 5y e%ulsifying e'o0y resin, 5ased on E'ichlorohydrin and 5is'henol-8, and a%ino a%ide 5ased hardener used 6ith the e'o0y for hardening* E'o0y resin used in the e0'eri%ent had viscosity of 3)00c's at 30 0C, density of 1*1= g%Cc%3 and '! value 1*12 <rdinary Portland ce%ent of fineness %odulus 2*-and locally availa5le sylhet sand 6ere used for %a(ing %ortar test s'eci%ens, 6hile stone chi's collected fro% &adha'ara used along 6ith Portland ce%ent and sylhet sand for %a(ing concrete s'eci%ens in the 'resent investigations* Pro'erties of Portland ce%ent and sieve analysis of sand used in this study re'orted in +a5le-1 and +a5le-2 res'ectively, 6hile 'articles si9e distri5ution of coarse aggregates "Stone chi's# re'orted in fig*-1* %a-le.1# Pro'erties of Portland ce%ent used in the e0'eri%ent +est 'erfor%e d 1* /ineness test 2* Setting ti%e Initial /inal 3* Co%'ressive strength 1 day 2. day Result 0*0).D 2 hours 3 hours 14*-2 &Pa 1- &Pa
% Retainted

Coarse aggregate distribution 120 100 80 60 40 20 0 0 5 10 15 20 Seive opening (m m ) 25

/ig*1, Particle si9e distri5ution curve for coarse aggregate +he /ig*1 sho6s that 'article si9e of coarse aggregate is in the range of 4*1=-1-*0= %% and %ore than -0 D of aggregates are 6ithin 1= %% si9e* .1.1 /reparation of specimen# +o study the effect of 'oly%er on various 'ro'erties, s'eci%ens 6ere 're'ared 5y varying the 'oly%er 'ercentage fro% 0-1=D 5ased on total 6eight of the s'eci%ens* In case of 'oly%er %ortar %a0i%u% 1= 6t*D of e'o0y can 5e added, %ore than that causes 'ro5le%s in 'ro'er %i0ing that results lo6er strength, 6hereas %a0i%u% 10 6t* D of e'o0y can 5e added in 'oly%er ce%ent %ortar* 8 ce%ent-sand ratio of 1,3 5y %ass 6as (e't constant for %ortar s'eci%ens, 6hile ce%ent-sand-course aggregates ratio of 1,1*=,3 5y %ass 6as %aintained for concrete s'eci%ens* /or all %i0es the 6ater-ce%ent ratio "6Cc# 6as ad2usted to %aintain the 6or(a5ility "or flo6a5ility# of concrete through slu%' test* +he test 'rocedure follo6ed 8S+& C 143 using a cone sha'e %old, 203 %% in 5otto% dia%eter and 102 %% in to' dia%eter* =0*.%%E=0*.%% E=0*.%% cu5e si9e %ortar s'eci%ens and 1=2*4%%E 1=2*4%% E 1=2*4%% cu5e si9e concrete s'eci%ens 6ere 're'ared follo6ing the 'rocedure 'rescri5ed 5y 8S+&, C10- for co%'ressive strength test* 8fter %oulding the s'eci%ens are allo6ed to cure in

2*

Setting ti%e of Portland ce%ent 6as deter%ined 5y ?icat 7iddle follo6ing 8S+& standard %ethod "C 1-1-.2#* Co%'ressive strength and fineness of Portland ce%ent also deter%ined follo6ing 8S+& standard %ethod "C-10-#* %a-le. # Seive analysis of Sylhet sand Seive si9e 4*1= %%
@

&ass retained "D# -

Cu%ulative %ass retained "D# -

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Proceedings of the Conference on Engineering Research, Innovation and Education 2010 CERIE 2010, 11-13 January, Sylhet, angladesh
the %ould for 24 hours* +he concrete s'eci%ens 6ere de%oulded after 24 hours and then stored in 6ater in case of conventional concreteC%ortar and 'oly%er ce%ent concreteC%ortar 5ut 'oly%er concreteC%ortar s'eci%ens "'oly%er used as a only 5inder# stored in dry 'laces for air curing* Curing under 6ater is not re:uired for 'oly%er concreteC%ortar since Portland ce%ent is not used in the s'eci%en* . Methods . .1 )alculation of apparent and true density0 and porosity# +he 'ara%eters are deter%ined 5y the follo6ing relations, (3) a = W0 C V0 +he results of 'oly%er addition on co%'ressive strength of 'oly%er %ortar and 'oly%er ce%ent %ortar are sho6n in /igs*2 and 3, res'ectively* +he co%'ressive strength of un%odified %ortar s'eci%en is 1.*23 &Pa at 2. days curing* It can 5e seen that the co%'ressive strength of 5oth 'oly%er ce%ent %ortar and 'oly%er %ortar increases 6ith increasing 'oly%er co%'osition* +he fig*2 and 3 sho6s that the rate of strength gain of 'oly%er %ortar is higher than 'oly%er ce%ent %ortar and un%odified nor%al Portland ce%ent %ortar* +he strength gain rate of 'oly%er %odified %ortar is a5out is a5out .)D of ulti%ate strength at 1 days curing 6hereas un%odified nor%al Portland ce%ent %ortar gains only )0D of it>s ulti%ate strength*
Effect of com position on strength of PM 80

T =
and

W0 V0 "W W0 # C w

(4)

= 1 a C T

(5 )

Compressive strength (Mpa)

70 60 50 40 30 20 10 0 0 5 10 15 20 25 Curing tim e (day) 30

Fhere a, T and are res'ectively a''arent density, true density and 'orosity; V0 is the 5ul( volu%e of the sa%'le, w is the density of 6ater, W0 is the dry 6eight and W is the 6eight of the 6et s'eci%en at e:uili5riu%* . . )alculation of )oefficient of %hermal *xpansion# 8 5ar ty'e sa%'le 6as 're'ared and cured for 2. days at roo% te%'erature+ 1 and length of the s'eci%en 6as %easured G1* +hen the s'eci%en 'laced in a autoclave and heated it u' to + 20C* If the roo% te%'erature is +10C then the te%'erature difference H+I +20- +10 8ccording to the la6 of ther%al e0'ansion

/ig* 2 Co%'ressive Strength vs* curing ti%e relationshi' for e'o0y %odified %ortars* "@#7or%al, %odified 6ith "# 10 6t*D E'o0y, "# 12 6t*D E'o0y, "# 14 6t*D E'o0y and "# 1= 6t*D E'o0y

/inally, Poly%er %ortar 'rovides 10 &Pa at 2. days using 1= 6t*D e'o0y "5ased on total 6eight of the s'eci%en#* <n the other hand, 'oly%er ce%ent %ortar can 'rovide %a0i%u% =3 &Pa at 2. days curing using 10 6t*D e'o0y "5ased on total 6eight of the s'eci%en#*
60 50 Compressive strength (MPa) 40 30 20 10 0 0 5 10 15 20 Curing tim e (Day) 25 30 Effect of com position on PCM

G2 - G1 L1 "+2 - +1#

(6)

Fhere G2I Gength of the s'eci%en at +20C te%'erature and JI Coefficient of ther%al E0'ansion . .3 )ompressi1e and %ensile strength measurement# +he co%'ressive strength of different Poly%er &odified Concrete "P&C# and Poly%er Concrete "PC# 6ere deter%ined 5y 3niversal +esting &achine "&odel 7o*+I C&*C; Ca'acity-300 +on#*

3. R*S(+%S A$' 'IS)(SSI&$

/ig* 3 Co%'ressive Strength vs* curing ti%e relationshi' for e'o0y %odified %ortars* "@#7or%al, %odified 6ith "# 4 6t*D E'o0y, "# = 6t*D E'o0y, "# 1 6t*D E'o0y and "# 10 6t*D E'o0y

+he curve for = 6t*D and 1 6t*D " 5ased on total 6eight of the s'eci%en# e'o0y %odified
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Proceedings of the Conference on Engineering Research, Innovation and Education 2010 CERIE 2010, 11-13 January, Sylhet, angladesh
%ortar sho6s al%ost sa%e ulti%ate strength can 5e e0'lained 5y the for%ation of sta5le %i0ture re:uired so%e concentration of e'o0y* 8fter the for%ation of sta5le %i0ture, very little change in concentration 'rovides higher strength co%'aratively* Si%ilarly, in case of 'oly%er concrete, 'oly%er %odification i%'roves co%'ressive strength %ar(edly "/ig*4#* Even the strength gain rate is also higher as 'oly%er %ortar* +he fig* sho6s that curve for 14 6t*D " 5ased on total 6eight of the s'eci%en# sho6s shar' increase in co%'ressive strength co%'arative to the curve for 10 6t*D and 12 6t*D* It can 5e e0'lained 5y the sa%e cause of for%ation of sta5le %i0ture descri5ed in case of PCC*
100 90 80 70 60 50 40 30 20 10 0 0 Effect of com position on strength of PC

+his result can 5e e0'lained 5y; the addition of e'o0y 6as not solu5le to 6ater as a result e'o0y 6as not %i0ed ho%ogeneously 6ith 6hole %ass* +his i%'ro'er %i0ing results unsteady strength gain* 8lthough %any researchers re'orted higher strength of 'oly%er ce%ent concrete, the author o5served 'ro5le% in 'ro'er %i0ing in case of PCC 'articularly for those 'oly%ers 6hich are insolu5le to 6ater* 3.1. /orosity0 apparent density and true density of different types of mortar Percentage of 'orosity, a''arent density and true density are deter%ined for nor%al and 'oly%er %odified %ortar* +he o5tained result is su%%ari9ed in ta5le-3* +a5le-3* Porosity, a''arent density and true density of different ty'es of %ortar +y'es of %ortar 3n%odified nor%al %ortar Poly%er ce%ent %ortar Poly%er %ortar Porosity "D# 1*=0 =*01 0*=4 8''* density "g%Ccc# 2*11*.1 1*.3 +rue density "g%Ccc# 2*31 1*-1 1*.4

Compressive strength

(MPa)

10 15 20 Curing Tim e (Day)

25

30

/ig* 4 Co%'ressive Strength vs* curing ti%e relationshi' for e'o0y %odified Concrete* "# 7or%al, %odified 6ith "# 10 6t*D E'o0y, "# 12 6t*D E'o0y and "# 14 6t*D E'o0y

+he fig* 4 sho6s that al%ost -0D strength achieved 6ithin first 1 days curing 6hich is very %uch significant 'ro'erties to consider this %aterials as a re'air %aterials* ut, in case of 'oly%er ce%ent concrete, the rate of strength gain is not noticea5le "/ig*=# co%'arative to the rate of strength gain 5y 'oly%er %ortar or 'oly%er concrete s'eci%ens*
E f f e c t o f c o m po s itio n o n s tre n gth o f P C C 40 35

Compressive strenght (MPa)

30 25 20 1 5 1 0 5 0 0 1 0 20 C uring tim e (D a y) 30

+he result sho6s that the addition 'oly%er reduces the 'orosity and density* It can 5e e0'lained 5y the additions of 'oly%er in %ortar fill u' the voids inside the %ortar 6hich results the decrease in 'orosity* In case of 'oly%er %ortar "no Portland ce%ent 6as added#, there 6as not re:uired to add any 6ater 6hereas, in case of un%odified nor%al Portland ce%ent %ortar 6ater added for 'ro'er hydration that occu'ied so%e s'ace in %ortar during casting* 8fter casting e0tra 6ater dried out, this creates voids in nor%al %ortar s'eci%en* +his is 6hy in case of 'oly%er %ortar s'eci%en sho6s lo6est 'orosity* 3. )oefficient of thermal expansion of different types of mortar Shrin(age or e0'ansion is volu%e change 'ro'erty 6hich is %easured 5y %onitoring 'eriodically the length changes of the s'eci%en e0'osed to controlled environ%ental condition* +his 'ro'erty can 5e calculated using ther%al e0'ansion* +herefore, the coefficient of ther%al e0'ansion is deter%ined for nor%al and 'oly%er %odified %ortar to (no6 a5out shrin(age 'ro'erty of the %aterial* +he o5tained result is su%%ari9ed in ta5le-4

/ig* =Co%'ressive Strength vs* curing ti%e relationshi' for e'o0y %odified Concrete* "#7or%al, %odified 6ith "@#4D E'o0y, "# 1 6t*D E'o0y, "# 2 6t*D E'o0y, "# 3 6t*D E'o0y and "K# = 6t*D E'o0y

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Proceedings of the Conference on Engineering Research, Innovation and Education 2010 CERIE 2010, 11-13 January, Sylhet, angladesh
+a5le-4* Coefficient of ther%al e0'ansion of different ty'es of %ortar Sa%'le ty'e 3n%odified nor%al %ortar Poly%er %ortar Coefficient of ther%al E0'ansion J 1*3 E10-0= C0C 0*2) E10-0= C0C

3. A)!$&4+*'5*M*$%
+he research 6as funded 5y the &inistry of !ousing and Pu5lic For(s, the Peo'le>s Re'u5lic of angladesh "Pro2ect code, 1100C 8'ril 11, 2001#* +he authors are than(ful to Engr* Rea9 3ddin Sar(er, Engr* 8(taru99a%an, &d* &ir9a Shah2ahan, &d* Shahidullah (han and &d* Is%ail !ossain of housing and 5uilding research institute for their hel'ful suggestions, consultations and continuous ins'iration*

+he result sho6s clearly that the conventional %ortars are %ore sensitive to the hot-dry environ%ent 6hich accelerate the %oisture loss and enhance the shrin(age* $ra%atic reduction in shrin(age can 5e o5tained using 'oly%ers* Poly%er %ortar sho6s a reduction of %ore than 33 ti%es co%'ared to the conventional %ortar* +his 'ro'erty is very %uch significant for %aterials of 'lastering 6or(*

6. R*7*R*$)*
1* 8CI =4.*3R--=*, "2000#, State of the art re'ort on 'oly%er %odified concrete, In: ACI manual of concrete practice, 'art-=, /a%ington !ills, 3S8 8%erican Concrete Institute, ''*=4.*3R-1-=4.*3R-41* $i(eou, J* +*, "1-1.#, Poly%ers in concrete, ne6 construction achieve%ents on the hori9on, Procee in!" of T#e $econ International Con!re"" on Pol%mer" in Concrete, 8%erican Concrete Institute "8CI# $etroit, &ich*, ''* 1-. &ehta PL, &onteiro PJ&*, "1--3#, Concrete structure, 'ro'erties and %aterials, &n e ' (n!lewoo Cliff", 7J, Prentice !all, ''*41.23* &ir9a J, &ir9a &S, Ga'onite R, "2002#, Ga5oratory and field 'erfor%ance of 'oly%er %odified ce%ent 5ased re'air %ortars in cli%ates, Con"truction )uil in! material"* 1), ''*3)=-14* <ha%a M*, "1-.1#, Princi'le of late0 %odification and so%e ty'ical 'ro'erties of late0 %odified %ortar and concrete, ACI +aterial" ,ournal* .)"7ov-$ec#,=11-. ?i'ulanandan, C* and $har%ara2an, 7* "1-.-#, N8nalysis of /racture Para%eters of E'o0y-Poly%er ConcreteO, ACI +aterial" ,ournal* .)"4#, 3.3-3-3

2. )&$)+(SI&$
+he result of this study sho6s that the addition of 'oly%er to Portland ce%ent %ortar i%'roves 6or(a5ility and increases co%'ressive strength and decreases 'orosity* E'o0y %odified 'oly%er %ortar 'rovides higher co%'ressive strength and lo6er 'ercentage of 'orosity* It has higher adhesion 'ro'erties to the old structure* So this %aterial is very %uch effective for 'lastering and re'airing 6or(s* +hese %aterials can 5e candidate %aterials for /erro ce%ent a''lication instead of ce%ent %ortar* In case of concrete, Poly%er concrete sho6s su'erior %echanical 'ro'erties* +his %aterial can 5e used 6here higher co%'ressive strength is re:uired* It can 'rovide early strength 6ith :uic( setting ti%e* It has lo6er 'orosity co%'arative to nor%al concrete so it can 5e the candidate %aterial for da%' 'roof* $ue to high strength and light 6eight 'ro'erties, PC 6ould 5e highly effective in the construction of high rise 5uilding as 6ell as of structures 6ith s'ecific re:uire%ents such as in %arine environ%ent, for 'rotection fro% flood and earth:ua(e* In the coastal area of angladesh, hydraulic structures and constructional 6or(s could 5e done 5y Poly%er %odified %aterials* 2*

3*

4*

=*

)*

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