1 TECHNICAL GUIDELINES 2 Prepared by the International Concrete Repair Institute 3 Guide for Selecting and Specifying Materials for Repair of Concrete Surfaces 4 Guideline No. 320.2R–xx (formerly No. 03733) 5 6 Copyright © xxxx International Concrete Repair Institute 7 All rights reserved. 8 International Concrete Repair Institute 9 10600 West Higgins Road, Suite 607, Rosemont, IL 60018 10 Phone: 847-827-0830 11 Web: www.icri.org 12 E-mail: info@icri.org 13 Page 1 of 92 Fax: 847-827-0832 June 2015 1 About ICRI Guidelines 2 The International Concrete Repair Institute (ICRI) was founded to improve the durability of concrete repair 3 and enhance its value for structure owners. The identification, development, and promotion of the most 4 promising methods and materials are primary vehicles for accelerating advances in repair technology. 5 Working through a variety of forums, ICRI members have the opportunity to address these issues and to 6 directly contribute to improving the practice of concrete repair. 7 A principal component of this effort is to make carefully selected information on important repair subjects 8 readily accessible to decision makers. During the past several decades, much has been reported in the 9 literature on concrete repair methods and materials as they have been developed and refined. Nevertheless, 10 it has been difficult to find critically reviewed information on the state of the art condensed into easy-to-use 11 formats. 12 To that end, ICRI guidelines are prepared by sanctioned task groups and approved by the ICRI Technical 13 Activities Committee. Each guideline is designed to address a specific area of practice recognized as 14 essential to the achievement of durable repairs. All ICRI guideline documents are subject to continual 15 review by the membership and may be revised as approved by the Technical Activities Committee. 16 Technical Activities Committee 17 Fred Goodwin, Chair 18 James E. McDonald, Secretary 19 Peter DeNicola 20 Pierre Hebert 21 Gabriel A. Jimenez 22 Peter R. Kolf Page 2 of 92 1 Ken Lozen 2 Kevin Michols 3 Mark Nelson 4 5 6 Karl Rickert 7 Lee Sizemore 8 Aamer Syed Monica M. Rourke 9 10 11 12 John Weisbarth 13 Dale Campbell 14 Mark A. DeStefano 15 Ashish Dubey 16 Pierre Hebert 17 David Karins 18 Peter Kolf 19 Jim McDonald 20 Kevin Michols 21 Michael Paipal 22 Jeff Smith 23 Aamer Syed 24 Patrick Watson Producers of this Guideline 25 Page 3 of 92 1 ICRI Committee 320, Concrete Repair Materials and Methods 2 Ashish Dubey (CHAIR) 3 Frank Verano (SEC) 4 Richard Braun 5 Joe Daley 6 Peter DeNicola 7 Mark A. DeStefano 8 Luis Diaz DeLeon 9 Scott DiStefano 10 I. George Dorosh 11 David Flax 12 Andrew S. Fulkerson 13 Steven Geiger 14 Fred Goodwin 15 Pierre Hebert 16 James Hicks 17 David G. Karins 18 Peter R. Kolf 19 Kiley P. Marcoe 20 James E. McDonald 21 Kevin A. Michols 22 Paul Millette 23 Brian Mintz Page 4 of 92 1 Matthew Mowrer 2 Michael Paipal 3 Clyde Porter, Jr. 4 Jeffery G. Smith 5 Robert Swan 6 Aamer Syed 7 Brian J. Wolfe 8 Page 5 of 92 1 Synopsis 2 The purpose of this guide is to aid the designer, specifier, contractor, and manufacturer to make rational 3 informed decisions in selecting materials for the repair of concrete surfaces. Its primary focus is on the 4 components and structure of the selection process itself. To assist with the identification and prioritizing of 5 the performance requirements, a detailed section on material properties and test methods has been included. 6 The state of the art of repair material selection has changed a great deal since this document was originally 7 published. Minor changes were added in 2009, although much of the text remains from the original 03733 8 1996 publication. The adoption of ICRI 320.3R, Guideline for Inorganic Repair Material Data Sheet 9 Protocol; ACI 364.3R, Guide for Cementitious Repair Material Data Sheet; ACI 562, Code Requirements 10 for Evaluation, Repair, and Rehabilitation of Concrete Buildings; ACI 546.3R, Guide for the Selection of 11 Materials for the Repair of Concrete; and other documents impacts the content of this document and 12 requires harmonization with these newer documents. 13 Keywords 14 Bond strength; constructability; dimensional behavior; durability; materials selection; test methods 15 This document is intended as a voluntary guideline for the owner, design professional, and concrete repair 16 contractor. It is not intended to relieve the professional engineer or designer of any responsibility for the 17 specification of concrete repair methods, materials, or practices. While we believe the information contained 18 herein represents the proper means to achieve quality results, the International Concrete Repair Institute 19 must disclaim any liability or responsibility to those who may choose to rely on all or any part of this guide. 20 Page 6 of 92 1 Contents 2 The Material Selection Process ............................................................................ 2 3 Concept of Surface Repair ................................................................................ 3 4 Structural Applications ..................................................................................... 3 5 1.0 Project Objectives ........................................................................................... 4 6 Material Selection Checklists 7 Owner Requirements ........................................................................................ 5 8 Service Conditions ............................................................................................ 6 9 Application Conditions ..................................................................................... 7 10 2.0 Material Properties ......................................................................................... 8 11 Service Conditions: Structural Properties ......................................................... 9 12 Service Conditions: Exposure ......................................................................... 10 13 Service Conditions: Dynamic Loading ........................................................... 11 14 Application Conditions ................................................................................... 12 15 Owner Requirements ...................................................................................... 12 16 3.0 Determining Properties ................................................................................ 13 17 3.1 Bond Strength ............................................................................................ 14 18 3.1.1 Direct Tensile ................................................................................ 14 19 3.1.2 Direct Shear ................................................................................. 15 20 3.1.3 Slant Shear ................................................................................... 15 21 3.2 Dimensional Behavior ............................................................................... 16 22 3.2.1 Drying Shrinkage .......................................................................... 16 23 3.2.2 Coefficient of Thermal Expansion ................................................ 18 Page 7 of 92 1 3.2.3 Modulus of Elasticity .................................................................... 18 2 3.2.4 Creep (Tensile and Compressive) ................................................ 19 3 3.2.5 Restrained Shrinkage .................................................................... 20 4 3.3 Durability Properties.................................................................................. 21 5 3.3.1 Permeability ...................................................................................... 21 6 3.3.2 Water Vapor Transmission ........................................................... 21 7 3.3.3 Resistance to Freezing and Thawing ........................................... 22 8 3.3.4 Resistance to Scaling .................................................................... 22 9 3.3.5 Sulfate Resistance ......................................................................... 23 10 3.3.6 Alkali-Aggregate Reaction ........................................................... 23 11 3.3.7 Abrasion Resistance ...................................................................... 24 12 3.4 Mechanical Properties ............................................................................... 25 13 3.4.1 Tensile Strength ............................................................................ 25 14 3.4.2 Flexural Strength ........................................................................... 25 15 3.4.3 Compressive Strength ................................................................... 26 16 3.5 Constructability Properties ........................................................................ 26 17 3.5.1 Flow Characteristics...................................................................... 26 18 3.5.2 Rate of Strength Gain.................................................................... 27 19 3.5.3 Exothermic Temperature Changes ................................................ 27 20 3.5.4 Hot and Cold Weather Applications ............................................. 27 21 3.5.5 Working Time ............................................................................... 28 22 3.5.6 Compatibility with Surface Treatments ........................................ 28 23 3.5.7 Compatibility with Substrate ........................................................ 28 Page 8 of 92 1 3.6 Summary.................................................................................................... 28 2 4.0 Selecting Repair Materials ........................................................................... 29 3 Material Properties .......................................................................................... 29 4 Selection Considerations ................................................................................. 29 5 Table: Typical Characteristics of Selected Repair Materials ................... 32 6 5.0 References ..................................................................................................... 34 7 5.1 Referenced Standards and Reports ........................................................... 34 8 5.2 Cited References ....................................................................................... 34 9 Page 9 of 92 1 The Material Selection Process 2 The selection of a repair material depends on many factors. The evaluation process determines the cause 3 and effect of the damage, deterioration, or design plus construction deficiency such as leakage, settlement, 4 deflection, wearing, spalling, disintegration, cracking, etc. The decision to perform repair is based on a 5 number of factors including whether if the structure is salvageable, if the effects are tolerable to have a 6 deferred repair, and what the owner requirements are such as budget, time, and serviceability. Repairs are 7 required to address safety issues, structural catastrophe, use dysfunction, leakage, effects on the 8 environment, aesthetics, preventative maintenance and changes in code requirements. 9 Once the decision has been made to perform repairs, a condition survey is needed to evaluate, quantify, and 10 document the affected areas. The results of this survey are then analyzed based on the owner considerations 11 such as urgency, cost, expectations, service life, aesthetics and the engineering criteria to include structural 12 requirements, constructability, environment, and serviceability. The repair strategy then balances what 13 alternatives are available for surface preparation, material properties, and application methods. Material 14 selection is only one of the many parts of this decision making process. 15 Often a specification is used for suppliers, purchasers, and users of materials, products, or services to 16 understand and agree upon all requirements. A specification is a type of a standard which is often referenced 17 by a contract or procurement document. It provides the necessary details about the specific requirements. 18 Specifications may be written by government agencies, standards organizations (such as ASTM, ISO, CEN, 19 ICRI, ACI, etc.), trade associations, private companies, public corporations, and others. Common 20 specification types are prescriptive, performance, and proprietary specifications. 21 Prescriptive specifications list what ingredients, quantities of those ingredients, and tolerances for each 22 additive to be used as the recipe for the material formulation. Performance specifications list properties, Page 10 of 92 1 methods for determining those properties, and acceptable values or ranges for those properties. Proprietary 2 specifications list specific products or material sources that are acceptable. Combining these types of 3 specifications in construction contracts often causes confusion due to the conflict between what a material 4 should contain, how the material should function when applied, and how the product is represented in the 5 manufacturer’s literature. 6 If proprietary specification cannot be used as a sole source, often the phrase “or equal” is used. Without the 7 same values and methods used for obtaining the data for both the specified and proposed equivalent 8 material, doubt remains if the alternate material is indeed equivalent as well as if the composition of the 9 proposed alternative is possible to be determined or even relevant. This forms the basis for the increased 10 importance of performance specifications in construction contracts. 11 Performance based specifications for a class of materials are frequently developed through a consensus 12 organization and can result in the composite of lowest performance of the materials from those members of 13 the standards organization. As knowledge is gained about the relevant properties needed to select a 14 compatible repair material for a specific repair situation, it is hoped that performance based specifications 15 based on the material properties required for the application constraints, the service conditions, and the 16 design properties will become more commonly used in the industry. 17 18 Concrete repair materials can be formulated to provide a wide variety of properties. Because the properties 19 affect the performance of the repair, choosing the right material requires careful study. This guide is 20 designed as a tool to help the designer, specifier, contractor, and manufacturer make the best possible 21 decisions in selecting materials for the repair of concrete surfaces. Its primary focus is on the components 22 and structure of the selection process itself. To assist with the identification and prioritizing of performance Page 11 of 92 1 requirements, a detailed section on material properties and test methods has been included. Users should 2 note that although there are some references to polymer-based material in that section, the emphasis 3 throughout is on cement-based materials. 4 Page 12 of 92 1 Selecting materials for surface repair is a complex process. Not only must constructability and service issues 2 be considered, selection must also be guided by an understanding of the owner’s (user’s) concept, the 3 anticipated service life, applicable codes, and the engineering requirements. It is only after these criteria 4 have been defined and the required material properties identified that the selection of specific materials can 5 be made. Often more than one material or system of materials will satisfy the established requirements. 6 Final selection of materials is based on the relationship between cost, performance, and risk. (See Emmons 7 (1993) for additional information on the material selection process.) 8 The initial step in the process of producing durable concrete repairs is to determine the cause(s) and extent 9 of existing deterioration. This forensic phase merits separate treatment and is beyond the scope of this 10 document. For further information on structural evaluation see ACI 364.1R*, Guide for Evaluation of 11 Concrete Structures Before Rehabilitation and ICRI 210.4, Guide for Nondestructive Evaluation Methods 12 for Condition Assessment, Repair, and Performance Monitoring of Concrete Structures. 13 * References cited in this manner are from the ACI Manual of Concrete Practice, American Concrete Institute 14 The next step in the material selection process is to consider owner requirements, application conditions, 15 and service conditions. These data are needed to develop criteria for determining the material properties 16 which will best meet the engineer’s and owner’s objectives. 17 Section 1 of this guide includes checklists to help ensure that the most important considerations are 18 addressed. 19 Section 2 reviews the material properties that should be assessed for relevance on every project. This 20 section also illustrates the likely consequences of omission or of unsuitable choices for each property. Page 13 of 92 1 Section 3 works through the process of determining performance requirements and establishing priorities. 2 Rarely, if ever, will a material provide all of the properties a specifier would like to obtain. Prioritizing the 3 desired properties will help ensure the best possible outcome when choices need to be made to achieve the 4 most effective mixture of properties. Examples are provided to assist in relating service and user needs to 5 required material properties. 6 Section 4 summarizes selection considerations and suggests resources that may help identify materials 7 which provide required properties. A table showing typical properties of the most common repair materials 8 is included. 9 Concept of Surface Repair 10 The repair of concrete surfaces involves the construction of a composite material that, unavoidably, will 11 differ from the original concrete (Fig. 1-1). The new composite consists of the following elements: 12 i. Original concrete substrate prepared to receive repair material. 13 ii. Interface between existing concrete and new repair material. 14 15 16 17 18 iii. New repair material. iv. Protective or aesthetic treatments. 19 The selection of a suitable repair material is a process which must consider not only application 20 requirements and durability properties, but, more importantly, it must ensure that the selected material will 21 be compatible with the substrate for the repair to be durable with applicable maintenance. 22 The design of a repair should consider the compatibility of the repair materials and the materials of the 23 existing structure. Compatibility of repair materials and systems include dimensional compatibility, bond 24 compatibility and durability, mechanical compatibility, and electrochemical and permeability compatibility. Page 14 of 92 1 Generally, the intent is to use a repair material or repair system that has physical, mechanical, and other 2 properties that are close to those of the parent material to provide long-term performance. Individual repair 3 materials may have different properties yet will perform satisfactorily when used as part of a repair system. 4 The selection of reinforcement material should consider the durability, performance at elevated 5 temperatures, and ductility. Electrical and chemical reactivity between the repair material, the reinforcement 6 used in the repair, other embedded items, and the existing reinforcement should also be considered. This 7 balance is necessary if the repair system is to best withstand all stresses and strains induced by the total load 8 envelope without distress or deterioration in a specified environment over the expected service life. For 9 detailed discussions of compatibility issues and the need for a rational approach to durable concrete repairs, 10 see Emmons, Vaysburd, and McDonald (1993 and 1994). 11 Several models for prioritization of repair material selection have been published. Morrisey (2012) provides 12 a forced ranking weighting system to subjectively evaluate the relative importance of repair material 13 properties based on situational factors. Another weighting system was developed at the Iowa Dept. of 14 Transportation (2004). A more detailed review of repair selection and a proposed model is discussed by Do 15 and Kim (2012). 16 Material incompatibility is a major cause of repair failures. Giving high priority to ensuring compatibility 17 between the repair material and the existing substrate for the anticipated range of service conditions will 18 produce good material selection decisions. Compatibility considerations must include the behavior of the 19 material in both cured and uncured states. The most important material requirement is dimensional behavior 20 relative to that of the substrate to be repaired. The dimensional responses of the repair material are not 21 always identical to those of the substrate, and differential volume changes will cause internal stresses to 22 develop. Typically, these stresses will affect all four elements of the repair composite: the substrate, the 23 interface, the repair material itself, and the protective or aesthetic treatments. High internal stress may result Page 15 of 92 1 in tension cracks, loss of load-carrying capability, or delamination, and may contribute to material 2 deterioration or reduced service life. 3 Structural Applications 4 Another difficult challenge is selecting surface repair materials for structural load-carrying applications. 5 Ideally, the repair material would assume the stress levels and distribution as they existed in the fully 6 functional member. Repair efficiency is defined as the ratio of stress carried by the repair compared to the 7 stress carried by the member before deterioration and repair. There are two obstacles to achieving 100% 8 repair efficiency: 9 i. How is the repair material loaded initially? Are loads removed from the structure during repair? 10 ii. How will the dimensional behavior of the repair material affect the level of stress carried by the 11 repair? 12 It is unlikely that materials will be found which fill the repair cavity without shrinking during curing, and 13 behave identically as the substrate in response to loads and changes in temperature and moisture. Repair 14 priorities established earlier in the planning process may require that trade-offs be made. Material selection 15 is a process of arriving at informed compromises. 16 1.0 Project Objectives 17 Before the material selection process can begin, the specifier will need to identify the following: 18 i. Cause(s) of Deterioration 19 Determining the cause(s) of existing deterioration merits separate treatment and is beyond the scope of 20 this document. 21 ii. Owner Requirements Page 16 of 92 1 The expectations for the project needs to be clearly understood. Expected service life, appearance, 2 structure utilization needs during rehabilitation, and budget are questions that must be addressed at the 3 outset. 4 iii. Service Conditions 5 All components of the load envelope including weather factors, chemical environment, and live loads 6 need to be assessed to identify the physical and mechanical properties needed. 7 iv. Application Conditions 8 Expected weather conditions, access, project time frame, and operating conditions may critically affect 9 material selection. 10 The checklist which follows will help ensure that many of the most important issues will be considered and 11 resolved at the optimum time before the project is underway. 12 Material Selection Checklist 13 Owner Requirements 14 Required appearance: 15 Yes No Comments 16 Repair visible: ___ ____ _____________________ 17 Crack free: ___ ____ _____________________ 18 Surface texture: ___ ____ _____________________ 19 Color considerations: ____ _____________________ 20 21 Repair work interference with the use of the structure: Page 17 of 92 1 _________________________________________________ 2 _________________________________________________ 3 _________________________________________________ 4 Return to service time: ______________________________ 5 _________________________________________________ 6 7 Expected life of repair: (See ACI 365.1R) 8 How long: ________________________________________ 9 Maintenance interval: _______________________________ 10 11 Tolerance for repair failure: 12 Type of failure: 13 Cracking: _____________ 14 Disintegration:_________ 15 Delamination: _________ 16 Appearance: __________ 17 18 Effect of failure on: 19 Health and safety: __________________________________ 20 _________________________________________________ Page 18 of 92 1 Process interruption: ________________________________ 2 _________________________________________________ 3 Structural performance: _____________________________ 4 _________________________________________________ 5 Environment:______________________________________ 6 _________________________________________________ 7 Page 19 of 92 1 Material Selection Checklist 2 Service Conditions (See ACI 562 Ch. 5, 6, 7) 3 Load carrying requirements: 4 Dead loads: ____________ 5 External loading: 6 Wheel: ___________________________________ _______________ 7 Pedestrian: ___________________________________ _______________ 8 Static: ___________________________________ _______________ 9 Impact: ___________________________________ _______________ Yes Live loads: _____________ No Comments 10 Liquids—static: __________________________________ _______________ 11 Liquids—moving: ________________________________ _______________ 12 Soil—lateral: ___________________________________ _______________ 13 Hydrostatic pressure: _____________________________ _______________ 14 Wind: ___________________________________ _______________ 15 Snow: ___________________________________ _______________ 16 17 18 Page 20 of 92 1 Exposure conditions: 2 Atmospheric gases: Yes No Type: ______________________ 3 Concentration: ______________ 4 Duration: ___________________ 5 Frequency:__________________ 6 Chemicals in contact: Yes No Type: _______ (See ACI 515.2R) 7 Concentration: ______________ 8 Temperature: ________________ 9 Duration: ___________________ 10 Frequency __________________ 11 UV exposure: Yes No Type: ______________________ 12 Concentration: ______________ 13 Duration: ___________________ 14 Frequency:__________________ 15 Moisture conditions: Yes No Type: ______________________ 16 Range: 17 Duration: ___________________ 18 Frequency:__________________ 19 Temperature extremes: Page 21 of 92 Yes No __________ Type: ______________________ 1 Range: _____________________ 2 Duration: ___________________ 3 Frequency:__________________ 4 Application conditions: 5 Access: __________________________________________ 6 _________________________________________________ 7 Wind velocity: _____________________________________ 8 Temperature: Substrate: ______ Environment:_________ 9 Moisture: Substrate:_______ Environment:__________ 10 Return to service time: ______________________________ 11 Loading: _________________________________________ 12 Vibrations:___________________________________ 13 ____________________________________________ 14 Fatigue: _____________________________________ 15 ____________________________________________ 16 Deflection:___________________________________ 17 ____________________________________________ 18 19 Geometric configuration of repair: Page 22 of 92 1 Exposed surface area: _______________________________ 2 _________________________________________________ 3 Surface orientation: 4 Horizontal: _____Vertical: ________ Overhead: _________ 5 Thickness of repair:_________________________________ 6 _________________________________________________ 7 Size of exposed reinforcing bars: ______________________ 8 _________________________________________________ 9 Spacing of reinforcing bars: __________________________ 10 _________________________________________________ 11 Clearance between reinforcing bars and substrate: _________ 12 _________________________________________________ 13 Clearance between reinforcing bars: ____________________ 14 _________________________________________________ 15 16 Application method and placement properties: 17 Method: __________________________________________ 18 Properties: ________________________________________ 19 Flowability: _________________________________ 20 Non-sag: ___________________________________ Page 23 of 92 1 Set time: ___________________________________ Page 24 of 92 1 2.0 Material Properties 2 Selecting repair materials that will perform satisfactorily under anticipated application and service 3 conditions requires an understanding of how the new composite will respond to those conditions. For each 4 condition, a response (effect) is generated. The response may occur at one or more locations within the 5 repaired member: the surface, repair material, reinforcing steel, bond interface, or the substrate. 6 Example 1 7 Condition: Calcium chloride and moisture deposited on surface. 8 Response: As this cycle is repeated over time, chloride and moisture will penetrate through the concrete 9 cover to the reinforcing steel. As threshold concentrations are reached, corrosion begins. Cracking allows 10 easy ingress of water and chemicals and greatly accelerates the deterioration by providing a direct path to 11 reinforcing steel as well as a site for concentration of salt deposits. 12 Example 2 13 Condition: Steel wheel travel over repaired joint nosing. 14 Response: Surface of repair is subjected to impact loading. This load will be distributed to the interface 15 between the substrate and the new nosing material. If the load is not efficiently transmitted across the 16 interface, failure of the repair material is likely. 17 Understanding the repair material’s response to each component of expected service conditions helps the 18 user establish the specific material properties required to produce a durable repair. 19 To help the user identify required properties, the tables on the following pages provide examples of the 20 structural, service, constructability, and appearance issues that should be addressed and resolved in the 21 planning stage for most repair projects. Page 25 of 92 1 Service Conditions: Structural Properties Undesirable Response Performance Requirements (results if wrong material is selected) Desirable Properties Bond to substrate Tensile bond of repair Loss of bond, delamination; deterioration due to ingress of deleterious materials; system > tensile strength of properly prepared substrate concrete lack of load transfer. Load carrying as intended by the engineer Does not carry loads as anticipated, overstressing Modulus of elasticity similar to substrate either substrate or repair material. Load path remains in substrate concrete. Very low compressive creep Carries loads initially, but over time, the repair relaxes under creep deformation. Load path transfers back to the substrate concrete. Page 26 of 92 Very low drying shrinkage Drying shrinkage causes material to lose volume, reducing its ability to carry compressive loads. Load path transfers back to the substrate concrete 1 2 Note to Reviewers: 3 Please note that due to the editorial changes, the drawings on the previous page and this page are not in their respective appropriate boxes/rows. The final editorial review of the document will be performed by the ICRI staff and that will take care of the formatting changes and put the figures in their appropriate boxes/rows. 4 5 6 Page 27 of 92 1 Service Conditions: Exposure Repair Exposure Undesirable Response Desirable Procedures Condition/Symptoms (results if wrong material is selected) / Properties Ambient temperature Cracking in repair material due to Thermal coefficient similar changes thermal contraction stresses to that of substrate Spalling due to thermal expansion Thermal coefficient similar stresses in repair material or substrate to that of substrate (bond strength or substrate strength < repair tensile strength) Temperature changes Deformation due to thermal within repair material at expansion from high exotherm Low exotherm during cure early ages Cracking due to thermal contraction stresses in repair material Rust staining, cracking Corrosion of reinforcing steel; Effective cover, low adjacent to reinforcement, Disintegration of cement matrix permeability, no cracks, reinforcement section loss adjacent to reinforcement corrosion mitigation Moisture conditions, Disintegration of cement matrix, Resistance to freezing and saturation; freezing and surface scaling thawing thawing Page 28 of 92 Moisture conditions Cracking due to improper curing, Proper curing, low plastic plastic shrinkage, drying shrinkage shrinkage, low drying shrinkage, low permeability 1 2 Note to Reviewers: 3 Please note that due to the editorial changes, the drawings on the previous page and this page are not in their respective appropriate boxes/rows. The final editorial review of the document will be performed by the ICRI staff and that will take care of the formatting changes and put the figures in their appropriate boxes/rows. 4 5 6 7 8 Page 29 of 92 1 Service Conditions: Dynamic Loading Repair Exposure Undesirable Response Desirable Procedures Condition/Symptoms (results if wrong material is selected) High velocity water flow Erosion by cavitation Low velocity flow with Erosion by abrasion waterborne debris Vehicle wheels Abrasion damage to surface Edge spalling at joints Impact Impact Page 30 of 92 Spalling / Properties High compressive strength; high tensile strength; small size aggregate; specialty coatings High abrasion resistance; high compressive strength; large size aggregate; specialty coatings High compressive strength; high abrasion resistance; specialty toppings High compressive, tensile, and bond strengths; high surface hardness for joint filler material (example, Shore A Hardness); tensile anchorage into substrate; armored joint edges High compressive, tensile, and bond strengths; tensile anchorage into substrate High tensile and impact strengths; internal tensile reinforcement; high compressive strength Fatigue Resistance Cracking and crack propagation, loss of bond Malleability; energy absorption; toughness 1 2 Note to Reviewers: 3 Please note that due to the editorial changes, the drawings on the previous page and this page are not in their respective appropriate boxes/rows. The final editorial review of the document will be performed by the ICRI staff and that will take care of the formatting changes and put the figures in their appropriate boxes/rows. 4 5 6 7 Page 31 of 92 1 Application Conditions Desirable Procedures Condition Performance Requirements / Properties Constructability Working time Quick turnaround time Adequate for mixing and application method Rapid strength gain Longer working time is better if return to service constraints can be met Consistency and rheology As needed for application method and repair orientation Trowel overhead Material availability Adequate shelf life, delivery schedule coincident with application usage Non-sag Ambient storage, convenient package size, local supply Page 32 of 92 Environmental Vibration, dust, noise, debris removal, hazardous material abatement considerations Access Shall satisfy governing regulatory requirements Allocated working time, equipment clearance, utility requirements, Appropriate for repair weight restrictions application 1 2 Owner Requirements Performance Requirements Undesirable Response Desirable Procedures / (results if wrong material is selected) Appearance Properties Drying shrinkage cracks Low drying shrinkage Plastic shrinkage cracks, Low surface water loss during bleeding, settlement, placement, stable mixtures, absorption, evaporation proper substrate and formwork conditioning Installed cost Change orders, overruns In accordance with repair analysis Page 33 of 92 Return to use Delays, penalties Corresponds with forecast schedule Service life less than High maintenance and life-cycle Low life-cycle cost, periodic required cost inspection and preventative maintenance Cleanability Stains, contamination Smooth, impervious surface, thermal shock resistant (steam cleaning) Slip resistance Liability, injury Texture appropriate for traffic conditions 1 2 Note to Reviewers: Please note that due to the editorial changes, the drawings on this page and previous two pages are not in their respective appropriate boxes/rows. The final editorial review of the document will be performed by the ICRI staff and that will take care of the formatting changes and put the figures in their appropriate boxes/rows. 3 4 5 6 7 8 Page 34 of 92 1 3.0 Determining Properties 2 Repair materials should not be specified until the properties that will best satisfy overall project objectives 3 are determined. These properties need to be identified and prioritized. The availability of a material 4 providing all of the optimum values of the many properties under consideration is unlikely. Optimizing one 5 property will most likely be achieved at the expense of other needed properties. For example, an increase in 6 cement content to obtain high compressive strength will usually be accompanied by an increase in drying 7 shrinkage. 8 The highest repair performance cannot be achieved unless competing demands have been prioritized, and 9 those properties most critical to the success of the repair are identified to facilitate selection of an 10 appropriate repair material and repair method. 11 Once the needs and performance criteria for the repair project are established (1.0 Project Objectives), a list 12 of desirable properties is developed. Properties should be classified and organized as basic or special needs. 13 Basic properties are those required to produce a fundamentally sound repair. Typically, these will be 14 consistent through a broad range of repair applications. 15 Special properties are those which provide material performance to enhance durability within a specific load 16 criteria. Since the relative importance of special properties is highly situational, the mix of properties 17 selected may vary substantially from one application to the next. Once basic requirements have been 18 identified, special property needs may be identified and ranked in descending order of importance. 19 Properties which are not required should not be listed. Making compromises in basic properties to enhance 20 special property performance risks repair failure. Two sample lists are shown on the following page. Page 35 of 92 1 Note: Although this section contains some references to polymer matrix materials, the emphasis 2 throughout is on cement-based materials. “Polymer-modified” repair materials should not be confused with 3 “polymer” repair materials and mortars. Typically, “polymer-modified” refers to the addition of a latex 4 (powder or liquid) to an inorganic cement-based mortar. When cured, the resulting concrete contains a 5 continuous, interconnected matrix of latex polymer particles. The Concrete Repair Terminology defines the 6 following terms: 7 concrete, polymer—a composite material in which the fine and coarse aggregates are bound together in a 8 dense matrix with a polymer binder; also known as resin concrete. 9 concrete, polymer-modified—a mixture of water, hydraulic cement, aggregate, and a monomer or polymer; 10 polymerized in place when a monomer is used 11 Polymer concretes and repair mortars are generally thermosetting plastic materials, usually containing an 12 aggregate filler. Materials such as epoxies, polyesters, vinyl esters and methyl-methacrylates are 13 “polymers.” Page 36 of 92 1 Examples of Prioritizing Property Needs Example 1: Partial column repair Example 2: Slab resurfacing The columns exhibit numerous spalls caused by Constant abrasion of wheel loads cuts depressions in carbonation and subsequent corrosion. The environ- the slab, causing the surface to become irregular. mental temperature is fairly stable throughout the year. Exterior environment is subject to chlorides. To assure adequate load distribution throughout the member, the repair composite must be able to carry a proportional amount of the compressive load. Basic property needs Basic property needs 1. Bond new to old 1. Bond new to old 2. Very low drying shrinkage 2. Very low drying shrinkage Special property needs Special property needs 1. Modulus of elasticity similar to existing concrete 1. Similar coefficient of thermal expansion 2. Very low compressive creep 2. Sufficient abrasion resistance 3. Resistance to carbonation and moisture intrusion 3. Compressive strength to transfer wheel loads to underlying concrete substrate 4. Low permeability to reduce exposure of steel reinforcing to chlorides 2 Page 37 of 92 1 3.1 Bond Strength 2 In most cases, good bond between the repair and the existing concrete substrate is a primary requirement for 3 a successful repair. Bond failure between repair materials and an adequately prepared concrete substrate are 4 not common and a properly prepared substrate will almost always provide sufficient bond strength. 5 However material properties that can lead to bond failure are differential thermal strains and drying 6 shrinkage. 7 Bond is best specified as a surface preparation requirement. The test methods described in the section “Bond 8 Strength” of ACI 546.3R describe the various test methods in common use. Bond test values are most valid 9 when used in conjunction with surface preparation, application techniques, and substrate of the actual or a 10 similar repair. Systematic follow-up testing on completed repairs should generally be specified to verify 11 compliance with engineering requirements. Of the test methods described, direct tensile test is the only 12 method which can provide on-site strength data. 13 3.1.1 Bond Strength—Direct Tensile Test 14 Direct tensile testing (Fig. 3-1) measures the tensile bond or tensile strength of surface repairs and overlays. 15 Tensile testing will expose the location of the weakest link in the composite system (repair material, 16 interface, and substrate). Uniaxial testing equipment can be used to perform both field and laboratory tests. 17 In-situ testing is performed by coring through the repair material into the substrate (Caution—In post- 18 tensioned structures, proceed with extreme caution; Tendons should be located prior to conducting any 19 coring operations). The coring procedures should be conducted in accordance with ICRI Technical 20 Guideline No. 210.3R (formerly No. 03739), Guide for Using In-Situ Tensile Pulloff Tests to Evaluate 21 Bond of Concrete Surface Materials, so as to not break off the core at the substrate. The drilling equipment 22 should be in good condition and secured to avoid lateral movement and maintain proper alignment to the Page 38 of 92 1 coring surface, without unnecessary movement that could negatively impact the test sample. While the core 2 remains connected to the substrate, a tensioning device is attached to the core and loaded until failure 3 occurs. Tensile values are determined by dividing the load at failure by the cross-sectional area of the core. 4 Test Methods: 5 ASTM C1583, Standard Test Method for Tensile Strength of Concrete Surfaces and the Bond Strength or 6 Tensile Strength of Concrete Repair and Overlay Materials by Direct Tension (Pull-off Method) 7 ICRI Technical Guideline No. 210.3R (formerly No. 03739), Guide for Using In-Situ Tensile Pulloff Tests 8 to Evaluate Bond of Concrete Surface Materials 9 CAN/CSA-A23.2, Test Methods and Standard Practices for Concrete 10 Minimum Requirement: The required repair material to concrete substrate bond strength should be 11 determined for each specific project based on a combination of structural strength requirements, long-term 12 durability of the repair, and volume change compatibility. Experience demonstrates that bond strengths of 13 250 psi or greater can be achieved with readily available surface preparation and repair techniques in 14 moderate-to good-quality concrete substrates. In addition, most concrete surface repair or overlay repair 15 materials have a direct tensile strength (CRD C 164) in excess of 250 psi. Accordingly, concrete repair 16 materials should have the potential to achieve a minimum repair material to concrete substrate bond strength 17 of 250 psi, or at least the direct tensile strength of the repair material. Most repair material manufacturers 18 report bond strength on their data sheets. This bond strength should be determined and reported as indicated 19 in Section 5.12 of Guideline No. 320.3R-2012 – Guideline for Inorganic Repair Material Data Sheet 20 Protocol. 21 In the field, the tensile bond strength may be limited by the in-situ tensile pull-off strength of the prepared 22 concrete substrate. Therefore, the required pull-off strength criteria for a specific project should not exceed 23 the in-situ tensile pull-off strength of the existing substrate or the direct tensile strength of the repair or Page 39 of 92 1 overlay material, whichever is lower. Field trials are recommended to evaluate the capacity of the existing 2 concrete substrate and the repair material installation. If field trials demonstrate that the in-situ tensile pull- 3 off strength of the existing concrete substrate or the repair material is inadequate, the advisability of making 4 the repair should be re-evaluated. Further discussion on bond testing and acceptance criteria are discussed in 5 ICRI 210.3R. If unexpected job conditions are encountered, including lower or higher strength of the 6 existing concrete substrate to be repaired, acceptance criteria may have to be adjusted to meet specific 7 project conditions. 8 Commentary: The direct tensile test (ICRI 210.3R and ASTM C1583) is an important quality 9 assurance/quality control test. Both ICRI 210.3R and ASTM C1583 provide a description of the procedures 10 and equipment needed for tensile testing. The test method provides a reasonable technique for evaluating 11 materials, substrate, preparation, and placement procedures. Significant substrate or material weakness or 12 deficiencies in preparation or placement can be detected with using this test. 13 14 3.1.2 Bond Strength—Direct Shear Test 15 Direct shear testing (Fig. 3-2) measures the shear strength of the bond between the repair material and the 16 substrate. A special guillotine apparatus is used to subject core specimens to direct shear loads. Specimen 17 cores for testing may be removed from the field or prepared in the laboratory. Shear bond values are 18 determined by dividing the recorded load at failure by the bond area. 19 Test Method: Michigan DOT Shear Bond 20 Minimum Requirement: (see commentary) 21 Commentary: Values derived from this method are highly dependent upon substrate strength and surface 22 preparation methods. For comparison purposes, differences between specimens having different substrate Page 40 of 92 1 strengths and surface preparation methods will render the testing data meaningless. The most useful testing 2 of this type will be done with substrate materials removed from the structure to be repaired, and prepared 3 exactly as they would be by field personnel. If shear bond values are specified as material requirements, 4 they should be verified as described immediately above. If measurement of tensile bond in the repair 5 composite is specified, it may be redundant to also specify direct shear bond requirements. 6 Refer to ACI 546.3R for discussion of additional methods of evaluating bond strength. 7 8 3.1.3 Bond Strength—Slant Shear Test 9 Bond strengths determined by slant-shear tests (Fig. 3-3) are most often reported by material suppliers. 10 Bond values are determined by dividing the load at failure by the elliptical bond area. 11 Test Methods: 12 ASTM C882, Bond Strength of Epoxy-Resin Systems Used with Concrete** 13 ASTM C1042, Bond Strength of Latex Systems Used with Concrete 14 Test Methods (continued): 15 AASHTO T237, Testing Epoxy Resin Adhesive*** 16 ** Test methods cited in this manner are from the ASTM International Annual Book of ASTM Standards. 17 ***Test methods cited in this manner are from the American Association of State Highway and Transportation Officials Standard Specifications 18 for Transportation Materials and Methods of Sampling and Testing. 19 Minimum Requirement: (see commentary) 20 Commentary: Bond strengths determined by slant shear tests are highly dependent on the compressive 21 strength of the substrate portion of the test cylinder. Therefore, slant shear bond strengths have little or no Page 41 of 92 1 value in comparing alternate materials—unless the tests were conducted with equal substrate strengths. 2 Results of screening tests reported by Best and McDonald (1990) indicated that for a constant substrate 3 strength, slant shear bond strengths for both dry and wet surfaces are generally proportional to the 4 compressive strength of the repair material. Subsequent tests on selected repair materials revealed poor 5 correlation between bond strengths determined by slant-shear and direct tension test methods. 6 3.2 Dimensional Behavior 7 Relative dimensional changes between a surface repair material and an existing substrate can affect bond, 8 ability to carry loads, durability, and appearance. Drying shrinkage, thermal coefficient, modulus of 9 elasticity, and creep are all material properties which influence dimensional behavior. The U. S. Army 10 Corps of Engineers initiated a research program to develop performance criteria for repair materials that are 11 dimensionally compatible with existing concrete substrate. Their findings are summarized in the following 12 four reports: 13 i. "Performance Criteria for Concrete Repair Materials, Phase I," Technical Report REMR-CS-47 14 (Emmons and Vaysburd 1995). 15 http://www.dtic.mil/dtic/tr/fulltext/u2/a295136.pdf 16 ii. "Performance Criteria for Concrete Repair Materials, Phase II Laboratory Results," Technical Report 17 REMR-CS-57 (Emmons, Vaysburd, Poston, Dalrymple, and McDonald 1998). 18 http://acwc.sdp.sirsi.net/client/search/asset/1004727 19 iii. "Performance Criteria for Concrete Repair Materials, Phase II Field Studies," Technical Report 20 REMR-CS-60 (Poston and Kesner 1998). 21 http://acwc.sdp.sirsi.net/client/search/asset/1004730 22 23 iv. Performance Criteria for Concrete Repair Materials, Phase II Summary Report," Technical Report REMR-CS-62 (Vaysburd, Emmons, McDonald, Poston, and Dalrymple 1999). Page 42 of 92 1 http://acwc.sdp.sirsi.net/client/search/asset/1004732 2 3 3.2.1 Drying Shrinkage 4 It is extremely important to minimize drying shrinkage for cement-based materials. Experimental results and 5 in-situ performance strongly suggest that volume changes in cement-based repair materials lead to many 6 failures (Fig. 3-4). These include shrinkage cracking, delamination, loss of load-carrying capacity, corrosion 7 of embedded reinforcing steel, and poor appearance (Fig. 3-5). One of the greatest challenges in the 8 selection of repair materials is to achieve relative dimensional compatibility with the substrate. Though 9 difficult, the selection of repair materials with minimal drying shrinkage is critical for durable repairs. 10 The identification and selection of low shrinkage materials requires an understanding of the drying 11 shrinkage process. Repair materials are frequently mixed and placed with more water than needed for 12 hydration. As the repair assumes the humidity of the surrounding environment, the material shrinks in 13 volume, and tensile stresses accumulate in the repair material. Wet curing of cementitious materials will 14 postpone the start of the drying process, and may cause slight expansion. As the repair material contracts, it 15 resists cracking until the stress exceeds its tensile strength. The time required for a repair material to attain a 16 stable drying shrinkage is dependent upon several variables including: 17 • Ambient temperature 18 • Wind speed 19 20 • Mass or thickness of the material (larger mass or a greater thickness takes longer for the drying shrinkage 21 Rate of hydration process to complete) Page 43 of 92 1 2 • Permeability of the repair material (low permeability material takes longer for the drying shrinkage process to complete) 3 • Ambient relative humidity (the drying shrinkage process is faster in dry environments) 4 • Relative humidity of the substrate 5 The majority of ultimate drying shrinkage may occur within thirty days, or require as long as a year and 6 longer to complete depending on ambient conditions, the geometry and depth of the repair, and the amount 7 of moisture present in the repair material and substrate. 8 9 Test Method: ASTM C157, Length Change of Hardened Hydraulic Cement Mortar and Concrete, as 10 modified in ICRI 320.3R. The use of smaller dimension specimens (i.e. 1x1x10” [25x25x250 mm]) will 11 accelerate the shrinkage rate compared to larger dimension specimens (3x3x10” [75x75x250 mm] or 12 4x4x10” [100x100x250 mm]) due to a higher surface to volume ratio in the smaller specimens. Ultimate 13 length change values (which can take up to a year) should be comparable between the different specimen 14 sizes. Other drying shrinkage and volume change methods are discussed in the section “Volume Stability” 15 of ACI 546.3R. 16 17 Commentary: A preferred repair material would have low drying shrinkage. Although repair materials 18 with low drying shrinkage may crack after placement, high drying shrinkage materials carry a much higher 19 probability of developing drying shrinkage cracks. Shrinkage values vary greatly between mixture 20 proportions, manufacturers, and products. This fact was demonstrated by Gurjar and Carter (1987) in tests 21 on forty-six repair materials. These test results have been sorted and categorized as shown in Fig. 3-7 22 (previous page). The magnitude of variation in these data is convincing evidence that careful investigation 23 of actual shrinkage properties needs to precede the selection of suitable repair materials. Page 44 of 92 1 3.2.2 Coefficient of Thermal Expansion 2 All materials expand and contract with changes in temperature. For a given change in temperature, the 3 amount of expansion or contraction depends on the coefficient of thermal expansion of the material (Fig. 3- 4 8). 5 Test Methods: 6 Various test methods used for determination of the coefficient of thermal expansion are discussed in the 7 section “Coefficient of thermal expansion” in ACI 546.3R. A recommended test method for cementitious 8 materials is discussed in ICRI 320.3R. 9 Commentary: A large difference between the coefficient of thermal expansion of repair material and 10 substrate could cause dimensional incompatibility in the two materials leading to system failure. Although 11 the coefficient of thermal expansion of conventional concrete will vary somewhat, depending on the type of 12 aggregate, it is usually assumed to be about 6 millionths per degree Fahrenheit (6 x 10-6/°F; 10.9 x 10-6/°C). 13 Generally, cement-based repair materials will exhibit a coefficient of thermal expansion similar to that of 14 concrete. However, the use of polymer-matrix based materials in repairs subject to wide variations in 15 temperature will require careful consideration. According to ACI 503.5R, the coefficient of thermal 16 expansion for unfilled polymers such as methyl methacrylates, epoxies, polyesters, polyurethanes, and 17 styrene-butadiene is 4 to 18 times greater than that of concrete. The addition of fillers or aggregate to 18 polymers will improve thermal compatibility—but the coefficient of expansion for the polymer-aggregate 19 combinations will still be 1.5 to 5 times that of concrete. As a result, polymer repair materials will attempt to 20 expand or contract more than the concrete substrate. This movement, when restrained through bond to the 21 existing concrete, induces stress that can cause cracking and delamination as the repair material attempts to 22 contract, or buckling and spalling as it expands. Thermal compatibility is especially important in large Page 45 of 92 1 repairs. To minimize expansion and contraction stress, polymer mortars and polymer concretes are typically 2 recommended only in small volume repairs when used in exterior applications. 3 3.2.3 Modulus of Elasticity 4 Modulus of elasticity is a measure of stiffness. Higher modulus materials will deform less under a given 5 load than will lower modulus materials (Fig. 3-9). 6 Test Methods: 7 Test methods for determination of the modulus of elasticity are described in ACI 546.3R. 8 Recommended Value: (see commentary) 9 Commentary: In general, the modulus of elasticity of a structural repair material should be similar to that 10 of the concrete substrate or the effects of the differing modulus should be considered in the design of the 11 repair. Compatibility between the modulus of elasticity for a structural repair material and concrete 12 substrate helps to achieve a uniform load transfer across the repaired section. For non-structural 13 applications, it is sometimes considered desirable to specify a repair material with a lower modulus of 14 elasticity than that of the substrate to minimize the load likely to be transferred to the repair and thereby 15 reducing the potential for cracking and delamination. In particular, a repair material with lower modulus of 16 elasticity than that of the substrate may also be desirable if the repair material has volume stability or 17 thermal compatibility properties that differ significantly from those of the substrate concrete. If a repair is 18 intended to share load with the existing structure (structural repair), it is desirable for the modulus of 19 elasticity of both materials to match as closely as possible. Significant deviations in the modulus of 20 elasticity of repair material and concrete substrate can lead to uneven load distribution and premature 21 system failure. Additional discussion can be found in ACI Technical Note ACI 364.5T-10 Importance of 22 Modulus of Elasticity in Surface Repair Materials. Page 46 of 92 1 3.2.4 Creep (Tensile and Compressive) 2 Creep is time-dependent deformation due to sustained load (Fig. 3-10). Tensile or compressive creep can 3 be important if significant stress is induced in the repair material due to restraint of shrinkage strains or 4 factors such as thermal movement or application of loads. For repairs that are not subjected to significant 5 compressive forces, compressive creep may not be a significant property to consider. 6 significant property for repair materials. Tensile creep can reduce the cracking of repair materials by 7 relaxing the tensile stress over time. No commonly accepted, standardized test method is available for 8 measuring tensile creep, and there is no consensus regarding a correlation between tensile and compressive 9 creep (Pigeon and Bissonnette 1999; Iriya et al. 1999; Iriya et al. 2000; Beaudoin 1982). Tensile creep is a 10 Test Methods: 11 Test methods for determination of creep are discussed in ACI 546.3R. 12 Commentary: In structural repairs, creep of the repair materials generally should be similar to that of the 13 concrete substrate. For (non-structural) protective repairs, however, higher creep is sometimes considered to 14 be an advantage. In the latter case, strain relaxation through tensile creep may reduce the potential for 15 cracking (Fig. 3-11). 16 Although creep of concrete in compression has been extensively investigated, information on tensile creep 17 behavior is limited. The lack of published data is attributed to the fact that concrete is rarely subjected to 18 direct tension. Also, there are significant experimental difficulties when a uniaxial load is required and 19 strains have to be measured very accurately, especially in a material which is drying under load and where 20 shrinkage is the predominant deformation. 21 Page 47 of 92 1 It should be noted that polymer mortars and concrete exhibit widely differing creep behavior because the 2 binders in polymer mortars are fundamentally different from the cement binder in concrete. 3 3.2.5 Restrained Shrinkage 4 The restraint of shrinkage which occurs when a repair material is bonded to a substrate will produce tensile 5 stress in the repair material. Because concrete also creeps in response to sustained loads, a complex 6 interaction between strength gain, shrinkage, modulus, creep, and other factors governs the cracking 7 potential of the material. 8 Test Method: ASTM C1581, Test Method for Determining Age at Cracking and Induced Tensile Stress 9 Characteristics of Mortar and Concrete Under Restrained Shrinkage. This test method also commonly 10 known as the “Ring Test” is also described in the ACI 546.3R as well as ACI 364.3R reports. 11 Commentary: ASTM C1581 was adopted in 2004 and revised in 2009. Some guidance regarding the 12 interpretation of results is provided in the appendix and references of the test method. ASTM suggests 13 reporting the following information: 14 • Properties of the material being tested: mixture proportions, air content, slump/flow and density of 15 concrete mixtures, and mixture proportions; flow; and density of mortar mixtures 16 • Type and duration of curing 17 • Daily ambient temperature and relative humidity data for the test environment 18 • Plots of steel ring strain versus specimen age for each test specimen 19 • Average age at cracking 20 • Age when the test was terminated for specimens that have not cracked during the test 21 • Average initial strain 22 • Average maximum strain Page 48 of 92 1 • Plots of net strain versus square root of elapsed time for each specimen 2 • Average stress rate at cracking or at the time the test was terminated 3 4 5 6 7 Recommended Values In this test, longer time to cracking is preferred. ASTM C1581 provides guidance for classification of different materials based on the results of this test in the appendix to the test method. The table below lists this classification: 8 9 10 11 12 13 14 15 16 17 18 19 20 The net time-to- cracking for the material is the difference between the age at cracking and the age drying 21 was initiated. If a test material cracks during the period of curing (that is, before drying is initiated), the net 22 time-to-cracking is zero. A classification table shown above for cracking potential based on the net time-to- 23 cracking and the average stress rate at cracking or at the time the test is terminated is provided to aid in the 24 comparison of materials. The net time-to-cracking classification in Table X1.1 can be used to assess the 25 relative performance of materials that crack during the test. For materials with average stress rates lower 26 than 0.10 MPa/day [15 psi/day] that have not cracked during the test, the magnitudes of average stress rate 27 can be compared to assess the relative potential for cracking. This allows for an appropriate comparison of 28 materials where time constraint does not permit testing to be carried out until cracking occurs. X1. Interpretation of Results TABLE X1.1 Potential for cracking classification Net Time-to-Cracking, tcr, days 0 < tcr ≤ 7 7 < tcr ≤ 14 14 tcr ≤ 28 tcr > 28 Average Stress Rate, S (MPa/day) S ≥ 0.34 0.17 ≤ S < 0.34 0.10 ≤ S < 0.17 S < 0.10 Average Stress Rate, S (psi/day) S ≥ 50 25 ≤ S < 50 15 ≤ S < 25 S < 15 Potential for Cracking High Moderate-High Moderate-Low Low 29 30 3.3 Durability Properties 31 Durability of concrete is defined as its ability to resist weathering action, chemical attack, abrasion, and any 32 other conditions of service. If a repair becomes necessary because of deterioration of the existing concrete, it 33 is essential to establish the cause and extent of deterioration. Based on this information, a repair strategy can Page 49 of 92 1 be selected which will provide a durable repair. A durable repair will retain its original form, quality, and 2 serviceability when exposed to its environment. Material properties that can affect the durability of a repair 3 are discussed in the following paragraphs. 4 3.3.1 Permeability 5 Permeability is defined as the property that governs the rate of flow of a fluid (liquid or gas) into a porous 6 solid (Mehta and Monteiro 1993). This property is a useful indicator of the corrosion protection which a 7 material may provide. Soluble chlorides which can lead to chloride-induced corrosion are typically carried 8 in solution through the pore structure from the surface to the steel reinforcing. Low permeability will reduce 9 the rate at which chlorides penetrate the protective cover. 10 Similarly, low permeability will reduce the rate at which atmospheric or dissolved CO2 diffuses through the 11 pore structure of the concrete cover. This process, known as carbonation, lowers material pH, and 12 depending on the depth of carbonation, depth of steel reinforcement, and availability of moisture and 13 oxygen, may lead to corrosion of steel reinforcement. 14 Test Methods: 15 AASHTO T259, Resistance of Concrete to Chloride Ion Penetration 16 AASHTO T277, Rapid Determination of the Chloride Permeability of Concrete 17 ASTM C1202, Electrical Indication of Concrete’s Ability to Resist Chloride Ion Penetration 18 ASTM C1543, Standard Test Method for Determining the Penetration of Chloride Ion into Concrete by 19 Ponding 20 The test data produced by AASHTO T277 and ASTM C1202 are generally known as “rapid chlorides.” The 21 title of the ASTM C1202 method, “Electrical Indication of Concrete’s Ability to Resist Chloride Ion Page 50 of 92 1 Penetration,” is a more accurate statement of the property being assessed. These tests do not directly 2 measure permeability of the material. 3 Commentary: There are many repair strategies which can be employed to delay the damaging effects of 4 aggressive chemicals such as chlorides. A common approach is to select and install low permeability repair 5 materials (including overlays) that will resist chloride penetration. Other methods include the use of crack 6 injection, crack and joint sealants, surface sealers, coatings and membranes. The common practice of using 7 rapid chloride data to specify allowable permeability is controversial. (Pfeifer, McDonald, and Krauss 8 1994). The presence of some inorganic admixtures and free ions such as chloride ions in the concrete can 9 result in the passage of electrical charge (coulombs) indicating a higher apparent permeability. Data 10 generated by AASHTO T259 are considered to be a more reliable indicator of material permeability. 11 Rapid chloride data alone should not be used for purposes of comparison unless the correlation for the 12 specific material type has been established using the long-term chloride ponding procedure described in 13 AASHTO T259. 14 3.3.2 Water Vapor Transmission 15 Water vapor transmission rate is defined by ASTM as the steady water vapor flow in a unit of time through 16 a unit area of a body, normal to specific parallel surfaces, under specific conditions of temperature and 17 humidity at each surface. 18 Test Method: ASTM E96, Water Vapor Transmission of Materials (Fig. 3-12). 19 Commentary: If impermeable materials are used for large repairs, water vapor transmitted through the 20 concrete substrate can be trapped at the interface between the repair and the substrate. This entrapped water 21 can be a particularly troublesome problem in relatively thin repairs subject to cycles of freezing and 22 thawing. The hydraulic pressure caused by freezing of the entrapped moisture may result in debonding of Page 51 of 92 1 the repair, or the substrate will become critically saturated and, if the concrete does not contain properly 2 entrained air, the substrate will likely suffer freeze-thaw deterioration. Shotcrete repairs to a navigation lock 3 wall illustrate this problem (HQUSACE 1995). The generally good resistance of shotcrete to cycles of 4 freezing and thawing (despite a lack of entrained air) is attributed in part to its low permeability, which 5 minimizes the ingress of moisture, thus preventing the shotcrete from becoming critically saturated. When 6 moisture migrates through the substrate, however, the shotcrete is unable to efficiently transmit this 7 moisture to the exposed surface, and the existing concrete becomes saturated. Subsequent cycles of freezing 8 and thawing will result in failure of the repair (Fig. 3-13). Cores through the repair show the remaining 9 shotcrete to be in generally good condition; however, the original concrete immediately behind the shotcrete 10 exhibits significant deterioration (Fig. 3-14). Cores of similar concrete from portions of the wall which did 11 not receive a shotcrete overlay were in generally good condition from the surface inward. 12 3.3.3 Resistance to Freezing and Thawing 13 The causes of deterioration from freezing and thawing are complex and are not exclusively derived from the 14 expansive pressure generated by water in its frozen state. It is, however, sufficient to define freezing and 15 thawing deterioration as failure in the cement matrix or in porous aggregate particles which occurs when the 16 material is frozen while critically saturated. A material that has demonstrated resistance to freezing and 17 thawing in laboratory tests or previous field applications should be specified for repairs that will be 18 subjected to this service condition. 19 Test Method: ASTM C666, Resistance of Concrete to Rapid Freezing and Thawing 20 Procedure A: rapid freezing and thawing in water (most common method). 21 Procedure B: rapid freezing in air and thawing in water. 22 Recommended Value: (see commentary) Page 52 of 92 1 The test is designed to run 300 cycles or until the relative dynamic modulus reaches 60% of original value. 2 Data from a reduced number of cycles may not be used for comparative purposes—unless the procedure 3 was terminated by dynamic modulus limitations. 4 Commentary: The normal test for evaluating freeze-thaw resistance, ASTM C666, exposes specimens to 5 freezing at an intermediate level of maturity with no opportunity for drying prior to testing and exposes 6 them to a very rapid freezing cycle. There are many examples of repair materials, among them certain latex- 7 modified formulations that perform well in field applications but cannot yield a high durability factor when 8 tested in accordance with C666. Although the test is excellent for assessing the resistance to freezing and 9 thawing of young saturated specimens to severe exposure, the resistance of mature specimens to more 10 typical exposures might be better assessed by altering the age-at-test and specimen-conditioning 11 requirements of C666 to more accurately reflect actual service conditions, or by replacing it with a critical 12 dilation test such as ASTM C671, Critical Dilation of Concrete Specimens Subjected to Freezing. (For 13 further information, see ACI 201.2R.) 14 3.3.4 Resistance to Scaling 15 Scaling is defined as the flaking or peeling away of the near-surface portion of hardened concrete or mortar. 16 This loss of cement mortar from the finished surface can be caused by hydraulic and osmotic pressures 17 caused by freezing. Scaling is frequently initiated by the application of deicing chemicals in below-freezing 18 conditions. Moderate to severe scaling deterioration will expose coarse aggregate. Scaling resistance should 19 be considered whenever the repair material will be subjected to deicing chemicals. 20 Test Method: ASTM C672, Scaling Resistance of Concrete Surfaces Exposed to Deicing Chemicals 21 (Modified) 22 Modification: collect and weigh scaled material after every fifth cycle in lieu of the visual rating system. Page 53 of 92 1 Recommended Values: <0.10 lb/ft2 (0.5 kg/m2) loss at 50 cycles (Fig. 3-15). 2 Commentary: ASTM C672 is widely accepted as a good indication of resistance to scaling from deicing 3 chemicals. The modification noted above provides for a more objective rating of individual materials. A 4 repair material with a scaling resistance classified as good or very good is appropriate for applications 5 exposed to freezing and thawing cycles. 6 3.3.5 Sulfate Resistance 7 Sulfate attack causes the chemical decomposition of certain binder compounds in hydrated cement paste 8 (Fig. 3-16). Decay of organic matter in marshes and shallow lakes is a primary source of naturally occurring 9 sulfates. Soils in regions long ago covered by inland seas frequently contain enough water-soluble sulfates 10 to precipitate sulfate attack. Other sources of sulfate include chemical process effluent, agricultural runoff, 11 and wastewater treatment. Sulfate resistance must be considered for the repair of structures exposed to these 12 environments, such as piers, dams, bridge columns, buried concrete pipe, wastewater treatment facilities, 13 transmission tower footings, and highway pavements. 14 Test Method: ASTM C1012, Length Change of Hydraulic-Cement Mortars Exposed to Sulfate Solutions. 15 Recommended Value: The ASTM subcommittee which developed C1012 recommended adoption of the 16 following performance criteria: 17 Moderate Sulfate Resistance: 0.10% maximum expansion at 6 months 18 High Sulfate Resistance: 0.05% maximum expansion at 6 months 19 Commentary: This test is considered to be a reliable indicator of the resistance of cement-based materials 20 to sulfate attack (Figure 3.17). The test method is suitable for use on Portland -cement mortars, mortar 21 blends containing pozzolans or slags, and polymer-modified mortars. Page 54 of 92 1 3.3.6 Alkali-Aggregate Reaction 2 Alkali-aggregate reaction is a chemical reaction in either mortar or concrete between alkalis (sodium or 3 potassium) from cementitious materials or other sources, and certain constituents of some aggregates. There 4 are two general types of alkali-aggregate reaction: alkali-silica reaction and alkali-carbonate reaction. 5 Products of either reaction may cause abnormal expansion and cracking of mortar or concrete in service 6 (Fig. 3-18). Expansion and cracking may develop within a few weeks or may not appear for a number of 7 years after the mortar or concrete is placed. 8 Test Methods: 9 ASTM C227, Potential Alkali Reactivity of Cement-Aggregate Combinations (Mortar-Bar Method) 10 ASTM C289, Potential Reactivity of Aggregates (Chemical Method) 11 ASTM C295, Petrographic Examination of Aggregates for Concrete 12 Recommended Values: Criteria for evaluating the potential alkali reactivity of aggregates is discussed in 13 ACI 201.2R and Appendices D and E of EM 1110-2-2000 (HQUSACE 1994). 14 Commentary: When the section thickness of repairs exceeds 1 to 2 in. (25 to 50 mm), manufacturers 15 typically recommend the addition of coarse aggregate to repair mortars. The addition of aggregate improves 16 dimensional stability, reduces exothermic heat, and generally results in a more economical repair. Although 17 aggregate selection is systematically considered in original concrete construction, it is routinely overlooked 18 for repair materials. This oversight can be costly because repair materials are likely to contain not only 19 relatively higher levels of high-alkalinity cement, but a complex mixture of chemical and mineral 20 admixtures as well. Page 55 of 92 1 When available, the field performance record of a particular aggregate, if it has been used with cement of 2 high-alkali content, can be used to judge its reactivity. Laboratory tests should be made on aggregates from 3 new sources, and when service records indicate that reactivity may be possible. 4 3.3.7 Abrasion Resistance 5 Abrasion resistance is defined as the ability of a surface to resist being worn away by rubbing and friction. 6 Factors that influence the abrasion resistance of a repair material include amount and quality of aggregate, 7 compressive strength, mixture proportions, type of material, finishing procedures, curing, and surface 8 treatment. 9 Test Methods: The following test methods provide a variety of procedures for determining the relative 10 resistance of repair materials to abrasion. The test methods are not intended to provide a quantitative 11 measurement of the length of service that may be expected from a specific material. 12 ASTM C418, Abrasion Resistance of Concrete by Sandblasting, covers the laboratory evaluation of the 13 relative resistance of concrete surfaces to abrasion by sandblasting. The procedure produces a cutting action 14 which tends to more severely abrade the less resistant components of the concrete (repair material). 15 ASTM C779, Abrasion Resistance of Horizontal Concrete Surfaces, provides three procedures (revolving 16 disks, dressing wheels, and ball bearings) for determining the relative abrasion resistance of horizontal 17 concrete surfaces. The procedures differ in the type and degree of abrasive force they impart and are 18 intended for use in determining variations in surface properties of cement-based materials. 19 ASTM C944, Abrasion Resistance of Concrete or Mortar Surfaces by the Rotating Cutter Method. The 20 primary application of this method is to evaluate the abrasion resistance of 6-in. (150-mm) core samples 21 which do not have sufficient surface area to permit testing in accordance with ASTM C418 or C779. Page 56 of 92 1 ASTM C1138, Abrasion Resistance of Concrete (Underwater Method), covers a procedure for determining 2 the relative resistance of concrete (including concrete overlays and impregnated concrete) to abrasion 3 underwater. This procedure simulates the abrasive action of water-borne particles (silt, sand, gravel, and 4 other solids). 5 Commentary: For material performance comparisons, the test data being evaluated must be generated by 6 the same method. It is worth noting that the replication of these tests is relatively poor. With coefficients of 7 variation ranging from 6 to 21% for single operator/same machine results, moderate differences in 8 performance may not be reliably detected. Of the four methods, C779-A (revolving disks) has the highest 9 precision. 10 3.4 Mechanical Properties 11 Repair materials require mechanical properties to carry and transfer loads similar to the concrete which is 12 being repaired. In addition to externally applied loads, repair materials must also absorb and resist stress 13 caused by restrained volume changes, including drying shrinkage and thermal expansion or contraction. 14 3.4.1 Tensile Strength 15 Tensile strength is an indication of a material’s ability to withstand tensile stress. Higher tensile strength can 16 generally be expected to improve the resistance of a repair material to internal tensile stresses such as those 17 due to restrained volume changes. While there are a number of ways to measure tensile strength, two of the 18 more common methods follow. Direct tensile pull-off bond strength (Section 3.1.1, ASTM C1583) should 19 not be confused with splitting tensile strength (ASTM C496) or direct tensile loading of a briquette (ASTM 20 C190). While all three of these tests have the ability to evaluate tensile properties of the material, the values 21 produced by these three tests are different and should not be taken as comparative to each other. 22 Test Methods: (Fig. 3-19) Page 57 of 92 1 ASTM C190, Tensile Strength of Hydraulic Cement Mortars (discontinued) 2 ASTM C496, Splitting Tensile Strength of Cylindrical Concrete Specimens 3 CRD-C 164 Direct Tensile Strength of Cylindrical Concrete or Mortar Specimens* 4 * http://gsl.erdc.usace.army.mil/SL/MTC/handbook/crd_c164.pdf (U.S. Army Corps of Engineers) 5 Commentary: In many situations, repair materials are required to carry and transfer tensile loads. The 6 tensile strength of a cement-based material is often estimated to be approximately 10% of its compressive 7 strength. However, the tensile strengths of repair materials can vary significantly and are not necessarily 8 predictable from compressive strengths. 9 Tensile strength measured using the C190 method is determined by a direct tensile loading of a briquette 10 specimen. The small size of the briquettes—cross section of 1 square inch (650 mm2)—make it difficult to 11 use with materials containing aggregate. Even though ASTM discontinued C190 in 1991, the procedure is 12 still used for lack of an alternate direct tensile test. 13 The splitting tensile strength is a compressive test of a horizontal cylinder across its diameter. While not a 14 direct tensile test, it is simpler to run and can be used to test materials containing aggregate or cores taken 15 from the field. Either procedure can provide an indication of the tensile strength of a material. However, the 16 results of the two tests are different. The splitting tensile strength (C496) produces a somewhat larger 17 number than the direct tensile strength (C190). 18 The rate of tensile strength gain is also important and can be assessed by examining the tensile strength of a 19 material at various ages, including some early age results (that is, 3 or 7 days). In general, the rate at which a 20 material develops tensile strength must be rapid enough to exceed the induced tensile stress such as from 21 drying shrinkage. Page 58 of 92 1 3.4.2 Flexural Strength 2 Flexural strength is a measure of a repair material’s resistance to bending. When repairs are likely to be 3 subjected to bending, specifying flexural strength should be considered. While there are a number of test 4 procedures for measuring flexural strength, two of the more common methods are listed below. 5 Test Methods: (Fig. 3-20) 6 ASTM C78, Flexural Strength of Concrete Using Simple Beam with Third-Point Loading 7 ASTM C348, Flexural Strength of Hydraulic Cement Mortars 8 ASTM C42, Obtaining and Testing Drilled Cores and Sawed Beams of Concrete 9 Commentary: ASTM C78 and ASTM C348 apply a load to the center of a stationary beam in order to 10 determine the flexural strength. The differences are in the loading points and the size of the beam. C78 uses 11 a third point loading (four contact points), and the reported result is a modulus of rupture in psi. C348 uses a 12 1-1/2 x 1-1/2 x 6½ in. (40 x 40 x 160 mm) beam while C78 uses a larger beam where the cross section is 13 square and the length is three times the width of the beam—typical 6 to 8 in. (150 to 200 mm) in width and 14 18 to 24 in. (450 to 600 mm) in length. Test results using the third-point loading in C78 to determine 15 modulus of rupture are usually higher than the flexural strengths determined using C348. For purposes of 16 comparison, the results from these methods cannot be used interchangeably. The exclusive use of C348 for 17 mortar specimens and C78 for concrete specimens is recommended. 18 3.4.3 Compressive Strength 19 The compressive strength of a repair material is a basic measure of its ability to carry compressive loads. 20 Test Methods: 21 ASTM C109, Compressive Strength of Hydraulic Cement Mortars Page 59 of 92 1 ASTM C39, Compressive Strength of Cylindrical Concrete Specimens 2 (The two test methods above do not directly correlate, but can be compared using the equation: C109 result 3 x 0.85 = C39 result.) 4 ASTM C42, Obtaining and Testing Drilled Cores and Sawed Beams of Concrete 5 Commentary: For many applications, compressive strengths of repair materials should approximate the 6 substrate strength. Differences in compressive strengths usually indicate differences in modulus of elasticity 7 as well (see commentary under modulus of elasticity). Differences between repair material and substrate in 8 these properties will generally affect strains and load transfer between the two materials. High compressive 9 strengths are frequently achieved by increasing the cement content in the mixture design. Possible negative 10 effects of higher cement content include increased drying shrinkage and increased temperature rise. In the 11 specification process, the relative importance of this property needs to be carefully weighed against other 12 desirable durability properties. High compressive strengths may, in some instances, adversely affect other 13 properties needed to achieve a durable repair. 14 3.5 Constructability Properties 15 Constructability properties are properties of materials during early age and include plastic properties, initial 16 set, and curing requirements. Some properties are designed to facilitate placement, but may adversely affect 17 other material properties. 18 Surface repair material selection must consider the physical properties (e.g. shrinkage, bond strength, 19 modulus of elasticity) needed to produce a repair composite capable of fulfilling its intended function. 20 However, obtaining the desired results from the installed product can be difficult if constructability issues 21 are not identified or properly communicated. Page 60 of 92 1 For example, field conditions such as a combination of high wind and low humidity can adversely affect a 2 material’s shrinkage. Ambient, substrate surface, and material temperatures can influence setting 3 characteristics and strength gain relationships. Field changes in the water-to-cement or polymer-to-cement 4 ratios can affect many of the critical properties of the material. Incorrect mixing, placement, finishing, and 5 curing can also alter the installed material’s properties. Knowing how field conditions may affect the 6 material is an important step in the selection process. 7 An understanding of the physical and chemical properties of a material in its plastic state should influence 8 the selection of the method of placement. Trowelable products, for example, have significantly different 9 consistencies than those repair materials which are to be pumped. In turn, the selection process for a repair 10 material to be placed in a small void at a twelfth floor spandrel beam will differ greatly from that which will 11 be needed for a balcony slab replacement at the first floor level. Constructability is also influenced by the 12 owner’s operating requirements. These requirements may include limited work space, no tenant 13 interference, night work only, short duration, no noise, no odors, no dust, etc. 14 In addition to selecting a surface repair material based on physical performance criteria, the constraints of 15 the field conditions should be evaluated. Detailed application instructions will minimize the risk of altering 16 the physical properties of the installed material. 17 3.5.1 Flow Characteristics 18 Commentary: Repair material flow characteristics provide important properties which allow repair 19 materials to penetrate and consolidate into repair cavities. With certain placement techniques, including 20 form and pump, form and cast-in-place, or grouted pre-placed aggregate, flow characteristics are critical 21 aspects for successful repair. For most of these applications, slump (or, slump flow or spread in the case of 22 self consolidating concrete (SCC)) requirements are satisfactory for specifying flowability. In grouted Page 61 of 92 1 preplaced aggregate applications, performance specifications require flowability to be measured with a flow 2 cone (ASTM C939, Flow of Grout for Preplaced-Aggregate Concrete). High slump does not guarantee that 3 the material will pump through a pump line and into a confined cavity. Pumpability is influenced by 4 aggregate shape, gradation, and content of fines; size of pump line; pump line length; and type of pump. 5 Enhancing flow characteristics may adversely affect other critical properties, including material segregation, 6 shrinkage, strength and permeability. The flow properties of materials are also a function of the mixing 7 shear and time. ICRI Technical Guideline No. 320.5R, Pictorial Atlas of Concrete Repair Equipment, can 8 be used as a means of specifying mixing equipment. 9 3.5.2 Rate of Strength Gain 10 Commentary: Rapid strength gain, as measured by compressive strength, is important to minimize 11 shutdown time in many repair environments such as traffic areas. Insufficient strength gain prior to use may 12 result in damage to the repair material or bond line. The desired strength and time duration should be 13 specified where required. The rate of strength gain is highly dependent upon the temperature of cure. Higher 14 temperatures will result in faster strength gain; lower temperatures will result in slower strength gain. 15 Accurate measurement of in situ strength is best accomplished by match-curing specimens at temperatures 16 similar to those which exist in the in situ repair material. 17 3.5.3 Exothermic Temperature Changes 18 Commentary: When water is added to cement, the reaction is exothermic, and a considerable amount of 19 heat can be generated over an extended period of time. The heat liberated up to a specific time or age is 20 measured in calories per unit weight of cement (cal/g). High-early strength cements are finer than other 21 types of cement and sometimes contain other active chemical compounds, thereby producing higher earlier 22 strengths and a more rapid release of heat. In thick section repair applications, failure to recognize the heat Page 62 of 92 1 factor and to provide for its dissipation will often result in thermal cracking. Thermal cracks are caused 2 principally by the tensile stress created by steep temperature gradients that can develop between the interior 3 and surfaces of curing concrete, as well as by the restraint of volume changes which occur as the material 4 cools. While several design and construction practices are available to minimize thermal stresses, restricting 5 the amount of heat generated is a fundamentally sound approach for mitigating thermal cracking. When 6 positive control over temperature rise is desired, upper limits on the heat of hydration of the cement may be 7 imposed through ASTM C150, Specification for Portland Cement; ASTM C595, Specification for Blended 8 Hydraulic Cements; ASTM C1157, Standard Performance Specification for Hydraulic Cement; and ASTM 9 C1600, Standard Specification for Rapid Hardening Hydraulic Cements. 10 3.5.4 Hot and Cold Weather Applications 11 Hot weather is defined as any combination of high temperature, low relative humidity, and wind velocity 12 that impairs the quality of fresh or hardened repair material or otherwise results in abnormal properties. The 13 effects of hot weather are most critical during periods of rising temperature, falling relative humidity or 14 both. Precautionary measures required on a calm, damp/humid, overcast day will be less strict than those 15 required on a dry, sunny, windy day, even if the air temperature is identical. 16 Adverse effects of hot weather include plastic shrinkage cracking, drying shrinkage cracking (from high 17 water demand), poor or no bond, and poor surface finishes due to rapid setting (Fig. 3-21). 18 Cold weather is defined as a period when, for more than three consecutive days, the average daily 19 temperature is less than 50°F (10°C) and the air temperature never rises above 55°F (13 °C) for more than 20 12 hours in any 24-hour period. Cold weather’s adverse effects include retarded strength gain, freezing of 21 repair material and subsequent deterioration, and poor bond between the substrate and the repair material. Page 63 of 92 1 The specifier must ensure that the materials selected are appropriate for the conditions of application. ACI 2 305.1, Hot Weather Concreting and ACI 306.1R, Cold Weather Concreting specifications provide excellent 3 information, and can aid in making repairs with materials not specifically manufactured for use in climatic 4 extremes. 5 3.5.5 6 Commentary: Working time is the amount of time available after a material is mixed until the material 7 begins to set. Working time may become critically shortened and interfere with proper placement techniques 8 at higher temperatures, especially for rapid setting materials. Working time is generally measured as 9 number of minutes at a given temperature. Working Time 10 3.5.6 11 Commentary: In many repair situations, surface repair materials are used in conjunction with surface- 12 applied coatings, linings, membranes, or sealers. Many delamination failures of surface-applied treatments 13 have occurred in which the separation from the repair material was caused by some type of material or 14 application incompatibility. Form release agents and curing compounds should be evaluated as materials 15 that may affect adhesion or penetration of other surface treatments. 16 The specifier should identify those materials which pose a compatibility risk and determine whether these 17 materials can be used together. This may be done by pilot/mockup testing, by previous experience, or by 18 consulting the appropriate material manufacturers. 19 3.5.7 Compatibility with Substrate Compatibility with Surface Treatments Page 64 of 92 1 Commentary: Some repair materials may generate adverse chemical reactions when exposed to certain 2 substrate conditions. The specifier should question the product manufacturer to determine if the material 3 being evaluated has the potential to react with the substrate being repaired. 4 3.6 Summary 5 Profiles of desired material properties or performance criteria for typical repair applications can be found in 6 the following documents: 7 i. ICRI 320.3R, Guideline for Inorganic Repair Material Data Sheet Protocol. 8 ii. "Performance Criteria for Concrete Repair Materials, Phase I," Technical Report REMR-CS-47 9 10 11 (Emmons and Vaysburd 1995). http://www.dtic.mil/dtic/tr/fulltext/u2/a295136.pdf iii. Performance Criteria for Concrete Repair Materials, Phase II Summary Report," Technical Report 12 REMR-CS-62 (Vaysburd, Emmons, McDonald, Poston, and Dalrymple 1999). 13 http://acwc.sdp.sirsi.net/client/search/asset/1004732 14 These guidelines can aid the user to matching requirements with the typical characteristics of selected 15 materials. 16 4.0 Selecting Repair Materials 17 Most repair projects will have unique conditions and special requirements that must be thoroughly examined 18 before the final repair material criteria can be determined. Once the criteria for a durable repair have been 19 established, materials with the properties necessary to meet these criteria should be identified. A variety of 20 repair materials have been formulated to provide a wide range of properties. Since these properties will Page 65 of 92 1 affect the performance of a repair, selecting the correct material for a specific application requires careful 2 study. 3 Material Properties 4 Properties of the materials under consideration for a given repair may be obtained from the 5 following: 6 • Manufacturer’s data sheets 7 • Evaluation reports 8 • Contact with suppliers 9 • Tests results 10 Manufacturer’s data for properties such as compressive strength, flexural strength, tensile strength, and 11 slant-shear bond are frequently reported in material data sheets provided by suppliers. However, other 12 material properties of equal or greater importance, such as drying shrinkage, modulus of elasticity, tensile 13 bond strength, creep, permeability, and water vapor transmission, may not be reported. Experience indicates 14 that the material properties reported in manufacturer’s data sheets are generally accurate for the conditions 15 under which they were determined. However, the designer should beware of those situations in which data 16 on pertinent material properties are not reported; unfavorable material characteristics are seldom reported. 17 Material properties pertinent to a given repair should be requested from manufacturers if they are not 18 included in the data sheets provided. General descriptions of materials, such as “compatible,” “non-shrink,” 19 etc. should be disregarded unless the claims are supported by data determined in accordance with 20 standardized test methods. Material properties determined in accordance with “modified” standard tests 21 should be viewed with caution, particularly if the modifications are not described. Page 66 of 92 1 The repair material manufacturer should demonstrate performance using consensus-based test methods 2 developed by a national standards body whenever possible. In cases where these test methods are modified 3 or not standardized, the modifications or non-standardized methods should be sufficiently documented in 4 writing so that the published values may be verified by outside parties if so required when reproducibility is 5 considered. Testing, whether performed by the material manufacturer or independently in accordance with 6 written material manufacturer’s instructions should use test methods sufficiently documented to allow 7 replication of the tests with consideration of the reproducibility of the test. 8 Acceptable proprietary repair material(s) other than site mixed portland-cement mortar may alternatively be 9 used for repair. Repair materials include, but are not limited to, commercial repair material(s) products, 10 including: latex modified cement mortar conforming to Type II in ASTM C1059, Latex Agents for Bonding 11 Fresh to Hardened Concrete; epoxy mortars and epoxy compounds conforming to ASTM C881/C 881M, 12 Epoxy-Resin-Base Bonding Systems for Concrete; packaged, rapid hardening concrete repair materials 13 conforming to ASTM C928, Packaged, Dry, Rapid-hardening Cementitious Materials for Concrete Repairs; 14 packaged, mortar and concrete conforming to ASTM C387, Packaged, Dry, Combined Materials for 15 Concrete and High Strength Mortar; rapid hardening cement conforming to ASTM C1600, Rapid 16 Hardening Hydraulic Cement; shotcrete conforming to ASTM C1436, Materials for Shotcrete and 17 C1480/1480M, Packaged, Pre-Blended, Dry, Combined Materials for Use in Wet or Dry Shotcrete. Use 18 repair material(s) in accordance with the repair material manufacturer’s recommendations. The repair 19 material manufacturer’s written instructions should be followed unless not accepted by the 20 Architect/Engineer. If the repair material manufacturer’s written instructions are modified, these 21 modifications should be submitted to the Architect/Engineer for review and acceptance. Page 67 of 92 1 Results of tests on a variety of repair materials are available from several government agencies and 2 independent testing laboratories. For example, the REMR Notebook (USAEWES 1985) currently contains 3 133 Material Data Sheets that include material descriptions, uses and limitations, available specifications, 4 manufacturer’s test results, and Corps test results. 5 Reputable material suppliers can assist in identifying those materials and associated properties that have 6 proven successful in previous repairs, provided they are made aware of the conditions under which the 7 materials will be applied and the anticipated service conditions. 8 The formulations for commercially available materials are subject to frequent modifications for a number of 9 reasons, including changes in ownership, changes in raw materials, environmental regulations, and new 10 technology. Sometimes these modifications result in changes in material properties without corresponding 11 changes to the manufacturer’s data sheets or notification of the modified formulation by the material 12 supplier. Consequently, testing of the repair material is recommended if achieving certain specific material 13 properties is considered critical to the viability or durability of the repair. 14 Selection Considerations 15 It is likely that more than one type of material will satisfy the design criteria for durable repair of a specific 16 structure. However, it is necessary to consider other important factors such as ease of application, cost, and 17 available labor skills and equipment in selection of the repair material. To match the properties of the 18 concrete substrate as closely as possible, Portland-cement concrete or similar cementitious materials are 19 frequently the best choices for repair. There can be exceptions, however, such as for repairs that must be 20 resistant to chemical attack where use of protective coatings would be impractical. Finally, it should be 21 understood that repairing “like with like” will not necessarily achieve a completely compatible repair since 22 certain properties are time-dependent and the existing substrate has often been in place for many years. Page 68 of 92 1 2 Typical characteristics of some common repair materials are provided in the table below. 3 Page 69 of 92 1 Typical Characteristics of Some Common Repair Materials (see ACI 546.3R for further information) Ingredients Application requirements Typical Material Thickness Binder material limitations Installation Curing temperature admixtures1 portland cement portland water reducing 0.5 to 2.0 in.3 40 to 90°F wet mortar cement air-entraining (13 to 50 mm) (5 to 32°C) 7 days portland cement portland water reducing >1.75 in. 40 to 90°F wet concrete cement air-entraining (>44 mm) (5 to 32°C) 7 days >1.25 in. 40 to 90°F wet (>30 mm) (5 to 32°C) 7 days 45 to 95°F wet (7 to 35°C) 2 days 0.25 to 2.0 in. 45 to 95°F moist (6 to 50 mm) (7 to 35°C) 3 days >0.5 in. 0 to 100°F air microsilica-modified silica fume, portland portland cement HRWR2, cement concrete air-entraining polymer-modified portland portland cement >1.25 in. polymer latex cement (>30 mm) concrete polymer-modified non-sag fillers, portland portland cement polymer latex cement mortar magnesium Page 70 of 92 or powder magnesium — phosphate cement phosphate concrete cement preplaced aggregate portland concrete cement epoxy mortar epoxy resin (>19 mm) (-18 to 40°C) pozzolans, >3.0 in. 40 to 90°F wet fluidifier (>76 mm) (5 to 32°C) 7 days 0.13 to 0.50 in. 50 to 90°F (4 to 13 mm) (10 to 32°C) 0.25 to 0.5 in. 20 to 120°F sand methyl methacrylate (MMA) acrylic resin air sand concrete air (6 to 13 mm) ([-6] to 50°C) >0.5 in. 40 to 90°F wet (>13 mm) (5 to 32°C) 7 days silica fume, pozzolans, portland water reducing shotcrete cement admixture, accelerator, latex 1 2 1 3 The materials shown in this column are examples of additives/admixtures which may be used to adjust properties in cementbased materials. 4 2 High range water reducer 5 3 Portland cement mortars that are durable in application thicknesses of less than 1.5 in. (38 mm) are generally prepackaged, 6 proprietary formulations. 7 Page 71 of 92 1 Note: the material properties shown in this table vary between products and from manufacturer to manufacturer and are shown 2 for comparison purposes only. See ACI 546.3R Table 2.1 and 2.2. Material properties Compressive strength Perme- Coefficient Freeze- Drying Elastic ability of thermal ExoComments thaw 1 hr. shrinkage4 Non-sag 24 hrs. 3 days 28 days modulus (% of expansion quality therm resistance concrete) similar to moderate 650 psi 2500 psi 5000 psi 3.4 x 106 psi 104 0 substrate (5 MPa) (20 MPa) (35 MPa) similar to 650 psi 2500 psi 5000 psi 3.8 x 106 psi 104 low (2.3 x (5 MPa) (20 MPa) (35 MPa) similar to 3000 psi 4000 psi 7500 psi low (2.6 x (25 MPa) (30 MPa) (50 MPa) (2.8 x 104 MPa) similar to 2000 psi 4000 psi 6000 psi 2.5 x 106 psi substrate (15 MPa) (30 MPa) (40 MPa) (1.7 x 104 MPa) similar to 1500 psi 3000 psi 5000 psi 2.5 x 106 psi 104 0 0 substrate similar to 2000 psi (10 MPa) (25 MPa) (35 MPa) (1.7 x 6400 psi 7000 psi 8400 psi 4.7 x 106 psi 104 (14 MPa) (44 MPa) (50 MPa) (60 MPa) similar to 0 500 psi 2250 psi 4500 psi Page 72 of 92 good N/A low — 60 good good low — 50 excellent N/A low — moderate — low to (2.2 x excellent MPa) low very low 90 50 substrate — 4 x 106 psi substrate moderate moderate moderate MPa) 0 low good MPa) 0 substrate 90 excellent 90 good low high — 100 good N/A low — MPa) 3.8 x 106 psi substrate (4 MPa) (15 MPa) (35 MPa) (2.6 x 104 MPa) 1.5 to 5 x 9000 psi 11000 psi 12000 psi 1.6 x 106 psi 104 low 0 concrete 1.5 to 5 x 4000 psi — 10 (70 MPa) (80 MPa) (85 MPa) (1.1 x 12000 psi 12000 psi 12000 psi 2.0 x 106 psi 104 similar to moderate (1.4 x (85 MPa) (85 MPa) (85 MPa) 800 psi 3500 psi 5000 psi 3.8 x 106 psi (35 MPa) 104 (25 MPa) (2.6 x good MPa) 1 2 4 Drying shrinkage: Very low <0.025% 3 Low 0.025% to 0.05% 4 Moderate 0.05% to 0.1% 5 High >0.1% 6 5 Vapor is highly flammable, pungent odor may cause problems in confined or poorly ventilated spaces. 7 Page 73 of 92 ACI 503.4 N/A high cause problems5 60 (5 MPa) excellent MPa) 0 substrate high vapor may 10 (30 MPa) moderate MPa) moderate concrete excellent N/A low ACI 506R 1 5.0 References 2 5.1 Referenced Standards and Reports 3 The standards and reports referenced were the latest editions at the time this document was prepared. 4 Because these documents are revised frequently, the reader is advised to contact the proper sponsoring 5 group if it is desired to refer to the latest version. 6 American Association of State Highway and Transportation Officials (AASHTO) 7 www.transportation.org 8 Standard Specifications for Transportation Materials and Methods of Sampling and Testing, Two Parts, 9 Washington, DC 10 American Concrete Institute (ACI) 11 www.concrete.org 12 Manual of Concrete Practice, Six Parts, Farmington Hills, MI 13 o ACI 201.2R, “Guide to Durable Concrete.” 14 o ACI 302.1R, “Guide for Concrete Floor and Slab Construction.” 15 o ACI 305.1, “Specification for Hot Weather Concreting.” 16 o ACI 306.1R, “Standard Specification for Cold Weather Concreting.” 17 o ACI 364.1R, “Guide for Evaluation of Concrete Structures Prior to Rehabilitation.” 18 o ACI 364.3R, “Guide for Cementitious Repair Material Data Sheet.” 19 o ACI 365.1R, “Service-Life Prediction State-of-the-Art Report.” 20 o ACI 503.4, “Standard Specification for Repairing Concrete with Epoxy Mortars.” 21 o ACI 503.5R, “Guide for the Selection of Polymer Adhesives with Concrete.” Page 74 of 92 1 o ACI 506R, “Guide to Shotcrete.” 2 o ACI 515.2R, “Guide to Selecting Protective Treatments for Concrete.” 3 o ACI 546.3R, “Guide for the Selection of Materials for the Repair of Concrete.” 4 o ACI 562, “Code Requirements for Evaluation, Repair, and Rehabilitation of Concrete Buildings.” 5 6 ASTM International 7 www.astm.org 8 Annual Book of ASTM Standards, West Conshohocken, PA 9 ASTM STP 169D Significance of Tests and Properties of Concrete and Concrete Making Materials 10 International Concrete Repair Institute (ICRI) 11 www.icri.org 12 ICRI Publications Catalog, Rosemont, IL 13 U. S. Army Corps of Engineers (USACE) 14 www.wes.army.mil/SL/MTC/handbook/handbook.htm 15 Handbook for Concrete and Cement, Vicksburg, MS 16 Page 75 of 92 1 5.2 Cited References 2 Best and McDonald 1990 3 Best, J. Floyd, and McDonald, James E. 1990 (Jan). “Spall Repair of Wet Concrete Surfaces,” Technical 4 Report REMR-CS-25, U.S. Army Engineer Waterways Experiment Station, Vicksburg, MS, 37 pp. 5 Beaudoin 1982 6 Beaudoin, J. J. 1982. “Fibre-Reinforced Concrete,” Canadian Building Digest, CBD-223, National Research 7 Council Canada, Institute for Research in Construction. 8 Do and Kim 2012 9 Do, J.Y. and Kim, D.K. 2012 (Jun). “AHP-Based Evaluation Model for Optimal Selection Process of 10 Patching Materials for Concrete Repair: Focused on Quantitative Requirements,” International Journal of 11 Concrete Structures and Materials, Vol. 6, No. 2, pp. 87–100. 12 Emmons 1993 13 Emmons, Peter H. 1993. Concrete Repair and Maintenance Illustrated, R.S. Means Co., Inc., Kingston, 14 MA, 295 pp. 15 Emmons and Vaysburd 1995 16 Emmons, Peter H., and Vaysburd, Alexander M. 1995 (Apr). “Performance Criteria for Concrete Repair 17 Materials, Phase I,” Technical Report REMR-CS-47, U.S. Army Engineer Waterways Experiment Station, 18 Vicksburg, MS, 125 pp. 19 Emmons, Vaysburd, and McDonald 1993 20 Emmons, Peter H., Vaysburd, Alexander M., and McDonald, James E. 1993 (Sep). “A Rational Approach to 21 Durable Concrete Repairs,” Concrete International, V. 15, No. 9, pp. 40-45. Page 76 of 92 1 Emmons, Vaysburd, and McDonald 1994 2 Emmons, Peter H., Vaysburd, Alexander M., and McDonald, James E. 1994 (Mar). “Concrete Repair in the 3 Future Turn of the Century—Any Problems?” Concrete International, V. 16, No. 3, pp. 42-49. 4 Emmons, Vaysburd, Poston, Dalrymple, and McDonald 1998 5 Emmons, Peter H., Vaysburd, Alexander M., Poston, Randall W., Dalyrymple, W., and McDonald, James 6 E. 1995 (Sep). “Performance Criteria for Concrete Repair Materials, Phase II Field Studies,” Technical 7 Report REMR-CS-60, U.S. Army Engineer Waterways Experiment Station, Vicksburg, MS, 300 pp. 8 Gurjar and Carter 1987 9 Gurjar, Suresh, and Carter, Paul. 1987 (Mar). “Alberta Concrete Patch Evaluation Program,” Report No. 10 ABTR/RD/RR-87/05, Alberta Transportation & Utilities, Edmonton, AB, Canada. 11 HQUSACE 1994 12 Headquarters, U.S. Army Corps of Engineers. 1994 (Feb). Standard Practice for Concrete for Civil Works 13 Structures, Engineer Manual 1110-2-2000, Washington, DC, 121 pp. 14 HQUSACE 1995 15 Headquarters, U.S. Army Corps of Engineers. 1995 (Jun). Evaluation and Repair of Concrete Structures, 16 Engineer Manual 1110-2-2002, Washington, DC, 184 pp. 17 Iowa DOT 2004 18 Iowa Department of Transportation (2004) 19 http://www.iowadot.gov/operationsresearch/reports/reports_pdf/hr_and_tr/reports/tr428vol3.pdf Page 77 of 92 1 Iriya, Hattori, and Umehara 1999 2 Iriya, K., Hattori, T. and, Umehara, H. 1999 (Jun). “Study on the Relationship Between Compressive Creep 3 and Tensile Creep of Concrete at an Early Age,” Concrete Library International, Japan Society of Civil 4 Engineers, No. 33, pp. 185-198. 5 Iriya, Negi, Hattori, and Umehara 2000 6 Iriya, K., Negi, T., Hattori, T., and Umehara, H. 2000 (Jun). “Study on Tensile Creep of Concrete at an 7 Early Age,” Concrete Library International, Japan Society of Civil Engineers, No. 35, pp. 135-150. 8 Mehta and Monteiro 1993 9 Mehta, P. Kumar, and Monteiro, P.J., 1993, Concrete Structures, Properties, and Materials, Prentice-Hall, 10 Inc., Englewood Cliffs, NJ, 548 pp. 11 Morrisey 2012 12 Morrisey, P. 2012 (Dec). “Flashcards For Engineers”, Concrete Construction, pp. 12-14. 13 http://www.concreteconstruction.net/repair/flashcards-for-engineers.aspx 14 Pfeifer, McDonald, and Krauss 1994 15 Pfeifer, Donald W., McDonald, David B., and Krauss, Paul D. 1994 (Jan-Feb). “The Rapid Chloride 16 Permeability Test and Its Correlation to the 90-Day Chloride Ponding Test,” PCI Journal, pp. 38-47. 17 Pigeon and Bissonnette 1999 18 Pigeon, Michel and Benoît, Bissonnette. 1999 (Nov). "Tensile Creep and Cracking Potential of 19 Thin Concrete Repairs," Concrete International, Vol. 21, No. 11, pp. 31-35. Page 78 of 92 1 Poston and Kesner 1998 2 Poston, Randall W. and Kesner, Keith E. 1998 (Apr). “Performance Criteria for Concrete Repair Materials, 3 Phase II Laboratory Results,” Technical Report REMR-CS-57, U.S. Army Engineer Waterways Experiment 4 Station, Vicksburg, MS, 95 pp. 5 USAEWES 1985 6 U.S. Army Engineer Waterways Experiment Station, 1985, The REMR Notebook, with periodic 7 supplements, Vicksburg, MS. 8 Vaysburd, Emmons, McDonald, Poston, and Dalrymple 1999 9 Vaysburd, Alexander M., Emmons, Peter H., Poston, Randall W., Dalyrymple, W., and McDonald, James 10 E. 1999 (Mar). “Performance Criteria for Concrete Repair Materials, Phase II Summary Report,” Technical 11 Report REMR-CS-62, U.S. Army Engineer Waterways Experiment Station, Vicksburg, MS, 73 pp. 12 13 Page 79 of 92 1 2 Fig. 1-1: Elements of a composite system 3 4 5 Fig. 3-1: Direct tensile bond test Fig. 3-2: Shear bond test Fig. 3-3: Slant shear bond test 6 7 8 sh Drying Shrinkage (sh) If sh = 0 No stress occurs. If sh > 0 Shear bond is stressed. Loads carried by repair are reduced; tension in repair material 9 If the old material has already developed a stable drying shrinkage volume, the following stresses will occur according to the amount of drying shrinkage of the new material. 10 Fig. 3-4: In repair applications, drying shrinkage causes stress at the interface Page 80 of 92 1 2 3 4 Fig. 3-5: Shrinkage cracks 5 Page 81 of 92 1 2 Magnitude, % Classification < 0.025 very low 0.025 to 0.05 low 0.05 to 0.10 moderate > 0.10 high Fig. 3-6: Drying shrinkage classification 3 Page 82 of 92 1 2 3 4 Fig. 3-7: Test results of 46 repair materials. The magnitude of variation demonstrates the need for careful 5 investigation of actual shrinkage properties. A typical value of concrete of 0.05% was used for comparison 6 in this study. 7 Page 83 of 92 1 2 3 n 4 o 5 6 7 Thermal coefficient of expansion () Given a temperature increase evenly distributed through the materials, the following stresses will occur according to the relationship of the thermal coefficients of the new and old materials. 8 9 Fig. 3-8: Thermal coefficient of expansion 10 11 Page 84 of 92 n = 0 No stress occurs. Ifn > 0 Shear bond is stressed. 1 2 If Enew = Eold No stress occurs. 3 4 Eold 5 6 7 Enew Modulus of elasticity (E) In the absence of drying shrinkage or other considerations and given an evenly distributed load, the following stresses will occur according to the relationship of the modulus of elasticity of the new and old materials Shear bond is stressed with differential displacement in the two materials. Stiffer material may become overstressed to maintain displacement compatibility in the two materials. 8 9 10 If Enew > Eold Fig. 3-9: Modulus of elasticity 11 12 Page 85 of 92 1 2 If (cr) new = 0 No stress occurs. 3 cr Creep (cr) 4 5 If the old material has already developed a stable creep volume, stresses will develop according to the amount of creep occurring in the new material 6 7 Fig. 3-10: Tensile creep 8 9 Page 86 of 92 If (cr) new > 0 Shear bond is stressed. Loads carried by repair are reduced. 1 2 3 4 Fig. 3-11: Tensile stress relief through tensile creep 5 Page 87 of 92 1 2 3 4 Fig. 3-12: Test method for water vapor transmission 5 6 Page 88 of 92 1 2 3 Fig. 3-13: Spalled shotcrete repair of a navigation lock wall 4 5 Fig. 3-14: Core samples from same repair 6 7 Page 89 of 92 1 Magnitude 2 Classification < 0.01 lb/ft2 very good 0.01 - 0.10 lb/ft2 good 0.10 - 0.20 lb/ft2 fair > 0.20 lb/ft2 poor/fail Fig. 3-15: Scaling resistance classification 3 4 5 6 Fig. 3-16: Cracking is often the first sign of sulfate attack 7 8 Page 90 of 92 1 Sulfate content Soil water Negligible under 0.1% under 150 ppm (mg/liter) Moderate 0.1 to 0.2% 150 to 1500 ppm Severe 0.2 to 2.0% 1500 to 10,000 ppm Very severe over 2.0% over 10,000 ppm Level of exposure 2 Fig. 3-17: Sulfate attack classification 3 4 5 6 Fig. 3-18: Alkali silica reaction—cracks develop in cement paste surrounding reactive aggregate Page 91 of 92 1 2 3 Fig. 3-19: Tensile strength test methods Fig. 3-20: Flexural strength test methods 4 5 6 7 Fig. 3-21: Pattern cracking develops in surfaces allowed to dry out 8 Page 92 of 92