effects of polymer–cement ratio and accelerated curing on flexural behavior of hardener-free...

8/12/2019 Effects of polymercement ratio and accelerated curing on flexural behavior of hardener-free epoxy-modified mor

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O R I G I N A L A R T I C L E

Effects of polymercement ratio and accelerated curing

on flexural behavior of hardener-free epoxy-modifiedmortar panels

Muhammad Aamer Rafique Bhutta

Received: 5 June 2009 / Accepted: 7 December 2009 / Published online: 18 December 2009

RILEM 2009

Abstract This experimental study reports the appli-

cability of hardener-free epoxy-modified mortar pan-

els to permanent forms as precast concrete products.

Hardener-free epoxy-modified mortars are mixed

using a Bisphenoal A-type epoxy resin without any

hardener with various polymercement ratios and

steel fiber reinforcement, and subjected to different

curings. Hardener-free epoxy-modified mortar panels

are prepared with same polymercement ratios and

steel fiber reinforcement on trial, and tested for

flexural behavior under four-point (third-point) load-ing. The effects of polymercement ratios and

curings on strength properties of hardener-free

epoxy-modified mortars, and on the flexural strength,

flexural stress-extreme tension fiber strain relation,

flexural loaddeflection relation of hardener-free

epoxy-modified mortar panels were examined. The

adhesion in tension (to placed concrete) of the

hardener-free epoxy-modified mortar panels was also

tested. As a result, the hardener-free epoxy-modified

mortar panels develop a high flexural strength, large

extensibility and good adhesion to the placed con-crete. The epoxy-modified mortar panels are more

ductile and have high load-bearing capacity than

unmodified mortar panels and can be used as precast

concrete permanent forms in practical applications.

Keywords Epoxy resin Hardener-free epoxymodified mortar Permanent form Polymercementratio Flexural behavior Adhesion

1 Introduction

Japan lays great emphasis on the issue of global

environment protection, therefore, environment-con-

scious construction materials have been used, and

sustainable concretepolymer composites have been

vigorously developed. Recently, the construction

industry has seen the development and use of such

sustainable concretepolymer composites which are

permeable polymer-modified concretes, repairing

systems using polymer-modified mortars for rein-

forced concrete structures, polymer-modified cemen-

titious waterproofing systems and so on, particularly,epoxy-modified mortars and concretes without any

hardeners are newcomers in the construction indus-

try. A lot of work has been done in the research and

development of epoxy-modified mortars and con-

cretes in Japan and it has been reported that epoxy

resin without any hardener in epoxy-modified mortars

and concretes can harden in the presence of alkalis

or hydroxide ions (OH-) from calcium hydroxide

[Ca(OH)2] as one of cement hydrates [1, 2]. Like

M. A. R. Bhutta (&)

Department of Structures and Materials Faculty of Civil

Engineering, Universiti Teknologi Malaysia, Skudai,

Johor, Malaysia

e-mail: [email protected]

Materials and Structures (2010) 43:429439

DOI 10.1617/s11527-009-9578-8


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polymer-modified mortars and concretes, epoxy-mod-

ified mortars and concretes are also superior in

properties [35]. They have excellent chemical resis-

tance, high strength development, abrasion resistance,

freezethaw resistance and water-tightness compared

to conventional cement mortar and concrete. In Japan,

polymer-impregnated mortar permanent forms havebeen employed only in the limited applications, giving

a good costperformance balance for them, for the past

30 years [69]. Only one company currently produces

the polymer-impregnated mortar permanent forms as

commercial products to order in Japan. The manufac-

turing process and material cost of polymer-impreg-

nated mortar permanent form is relatively high. The

purpose of this experimental study is to examine the

applicability of epoxy-modified mortar panels to

permanent forms as precast concrete products as

alternate of polymer-impregnated mortar permanentforms. In the present paper, hardener-free epoxy-

modified mortars using a bisphenol A-type epoxy resin

without any hardener, with polymercement ratios of

0, 10,15 and 20% (epoxy-cement ratios) and with steel

fiber reinforcement [steel fiber content of 1.2%

(volume fraction)] were prepared and subjected to

different curing conditions, and tested for strength

properties. The effects of polymercement ratios and

curings on strength properties of hardener-free epoxy-

modified mortars are examined. Hardener-free epoxy-

modified mortar panel specimens sized 450 9 900 9

30 mm were also manufactured using same polymer

cement ratios and same steel fiber reinforcement

content. Based on previous research work results

reported by Ohama et al. [4] and present study, the

panel specimens were subjected to optimum curing

condition [1-d moist [20C, 90% (RH)] ? 1-d steam

(90C) ? 1-d heat (120C)]. The cured hardener-free

epoxy-modified mortar panel specimens are tested for

flexural behavior under four-point (third-point)

loading. The flexural strength, flexural stress-extreme

tension fiber strain relation, flexural loaddeflection

relation were investigated. The effects of polymer

cement ratio and accelerated curing on flexural

behavior of hardener-free epoxy-modified mortar

panel specimens are observed. To examine the adhe-

sion in tension of epoxy-modified mortar panels toplaced concrete, fresh concrete is placed on the epoxy-

modified mortar panels attached to molds (450 9

900 9 30 mm), and subjected to a 28-d dry [20C,

60% (RH)] curing. The effect of polymercement ratio

on the adhesion or bond strength of hardener-free

epoxy-modified mortars to placed concrete was also

discussed. Consequently, the hardener-free epoxy-

modified mortar panels develop a high flexural

strength, large extensibility and good adhesion to the

placed concrete. The hardener-free epoxy-modified

mortar panels are more ductile and have high load-bearing capacity than unmodified mortar panels and

can be used as precast concrete permanent forms in

practical applications.

2 Materials

2.1 Cement

Ordinary Portland cement as specified in JIS (Japa-

nese Industrial Standard) R 5210 (Portland cement)

was used. The physical properties and chemical

compositions of the cement are given in Table 1.

2.2 Aggregate

Crushed aggregate and two types of crushed sands

were used as coarse and fine aggregates. Table2

gives the properties of the aggregates.

Table 1 Physical properties and chemical compositions of cement

Density

(g/cm3

)

Blaine specific

surface

Setting time (h-min) Compressive strength of mortar (MPa)

Initial set Final set 3d 7d 28d

3.16 3370 210 330 28.8 43.6 61.2

Chemical compositions (%)

MgO SO3 ig. loss

1.48 2.12 1.90

430 Materials and Structures (2010) 43:429439


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2.3 Epoxy resin

Diglycidyl ether of bisphenol A was used as an epoxy

resin or hardener-free epoxy resin. The constitutional

formula of the epoxy resin is expressed in Fig.1. The

properties of the epoxy resin are shown in Table 3.

2.4 Steel fiber reinforcement

Commercially available steel fibers were used as

reinforcement. The properties of steel fibers are

shown in Table4.

3 Test program

3.1 Mixing of hardener-free epoxy-modified

mortars

According to JIS A 1171 (Test methods for polymer-

modified mortar), all hardener-free epoxy-modified

mortars were mixed using mix proportions as shown

in Table5with polymercement ratios (P/C) of 0, 10,

15 and 20%, steel fiber content of 1.2% (volume

fraction) and a superplasticizer.

3.2 Preparation of hardener-free epoxy-modified

mortar specimens for strength tests

Beams specimens 40 9 40 9 160 mm for flexuraland compressive strength tests and cylindrical spec-

imens U50 9 100 mm for tensile strength test were

molded using hardener-free epoxy-modified mortars,

and subjected to the following curings:

(1) Steam curing: [1-d moist (20C, 90%(RH)] ?

2-d steam(90C)]

(2) Autoclave ? heat curing: [1-d moist (20C,

90%(RH) ? autoclave (120C, 3 h) ? 1-d heat

(120C)]

(3) Steam ? heat curing: [1-d moist [20C, 90%

(RH)] ? 1-d steam (90C) ? 1-d heat (120C)]

Table 2 Properties of aggregates

Type of aggregate Size (mm) Fineness modulus Bulk density (kg/l) Density (g/cm3

) Water absorption (%)

Finea

0.152.5 3.29 1.48 2.62 0.94

2.55 4.83 1.64 2.63 0.58

Coarseb

520 6.61 1.66 2.63 0.54

a Aggregate for epoxy-modified mortar panels, b aggregate for placed concrete

CH2 CH CH2

CH3

CH3

CO O

O

CH2 CH2CH

CH3

CH3

C O

O

CH2 CH CH2

OH

O

n*

*n= 0.1 0.2

Fig. 1 Constitutional

formula of diglycidyl ether

of bisphenol A

Table 3 Properties of bisphenol A epoxy resin

Epoxy equivalent Molecular weight Density (g/cm3, 20C) Viscosity (mPa s, 20C) Flash point (C)

184 380 1.16 38000 264

Table 4 Properties of steel fiber

Size (mm) Tensile strength (MPa) Elastic modulus (GPa) Elongation (%)

/ 0.3 9 0.4 9 15 585 200 50

Materials and Structures (2010) 43:429439 431


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3.3 Preparation of hardener-free epoxy-modified

mortar panel specimens for flexural behavior

For flexural behavior, mortar panel specimens

450 9 900 9 30 mm were molded and subjected tooptimum curing condition [1-d moist [20C, 90%

(RH)] ? 1-d steam (90C) ? 1-d heat (120C)]. The

manufacturing process of hardener-free epoxy-mod-

ified mortar panel specimens and their view after

demolding are shown in Figs. 2and3, respectively.

3.4 Preparation of specimens for adhesion test

in tension

Preparation of specimens for adhesion in tension,

ready-mixed concrete with specified design compres-sive strength of 30 MPa is placed on the epoxy-

modified mortar panels attached to molds (450 9

900 9 300 mm) as shown in Fig. 4, and subjected to

a 28-d dry [20C, 60% (RH)] curing. Ready-mixed

concrete having slump of 80 mm and air content of

Table 5 Mix proportions of hardener-free epoxy-modified mortars

w/c (%) s/a (%) P/C (%) Mix proportions (kg/m3

)

Water Cement Sand Steel fibre Admixturea

0.152.5 mm 2.55 mm

35.0 58.0 0 175 500 958 715 95 3.534.8 10 174 500 958 715 95 3.5

34.6 15 173 500 958 715 95 3.5

34.4 20 172 500 958 715 95 3.5

aSuperplasticizer

Fig. 2 Manufacturing of hardener-free epoxy-modified mortar panel specimens

Fig. 3 A view of hardener-free epoxy-modified mortar panel specimen



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4.5% was used. The mix proportions of ready-mixed

concrete is given in Table6. The hardener-free

epoxy-modified mortar panel specimens have rough

surface on back for mechanical interlocking or

bonding to placed concrete.

4 Testing procedures

4.1 Strength tests for hardener-free epoxy-

modified mortar specimens

Beams specimens were tested for flexural and

compressive strengths in accordance with JIS A

1171. According to JIS A 1185, splitting tensile

strength of specimens was done.

4.2 Flexural test for hardener-free epoxy-

modified mortar panel specimens

The hardener-free epoxy-modified mortar panel spec-

imens were tested for flexural behavior under four-point (or third-point) loading with a span of 750 mm

and a loading rate of 50 N/s by using the Amsler-type

universal testing machine. Figure5 illustrates the

setup of flexural test for the steel fiber reinforced

epoxy-modified mortar specimen. At the same time,

the central (or midspan) deflection of the specimens

was measured by a sensitive LVDT (linear variable

differential transformer), and their extreme tension

fiber strain was measured by the three 30-mm-long

paperback electrical strain gages installed on the

extreme tension fiber at the midspan. Their flexural

toughness was calculated as an area under a flexural

loaddeflection curve up to a deflection at the

maximum flexural load (at failure load). Their flexural

strength was calculated using the following Eq.1

rf P

bh2 1

where rf is flexural strength (MPa), P is maximum

flexural load (N), is span (mm), b is width (mm) of

specimen, andhis thickness (mm) of specimen. Their

flexural modulus of elasticity was calculated by the

following Eq.2

Ef 23P3

54bh3d 2

whereEfis flexural modulus of elasticity (10

-3

GPa),P is flexural load (N), d is central (midspan)

deflection (mm), is span (mm), b is width (mm)

of specimen, and h is thickness (mm) of specimen.

4.3 Adhesion test in tension

According to JIS 6909, the cured specimens were

tested for adhesion in tension by using manually

operated jack pull-gage. A set up for adhesion test in

tension is shown in Figs. 6and7.

5 Test results and discussion

5.1 Effects of polymercement ratio and

accelerated curings on strength properties

of hardener-free epoxy-modified mortars

Figure8 illustrates the polymercement ratio versus

compressive, flexural and tensile strengths of

Fig. 4 (1) Installation of

hardener-free epoxy-

modified mortar panel

specimens. (2) Placement of

concrete on hardener-free

epoxy-modified mortar

panel specimens

Table 6 Mix proportions of placed concrete for adhesion test

w/c

(%)

s/a

(%)

Mix proportions (kg/m3

)

Water Cement Sand Aggregate Admixturea

48.5 44.1 160 330 800 1016 3.30

aWater-reducing agent



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accelerated-cured hardener-free epoxy-modified mor-

tars with steel fiber reinforcement. The effects of

polymercement ratio and accelerated curing

conditions on the strengths of hardener-free epoxy-

modified mortars are considerable. The strengths of

hardener-free epoxy modified mortars with polymer

Fig. 5 Setup of flexural

test for hardener-free

epoxy-modified panel

specimen

Fig. 6 Adhesion of steel plates to hardener-free epoxy-modified mortar panel specimens

P

Load cell

Central hole jack

Continuous thread stud

Steel stand

Steel plate Epoxy-modified mortar

panel specimen

Fig. 7 A set up for

adhesion test in tension



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cement ratios of 10, 15 and 20% are significantly

increased compared to unmodified mortars (with a

polymercement ratio of 0%). Except for steam cured

[1-d moist (20C, 90% (RH)] ? 2-d steam (90C)]

hardener-free epoxy-modified mortars, the compres-

sive, flexural and tensile strengths of auto-

clave ? heat cured and steam ? heat curedhardener-free epoxy-modified mortars are increased

with increasing polymercement ratio. The compres-

sive, flexural and tensile strengths of steam cured

hardener-free epoxy-modified mortars increased with

increasing polymercement ratio, and reached its

maximum at polymercement ratios of 10 to 20%.

The reason for this is that the strength development of

steam cured hardener-free epoxy modified mortars

with high polymercement ratios needs mature

hardening reaction to get higher degree of hardening

of the hardener-free epoxy resin [4,5]. The strengthsof hardener-free epoxy-modified mortars are remark-

able due to maximum hardening reaction during

autoclave ? heat curing and steam ? heat curing.

The compressive, flexural and tensile strengths of the

steam ? heat cured hardener-free epoxy-modified

mortars are somewhat higher than those of the

autoclave ? heat cured ones. The application of heat

curing to the autoclave- or steam-cured hardener-free

epoxy-modified mortars, the hardener-free epoxy

resin in the mortars can harden completely by the

acceleration of its hardener reaction due to the heatcuring in the presence of alkalis or hydroxide ions

(OH-) produced by the hydration of cement in the

mortars, and contributes to the strength development

of the mortars. It is evident from the results of SEM

observation of microstructures and disappearance of

epoxy group in hardened epoxy resin in Infrared

spectroscopy reported by Ohama et al. [3]. The

hardening reaction of the hardener-free epoxy resin in

the presence of the hydroxide ions in the mortars can

be expressed by the following formula [2, 10]:

The significant increase in strengths of hardener-

free epoxy-modified mortars is a result of a strong

adhesion between comatrixes (cement hydrates ?

epoxy resin) and fine aggregates and steel fibers due

to steam ? heat curing. This can be attributed to the

good timing of the interaction between the cement

hydration and hardening of the hardener-free epoxy

resin, and then the development of strong bond

between comatrixes (cement hydrates ? epoxy resin)

and fine aggregates and steel fibers.

Fig. 8 Polymercement ratio versus compressive, flexural and

tensile strengths of accelerated-cured hardener-free epoxy

modified mortars

OH

Hardened epoxy resin

O CH2 CH CH2

n

O CH2 CH CH2 O

Epoxy resin

CH2 CH CH2 O CH2 CH CH2 O

HOO n from cementhydration

OHO

nOH



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5.2 Flexural behavior of hardener-free

epoxy-modified mortar panel specimens

Figures9, 10, 11, 12 represent the flexural stress-

extreme tension fiber strain curves for hardener-free

epoxy-modified mortar panel specimens with poly-

mercement ratios of 0, 10, 15 and 20% and steelfiber reinforcement. The flexural stress-extreme ten-

sion fiber strain relationship of hardener-free epoxy-

modified mortar panel specimens with polymer

cement ratios of 10, 15 and 20% is much higher

than that of mortar panel specimens with polymer

cement of ratio of 0%. The maximum flexural stress

of the hardener-free epoxy-modified mortar panel

specimens is gradually increased with increasing

polymercement ratio and remarkably improved at

polymercement ratio of 20%.

Table7and Fig.13show the flexural behavior of

hardener-free epoxy-modified mortar panel speci-

mens with polymercement ratios of 0, 10, 15 and

20% and steel fiber reinforcement. The deflections of

mortar panel specimens with polymercement ratio

of 0% are found to increase linearly with maximum

flexural load until almost failure, but the deflections

of hardener-free epoxy-modified mortar panel spec-imens with polymercement ratios of 10, 15 and 20%

are increased almost linearly with increasing flexural

load until the maximum flexural load giving a brittle

failure. At this point, the difference in flexural

behavior due to hardener-free epoxy resin modifica-

tion to mortar panel specimens with polymercement

ratios of 10, 15 and 20% and mortar panel specimens

with polymercement ratios of 0% is clear. The

maximum deflections, flexural toughness, flexural

Fig. 9 Flexural stress-extreme tension fiber strain curves for

mortar panel specimens with polymercement ratio of 0%


hardener-free epoxy-modified mortar panel specimens with

polymercement ratio of 10%


hardener-free epoxy-modified mortar panel specimens for



hardener-free epoxy-modified mortar panel specimens for




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strengths and flexural moduli of elasticity of the


mens are significantly increased by increasing poly-mercement ratio. The flexural strength, flexural

toughness and maximum deflections of hardener-free

epoxy-modified mortar panel specimens are more

than twice than that of mortar panel specimens with

polymercement ratio of 0%. The flexural moduli of

elasticity of hardener-free epoxy-modified mortar

panel specimens is also somewhat improved with

increasing polymercement ratio. The hardener-free

epoxy resin modification and the application of heat

curing to the steam-cured hardener-free epoxy-mod-

ified mortar panel specimens is proved to be effectiveto improve the strength properties. The steam curing

may provide an induction period for epoxy resin

hardening reaction in the hardener-free epoxy-mod-

ified mortars, and then an application of heat curing

to the steam-cured hardener-free epoxy-modified

mortars may cause the acceleration of the epoxy

resin hardening reaction in the presence of hydroxide

ions, and the evaporation of water in the mortars.

This contributes to the high-strength development in

the flexural behavior of hardener-free epoxy-modified

mortar panel specimens with polymercement ratios

of 10, 15 and 20%. From the above flexural behavior

trend, it is obvious that hardener-free epoxy-modified

mortar panel specimens are more ductile. This means

that hardener-free epoxy-modified mortar panel spec-

imens with polymercement ratios of 10, 15 and 20%have a high load-bearing capacity and large extensi-

bility compared to mortar panel specimens with

polymercement ratio of 0% as permanent form

application.

5.3 Adhesion test in tension of hardener-free

epoxy-modified mortar panel specimens to

placed concrete

Figure14 exhibits the adhesion test in tension of

hardener-free epoxy-modified mortar panel speci-mens to placed concrete. As mentioned in the

preparation of specimens for adhesion in tension,

the hardener-free epoxy-modified mortar panel spec-

imens have rough surface on back for mechanical

bonding to placed concrete. Therefore, the effect of

polymercement ratio on the adhesion test in tension

was not clearly observed. All specimens showed

cohesive failure in placed concrete substrate. The


mens with polymercement ratio of 15% gave higher

adhesion in tension of 2.6 MPa to placed concretewhich is higher than that of 1.8 MPa of polymer-

impregnated permanent forms or panels to placed

concrete [8].

6 Conclusions

Based on the above test results the following

conclusions may be drawn:

Fig. 13 A flexural load-deflection curves for hardener-free

epoxy-modified mortar panel specimens

Table 7 Flexural behavior of hardener-free epoxy-modified mortar panel specimens

Polymercement ratio

(P/C)

Flexural behavior

Max. extreme tension

fiber strain (910-6

)

Max. deflection

(mm)

Flexural

toughness (kN mm)

Flexural

strength (MPa)

Flexural modulus

of elasticity (GPa)

0 395 1.42 3.9 8.9 23.0

5 606 3.29 14.6 16.2 26.7

10 779 3.40 16.8 18.0 24.1

20 798 3.52 19.5 20.2 26.5



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1. The effects of polymercement ratio and accel-

erated curing on the strengths of hardener-free

epoxy-modified mortars are significantly marked.The strengths of accelerated-cured hardener-free

epoxy-modified mortars are increased with

increasing polymercement ratio. The applica-

tion of heat curing to autoclave- or steam-cured

hardener-free epoxy modified mortars causes a

significant improvement in their strengths

because of the acceleration of epoxy resin

hardening reaction in the presence of alkalis or

hydroxide ions and the elimination of water in

the mortars.

2. The maximum flexural stress of the hardener-freeepoxy-modified mortar panel specimens is grad-

ually increased with increasing polymercement

ratio and remarkably improved at polymer

cement ratio of 20%.

3. Modification of hardener-free epoxy resin to

mortar panel specimens increases the deflection

characteristics of all epoxy-modified mortar panel

specimens regarding to polymercement ratio.

The flexural strength, flexural toughness and

maximum deflections of hardener-free epoxy-

modified mortar panel specimens are more thantwice than that of mortar panel specimens with

polymercement ratio of 0%. The flexural moduli

of elasticity is also somewhat increased with

increasing polymercement ratio of hardener-free

epoxy-modified mortar panel specimens.

4. The effect of polymercement ratio on the

adhesion test in tension is not evident. All

specimens showed cohesive failure in concrete

substrate. The concrete with polymercement

ratio of 15% gives higher adhesion in tension of

2.6 N/mm2 to placed concrete.

5. The hardener-free epoxy-modified mortar panels

are more ductile and have high load-bearing

capacity than unmodified mortar panels and can

be used as precast concrete permanent forms in

practical applications.

Acknowledgements Theauthors wish to express their gratitude

and sincere appreciation to Research and Development Center,

TakamuraHoldingsCo., Ltd., forfinancing this research work and

conducting experiments in its laboratory.

References

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2. Ohama Y, Demura K, Uchikawa H (1995) Strength

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