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Moisture Protection for Concrete and Masonry

Rust-Oleum Corporation11 Hawthorn ParkwayVernon Hills, IL 60061Tel: 847-367-7700Fax: 847-816-2330Toll-Free: 800-553-8444Email: [email protected]: www.zinsser.com

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Moisture Protection for Concrete and Masonry

Rust-Oleum Corporation11 Hawthorn ParkwayVernon Hills, IL 60061

Provides an overview of methods of reducing moisture intrusion in concrete and masonry walls with an emphasis on the role of sealers and coatings.

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The American Institute of Architects · Course No. AEC207 · This program qualifies for 1.0 LU/HSW Hour.

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Purpose and Learning Objectives

Purpose: Provides an overview of methods of reducing moisture intrusion in concrete and masonry walls with an emphasis on the role of sealers and coatings.

Learning Objectives:

At the end of this program, participants will be able to:

• understand three types of masonry wall construction.

• recognize effects of moisture intrusion in masonry walls.

• describe four methods of reducing moisture intrusion, and.

• evaluate different types of sealers and coatings.






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Table of Contents

Introduction. 7.

Masonry Terms. 10.

Masonry Construction. 24.

Effects of Moisture Intrusion. 30.

Reducing Moisture Intrusion. 36.

Selecting a Sealer or Coating. 42.

Sealer and Coating Options. 52.

Conclusion. 68.

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Introduction






Introduction

We have been building and living in masonry structures for generations. Traditional masonry construction of 1900 and earlier was of a more massive form. Walls were much thicker than they are today and were solid masonry. These types of walls dealt with moisture intrusion by using the mass of the masonry to absorb the moisture and subsequently release it through evaporation. Although these structures haven’t survived unscathed, they have endured for many years.






Introduction

Modern buildings are much lighter skinned. Masonry can be as little as 3” thick. In many cases, they have minimal overhang at the top, allowing rain water from the roof or parapet wall to run down the face of the masonry.

As a result, in modern wall systems, rain water is allowed to be in contact with the masonry in larger quantities and for longer periods of time, thus leading to more opportunity for water penetration.

This course will introduce you to the methods of protecting concrete and masonry walls from water penetration with an emphasis on the role of sealers and coatings.






Masonry Terms






Masonry

Masonry units are available in different sizes, shapes, colors, textures and profile for practically every conceivable need. Units most commonly used are concrete block and clay brick.

The units are joined together by mortars made from a binder consisting of one or more cements for masonry, along with sand and water.

Masonry is widely used to construct small and large structures because of its attractive appearance, minimum maintenance, safety and economy.






Concrete

In its simplest form, concrete is a mixture of paste and aggregates. The paste, composed of portland cement and water, coats the surface of the fine and coarse aggregates. Through a chemical reaction with water called hydration, the cement coats the aggregate and then bonds together the mixture. The paste hardens and gains strength to form the rock-like mass known as concrete.






Four Basic Forms of Manufactured Concrete

Ready-Mix Concrete is the most common and accounts for three-fourths of all concrete. Each batch of ready-mix concrete is tailor made according to contractor specifications.

Pre-Cast Concrete products are cast in factory settings. Pre-cast benefits from tight quality control achievable at production plants. Products range from concrete brick and paving stones to bridge girders and structural components.






Four Basic Forms of Manufactured Concrete

Concrete Masonry Units: The standard concrete block is an 8 x 8 x 16 inch unit made mainly of Portland cement, sand, gravel and water. The most common application of concrete masonry is walls for buildings, retaining walls, chimneys and elevator shafts.

Mortar and Grout: Masonry mortar is composed of one or more cementitious materials, masonry, sand and sufficient water to produce a plastic, workable mixture. Grout for masonry is composed of similar materials but is generally mixed to a much more fluid condition and may also contain coarse aggregate.






Types of Pre-Cast Concrete Construction

Pre-cast concrete products are cast in a factory setting. These products benefit from tight quality control achievable at a production plant.

Tilt-up concrete is usually pre-cast for larger structures and is often poured in molds on site.

Poured in place concrete is a system of erected molds that are filled with concrete on site. These surfaces are usually very dense, possibly fluted or raked.

Poured in Place.Tilt-up Concrete.Pre-cast Concrete.






Concrete Masonry Units

Concrete masonry may be best known for its conventional 8 x 8 x 16-inch block. All concrete block is unique due to the inconsistency of sand, gravel, lightweight aggregate and design mix. This inconsistency in natural materials produces concrete blocks that vary significantly in porosity and surface texture from one geographical area to another, as well as from one batch to the next.






Concrete Masonry - Block Weight and Density

Concrete block is manufactured in three weights:

Lightweight: 35 lbs.Medium weight: 50 lbs.Normal weight: >60 lbs.

All of the above blocks must meet the ASTM C-90 compressive strength standards.

Since mason productivity is generally determined by the weight of the block being used, a lighter weight block provides increased productivity. A mason can lay 150 medium weight blocks a day or 193 lightweight blocks a day. This increased productivity leads to lower costs as labor accounts for 60% of overall wall costs.






Cement Materials - Mortar

Concrete masonry units must be stacked and bonded with mortar. Mortar is a plastic mixture of cement, lime, water and fine aggregates or sand which combine together through a chemical process of crystallization to form a hardened solid that bonds building units together.

Mortar joints can be tooled different ways affecting appearance and resistance to water penetration. Tests have proven that concave or v-joint tooling of mortar joints is the best choice for block or brick construction. These methods compress the mortar into the joint for greater bond and joint fill providing greater resistance to moisture infiltration.






Mortar Joints

Mortar joints play a large role in moisture penetration. Brick construction presents great variances in water absorption over the face of the wall. The mortar joints have a far greater absorption rate than the tight surface of brick.

Lime based cement mortars present proven improvement in resisting water intrusion. However, a sealed surface will be the best defense against moisture problems.

Susceptible to water penetration. Resists water penetration.






Mortar Joints

Head joints are the vertical joints, sometimes called "T" joints, between blocks. Bed joints are the horizontal joints that are formed between layers of block. These joints need to be completely filled in order to maintain good resistance to water penetration.

Leaks frequently occur due to cracked or missing mortar, particularly around head joints.

Top of Head Joint.

Middle of Head Joint.

Bottom of Head Joint.

Bed Joint.






Mortar Joints

The thickness of the mortar joint plays a role in preventing moisture penetration. The joint should be the full thickness of the face shell of the block.






Clay Bricks

Primary raw materials for modern clay bricks include surface clay, fire clays, shales or a combination of these. Clay and shale masonry units are most frequently selected as a construction material for their aesthetics and long term performance. Clay bricks are also visually appealing and durable.






Reinforcement

Reinforcement refers to the steel bars placed between layers of masonry to add to the tensile strength of the wall. Water infiltration into the cell of a masonry unit causes corrosion of rebar and fasteners which can lead to degradation of the reinforcement.






Masonry Construction






Wall Construction

The successful performance of a masonry or concrete wall depends on limiting the amount of water penetration and controlling any water that enters the wall system. If water penetration can be minimized, for all practical purposes, the wall system will perform well.

Masonry and concrete walls are often of two designs: single wythe or multiple wythe.






Multiple Wythe Walls

In double or multiple wythe walls the masonry is the exterior finish or veneer and is supported by a separate structural system. This may be masonry, steel or wood frame. These walls have a cavity between the structure and the masonry that allows for drainage of any water that infiltrates the cavity. The cavity wall accommodates moisture penetration by providing a collection and drainage system within the wall.

Water repellents can protect the double wythe exterior face from efflorescence and deterioration of mortar joints.






Single Wythe Walls

Single wythe masonry walls are walls that have no cavity or air space between the interior and exterior environments. Since a single wythe wall lacks a continuous drainage cavity, drainage occurs through the cores in the masonry, and positive drainage relies on flashing and weep holes.

A water resistant coating can be applied on the face to stop water from penetrating into the interior of the building.






Parapet Walls

Many block buildings have flat roofs with a parapet wall extending above the roof line.

A parapet wall must be capped and the backside waterproofed using metal, waterproofing membrane or elastomeric to prevent water from entering the wall.

Unacceptable cracked mortar cap on the parapet wall.

Cap..

Exterior wall extends above roof line.

Back side must be waterproofed.

Roof.






Solid Walls

A solid wall, also called a barrier wall, can be a solid grouted single wythe wall or a solid grouted composite cavity. As with the single wythe wall a water resistant coating applied to the face of the wall will restrict water infiltration.






Effects of Moisture Intrusion






Moisture Intrusion

Masonry is a porous material composed of a network of interconnected pores that water moves through by means of capillary suction. Water can enter a masonry wall through the individual masonry units, through the mortar or through any openings between the mortar and the unit. Therefore, it is important that a complete bond be formed between the masonry unit and the mortar and that the joint be full. Water can also penetrate a wall through any cracks in the masonry or mortar caused by structural stresses or movement of the structure.

Water that passes through exterior walls can damage interior wall finishes, floor coverings, ceilings, and building contents. Therefore, any water that enters a masonry system can cause damage.






Spalling

Water need not pass completely through exterior walls to cause damage.

Water that penetrates only the exterior face can cause staining, corrosion, mold and mildew, efflorescence and freeze-thaw spalling.

Spalling is caused by water freezing and expanding in the masonry substrate. The expansion causes the masonry or concrete to break apart. Spalling can also occur when rebar rusts and expands. The rust is caused by excessive moisture, salts or low pH in the concrete, masonry or mortar.






Efflorescence

Calcium salts which are inherently present in some building materials often leach out after initial construction creating a type of efflorescence sometimes referred to as "new building bloom".

But efflorescence also results when rainwater penetrates the masonry and dissolves these natural salts. When the masonry begins to dry, the water moves toward the surface and evaporates leaving the dissolved salts at the surface where they remain as white efflorescence. The calcium reacts with air to crystallize into hard white crusts.






Efflorescence

Efflorescence can be cleaned by brushing with a stiff brush. Muriatic acids and sulfamic acids are also commonly used. This must be done using gloves and a mask as these acids are dangerous. Safer products, although not as effective as muriatic and sulphamic acids, are available to remove both efflorescence and excess mortar build-up. These products clean concrete, brick and stone.






Lime Run

Mortar joints are particularly water absorbent and hold water in areas adjacent to the wet joints. As a result, these damp areas surrounding the joints take longer to dry out.

Lime run is a tough, stubborn stain that is often mistaken for efflorescence. Lime run is caused when mortar gets wet and excessive lime is leached out. These stains should be cleaned with a brush and hose using vinegar and water.






Reducing Moisture Intrusion







Because a building will always come in contact with water, snow and water vapor, water penetration into the building must be controlled. This is done in two ways:

• limiting water penetration into the assembly.

• controlling water that enters the assembly.







Controlling water that enters the system:

• parapet walls.• flashing.• weep holes.

Limiting water penetration into the assembly:

• sealers and coatings.• water repellent admixture: this is an integral water-repellent admixture system used in

single wythe concrete and masonry construction. Admixtures improve the quality, strength, durability and appearance of concrete.






Flashing and Weep Holes

Through-wall flashing is a membrane, installed in a masonry wall system, that collects water that has penetrated the exterior wythe and facilitates its drainage back to the exterior.

Such flashing is essential in a drainage wall or cavity wall system, and is required as a second line of defense in a barrier wall system or single wythe wall. Proper design requires flashing at wall bases, window sills, heads of openings, shelf angles, projections, recesses, bay windows, chimneys, tops of walls and at roofs.

Weep holes work in conjunction with the flashing, in order to properly drain any water collected on the flashing.

Flashing.

Weephole.






Weep Holes and Drainage Material

The air space between wythes must be kept clear of mortar and mortar droppings to allow proper drainage. Mortar droppings must not be allowed to block weep holes.

Drainage materials may be specified that prevent mortar from entering the air space or catch mortar droppings at the wall base. These materials are usually made of a plastic mesh or fabric porous enough to allow passage of water, but catch mortar from collecting at the base of the air space.

However, the use of drainage materials should not preclude good workmanship and an effort to keep the air space clean.

Clean cavity.

Cavity filled with mortar.






Sealers and Coatings

There are various coatings and sealers that are effective in preventing water intrusion. Some are considered water repellents which are generally transparent treatments that reduce absorption without hiding the surfaces or changing the texture. It is important to note that these coatings are breathable to different extents and do allow water vapor to enter and leave the surface of the masonry.

All wall coatings must be able to breathe to allow for the transfer of moisture vapor from one side of the coating to the other. Trapped moisture vapor could result in peeling or blistering of the coating.

Other treatments are referred to as waterproof coatings. Most waterproof coatings are pigmented opaque coatings that stop water and vapor from passing through the substrate. Though, again, some of these products do allow for vapor transmission.






Selecting a Sealer or Coating






Considerations

There are a multitude of water repellent sealers and coatings on the market. It is important to choose the proper one for your building based on product data available, viewing existing applications of the product and talking to the manufacturer about your specific requirements.

Considerations when choosing a sealer or coating:

• aesthetics.The desired look of the substrate after the sealer has been applied will help determine which product should be used.

• substrate porosity. Porosity of the surface will determine product choice.

• environmental concerns.These will determine product technology, ie. water or solvent, based odor and VOC content.






Considerations: Aesthetics

Clear water repellents highlight the beauty and texture of decorative concrete block.

Water repellents can also be mixed with latex paints to form concrete stains. These mixtures provide the strong bond of a water repellent and the color benefits of a paint. They provide a uniform color between the block and the mortar maintaining the texture and natural integrity of the concrete.






Considerations: Substrate Porosity - RILEM Tube TestThe selection of a water repellent sealer or coating must be based on the porosity of the substrate. This can be determined by using a RILEM test. This test can also be used to test the substrate after sealers or coatings have been applied to determine if the wall is properly sealed.

Developed by the European organization, RILEM, this test measures the amount of water absorbed into a vertical surface over a specific period of time.






Considerations: Substrate Porosity - RILEM Tube TestConstants for various types of masonry have been established which indicate that certain types of masonry are more inclined to absorb and distribute water throughout a structure.

The purpose of the tube is to detect leaks, predict vulnerability to water damage, diagnose water penetration problems, and determine the effectiveness of a water repellent treatment.

This is the easiest field test to validate performance of the water repellent applied.

Excellent protection

0Good protection.5Poor protection3CoatedDense.5Porous2Very porous5Uncoated

Rating(3 minute test)

Water Loss (mL)

Condition

Excellent protection

0Good protection.5Poor protection3CoatedDense.5Porous2Very porous5Uncoated

Rating(3 minute test)

Water Loss (mL)

Condition






Considerations: Substrate Porosity - RILEM Tube TestThe amount of absorption depends on wind speed and the composition, as well as the condition, of the masonry. Concrete, limestone, and brick for example have different pore sizes and will absorb water at different rates simply due to their varying internal structures.

The RILEM tube used to test vertical surfaces is pipe shaped with a circular brim at its base. Putty is wrapped around the brim and the tube is then sealed to the masonry unit and filled with five milliliters of water, which when full, roughly corresponds to an 88 mile per hour wind driven rain.






Considerations: Substrate Porosity - ASTM E514

ASTM E514 Standard Test Method for Water Penetration and Leakage Through Masonry.

This test method provides information that aids in evaluating the effect of four principal variables: materials, coatings, wall design, and workmanship.

It provides a procedure for determining the resistance to water penetration and leakage through unit masonry subjected to wind-driven rain.






Considerations: VOC and EPA Concerns

VOC regulations are constantly being restructured and tightened. Water repellant sealers have had numerous mandates for VOC content assessed in the last few years with ever increasing restrictions expected in the future.

All manufacturers of Architectural/Commercial Coatings present VOC content on their labels and literature. Many jurisdictions are adopting the Ozone Transport Commission’s (OTC) model rule although the more stringent South Coast Air Quality Management District (SCAQMD) VOC regulations apply in the Los Angeles area.






Other Considerations

Other considerations include:

• manufacturer’s recommended applications.Different coating resin systems have designated applications. If it isn’t clear from the material data sheets talk to the manufacturer.

• preference for a surface film or a penetrating sealer.Some sealers are a combination of both. Verify with the manufacturer and check the technical data sheets. A surface film will often have a higher volume solids percentage.

• consider application to a horizontal or vertical surface.Different products are designed to be used on vertical and horizontal surfaces.

• number of coats required.Coverage rates or sq. ft./gal and timing between coats are important considerations. Verify temperature requirements for application.






Other Considerations

• reapplication of the product.Inquire whether the material can be reapplied. Certain water repellents, within a specified period of curing time, will not accept a subsequent application of the same material.

• multiple product application.If it is necessary in your project to have a second coat of another material, for instance an anti-graffiti coating, verify that this product will accept a second coat of another material.






Sealer and Coating Options






Sealer and Coating Function

Different coatings perform and penetrate the substrate differently.

Penetrating silane/siloxane sealers react with the salts in the cementitious substrate.

Cementitous coatings provide a waterproof film that resists hydrostatic pressure.

SILANE/SILOXANE SEALERS

Penetrating acrylic barriers plug the pores of cementitious substrates.

ACRYLIC BARRIERS PIGMENTED WATERPROOFERS






Penetrating Silane/Siloxane Sealers

Penetrating silane/siloxane sealers restrict water intrusion by penetrating and “lining” the pores of concrete and masonry.

Silanes, siloxanes and blends of the two are examples of penetrating sealers that chemically react with salts and minerals in the masonry and mortar. These form strong permanent bonds beneath the surface and creat a hydrophobic zone that prevents water molecules from penetrating, while allowing free migration of water vapors.

Penetrating sealers tend not to alter the appearance of concrete and masonry.







Water-based silane/siloxane penetrate masonry and concrete up to 1/4 inch or more depending on surface porosity and moisture content at the time of applications. They provide a paintable, clear, non-yellowing natural finish.

These breathable and paintable sealers protect the substrate from the damaging effects of water intrusion, including efflorescence, freeze/thaw damage, spalling and deterioration of rebar.







The choice of a silane/siloxane sealer is determined by surface porosity.

Less porous concrete and masonry require lower active solids content.

More porous concrete and masonry require higher active solid content.

Red Brick.

Brick. Stucco.

Stone. Formed Concrete.

Stucco. Exposed Aggregate.

Pavers. Smooth Face Block.

Natural Stone.






Penetrating Acrylic Barriers

This type of coating restricts water intrusion by coating, covering and plugging the pores of a concrete/masonry system and allows for vapor transmission.

These paintable products are high performance water repellent sealers. Many contain the latest water based technology that protects against efflorescence, freeze/thaw damage, spalling and rusting of rebar and fasteners.






Penetrating Acrylic Barriers

The choice of a penetrating acrylic barrier is determined by surface porosity.

Less porous concrete and masonry substrates require products with lower total solids.

More porous concrete and masonry substrates require products with higher total solids.

Split Face Block.

Split Face Block.

Fluted Block.

Smooth Face Block.

Scored Block.

Pre-Cast Exposed Aggregate.

FlutedTilt-up.

Cast Concrete.

Exposed Aggregate.

Formed Concrete.






Graffiti Barrier Coatings: Clear Coating and Sealer

These one or two component coatings are used on sealed and unsealed painted surfaces to make graffiti removal easier. These products are specially designed to protect the underlying surface when graffiti is removed from concrete, masonry or natural stone surfaces.

They dry clear to maintain the surface integrity and natural beauty of the surface.






Specialty Water Repellant Sealers

Tintable water repellent sealers can be mixed with latex paint or solid stain to achieve unlimited colors which protect and beautify gray block.

These sealers don't peel like paint or elastomerics and reduce water absorption.

Texture is maintained and the aggregate is highlighted with application of this product.






Horizontal Clear Sealers

Horizontal clear sealers provide protection for interior and exterior concrete floors, patios, pool decks, driveways and stained or stamped concrete floors. These are protective coatings that stand up to foot or vehicular traffic, depending on the product that is used.

Performance features include:

• makes concrete surfaces easier to clean.• provides stain and water resistance.• works as a protective layer over decorative

concrete.• available in different finishes.






Water Repellent Paint Additives

Water repellent additives can be mixed with latex paints to decrease water absorption and extend the life of the paint.

The advantages of using water repellent additives in exterior latex paint are:

• protects from peeling paint and wood rot.• reduces brush, roller and lap marks.• beads water on painted surfaces.• increases open time during application.• extends life of the paint job.• reduces dirt pick up and staining.• makes surfaces easier to clean.• can be used on any substrate where

exterior paint is applied.






Cementitious Waterproofing Coatings

Pigmented waterproof coatings for cementitious surfaces can be used in both interior/exterior and above or below grade. They are thick surface finishes that completely cover the substrate and fill pores to protectagainst hydrostatic pressure.

These can be either latex or oil based products designed to prevent water from penetrating through the exterior wall to the interior of a building.

Some of these coatings are mold and mildew proof to prevent the growth of mold and mildew on the paint film.






Cemetitious Waterproof Coatings

Oil Base with Portland Cement.

Recommended for basements and other interior and exterior applications, these concrete and masonry coatings will hold back water pressure up to 34 psi. They contain portland cement and can be used above or below grade. They are also tintable and can be applied to damp or wet walls.

Please remember the exam password PORTLAND. You will be required to enter it in order to proceed with the online examination.






Cemetitious Waterproof Coatings

Latex with Silica Sand.

These coatings are used on interior and exterior concrete and masonry surfaces and are ideal for basements. Tintable to pastel and mid range colors and easily applied to dry walls, they will hold back water pressure up to 10 psi.






Cementitious Waterproof Coatings

Latex with Microspheres.

These are exterior waterproof coatings for stucco, block or concrete. They are able to hold back water up to 10 to 12 psi and have low VOC’s , less than 100 g/l. They can be applied to new concrete after 7 days. They are used for retaining walls, basements and other concrete and masonry walls as high performance block fillers.

Flexible.Tintable. Can be rolled. Easy to brush.






Cementitious Waterproof Coatings

What is efflorescence? Salt crystals (florescence) carried to the surface by moisture that should be removed immediately with a mild acid wash. Efflorescence becomes increasingly difficult to remove over time.

What is crypto-efflorescence? The deposition of salt within the pores of concrete below the exposed surface. Crypto-efflorescence often occurs between the concrete surface and the paint coating causing the finished coating to blister and peel off prematurely.

How do you prevent it? Prior to applying a cementitious waterproof coating a special efflorescence inhibitor can be applied. This is a specially formulated clear silane/siloxane sealer.

Crypto-florescence - florescence not visible on the original surface.






Conclusion






Conclusion

Limiting the amount of moisture that enters a wall assembly with the use of surface protection, including tooling of joints and use of sealers and coatings is the first line of defense against water penetration.

Planning for the removal of moisture that enters the assembly using internal drainage, flashing and weep holes is the second line of defense. Integration of these two systems using quality materials, sound construction techniques, proper specifications and detailing are the keys to preventing water penetration in a wall system.






Conclusion

©2007, 2016 Rust-Oleum Corporation. The material contained in this course was researched, assembled, and produced by Rust-Oleum Corporation and remains its property. Questions or concerns about the content of this course should be directed to the program instructor. This multimedia product is the copyright of AEC Daily.

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