National Conference

on
RECENT ADVANCES IN SCIENCE
AND ENGINEERING
NCRASE-2019

Presentation
on
“POLYMER MODIFIED CONCRETE” - A VERSATILE
SOLUTION FOR STRUCTURAL STRENGTHENING OF
DISTRESSED RCC STRUCTURES
BY
S D THANVI
ASSOCIATE PROFESSOR (CIVIL ENGG.)
“POLYMER MODIFIED CONCRETE” - A VERSATILE SOLUTION FOR STRUCTURAL STRENGTHENING OF DISTRESSED
RCC STRUCTURES

• In a severe and humid environment in coastal areas, Polymer

Modified Concrete is a versatile material for repair ,restoration
and rehabilitation of distressed RCC structures since it possess
superior moisture resistance properties and high early strength.
• It strengthens the RCC structural members and also makes it
highly durable structure.
• For retrofitting, Polymer Modified Concrete is being now widely
used for its cost effectiveness.
• Some of the major properties and approach for structural
strengthening of damaged concrete structures by using Polymer
Modified Concrete has been tried to explore here.
 “POLYMER MODIFIED CONCRETE” - A VERSATILE SOLUTION FOR
STRUCTURAL STRENGTHENING OF DISTRESSED RCC STRUCTURES

• The repair and rehabilitation of distressed concrete structures is

generally in a highly severe climate like coastal areas with high
humidity throughout the year.
• High rainfall along with higher level of chemical contents due to
industries in the atmosphere deteriorates Structures.
• Aged structures and also used beyond the design life of the
structure leads to deterioration of the structures.
• Various products available for repair and rehabilitation such as
Polymer Modified Concrete which is most cost effective for
retrofitting structures having the high early compressive
strength, tensile and flexural strength and reducing the brittle
nature.
 “POLYMER MODIFIED CONCRETE” - A VERSATILE SOLUTION FOR
STRUCTURAL STRENGTHENING OF DISTRESSED RCC STRUCTURES

• Polymer - modified concrete(latex modified) such as

styrene-butadiene, acrylic latex, polyvinyl acetate,
and ethylene vinyl acetate are being abundantly
used for structural repair and strengthening.
• Repair to distressed reinforced concrete elements
like beams, columns, walls etc, where access is
denied or not easy and non-compactable and for
structural strengthening by Jacketing of RCC columns
to increase load carrying capacity are areas where
application of micro concrete could be explored.
 “POLYMER MODIFIED CONCRETE” - A VERSATILE SOLUTION FOR
STRUCTURAL STRENGTHENING OF DISTRESSED RCC STRUCTURES

• Repair materials for Coastal areas

• Compatibility of the repair materials with the existing structure and durability
under inclement weathering in service are of much more importance,
• Apart from bond and compressive strength there are some other properties such
as Shrinkage, Coefficient of thermal expansion, modulus of elasticity and
permeability along with chemical and electrochemical compatibility which should
be considered during selection of a repair material.
• The selection of the material or combination of materials should then take into
account the workability, cost and availability of skilled manpower and user
handily equipments.
• The use of polymer modified materials for repair of concrete structures nowadays
is being frequently used. This repair material satisfies the requirements such as
appropriate workability, mix stability, life-long resistance, strength, compatibility
with existing structure adequate adhesion and low volatile content.
 “POLYMER MODIFIED CONCRETE” - A VERSATILE SOLUTION FOR STRUCTURAL
STRENGTHENING OF DISTRESSED RCC STRUCTURES

The major properties requirements of the polymer modified material vis-a-vis plain cement
mortar is as under tabulated:

Properties of Polymer-modified Plain cementious

mortar/concrete cementious

Compressive Strength (N/mm2) 30 – 60 20 – 50

Tensile Strength (N/mm2) 5 – 10 2–5

Modulus of elasticity (GPa) 15 – 25 20 – 30

Coefficient of thermal expansion (per ͦC) 10 – 20 × 10-6 10 × 10-6

Max. Service temp. ( ͦC) 100 – 300 >300

 “POLYMER MODIFIED CONCRETE” - A VERSATILE SOLUTION FOR
STRUCTURAL STRENGTHENING OF DISTRESSED RCC STRUCTURES

• Polymer Modified Concrete – A ready to use material

• Polymer modified concrete, a ready to use dry powder which requires only
addition of potable/drinkable water at site to produce a free flowing non shrink
repair.
• It is a cementious material with additives, which impart controlled expansion
characteristics in the plastic state while minimizing water demand.
• It is self compacting with high early and final compressive strength used where
hand applied polymer modified concrete is not possible due to inaccessible and
congested reinforcements.
• High early strength facilitates early reinstatement of the structure. The
advantages of using micro concrete over normal concrete encourages to adapt it.
• It offers excellent resistance to moisture ingress and makes repaired sections
highly durable.
• It is applied upto 100mm thickness at one stroke and addition of pre-calculated
aggregates of 12mm down may be required if thickness is more than 100mm
 “POLYMER MODIFIED CONCRETE” - A VERSATILE SOLUTION FOR
STRUCTURAL STRENGTHENING OF DISTRESSED RCC STRUCTURES

Days M.C – 1 M.C – 2 Specified

Water/Powder 0.15 0.15 0.15 – 0.16
ratio
Flow in mm 290 280 >250
Pot life in minutes 45 45 >30
Compressive
Strength (N/mm2)
1 Day 20.5 21.0 10.0
3 Days 36.0 32.0 30.0
7 Days 50.0 46.0 40.0
28 Days 64.0 54.5 50.0
 “POLYMER MODIFIED CONCRETE” - A VERSATILE SOLUTION FOR
STRUCTURAL STRENGTHENING OF DISTRESSED RCC STRUCTURES

• The properties of M.C – 1 and M.C – 2 reveals

that 60% of compressive strength as high as 30 –
36 N/mm2 is achieved within the first 3 days
making it a versatile material for early
reinstatement of the structure.
• Further the strength increases by another 5 – 10
% by 90 days and more. There is no bleeding and
settling of micro concrete. It has been observed
during its use
• The other properties related to flexural and
water absorption are as under:
“POLYMER MODIFIED CONCRETE” - A VERSATILE SOLUTION FOR
STRUCTURAL STRENGTHENING OF DISTRESSED RCC STRUCTURES

• (i)Flexural Strength: 5 N/mm2 at 28 days

• (ii)% water absorption after 24 hrs : 0.45
• (iii)Chloride content : Nil
• (iv)Depth of carbonation, mm : Passes the
Accelerated carbonation test
• (v) Coverage : 1.3 sqm per 25kg pack at 10mm
thickness ie 20kg/sqm for 10 mm thick
covering
“POLYMER MODIFIED CONCRETE” - A VERSATILE SOLUTION FOR
STRUCTURAL STRENGTHENING OF DISTRESSED RCC STRUCTURES
• Methodology for repair
• a) Supports: The RC members are properly supported on steel props before chipping the spalled/loose
concrete.
• b) Preparation of concrete structure: All the spalled cracked concrete or any other pre-applied mortar
shall be peeled off by chipping to expose the reinforcement. The concrete shall be chipped to a minimum
depth of 10mm behind the reinforcement. The areas to be repaired shall be prepared to get rectangular or
square shape with an inward tapering edge.
• c) Preparation of face of reinforcement: The exposed reinforcement should be cleaned thoroughly by
using wire brush, emery paper, remove rust, dust, scale etc along with the lateral ties/ stirrups. After
removal of the corroded portion, the diameter of the reinforcement shall be checked and compared with
the drawings.
• d) Providing additional reinforcement as per requirement: If the diameter of reinforcing bars is reduced
substantially (say > 20%) additional bars shall be provided as per the design requirement. The additional
reinforcement so provided shall be properly anchored/overlapped to the existing concrete with adequate
shear connectors. Weld mesh/chicken wire mesh shall be used if deem necessary.
• e) Providing shear connectors: Shear connectors of 8mm diameter shall be provided in holes of 14mm
diameter and 75mm deep. These shall be provided at every 500mm c/c on all the faces of the beams in
staggered form. The holes shall be cleaned with compressed air or water jet to remove all the dust etc.
and then the shear connectors shall be fixed in the holes using polyester resin anchor grout.
“POLYMER MODIFIED CONCRETE” - A VERSATILE SOLUTION FOR
STRUCTURAL STRENGTHENING OF DISTRESSED RCC STRUCTURES
• f) Coating reinforcement bars: The exposed and cleaned reinforcing bar shall be provided with a coat of
Epoxy Zinc Primer such that the coated film will have a dry film thickness of about 40 microns. The film shall
be continuous especially in the regions where pitting, imperfections etc., are present on the surface of the
bars. It is important that the rear portion of the bars should not be left without coating. If needed second
coat may be provided to achieve a uniform and continuous film. The additional reinforcement provided and
the shear connectors so coated with Epoxy Zinc Primer shall be kept to dry completely before further
treatment. The weld mesh / chicken wire mesh shall also be coated with Epoxy Zinc Primer.
• g) Epoxy based bonding agent: The base and hardener component of epoxy resin based bonding agent must
be mixed well to get a uniform grey colored mix. Apply the material to properly cleaned and dry concrete
structure using stiff nylon brush by scrubbing it well into the depth of concrete. The coat should be evenly and
well spread on the entire surface area of the repair patch. The mix material so prepared shall be applied
before the elapse of its pot life and the new repair mortar shall be applied before the elapse of overlay time.
As a fully dried epoxy resin coat acts as debonding layer, the repair material should be applied whilst the
bonding coat is tacky. In case the applied epoxy bond coat gets dry, an extra coat should be applied before
application of repair mortar.
• h) Formwork and shuttering: Slurry tight and strong steel formwork shall be provided. The shuttering for
encasement shall be kept ready such that the formwork shall be placed in the position and fixed such that the
micro concrete can be poured in to the formwork within the overlay time of the bonding agent (5hours).
Adequate supports shall be provided for the formwork. Care should be taken to ensure leak proof shuttering
during pouring of micro concrete.
 “POLYMER MODIFIED CONCRETE” - A VERSATILE SOLUTION FOR
STRUCTURAL STRENGTHENING OF DISTRESSED RCC STRUCTURES
• i) Micro concrete mix: It should be mixed using the appropriate water /powder ratio as
mentioned in the product data labeled/literature supplied . The mixing shall be done
mechanically only. Mixing shall be carried out for 3 to 5 minutes to ensure that homogenous
mix is obtained without any bleeding or segregation. In hot climate ice cooled water shall be
used to maintain the temperature of mixed material. If the encasing thickness is more than
100mm, and stone aggregates upto 50% by weight of micro concrete to the mixed micro
concrete directly into the mixer hopper. The stone aggregates must be 12mm and down shall
be clean, washed and dried. The mixing should be done for 3 minutes in mixer and then pre
weighed stone aggregates into the mixer. Mix further for 2 minutes till lump free mix is
obtained.
• j) Deshuttering after setting of micro concrete: The shuttering from the sides of the RC
members shall be removed after a period of 24 hours, However, the formwork of the soffit
shall be remained and removed after 3 days.
• k) Micro concrete placing in formwork: The mixer should be placed into the formwork using
a suitable funnel or through a hose pipe. It must be poured from one end only. A suitable
hopper/funnel arrangement shall be deployed at site to complete this operation. The placing
operation shall be continual and it shall not be stopped till the job is completed. To achieve
this sufficient (M-3)man, machine and materials shall be organized at site.
• l) Curing: All the repaired and encased portion shall be fully cured as per standard concrete
practices. Curing compound shall be used for effective curing of sides and soffits of beams. If
a curing compound is applied, care shall be taken to ensure that proper surface preparation is
carried out so as to remove any traces of curing compound on the surface. If this is not done,
 “POLYMER MODIFIED CONCRETE” - A VERSATILE SOLUTION FOR
STRUCTURAL STRENGTHENING OF DISTRESSED RCC STRUCTURES
• i) Micro concrete mix: It should be mixed using the appropriate water /powder ratio as
mentioned in the product data labeled/literature supplied . The mixing shall be done
mechanically only. Mixing shall be carried out for 3 to 5 minutes to ensure that homogenous
mix is obtained without any bleeding or segregation. In hot climate ice cooled water shall be
used to maintain the temperature of mixed material. If the encasing thickness is more than
100mm, and stone aggregates upto 50% by weight of micro concrete to the mixed micro
concrete directly into the mixer hopper. The stone aggregates must be 12mm and down shall
be clean, washed and dried. The mixing should be done for 3 minutes in mixer and then pre
weighed stone aggregates into the mixer. Mix further for 2 minutes till lump free mix is
obtained.
• j) Deshuttering after setting of micro concrete: The shuttering from the sides of the RC
members shall be removed after a period of 24 hours, However, the formwork of the soffit
shall be remained and removed after 3 days.
• k) Micro concrete placing in formwork: The mixer should be placed into the formwork using
a suitable funnel or through a hose pipe. It must be poured from one end only. A suitable
hopper/funnel arrangement shall be deployed at site to complete this operation. The placing
operation shall be continual and it shall not be stopped till the job is completed. To achieve
this sufficient (M-3)man, machine and materials shall be organized at site.
• l) Curing: All the repaired and encased portion shall be fully cured as per standard concrete
practices. Curing compound shall be used for effective curing of sides and soffits of beams. If
a curing compound is applied, care shall be taken to ensure that proper surface preparation is
carried out so as to remove any traces of curing compound on the surface. If this is not done,
 “POLYMER MODIFIED CONCRETE” - A VERSATILE SOLUTION FOR
STRUCTURAL STRENGTHENING OF DISTRESSED RCC STRUCTURES
• IV Evaluating quality of repair:
• Performance of a concrete repair shall have to be ensured
physically and safety, environmental aspect, life-cycle
assessment etc.

• The polymeric modified repair occasionally fail due to

improper surface preparation and compatibility issues etc.
The most of the failure occurs at the interface of the bonding
for which bond strength is very important.

• These repairs should be checked and tested using NDT to

exhibit satisfactory results under defined load after 28 days.
 “POLYMER MODIFIED CONCRETE” - A VERSATILE SOLUTION FOR
STRUCTURAL STRENGTHENING OF DISTRESSED RCC STRUCTURES
.Conclusion:
Based on experience gained in the field applications it is proven
that polymer modified concrete repair is versatile and highly
recommended for such use.
It could also be recommended for increasing load carrying
capacity of structures by jacketing columns and beams etc.
 “POLYMER MODIFIED CONCRETE” - A VERSATILE SOLUTION FOR
STRUCTURAL STRENGTHENING OF DISTRESSED RCC STRUCTURES

• THANK YOU ALL

• FOR

• PATIENCE HEARING