Latex-modified concrete and mortar for repair

Polymer emulsions improve bond, increase strength and resist chemical attack

ynthetic latexes are made by dispersing polymer particles in water to form a polymer emulsion. When these emulsions are added to portland cement conc re t e, the spheres of polymer will coalesce or come together to form a film that coats the aggregate particles and the hydrating cement grains and seals off voids. The resulting mixture develops higher strength, bonds better to existing concrete, has a higher resistance to chloride penetration and is more resistant to chemical attack than plain concrete. The three basic polymers used as latex modifiers for concrete or mortar are acrylics, styrene-butadiene rubbers (SBR) and polyvinyl acetates (PVA). PVAs are not generally recommended for use in wet environments because some types may hyd ro l y ze or break down chemically. Defoamers are incorporated into the polymer emulsions when they are manufactured to inhibit formation of excessive air that would be caused by foam generated during mixing of the mortar or concrete. Unlike conventional concrete, entrained air is not required for freezethaw durability of latex-modified concrete. Howe ve r, some air is entrained by the latex during the mixing process so it is common for a specification to include a maximum air content, say 6.5 percent, but not a minimum. The 28-day compressive strength of latex-modified concrete typically ranges between 3500 and 6000 psi and

Used primarily for bridge decks, parking ramps and other large expanses of concrete exposed to extreme weather, latex-modified concrete is resistant to freeze-thaw damage and to the harmful effects of deicing salts.

the shear bond strength at the same age will generally be between 325 and 450 psi. Flexural strengths at 28 days are between 900 and 1400 psi. The modulus of elasticity is somewhat lower than that of conventional concrete, with a typical value of 3,600,000 psi for a 6000 psi compressive strength mix.

Dosage and mixture proportions

Latex modified mortar, recommended for sections 14 to 34 inch deep, should have proportions of 1.0 part cement to 3.0-3.5 parts fine aggregate by weight. The water-cement ratio (including water in the latex) should be 0.30 to 0.40 by weight and the latex solids-cement ratio 0.10 to 0.20 by weight. Latex-modified concrete, recommended for sections 3 4 inch and deeper, should have proportions of 1 part cement to 2.5-3.1 parts fine aggregate to 1.4-2.0 parts

coarse aggregate by weight. The water-cement ratio (including water in the latex) should be 0.30 to 0.40 and the latex solids-cement ratio 0.10 to 0.20, both by weight. With these pro p o rt i o n s, the slump is normally 4 to 6 inches. Because the concentration of latex solids in commercial products va ri e s, the dosage in gallons of latex per

coat is brushed or broomed onto the prepared concrete surface. This bond coat can be the mixture used for the overlay or patch, or may be made by mixing undiluted latex with portland cement. The surface is first thoroughly wetted with clean water for not less than 1 hour prior to placement. After removing all free water but with the surface still damp, sufficient mixed material to coat all bonding surfaces is then placed and vigorously broomed to assure maximum contact with the old concrete. The rate of application of bonding material should be limited so that the bond coat doesnt dry before being covered with repair mortar or concrete needed to bring the repair to the required elevation.

Batching and mixing

For small volume work, 5- to 10-cubic-foot batch mixers may be used. All the latex and half the mixing water is placed in a prewetted drum. With the drum turning at

To enhance bond, latex-modified concrete is broomed into the prepared and dampened surface just ahead of the placing operation. An alternative method is to use a bond coat mixture of undiluted latex and portland cement prepared in a separate mixer.

100 pounds of cement will vary with the brand of latex. To determine the amount of a particular latex to be used, obtain the concentration or solids content from the label or manufacturers literature. This will be given either as pounds of polymer per gallon or as percent solids and weight per gallon. Calculate the gallons of the particular latex required to obtain the desired latex solids-cement ratio. For instance, assume that you want a mix with 16 percent latex solids by weight and a maximum water-cement ratio of 0.40. The emulsion to be used weighs 8.4 pounds per gallon and the latex solids comprise 48 percent of the total emulsion. To get 16 percent latex solids by weight of the cement the calculated quantities would be: 0.16 x 100 = 16 pounds of latex solids per 100 pounds of cement 0.48 x 8.4 = 4.0 pounds of latex solids per gallon of latex (the rest is 4.4 pounds of water) 16 / 4.0=4.0 gallons of latex per 100 pounds of cement Weight of water in 4 gallons of latex=4x4.4=17.6 pounds. If the water-cement ratio is not to exceed 0.4, then the maximum amount of additional water that should be used is 4017.6 = 22.4 pounds per 100 pounds of cement.

A curing cover of wet burlap and polyethylene sheet prevents shrinkage before latex in the concrete coalesces to form a polymer film. The cover is removed after 24 hours and the surface is permitted to air cure.

Bond coat
To obtain a high bond between the latex concrete overlay or mortar patch and the base concrete, a bond

minimum speed (16 to 18 rpm), aggregate and cement are next introduced, followed by the remainder of the mixing water needed to achieve the desired consistency. Total mixing time shouldnt exceed 4 minutes at slow speed, longer mixing times may incorporate excess air in the mix. For large areas such as bridge decks requiring more than 4 cubic yards of mixed material, mobile batcher mixers are recommended. Because of the relatively short working life for latex-modified mixes, the amount mixed will be limited by the placing and finishing timeabout 20 minutes. If the mortar or concrete is manipulated after the latex has coalesced, cracking may occur on drying. Due to the short working time, steel trowel finishes are difficult if not impossible to produce without surface cracking.

Curing procedures different from those for normal concrete

A polymer film formed as a latex coalesces helps to maintain high levels of internal moisture in the concrete. Because of this, prolonged curing is neither necessary nor recommended. To prevent shrinkage cracking before the film has formed, howe ve r, all finishing operations must be completed and the surface covered with a single layer of wet burlap as soon as the surface will support it. The curing cover is completed by placing a layer of polyethylene film over the wet burlap. This is left in place for 24 hours, after which the burlap and polyethylene are removed and the surface is permitted to dry for 3 to 5 days.

Precautions and limitations

Latex emulsions have a minimum temperature below which the polymer spheres will not coalesce to form a tough durable film. For this reason, the recommended low end of the range of placement temperatures is 45 F. Placement at 40 F is possible if temperatures are rising and if adequate additional curing time is allowed to compensate for the initially low temperature. Placement at temperatures above 85 F isnt recommended because the working time is too short. Styrene-butadiene rubber latexes develop a brownish coat after being exposed to sunlight and this may make them unsuitable for patching applications where color matching is important.

Availability and packaging

There are many sources of acrylic and SBR modifiers. Both are available in quart, gallon, 5- and 55-gallon containers for use in mortars or concretes for coating, topping, patching and leveling applications. In addition, SBR latex modifiers are used on larger projects such as bridge deck and parking garage resurfacing operations and are available in 5000-gallon tank trucks for these applications. Prequalification procedures for choosing styrene-butadiene latex modifiers are given in the 1978 Fe d e ra l Highway Administration Report No. FHWA-RD-78-35 entitled Styrene-Butadiene Latex Modifiers for Bridge Deck Overlay Concrete. The 124-page report is available from the National Technical Information Se rv i c e, U.S. Department of Commerce, Box 1553, Springfield, Virginia 22161.

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Copyright 1984, The Aberdeen Group All rights reserved