Flexible Polymer-Cement

Based Repair Materials

and Their Applications
By Ivan Razl
P ortland cement-based concrete and mortar
are two of the most widely used construction
materials. The low cost, high stiffness, high
of limestone and clay or limestone and shale. When
mixed with water, the anhydrous calcium silicates
and other constituents in the Portland cement
compressive strength, nonflammability, and ease of react chemically with the water, combining with
fabrication are the most obvious advantages of it (hydration) and decomposing in it (hydrolysis)
concrete. The low tensile strength; brittle nature; and hardening and developing strength.”
and, to some extent, long-term durability of concrete “Polymer is any class of natural or synthetic
represent its most serious limitations. Reinforcing substances composed of very large molecules,
concrete with steel provides the necessary tensile called macro-molecules, that are multiples of
strength, and the incorporation of fibers increases chemical units called monomers.”
the toughness (resistance to crack propagation) of “Composite material is a solid material that
concrete. The polymer modification of cement paste results when two or more different substances, each
greatly increases the tensile and flexural strengths with its own characteristics, are combined to create
and reduces the brittle nature (increases toughness) a new substance whose properties are superior to
of mortars and concrete. those of the original ...”
The performance characteristics of polymer-
History modified cement are controlled by characteristics
The ancient history of using natural polymers, of its individual components. The main character-
including asphalt, to modify lime and clay mortars istics of a polymer and hydrated portland cement
goes back to Babylonia, Egypt, and ancient India. paste are listed in Fig. 1. The type of cement paste,
The Europeans in the Middle Ages knew how type of polymer, and their respective quantities
to use oxen blood and egg whites to increase largely control the properties of polymer cement
the strength and durability of lime mortars. The composites. However, there are other influences
modern history of man-made modifiers starts in controlling the final properties of the composite
the late 1950s with the development of butadiene such as the type of surface-active agents used,
styrene, polychloroprene, and acrylic latex and mixing, and curing. There are a large number of
their use in modifying mortars and concrete. polymer (monomer) types that are used in modifi­
The main application of polymer-modified cation of portland cement paste. Figure 2 shows
cements at that time was in concrete repair. The the main classes of materials available. In this
use of polymers in the fabrication of bridge and article, discussion will be limited to polymer latexes
parking garage overlays was developed in the U.S. and redispersible polymer powders. These types
and Canada in the early 1970s. The main function of polymers can be further classified by their
of the polymer was to reduce concrete permea­bility chemical natures.
and increase resistance to chloride penetration, The glass transition temperature Tg of a
toughness, and adhesion. polymer is important, as it affects the flexibility
of polymer cement. Below the Tg temperature,
Classification polymers exhibit “glassy” behavior and are
The polymer-modified portland cement paste is relatively brittle with limited flexibility. When
a composite material consisting of an inorganic at temperatures above Tg , the polymer is more
cement paste and polymer. Both materials are flexible, tough, and exhibits a larger elongation in
totally different. Accepted definitions for portland tension. At Tg , other properties change, such as
cement, polymer, and composite material are as density, specific heat, dielectric coefficient, rates
follows (Encyclopedia Britannica): of gas/liquid diffusion through the polymer, and
“Portland cement is binding material in the conduct ­ivity. The mechanism of polymer modifi-
form of a finely ground powder, usually gray, that cation of portland cement is complex, but can be
is manufactured by burning and grinding a mixture schematically described in three separate steps:

20 Concrete Repair Bulletin September/October 2004

1. Immediately after mixing with water, the cement
paste particles start to hydrate and cement gel
begins to form on the surface of the particles;
2. Mixture of cement gel-covered unhydrated
cement particles is enveloped with a close-
packed layer of polymer particles; and
3. The closely packed polymer particles start forming
polymer films (membranes) after the removal
of water by hydration and evapor­ation.
The polymer modification results in an
improvement in mechanical properties, a decrease
in permeability, and an increase in chemical
resistance. The typical relationship between the
polymer content, expressed as polymer/cement
ratio (meaning the weight of polymer solids Fig. 1: Main characteristics of a polymer and hydrated portland
divided by the weight cement solids), is shown cement paste
in Fig. 3. The Tg of the acrylic polymer used in
the study presented in Fig. 4 was 55 °F (13 °C).
The polymer modification affects many other
properties, which are summarized in Fig. 5.
The typical application of polymer-modified
cements (mortars) are in concrete repair mortars,
polymer-modified cement coatings, and polymer-
modified concrete.

Flexible Polymer Cement

Composites and Applications
Highly flexible polymer-modified cements
(mortars) can be formulated using various types
of polymers with a low Tg temperature. The typical
tensile load deflection curves of non-reinforced
or reinforced polymer-modified cements (mortars)
at two different levels of polymer modifi­cation
are shown in Fig. 6 and 7, respectively. The key
reason for using these materials is their flexi­bility,
allowing waterproofing of concrete structures Fig. 2: Classification of polymers (monomers) used in modification of
with “moving cracks.” The crack bridging capa­city portland cement paste
of polymer-modified cement is shown in Fig. 8. In
addition, these materials, due to their high polymer
content, exhibit a considerably higher chemical
resistance (even in acidic environments) when
compared with conventional portland cement
mortars or concrete.

Case History—The Repair

of Concrete Digester Tank,
Bedford, Nova Scotia, Canada
In 1993 the concrete roof of a digester tank in
Bedford, Nova Scotia, collapsed. The most probable
reason for the failure was deterioration of the
prestressed gunite concrete combined with a
temporary excessive pressure in the tank. The
concrete roof was replaced with a “gas holding”
steel roof. Time and excessive pressure even-
tually caused the reinforced concrete tank, which
measured 35 ft (10.7 m) in diameter and 22 ft
(6.7 m) high, to develop vertical and horizontal Fig. 3: Glass transition temperature Tg of an amorphous
cracks. The repair required long-term sealing of the (non-crystalline) polymer

september/october 2004 Concrete Repair Bulletin 21

 cracks. Therefore, an additional protective coat
of a flexible portland cement-based material
was applied as a secon­dary waterproofing and
protective layer. The high level of polymer
modification provides a very low modulus of
elasticity material, with 10% direct tensile
elongation. The high flexibility allows crack
spanning of fine cracks and the high polymer
content provides improved chemical resistance
when compared with conventional concrete.
After cleaning the tank by sandblasting, the
vertical and horizontal cracks were covered using
a 16 gage galvanized welded fabric 12 in. (0.3 m)
wide with an opening of 2 x 1 in. (5.1 x 2.5 cm),
mechanically fastened to the concrete. After
the placement of the welded wire fabric, a 1/2 in.
(1.3 cm) thick layer of fiber-reinforced mortar was
applied to the concrete surface of the tank. The
Fig. 4: Typical relationship between polymer/cement ratio (p/c) and material was mechanically applied using the “wet
strength properties of a mortar ( Tg of the polymer = 13 °C) process” shotcrete method. The following day the
surface of the primary layer was thoroughly cleaned
with high-pressure water. Then a layer of flexible
cement, approximately 1/8 in. (0.3 cm) thick, was
• Adhesion increased rolled on in two coats. The waterproofing protective
• Modulus of elasticity increased or decreased system was air cured for approximately one
• Water vapor permeability decreased week before the tank was put back into use. No
• Hydraulic permeability decreased additional fabric reinforcement was used in the
• Drying shrinkage (at 28 days) decreased or increased flexible cement layer.
• Creep decreased or increased The performance of the repair has been excellent.
• Chemical resistance improved in some chemicals The interior of the tank was inspected in 1997,
• CO2 permeability decreased 4 years after the installation, and no leaks or deter­­
• Chloride penetration resistance increased ioration of the waterproofing system was found.
Further exterior inspections in 1999, 2000, and 2001
Fig. 5: Typical effects of polymer modification on performance of also revealed no leaking.
polymer-modified, portland cement mortars The key innovative feature of this project was
the crack spanning mechanism employed. The
crack spanning mechanism of the primary layer
cracks in the reinforced concrete wall as well as was as follows: the movement of the crack creates
concrete protection. a very high shear force at the interface of the
The designer selected two materials for the primary layer and the substrate concrete at the
repair: alkaline-resistant glass and polymer, fiber- edges of the crack. The presence of the welded
reinforced, micro-silica enhanced mortar as a wire fabric increases the tensile strength of
primary waterproofing layer and a highly flexible, the layer, thus forcing a small, 1/4 in. (0.6 cm)
polymer-modified cement as the secondary water- de-bonding on each side of the crack due to the
proofing and protective layer. presence of the high shear forces. The presence of
The crack spanning tests carried out on the high volume, high modulus fiber in the mortar
fiber-reinforced mortar showed that the maximum layer is also very important for arresting the
crack width of this material, reinforced with the crack trying to propagate through the layer. This
welded wire fabric placed over the cracks, was mechanism has been thoroughly tested and the site
approximately 0.03 to 0.04 in. (0.75 to 1 mm). evaluated. There is a limit to what crack movement
The tests and the practical experience with this this mechanism can span. Since there was a possi­
material system have also shown that if the crack bility of cracks exceeding this movement under
did telescope through the layer, it would be the full load of the liquids in the tank, a secondary
only hairline. Since it was difficult to accurately flexible cement layer was applied.
determine the movement of the cracks in the The crack spanning of the secondary layer is
reinforced concrete wall of the tank under the controlled by the flexibility and thickness of the
fully loaded condition, it was possible that the cement layer. The experience and the testing showed
primary waterproofing layer would develop fine that fine cracks are spanned using the flexible
through-cracks due to movement of the substrate cement material.

22 Concrete Repair Bulletin September/October 2004

 An additional important feature of this repair
is the long-term successful performance of
the polymer cement layer under continuous
immersion in heavily polluted liquids. Also, the
flexible cement, with its high level of polymer
modification, provides a better chemical resistance
in acidic environments when compared with
conventional concrete or mortar. The chemical
resistance of the material in various chemical
environments has been thoroughly investigated.

Case History—The Repair,

Waterproofing, and Chemical
Protection of a Wastewater
Treatment Facility, Windsor,
Ontario, Canada
In 1996 the city of Windsor, Ontario, undertook Fig. 6: Tensile stress strain curves of FCC, polymer level,
major repairs of reinforced concrete structures at nonreinforced, and reinforced
a wastewater treatment facility. The main problems
were cracking and leaks in concrete tanks immed­
iately behind the primary filtration station. There
was also some chemical deterioration at the
effluents level, approximately 15.7 in. (40 cm)
high and 0.16 to 0.2 in. (4 to 5 mm) deep. In
addition, reinforced concrete troughs (where the
flocculants are being introduced into the stream
of liquid) suffered from chemical deterioration,
approximately 0.24 to 0.31 in. (6 to 8 mm) deep,
due to the lower pH in that area. The reinforced
concrete structure was approximately 30 years
old. There were no signs of freeze/thaw damage
or spalling of concrete due to the corrosion of the
reinforcing steel.
The design engineers specified highly flexible
Fig. 7: Tensile stress strain curves of FCC, polymer level,
polymer-modified mortar coating to provide
nonreinforced, and reinforced
waterproofing and chemical protection of the
concrete tanks.
High-pressure water was used to clean the
surface of the concrete tanks. The vertical to
horizontal junctions (slab to wall) were coved
and surface deterioration was repaired where
required, using a thin set patching mortar (these
areas were relatively small in comparison with
the total area treated). The entire area was coated
with 0.08 in. (2 mm) thick flexible polymer-
modified mortar applied in two coats. The cracks
and the coves were reinforced with a polypro­
pylene mesh.

Case History—Municipal
and Industrial Land-fill Sites, Fig. 8: Crack spanning widths of FCC, polymer level 1 and 2,
Chemical Protection of Dry nonreinforced, and reinforced
Pre-Cast Manholes, Brantford,
Sarnia, Ontario, Canada
An extensive investigation of concrete man-
holes and concrete drainage pipes of municipal

september/october 2004 Concrete Repair Bulletin 23

 land-fill sites in Ontario, using a robotic TV Case History—Negative Side
camera investigation, showed that after 25 to
30 years of service, there was approximately
Waterproofing of Underground
0.47 to 0.59 in. (12 to 15 mm) deep concrete Parking Garage Slabs, Hotel
deterioration in many areas, due to chemical Carlton, Bratislava, Slovakia
attack. Since the specified design life of such The open pit method was used in construction
structures is presently changing from 30 to 100 years, of an underground parking garage structure in the
the design engineers have been looking for front of Hotel Carlton, Bratislava, Slovakia. The
various methods to increase the chemical resistance structure is situated near the Danube River with a
of wet or dry cast concrete pipes and manholes. very high ground water level. A preformed water-
The typically used epoxy coatings exhibit a proofing membrane was used on the positive site.
high chemical resistance, but in a negative side The water leaks that occurred during and shortly
application, the epoxy coating debonds, because after the construction were completely treated with
the water is getting behind the coating. The injections of a chemical grout (polyurethane).
polymer-modified mortars with a high content The ground slab, which exhibited severe water
of a low Tg polymer provide a considerable leaks, was waterproofed by using the following
improvement in chemical resistance when procedure: the active water penetration through
compared with portland cement mortar. This cracks was stopped using a hydraulic cement based
improvement is sufficient to increase the service water plug material. The slab was treated with two
life of the pre-cast concrete components to coats 0.08 in. (2 mm) thick of a highly flexible
presently specified levels and beyond. In addition, polymer-modified mortar, reinforced with a poly-
they do not exhibit the problem of de-bonding propylene fabric. In addition, the surface was coated
as the epoxy coatings do. Also, they are less with an acrylic, waterborne floor coating and two
expensive and easier to apply when compared coats of waterborne clear sealer to provide color
with the epoxies. to the surface. The treatment provided total water-
The dry-cast concrete pipes were cleaned proofing of the slab. The treatment has been now
using high-pressure water. The flexible polymer- functioning for more than 1 year without any sign
modified mortar was applied by spraying and of water penetration.
brushing. The brush was used to provide a
“pin-hole” free coating approximately 0.04 in.
(1 mm) thick. The second coat was applied in Case History—Repair,
the same manner and thickness. The material was Waterproofing, and Chemical
air-dry cured.
Protection of an Elevated,
Case History—Underground Reinforced Concrete Tank,
Reinforced Concrete Tanks, Chemical Works, Novaky, Slovakia
The reinforced concrete tanks used for the
Port of St. John’s, storage of calcium hydroxide solution have
Newfoundland, Canada deteriorated considerably over the last 40 years.
Large volume, underground reinforced concrete The excessive spalling of concrete due to
tanks were built during the World War II and used corrosion of the reinforcing steel and severe
for storing bunker oil. In 1997 it was decided to cracking were the main problems. The interior
refurbish the tanks and use them as storage tanks surface of the concrete tank was originally
for drilling mud used in oil drilling off the shore protected and waterproofed by a layer of a bitu-
of Newfoundland. The tanks exhibited severe minous material. This created an additional
cracking. The most serious problem was the concrete problem, since the bitumen was partly impreg-
contamination with oily residues and the original nated into the concrete surface.
bituminous protective coating. Deteriorated concrete was removed using
The concrete surface was cleaned using high- chipping hammers and high pressure water.
pressure water and sand in combination with Polymer-modified cement rust-proofing material
industrial degreasers. The degreasing of the surface containing corrosion inhibitors was applied over
was repeated several times. all the exposed steel. In the areas of high level of
The cracks were treated with a highly flexible bitumen contamination of the concrete surface,
polymer-modified mortar layer, reinforced with an a bonding layer, approximately 0.59 in. (15 mm)
approximately 5.9 in. (15 cm) wide polypropylene thick, of fiber reinforced wet shotcrete mortar
reinforcing fabric. The rest of the areas were enhanced by a high level of micro-silica, was used.
coated with a different type of a flexible polymer- Two layers of a highly flexible polymer-modified
modified mortar, designed to provide long-term mortar applied in the total thickness of approxi-
chemical resistance to drilling mud. mately 0.12 in. (3 mm), provided the final water-

24 Concrete Repair Bulletin September/October 2004

proofing and protection of the interior of the a bond to the surface that, even after extensive
reinforced concrete tank. The exterior of the tank was cleaning, still contained a significant content of oil
repaired using the same procedure and materials. residues impregnated into the surface of the
concrete tanks. The repairs have been very successful
Case History—Repair and in obtaining a high bond to the waterproofing
surface and providing a complete water-tightness
Waterproofing (Oil-Proofing) to the tanks.
of an Industrial Wastewater
Treatment Facility, Slovnaft Versatile Materials
Bratislava, Slovakia The polymer-modification of mortars or concrete
This industrial wastewater treatment facility mainly increases the toughness, and to some extent
treats water containing a high content of hydro- the tensile and bending strengths, of these materials.
carbon oil residues and dispersed solid materials By using a higher level of polymer modification
coming from the oil refining and petrochemical with a polymer exhibiting a low Tg , a high flexi­bility
manufacturing processes of the company. The of such composites can be achieved. The main use
liquid industrial wastes are subject to a complex of these materials is in thin section applications,
treatment process that takes place in various types in waterproofing, and in chemical protection
of reinforced concrete tanks. Over the course of of concrete structures. The high flexibility allows
many years the cracking of the concrete structures spanning of substrate cracks and provides water-
resulted in the penetration of the hydrocarbon proofing and protection that cannot be achieved
residues to the exterior of the structures. In 2000 using conventional mortars or high Tg polymer-
and 2001 a number of tanks were repaired and modified mortars.
waterproofed using the following procedures
and materials.
The interior surface of the concrete tanks was
coated with a 2 in. (5 cm) thick layer of oil and I v a n R a z l , P h D , P. E n g , i s
grease, which was mechanically removed first. This Technical Director of Gemite
was followed by the removal of delaminated concrete Products. Razl has extensive
by chipping out the cracked areas to form approx­ experience in research and
imately 1.6 x 1.6 in. (4 x 4 cm) grooves. The development of polymer and
concrete surface was cleaned with repeated treat- cement composite systems,
ments of industrial detergents and high-pressure concrete protection and restor­
water. The chipped-out grooves and delaminated ation materials, and novel
areas were patched with a fiber-reinforced, micro- building systems, including floor and roof systems.
silica enhanced repair mortar and the exposed He is a project leader and is responsible for all
reinforcing steel was treated with two coats of theoretical considerations, material design
polymer-modified mortar coating containing criteria, design of experiments, analysis and
migrating corrosion inhibitors. interpretation of data, and all the decisions that
The crack areas were brush coated with two coats will be made during a development program.
of a highly flexible polymer-modified mortar, for a Razl has undergraduate degrees from the Chemical
total thickness of 0.08 in. (2 mm). The entire surface Technology College, Zlin, Czech Republic, and the
was brush coated with two coats of flexible polymer- Chemical University, Pardubice, Czech Republic.
modified mortar for a total thickness of 0.06 in. He also has an MSc in Chemical Engineering
(1.5 mm). The smooth surface of the final coat was and a PhD in Chemical and Civil Engineering
achieved by using a steel trowel. from the University of Toronto. Razl is registered
The same procedure was used to repair the with The Association of Professional Engineers
exterior of the tank, but the relatively thick of Ontario, and is a member of many associations,
layer of flexible polymer-modified mortar was including the Construction Specifications Institute,
replaced with two coats of polymer-modified Canada; ICRI; ACI; the Building & Concrete
cement coating with a consistency of a thick Restoration Association of Ontario; the EIFS
latex paint. Conventional paint rollers were used Council of Canada; and the Toronto Society for
to apply this material. Coatings Technology.
Extensive evaluation and testing were carried
out prior to application in larger areas. The chemical
resistance and waterproofing characteristics under
the high water pressure of the flexible mortar
coating were thoroughly evaluated. A large number
of bond tests were also carried out to develop the
surface preparation procedures necessary to achieve

september/october 2004 Concrete Repair Bulletin 25