ABSORPTION AND POROSITY CHARACTERISTICS OF VARIOUS CONCRETE PATCH REPAIR MATERIALS THESIS Submitted to the Post Graduate of Civil Engineering Program in Partial Fulfillment of the Requirements for the Degree of Master of Engineering in Infrastructure Prepared by: NASSR OMER SHAHAT ASHLEMBO S941302040 MASTER OF CIVIL ENGINEERING GRADUATE PROGRAM - SEBELAS MARET UNIVERSITY 2015 i
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ACKNOWLEDGEMENT First and foremost, I would like to express my sincere thanks and appreciation to my academic supervisors Assoc. Prof. SA. Kristiawan, M.Sc.Ph.D. and Dr. Ir. Agus Parwito Rahmadi. M.S. who continuously guided me throughout every step of my study and generously shared their time and knowledge with me. My special thanks must be extended to technical staff members at the concrete Laboratory at UNS for their collaboration and assistance while carrying out my laboratory work. I am very grateful to my mother, father, brothers and sisters for their motivation and support throughout my study, and my beloved wife who cares, helps and encourages me, my children Fwzea and Omar who give me happiness during my study. Millions of words of thanks for fellow friends who showed their concern and support all the way. Their views and tips are useful indeed. Unfortunately, it is not possible to list all of them in this limited space. v
ABSTRACT Studying concrete porosity and absorption is very important for determining the compatibility and durability of concrete repair materials. The objectives of this research were: to know the absorption, porosity and compatibility of various repair materials, to know the extent of protection given by various repair materials on concrete based on the measurement of absorption and porosity. Percent of absorption and porosity were measured according to ASTM C642-06. Scanning Electron Microscope analysis was conducted to study the porous and bond behaviour of concrete with repair materials. Absorption and porosity rate were determined based on ASTM C 1585-04. The result showed that UPR-Mortar 50 % repair material had the lowest absorption and porosity measurements indicating that it provided sufficient protection. This repair material is compatible based on porosity and absorption, but incompatible based on bond strength because it had weakest bond with concrete when exposed to temperature. The highest measurement values for absorption and porosity were found for concrete with normal mortar repair material indicating that it did not provide sufficient protection. This repair material was compatible based on bond, but incompatible based on porosity and absorption. Based on Scanning electron microscope analysis, normal mortar repair with normal concrete had more pores but with strongest bond whereas UPR-mortar 50% repair material had weak bond after exposed to high temperature but lowest pores. The peculiar feature of this research is that better bond compatibility between repair materials and concrete does not guarantee good protection from absorption and porosity. Materials with weak bond strength can surprisingly have protection from concrete absorption and porosity. Keywords: Absorption, Compatibility, Concrete, MS, Porosity, Protection, Repair materials, SEM vi
Abstrak Mempelajari porositas beton dan absorpsi sangat penting untuk menentukan kompatibilitas dan durabilitas materi perbaikan beton. Tujuan dari penelitian ini adalah: untuk mengetahui absorpsi, porositas dan kompatibilitas dari berbagai bahan perbaikan, untuk mengetahui sejauh mana perlindungan yang diberikan oleh berbagai bahan perbaikan pada beton berdasarkan pengukuran absorpsi dan porositas. Persentase absorpsi dan porositas diukur sesuai dengan ASTM C642-06. Scanning Electron Microscope analisis dilakukan untuk mempelajari perilaku berpori dan ikatan beton dengan bahan perbaikan. Absorpsi dan tingkat porositas ditentukan berdasarkan ASTM C1585-04. Hasil penelitian menunjukkan bahwa UPR-Mortar 50% materi perbaikan memiliki absorpsi dan porositas terendah pengukuran yang menunjukkan bahwa itu memberikan perlindungan yang cukup. Materi perbaikan ini kompatibel berdasarkan porositas dan absorbsi, tapi tidak sesuai berdasarkan kekuatan ikatan karena itu ikatan yang paling lemah dengan beton bila terkena suhu. Nilai pengukuran tertinggi untuk penyerapan dan porositas ditemukan untuk beton dengan bahan perbaikan mortir yang normal menunjukkan bahwa hal itu tidak memberikan perlindungan yang cukup. Bahan perbaikan ini kompatibel berdasarkan ikatan, tetapi tidak sesuai berdasarkan porositas dan absorbsi. Berdasarkan Scanning analisis mikroskop elektron, perbaikan mortar normal dengan beton normal memiliki lebih banyak pori-pori tapi dengan ikatan kuat sedangkan UPR-mortir 50% bahan perbaikan memiliki ikatan lemah setelah terkena suhu tinggi tetapi pori-pori terendah. Fitur khas dari penelitian ini adalah bahwa kompatibilitas ikatan yang lebih baik antara bahan perbaikan dan beton tidak menjamin perlindungan yang baik dari penyerapan dan porositas. Bahan dengan kekuatan ikatan yang lemah mengejutkan dapat memiliki perlindungan dari penyerapan beton dan porositas. Kata kunci: Absorpsi, Kompatibilitas, Beton, MS, Porositas, Perlindungan, materi Perbaikan, SEM vii
TABLE OF CONTENTS Page TITLE... i ENDORSEMENT... ii STATEMENT... iii PROCLAMATION... iv ACKNOWLEDGEMENT... v ABSTRACT... vi ABSTRAK (Indonesian language)... vii TABLE OF CONTENTS... viii LIST OF TABLES... xi LIST OF FIGURES... xiv LIST OF SYMBOLS... xvii LIST OF APPENDIX... xviii CHAPTER I (INTRODUCTION)... 1 1.1 Background of the study... 1 1.2 Problem statement... 3 1.3 Objectives of the research... 4 1.4 Limit of the research... 4 1.5 Benefit of the research... 4 CHAPTER II (LITERATURE REVIEW AND BASIC THEORY)... 6 2.1. Literature review... 6 2.1.1. Absorption... 6 2.1.2. Porosity... 8 2.1.3. Compressive Strength... 9 2.1.4. Compatibility between Repair Material and Concrete Substrate... 10 2.2. Basic Theory... 12 2.2.1. Absorption... 12 2.2.2. Porosity... 14 2.2.3. Compressive Strength... 16 viii
2.2.4. Compatibility between Repair Material and Concrete Substrate... 17 2.3. Hypothesis... 25 CHAPTER III (RESEARCH METHOD)... 26 1. 2. 3. 3. 3.1. Location and Time... 26 3.2. Type of research... 26 3.3. Research variables and parameters... 26 3.4. Data collection... 27 3.4.1. Primary data... 27 3.4.2. Secondary data... 27 3.5. Method and Materials... 27 3.1. 3.2. 3.3. 3.4. 3.5. 3.5.1. Concrete Cylinder... 27 3.5.2. Slump Test... 29 3.5.3. Compressive strength (Test: ASTM C39/C39M 03)... 29 3.5.4. Repair materials... 30 3.5.5. Percent of Absorption and porosity (ASTM C642 06)... 35 3.5.6. Absorption rate (ASTM C1585 04)... 36 3.6. Data Analysis... 39 3.6.1. Compatibility of repair materials... 39 3.6.2. Relation between compatibility and protection... 40 3.7. Flow chart of research... 41 CHAPTER IV (RESULTS AND DISCUSSIONS)... 42 ix
4. 4. 4.1. Introduction... 42 4.2. Compressive strength test Result... 42 4.3. Absorption and porosity percent results (ASTM C642 06)... 43 4.3.1. Repair materials... 43 4.3.2. Concrete cylinder... 44 4.3.3. Concrete cylinder with repair materials... 45 4.3.4. Comparison compatibility and protection provided based on absorption and porosity percent... 47 4.4. Absorption rate results (ASTM C1585 04)... 51 4.4.1. Repair materials... 52 4.4.2. Concrete cylinder... 55 4.4.3. Concrete cylinder with repair materials... 56 4.4.4. Comparison compatibility and protection provided based on absorption rate... 59 4.5. Macro structure (MS) and Scanning Electron Microscope (SEM)... 64 4.5.1. Normal concrete with Normal mortar... 64 4.5.2. Normal concrete with UPR-Mortar 50% Repair... 65 4.5.3. Normal concrete with BASF Nanocrete R4... 67 4.5.4. Normal concrete with Sika Repair Mortar... 69 4.6. Summary of all test results... 70 4.1. 4.2. 4.3. 4.4. 4.5. CHAPTER V (CONCLUSIONS AND RECOMMENDATIONS)... 73 5. 5.1. Conclusion... 73 5.2. Recommendation for further commit works to user... 74 x
REFERENCES... 75 APPENDIX... 79 LIST OF TABLES Table 2.1 VicRoads classification for concrete durability based on AVPV... 14 Table 3.1 Parameters and Variables... 26 Table 3.2 Concrete mix design outputs at 30 MPa... 28 Table 3.3 The proportion of the initial mixture of Normal concrete (30 MPa)... 29 Table 3.4 Permissible time tolerances prescribed for concrete testing... 30 Table 3.5 Mixing ratio of repair material (Normal mortar)... 30 Table 3.6 The proportion of the initial mixture of repair material (Normal mortar)... 31 Table 3.7 Mixing ratio of repair commit material to (UPR-Mortar user 50%)... 32 Table 3.8 The proportion of the initial mixture of repair material xi
(UPR-Mortar 50%)... 32 Table 3.9 Mixing ratio of repair material (BASF Nanocrete)... 33 Table 3.10 The proportion of the initial mixture of repair material (BASF Nanocrete R4)... 33 Table 3.11 Mixing ratio of repair material (Sika Repair Mortar)... 34 Table 3.12 The proportion of initial mixture of repair material (Sika Repair Mortar)... 34 Table 3.13 Times and Tolerances for the Measurements Schedule... 39 Table 4.1 Compressive strength for Concrete cylinder... 42 Table 4.2 Final test results ASTM C642-06 for all repair material used... 43 Table 4.3 Final test results ASTM C642-06 for Normal concrete used... 45 Table 4.4 Durability based on absorption difference ( I) of Concrete cylinder... 45 Table 4.5 Table 4.6 Table 4.7 Table 4.8 Table 4.9 Table 4.10 Final test results ASTM C642-06 for Concrete cylinder with all repair material used... 46 Durability based on absorption difference ( I) of Concrete cylinder with repair materials... 46 Comparison of test results according to ASTM C642-06 for Normal concrete and Normal mortar... 47 Comparison of test results according to ASTM C642-06 for Normal concrete and UPR-Mortar 50%... 48 Comparison of test results according to ASTM C642-06 for Normal concrete and BASF Nanocrete R4... 49 Comparison of test results according to ASTM C642-06 for Normal concrete and Sika Repair Mortar... 50 xii
Table 4.11 Table 4.12 Table 4.13 Table 4.14 Final test results ASTM C642-06 for Concrete cylinder with all Repair materials... 51 Linear relationship (initial rate and secondary rate) according to ASTM C1585-4 of all repair materials... 54 Linear relationship (initial rate and secondary rate) according to ASTM C1585-4 of Normal concrete... 56 Linear relationship (initial rate and secondary rate) according to ASTM C1585-4 of Concrete cylinder with repair materials... 59 Table 4.15 Comparison of linear relationship according to ASTM C1585-4 for Normal concrete and Normal mortar... 60 Table 4.16 Comparison of linear relationship according to ASTM C1585-4 for Normal concrete and UPR-Mortar 50%... 61 Table 4.17 Comparison of linear relationship according to ASTM C1585-4 for Normal concrete and BASF Nanocrete R4... 62 Table 4.18 Comparison of linear relationship according to ASTM C1585-4 for Normal concrete and Sika Repair Mortar... 63 Table 4.19 Summary of all test results... 71 xiii
LIST OF FIGURES Figure 2.1 Effect of boiling on absorption... 14 Figure 2.2 The relationship between porosity and permeability of water... 15 Figure 2.3 Figure 2.4 Explain to the width of tube (pore size) determines how far the water is drawn up the tube... 15 Modeling the Compressive Strength Test and Crack Patterns in Concrete... 16 Figure 2.5 The various parts of a composite system... 17 Figure 2.6 Internal and external causes concurring towards structure deterioration.. 18 Figure 2.7 The most important types of compatibility that need to be considered in repair design... 19 Figure 2.8 Different types of volumetric commit to compatibility user... 20 xiv
Figure 2.9 Combined effect of drying shrinkage and loading on the development of normal and shear strains in a repaired beam... 21 Figure 2.10 Effect of elastic moduli mismatch... 22 Figure 2.11 Electrochemical incompatibility... 25 Figure 3.1 Schematic of the Procedure... 37 Figure 3.2 Flow chart of research... 41 Figure 4.1 Figure 4.2 Figure 4.3 Figure 4.4 The effect of (Normal mortar) on the protection of concrete and the compatibility between them... 49 The effect of (UPR-Mortar 50%) on the protection of concrete and the compatibility between them... 49 The effect of (BASF Nanocrete R4) on the protection of concrete and the compatibility between them... 50 The effect of (Sika Repair Mortar) on the protection of concrete and the compatibility between them... 50 Figure 4.5 Absorption rate average calculations of all repair material samples... 55 Figure 4.6 Figure 4.7 Figure 4.8 Figure 4.9 Figure 4.10 Absorption rate average calculations of all samples (Concrete cylinder)... 56 Absorption rate average calculations of all samples (Concrete cylinder with Sika Repair Mortar)... 59 Evaluation absorption rate of the normal concrete, normal mortar and concrete cylinder with normal mortar... 60 Evaluation absorption rate of the normal concrete. UPR-Mortar 50% and concrete cylinder with UPR-Mortar 50%... 61 Evaluation absorption rate of the normal concrete. BASF Nanocrete R4 and concrete cylinder with BASF Nanocrete R4... 62 xv
Figure 4.11 Figure 4.12 Figure 4.13 Figure 4.14 Figure 4.15 Figure 4.16 Figure 4.17 Figure 4.18 Figure 4.19 Evaluation absorption rate of the normal concrete. Sika Repair Mortar and concrete cylinder with Sika Repair Mortar... 63 Photos by the Macro structure (MS) shows compatibility condition between ordinary normal concrete with Normal mortar... 64 Photos by the Scanning Electron Microscope (SEM) shows compatibility condition between ordinary normal concrete with normal mortar... 65 Photos by the Macro structure (MS) shows compatibility condition between ordinary normal concrete with UPR-Mortar 50%... 66 Photos by the Scanning Electron Microscope (SEM) shows compatibility condition between ordinary normal concrete wit UPR-Mortar 50%... 67 Photos by the Macro structure (MS) shows compatibility condition between ordinary normal concrete with BASF Nanocrete R4... 68 Photos by the Scanning Electron Microscope (SEM) shows compatibility condition between ordinary normal concrete with BASF Nanocrete R4.. 68 Photos by the Macro structure (MS) shows compatibility condition between ordinary normal concrete with Sika Repair Mortar... 69 Photos by the Scanning Electron Microscope (SEM) shows compatibility condition between ordinary normal concrete with Sika Repair Mortar... 70 xvi
LIST OF SYMBOLS ASTM - American Society for Testing and Materials AAI - Absorption after immersion AAIB - Absorption after immersion and boiling I - The absorption rate Mt - The change in specimen mass in grams. at the time t a - The exposed area of the specimen. in mm 2 d - The density of the water in g/mm 3 BD d - Bulk density. dry BDAI - Bulk density after immersion BDAIB AD - - Bulk density after commit immersion to user and bioling Absorption density xvii
VPPS - Volume of permeable pore space (voids) A - Mass of oven-dried sample in air. g B - Mass of surface-dry sample in air after immersion. g C - Mass of surface-dry sample in air after immersion and boiling. g D - Apparent mass of sample in water after immersion and boiling. g g 1 - Bulk density. dry. Mg/m 3 g 2 - Apparent density. Mg/m 3 ρ - Density of water = 1 Mg/m 3 = 1 g/cm 3 MS - Macro structure SEM - Scanning Electron Microscope LIST OF APPENDIX APPENDIX Page 79 A B C D Concrete mix design and result of materials test for concrete Results of ASTM C642 06 test Results of ASTM C1585 04 test Pictures of materials and tests from the Laboratory xviii
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