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Application of polymer modified mortar concrete (PMM / PMC) in repairs

Er. Parbhakar Dwivedi


1, Structural repairs to RCG:

PMM/PMC are used to make up the damaged/lost cover concrete due to their better bond with substrate, including the reinforcement. In the repair and rehabilitation jobs, if replacement of old concrete is done by unmodified concrete, it can deteriorate due to carbonation and chemical attacks and further its adhesion to old concrete remains weak. In the initial stages of advent of polymers in repair field, the only reliable material used for making up the lost concrete was epoxy 1t is a very strong material and can easily give compressive strength of 60 to 70 N/sq. mm and high tensile strength of 20 to 30 N/sq. mm. The cost of epoxy repair is very high and also most of the reinforced concrete member to be repaired is of the strength 15 to 20 N/sq.mm it is not logical to introduce in it, intermittently, pockets of very high strength mortar. Due to this, the trend is shifting in favor of polymer modified cementitious mortars which have improved chemical and physical properties as compared to ordinary cement and concrete mortar The cost of these polymer mortar is one third the cost of epoxy mortar. In addition the polymer mortar cover is of the order of 10 to 15 mm in thickness above and such thickness itself can adequately take care of further chemical attack or subsequent carbonation.

2. Ultra rapid hardening polymer modified shotcrete:

Used for urgent repairs

Ultra Rapid Hardening Polymer Modified Shotcrete system can be classified in to two categories

(a) One, which uses a polymerisable monomer that reacts with Ordinary Portland cement at ambient temperature. This system is used as repair and protective material for concrete structures with leaking and flowing water. It uses magnesium acrylate monomer and its setting time can be controlled within few seconds or less. Fig 2.3 represents a schematic diagram of this shotcrete system.

(b) Second, which uses ultra-rapid hardening cement concrete with SBR latex and is often used for urgent construction and repair works.

3. Polymer Ferrocements:

For the purpose of improving the flexural behaviour and durability of conventional ferrocement, polymer- Ferrocements have been developed using latex modified mortars instead of ordinary cement-sand mortars, Use of SBR and EVA modified mortars is found to be very effective in improving their flexural behaviour, impact resistance, drying shrinkage and durability, Incorporation of short fibers such as steel and carbon fibers in the latex modified mortars is found to be further effective in improving such characteristics.

4 Anti washout underwater concrete:

The major requirements from anti-washout under water concrete are anti washout or segregation resistance, flowability, self-leveling ability and bleeding control. Anti-washout admixtures are water-soluble polymers and are classified in two types as Cellulose-type polymers such as MC and HEC and Poly-acryl amide and poly acryl amide-sodium acryl ate. These are added at polymer-cement ratios of 0.2% to 2.0% during mixing of the ordinary cement concrete. The water soluble polymer bonds to a part of mixing water by hydrogen bonds in the concrete and disperses in a molecule form in the mixing water. As a result, the mixing water is confined in the network structure of the dispersed polymer and becomes very viscous the very viscous water envelops cement and aggregate particles to impart an anti-washout character to concrete.

5 Protective anti corrosive and water proofing coatings:

Hydrated type flexible water proofing materials are polymer modified pastes of slrries with very high polymer: cement ratios of 50% or more and have been widely used as liquid applied water proofing membrane materials, repair materials, etc. The constituents normally comprise of Portland cement, silica sand, water and polymer latexes such SBR, PAE, EVA, SAE, epoxy and asphalt ilexes besides some other additives Thickness of such waterproofing membranes is 2 to 4 mm and is generally available in prepackaged type products. The performance advantages of such membranes are:

• Safe application due to no organic solvent system.

• Convenience of application as it does not require the surface to be dry.

• Good adhesion with the cementitious, metallic and most other substrates.

• Excellent elongation, flexibility and crack resistance.

• Good water proofness.

• Resistant to carbonation and chloride ion penetration.

PAE modified water proofing materials appear to have excellent elongation and water resistance. Crack bridging capacity of such flexible membranes is being successfully tested in Germany.

PN (Interpenetrating Polymer Network) coatings are also used as surface coatings for RCC structures for arresting further carbonation of cover concrete or other chemical attack by sealing their surface against ingress of environmental aggressive chemicals and their consequential attack on concrete.

6. Bond coats and grouts:

Polymer modified cement mortars as well as slurries are used as bond coats and grouts due to their very good adhesive qualities on cementitious as well as metallic surface.


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