Developments in Epoxy

Modified Portland
Cement Mortars
technical report
Developments in
Epoxy Modified
Portland Cement
Mortars
technical report

2
DEFINITIONS
Polymer Cements (PC) - a general term indicating
any polymer containing product used as an adhesive
or mortar or screed. The term is mainly used for
products containing polymer plus non-reactive filler
e.g. epoxy/sand.
Polymer Modified Portland Cement (PPC) -
products based on traditional inorganic Portland
cement as the main binder, with the addition of
emulsion polymer to act as an improver or
waterproofing agent. (Typically PVA, SBR or acrylic).
Epoxy Portland Cement (EMC) - these are PPCs in
which the emulsion polymer has been replaced
by an epoxy/hardener copolymer system i.e. as with
Incorez 148/010.
CHOICE OF EPOXY/HARDENER
Hardener
The following grade is recommended:
Incorez 148/010
This product has been chosen for its specific
characteristics:
a) Low viscosity, confers excellent workability.
b) Excellent emulsion stability in a cement rich
environment.
c) Synergistic curing properties with Portland cement.
d) Long pot life.
Epoxy
a) Normal liquid grade (DER353, Epikote 215)
b) Solid epoxy emulsion (Beckopox EP384)

ADVANTAGES OF EMC OVER PPC FORMULATING TIPS

i) Superior strength properties (typically twice the Superplasticiser - these are used to increase the
compressive strength of PPC). workability of cement pastes and should be added in
ii) Increased chemical resistance - particularly small doses to the EMC formulations. A naphthalene
towards mineral acids. sulphonate type is recommended.
iii) Reduced sensitivity to polymer rewetting, which
Water/cement ratio - affects the strength properties
can cause swelling/disbondment.
dramatically in all PPC and EMC formulations and
iv) Reduced drying shrinkage cracking enabling the
should be calculated to yield values <0.6 wherever
omission of curing membrane and improved
possible.
tolerance to hot dry climates.
v) Excellent adhesion to damp/old concrete without Graded Silica Sand - a selection of graded silica
the need for primers. sands are chosen to achieve a close packed, dense
structure. Only washed, dry, graded silica sand
should be used.
DISADVANTAGES Mixing Techniques - the hardener/epoxy should be
3 component packaging although there is potential to
mixed thoroughly at the outset and placed in the
reduce this to 2-component or even 1-component by
cement mixing container. The dry powder
use of dry liquid technique.
(cement/sand) blend should then be added to the
emulsified epoxy, slowly. A drill/paddle can be used
for mix quantities up to 10kg.
APPLICATION AREAS
i) Thin screeds or toppings requiring high strength
e.g. floor toppings in abattoirs, factory decking,
marine applications.
ii) Damp cellars to reduce the ingress of water from
external sources.
iii) Repair of tanks or reservoirs where permanent
contact with water occurs.
iv) Flooring screeds in the hygiene and food
industries or wherever chemical resistance is
important e.g. sewage treatment plant.
v) To reduce solvent based systems in enclosed
areas, which have little or no ventilation.

3
Developments in Epoxy Modified
Portland Cement Mortars
technical report

The last twenty years has seen a wide acceptance of POLYMER MODIFIED PORTLAND CEMENT systems,
mainly based on emulsions of thermoplastic polymers such as poly(styrene-butadiene) (SBR) and poly(acrylic-
esters) (PAE). The first UK Patent applied for however was in 1923 by Cresson1 in which natural rubber was in
an cementitious paving system. Since then a wide variety of applications have been made including bridge
repairs, car parking, ship decking and flooring. According to statistics, some countries are producing over
40,000 tons p.a. of polymer concrete.

The use of thermoplastic emulsions is claimed to improve a variety of mortar properties including strength,
waterproofness and adhesion. Strength (compressive, tensile, flexural) is often improved indirectly, since
water:cement ratio (w/c) can be reduced due to the improved workability found with emulsion polymer.
Normally, however, the direct addition of emulsion resin to a mortar will reduce the mortars compressive
strength unless a calculated reduction in w/c is made.

Improvements to the strength characteristics of mortar are seen as a major benefit to using polymer modified
systems; particularly since Portland cement compositions are weak in tension compared to other building
materials, see table 1 below.

table 1 strength properties for some building materials

SG Compressive Tensile Strength, Modulus of

Strength, MPa MPa Elasticity, MPa

Concrete 2.2-2.4 14-40 a 1.1-3.3 b 20,700-34,500

Steel, Construction 7.7-7.83 350-400 e 350-400 180,000-207,000

Aluminium (type 1100c) 2.55-2.80 90-160 e 90-160 e 73,000

Oak, redd 0.64-0.71 7.1 5.3 12,500

Polystyrene, high impact 0.98-1.10 - 14-45 1,750

ABS, medium impact 1.01-1.15 - 16.63 2,000-3,000

KEY
a Values depend on water:cement ratios, figures quoted are for 0.81 and 0.41 water:cement ratios.
b Values depend on water:cement ratios as in a, tensile is about 8% of compressive strength.
c Aluminium type 1100 as defined by the Aluminium Alloy Designation, USA.
d Figures quoted are for strengths perpendicular to the grain.
e Compressive strength is generally taken as being equal to tensile strength.

1
Cresson L: British Patent 191, 474, 12 Jan (1923)

4
In an ideal situation cementitious repair mortars, for instance, should possess similar strength properties to
base concrete. This is not easy to achieve since it is difficult to compact mortar and impossible to incorporate
steel reinforcement except possibly as fibres. The use of polymers is therefore claimed to be advantageous.
It is unfortunate, however, that the type of emulsion polymer in use, by virtue of its physio-chemical structure,
reduces in strength dramatically when rewetted. Unmodified mortar actually shows an increase in strength
when immersed in water, see table 2 below.

table 2 effect of water absorption on compressive strength of latex modified mortars

polymer-cement ratio. 20%

dry wet

300

250
compressive strength kg/cm2

200

150

100

50

Un SBR-1 SBR-2 PVDC-1 PVDC-2 NBR CR PAE PVAC

modified modified modified modified modified modified modified modified modified

types of mortar

This ability to reabsorb water, after curing, is a common feature of many emulsion polymers. This characteristic
may, however, have dramatic consequences in practice and can sometimes be the underlying cause of
disbondment, for example, when polymer modified flooring screeds are applied over damp concrete. Table 3
below indicates typical water absorption values for emulsion polymer films cast at 100 microns thickness and
allowed to cure for one month at 20C.

table 3 % weight increase after immersion

Polymer type Water Reagent

5% w/w hydrochloric acid

PAE 17.75 8.41

SBR 18.35 8.04

EPOXY* 1.25 2.53

*BIS A/F, Incorez 148/010 curing agent

5
Developments in Epoxy Modified
Portland Cement Mortars
technical report

The theoretical principals governing the strength of cement composites have been well documented and are
related to two major influences

1) Improvement in the cement / aggregate bond

The strength of ordinary mortar and concrete depends to a large extent on the strength of the aggregate-to-
cement paste bond. It has been shown by Alexander2 et al. that this bond strength is lower than the cement
paste bond strength. Because of this, initial cracking usually develops at the aggregate paste interface rather
than in the paste itself. Given their adhesive nature, certain emulsion polymers have a potential to improve the
aggregate to cement paste bond strength.

2) Reduction of stress in the vicinity of crack tips

The difference between theoretical and observed strengths in brittle materials is the
result of the presence of flows or cracks in the composite. This theory was postulated by
= 2ET Griffiths3 in 1920 and later applied to concrete by Kaplan4 and Glucklich5. According to
C Griffiths the presence of cracks initiates fracture as a result of high stress concentrations
induced at, or near to, the crack tips when the material is loaded. The Griffiths equation
is given as:

Where is the applied tensile stress, T is the specific surface energy, E is the modulus of elasticity and C is the length of the crack.

Hence lower strength is to be expected when longer cracks or discontinuities are present.

A further desirable requisite is to improve chemical resistance. Polymer modified Portland cement mortars
generally have good resistance to alkalis, fats and oils but poor resistance to acids, sulphates and some
solvents. Achieving these improvements would permit the use of polymer cements into application areas which
are currently dominated by wholly organic resin composites, such as the epoxy/sand screeds for the chemical
and sewage industry.

Waterbased Epoxy

One opportunity that has presented itself to Incorez has been the use of water borne epoxy polymers to
upgrade Portland cement mortars in those areas outlined above. Water borne epoxies and more importantly
the use of an appropriate curing agent, have rarely featured as polymer additives in Portland cement
technology. Some data exists, particularly in the USA, for applications and test work carried out notably by
McClain6. Other systems, mainly in Europe, have tried to adopt existing coatings resin technology with little
success. Many of the curing agents in particular are too viscous, or produce unworkable mortars. Some epoxy
systems are incompatible in a cement environment, where calcium ions cause precipitation of the resin
emulsion. Nevertheless epoxy polymers, since they exhibit high adhesive and tensile strength are more
chemically resistant than say acrylics, should prove to be advantageous in mortar compositions.

2
Alexander KM, Wardlow J and Gilbert DJ: Aggregate-Cement Bond, Cement Paste Strength and the Strength of Concrete, Proc. Conf.
Structure of Concrete and Its Behaviour Under load, London (1965), 59, Cement and Concrete Association, London (1968)
3
Griffiths AA: The Phenomena of Rupture and Flow in Solids, Phil. Trans, Ray Soc. A, 221,163 (1920)
4
Kaplan MF: Crack Propagation and the Fracture of Concrete, J. Am. Concrete Inst., 58, 591, (1961)
5
Glucklich J : On the Compression Failure of Plain Concrete, Theoretical and Applied Science Rep., No. 215, University of Illinois (1962)
6
McClain RR: Epoxy-Modified Cement Admixtures, Proceedings of Second Int. Congress on Polymers in Concrete, University of Texas,
Austin, 483 (1978)

6
In our development work two cementitious systems were examined:

i) a thin topping or thick coating, ref. EMC-3

ii) a 10mm self levelling screed, ref. PF-2

Formulations are outlined below. It must be remembered that both formulations are simplistic in design and do
not include fibres or microsilica, both of which would improve strength and resistance properties markedly. The
aim was merely to assess the influence of the polymer component rather than the cementitious mix design.

Guide Formulation for PF-2 Guide Formulation for EMC-3

Description Description
Epoxy modified cement floor screed, 10-25mm thickness Epoxy/cement waterproof coating, application thickness
for use in warehouse, cellars and industrial applications. 1mm. For use in cellars, tanking and general
Application by spiked roller or pump. damproofing work.
FORMULATION FORMULATION
PART A % by weight Supplier PART A % by weight Supplier
Silica sand (1.1-2.3mm) 22.24 Various Silica sand-Redhill 110 39.15 Sibelco
Silica sand (0.6-1.2mm) 18.85 Various Pulverised Fuel Ash 14.07 Pozzolanic
Silica sand - Redhill 65 3.77 Sibelco Pozzolan Lytag

Rapid hardening cement 22.66 Blue Circle Ordinary Portland Cement 23.50 Blue Circle
Pulversied Fuel Ash 7.54 Pozzolanic Hydrated Lime (Limbux) 1.55 Pozzolanic Lytag
Pozzolan Lytag Plasticiser (naphthalene 1.50 Sika
Plasticiser (naphthalene 0.75 Sika sulphonate eg. Sikament)
sulphonate eg. Sikament) PART B
Quartz Aggregate 11.36 Bush Beach Incorez 148/010 3.36 Incorez
MIX
(2-3mm) Water 13.50
PART B PART C
Incorez 148/010 1.39 Incorez Epikote 215 3.36 Momentive
Water 10.05 Total 100.00
PART C DATA
Epikote 215 1.39 Momentive Mix ratio= 3.9 : 1 (Part A: Parts B and C)
Total 100.00 Water/cement= 0.596
% polymer by weight cement= 25.55%
INSTRUCTIONS FOR USE
Compressive Strength = circa. 30N/mm2 (28 Days)
Mix parts B and C. Add half to the power mixer followed Working Life = circa. 1 hour at 200C
by Part A. Add the remainder of parts B and C after one
minute. After mixing, deposit flowing mixture onto floor
and place/deareate with spiked roller.

DATA
Mix ratio= 6.8 : 1 (Part A: Parts B and C)
Water/cement= 0.45
% polymer by weight cement= 11.04%
Working Life = circa. 1 hour at 200C

7
Developments in Epoxy Modified
Portland Cement Mortars
technical report

A variety of tests were carried out on the cementitious formulations incorporating the aqueous epoxy. Control
samples were also prepared using traditional thermoplastic emulsions based on SBR and PAE. A summary of
these tests is given in the following tables:

Ref. PF-2 Strength Test (BS6319)

Polymer Compressive Flexural Slant Shear

Modification Strength - N/mm2 Strength - N/mm2 Adhesion - N/mm2

Poly(styrene co-butadiene) 1 day 7 days 28 days 1 day 7 days 28 days 37.50

12.10 43.90 50.72 1.20 5.78 9.58

Incorez 148/010 + Epoxy 21.60 57.10 59.80 1.35 6.16 10.84 43.10

Ref. EMC-3 Strength Test (BS6319)

Polymer Compressive Flexural Slant Shear

Modification Strength - N/mm2 Strength - N/mm2 Adhesion - N/mm2

Poly(styrene co-acrylate) 1 day 7 days 28 days 1 day 7 days 28 days 18.50

(Acronal S702)
0.00 14.00 18.10 - 2.57 8.15

Incorez 148/010 + Epoxy 4.40 21.00 45.30 1.82 4.94 9.31 46.50

Ref. PF-2 Shrinkage - Expressed as % Change of Original Length

Polymer 1 Day 7 Days 14 Days 28 Days 56 Days

Modification

Poly(styrene co-butadiene) 0.05 0.08 0.09 0.092 0.015

Incorez 148/010 + Epoxy 0.05 0.08 0.08 0.104 0.125

Ref. EMC-3 Shrinkage - Expressed as % Change of Original Length

Polymer 1 Day 7 Days 14 Days 28 Days 56 Days

Modification

Poly(styrene co-acrylate) 0.00 0.02 0.075 0.102 0.120

Incorez 148/010 + Epoxy 0.07 0.08 0.180 0.228 0.245

8
Discussion

Strength Properties
Dramatic improvement in compressive strength is observed for EMC-3 formulations based on water borne
epoxy almost 2.5 times the value of an acrylic emulsion modification. Less dramatic results are observed with
PF-2 formulations, since the polymer content is lower and this has less of an influence in the system. Flexural
strength is marginally higher for both cementitious products by about 14% in comparison to ordinary emulsion
systems. Slant sheer adhesion prisms all showed cracking within the mortar rather than at the interface,
illustrating a high level of adhesion to old concrete.

Workability / Pot life

The epoxy modified systems showed only a slight reduction in workability compared to the emulsion polymers.
For instance, using a flow table (BS 4551:1980), the epoxy system, EMC-3, gave a reading of 215mm against
225mm for the styrene acrylic. This was measured 1hr after initial mixing. Pot life was assessed as
approximately 90 minutes for the epoxy cement and 120 minutes for the styrene acrylic.

Linear Shrinkage
Tests carried out to ASTM C82782 showed shrinkage with the epoxy modification to be higher than the
controls. The levels are quite small, however, when compared to say epoxy/sand screeds with shrinkage of
ca.2%. Shrinkage in the epoxy cement system is a result of chemical crosslinking, whereas standard. emulsion
polymers physically coalesce to form a loose network in the cement matrix. It is essentially the chemical
crosslinking of the epoxy which gives rise to a more intricate and ordered polymer structure in the cement
composition. This also accounts for the improvements in mechanical properties.

Chemical Resistance
This property was assessed by two methods,

i) By wt. change
ii) By change in compressive strength

In both cases samples were immersed in a variety of reagents for one month, at 200C, prior to testing.
Reagents used were:

Water
5% Sulphuric acid
5% Sodium hydroxide
5% Sodium hypochlorite
5% Sodium chloride
5% Non-ionic surfactant

Results showed that weight changes experienced by the epoxy system were much lower than those of the
controls. Overall weight changes were only one quarter to one third of the acrylic mortar. The increased epoxy
content in the EMC-3 formulation gave rise to an overall improved performance in chemical resistance
properties compared to PF-2. In particular, acid resistance was far superior for the epoxy system, compared to
the acrylic control, values were 0.8% change for the epoxy against 12% change for the acrylic.

Compressive strength tests also showed the epoxy system outperform the standard emulsion controls,
although this was likely since initial strength values for the epoxy were higher anyway. In terms of % retention
of original strength the epoxy mortars showed only a 5% improvement.

9
Developments in Epoxy Modified
Portland Cement Mortars
technical report

In summary, the chemical resistance tests showed that whilst the epoxy modification gave improvements over
traditional polymers, permeation of chemicals can still occur, albeit at a slower rate. It has to be borne in mind
that the polymers are strictly secondary binders in the mortars and complete protection of the cement paste by
the polymer is not possible.

Water Retaining Properties

During the course of our experiments with different test methods for compressive strength testing, it was also
seen that the epoxy system was less sensitive to the conditions under which samples were cured.
Thermoplastic emulsion polymers favour a drying out period cure, at 65%RH and hence thicker sections tend
to yield lower strength values. In our tests for instance the following results were found:

7 Day Compressive Strengths

Polymer Modification Compressive Strength N/mm2

Acrylic 50mm 70.7mm

Cube Cube

14.0 2.0

Incorez 148/100 + Epoxy 21.0 13.5

The ability of the water borne epoxy to synergistically strengthen the cement matrix, particularly in the
presence of water, was also evaluated by studying the tensile strength of pure polymer strips, in which water
has been included at a level of 25% of the formula wt.

Sample Tensile Strength N/mm2

Incorez waterborne epoxy 18.6

Incorez waterborne epoxy + 25% water 16.9

Acrylic 1.4

S.B.R. 0.9

In effect, the epoxy system, by virtue of its crosslinking mechanism, is hardly affected in terms of physical
properties by the presence of water. The epoxy polymer also demonstrates excellent water retaining
properties. For example, in the above tests small weighed pieces of cured polymer were placed in an oven at
1000C for 4 hrs. After this period samples were reweighed and water loss was observed to be only 2.6%. This
is a property of high potential value, particularly in hot countries, where loss of water by surface evaporation
causes major problems in application, particularly manifested by drying shrinkage cracking.

10
Further Work
In view of the increasing trend to employ solid epoxy emulsions a series of tests were conducted using this
system, as given in formulations PF-4 and EMC-4 below. The most notable points were:

a) Compressive strength values were between 80-90% of the corresponding liquid epoxy formulations.
b) Workability was virtually equal to the control emulsions (SBR, PAE).

Guide Formulation for PF-4 Guide Formulation for EMC-4

Description Description
Epoxy modified cement floor screed, 10-25mm thickness Epoxy modified waterproof coating, application thickness
for use in warehouse, cellars and industrial applications. 1mm. For use in cellars, tanking and general
Application by spiked roller or pump. damproofing work. Application by brush or spray gun.

FORMULATION FORMULATION
PART A % by weight Supplier PART A % by weight Supplier
Silica sand (1.1-2.3mm) 22.24 Various Silica sand-Redhill 110 39.15 Sibelco
Silica sand (0.6-1.2mm) 18.85 Various Pulverised Fuel Ash 14.07 Pozzolanic
Pozzolan Lytag
Silica sand - Redhill 65 3.77 Sibelco
Rapid hardening cement 22.66 Blue Circle Ordinary Portland Cement 23.50 Blue Circle
Pulversied Fuel Ash 7.54 Pozzolanic Hydrated Lime (Limbux) 1.55 ICI
Pozzolan Lytag Plasticiser (naphthalene 1.50 Sika
sulphonate eg. Sikament)
Plasticiser (naphthalene 0.75 Sika
sulphonate eg. Sikament) PART B
Quartz Aggregate 11.36 Bush Beach Incorez 148/010 1.70 Incorez
MIX
(2-3mm) Water 10.20
PART B PART C
Incorez 148/010 0.70 Incorez Beckopox EP384 8.33 Cytec
Water 8.73 Total 100.00
PART C DATA
Beckopox EP384 3.40 Cytec Mix ratio= 3.9 : 1 (Part A: Parts B and C)
Water/cement= 0.596
Total 100.00
% polymer by weight cement= 25.55%
INSTRUCTIONS FOR USE Compressive Strength = circa. 60N/mm2
Mix parts B and C. Add half to the power mixer followed
by Part A. Add the remainder of parts B and C after one
minute. After mixing, deposit flowing mixture onto floor
and place/deareate with spiked roller.

DATA
Mix ratio= 6.8 : 1 (Part A: Parts B and C)
Water/cement= 0.45
% polymer by weight cement= 11.04%

Conclusion
The foregoing research has illustrated how new and improved polymer modified Portland cement mortars,
based on water borne epoxy technology, can extend the already widening market for cement products. In
particular, high strength mortars can be easily achieved which are less prone to varience under different
conditions of humidity and thickness of section. There is also an additional benefit in that the strong water
retention properties of the epoxy/curing agent will reduce the tendency for drying shrinkage cracking to occur.

11
Manufacturers of specialist resins & polymers:
Oxazolidines
Waterborne epoxy curing agents
Polyurethane dispersions
Polyurethane/acrylic hybrid dispersions
Polyurethane prepolymers

Incorez Limited Incorez Corporation

Iotech House Miller Street 79 Bradley Street
Preston Lancashire Middleton Connecticut
PR1 1EA England 06457 USA

t: +44 (0)1772 201964 t: +1 (860) 613 1613

f: +44 (0)1772 255194 f: +1 (860) 613 1637
e: info@incorez.com e: info@incorez.com
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