Proceedings of the First Makassar International Conference on Civil Engineering (MICCE2010), March 9-10, 2010, ISB 978-602-95227-0-9

DIME SIO AL COMPATIBILITY BETWEE PATCH REPAIR MATERIALS CO TAI I G TYRE FIBERS A D CO CRETE U DER SHORT-TERM COMPRESSIVE STRESS
S.A. Kristiawan 1

ABSTRACT: Degradation of concrete will reduce service life of structural concrete. Patch repair may be ulitised to recover its appearence, dimension, load bearing capacity and durability of damaged concrete and thus extends its service life. Dimensional compatibility between patch repair material and the existing substrate is one of the performance criteria which determine the success of application of this material. Under compressive stress, the repaired concrete should perform as a composite system that will work together in its function as load bearing. This research is aimed to evaluate the dimensional compatibility of repair materials containing various tyre fiber content under shortterm compressive stress. The stress-strain relations of the repaired concrete (composite) under compressive stress were measured both on the existing concrete and on the patch repair material. A model is developed to predict the stress distribution in composite system by considering the different in strains measured on concrete substrate and repair material. The stress in the patch repair material calculated by this model is less than that based on iso-strain asumption. Keywords: compatibility, dimensional, repair material, stress distribution, tyre fiber.

INTRODUCTION Concrete has been utilized in the construction of many types of structures for ages. Nowdays, many of these structural concrete show signs of degradation due to a variety factors. Corrosion of reinforcement is a major cause of deterioration which disrupts the cover zone of reinforced concrete (Mangat and OFlaherty 2000). It is unfortunate that not only old structural concrete that has experience this kind of problem, but it can also be found in newly built structural concrete. Under severe enviroments where chloride concentration is very high such that in seashore area, steel reinforcement corrosion can occur just in few years. In many instances, this problem could be worst when there are combined with lack of good design and construction practices. Degradation of reinforced concrete will certainly shorthen the service life of the structural concrete. There are several choices of materials and methods that could be used to extend service life of this deteriorated concrete. In many cases and dependent on the extent of deterioration, patch repair may be the most cost-effective solution to recover the size and appearence of deteriorated concrete occured in cover zone. This method involves the removal of the deteriorated parts

and reinstatement with a fresh repair mortar (Hassan et al. 2001). Maintenance and repair or rehabilitation is becoming increasingly important part of design and construction industry. Much of the repair work undertaken in the first half of the century was relatively simple from a materials engineering perspective, as it primarily involved replacement of damaged or deteriorated concrete with conventional Portland cement based materials. While the conventional Portland cement based repair materials have served the construction industry well for many decades, there are many reported in the literature where performance has been less than satisfactory (Morgan 1996). New enhanced concrete repair and materials and systems have been introduced and found increasing utilization. Some of these repair materials have been developed specially for patch repair application and claimed to have a better performance compared to conventional mortar. Propetiary repair materials are usually protected by patents. Manufacturers are understandably reluctant to provide complete details of their materials. The information offered to potential users is in many cases indequate. Engineers and specifiers faced with a wide choice of materials and little guidance on their properties, may opt for materials having properties as close as possible to those of the base

Senior Lectures, Sebelas Maret University, Solo 57126, INDONESIA

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concrete . Since disclosure of the composition of repair materials is not realistically possible there is need to establish a set of requirements which should be based on performance related properties. Cabrera and Al-Hasan (1997) suggested these properties include dimensional stability, compatibility, strength and protection provided to the reinforcement. In term of dimensional stability, Robery and Shaw (1997) and Baluch et al (2002) noted the important to address restrained shrinkage effect, where repair product is bonded onto concrete. For a restrained situation, other properties of the repair materials such as creep and modulus of elasticity are as important as free shrinkage. All these properties ensure that the applied repair materials will be resistance to cracking due to restrained shrinkage effect. Banthia et al (2006) point out the role of fibers to mitigate such cracking. Currently, there are a wide range of fibers to be used to enhance the performance of repair materials including tyre fiber. Structural reinforced concrete repair requires a material that can to some extent strengthen the deteriorated concrete. The effectiveness of this strengthening influenced by compatibility of the combined system (concrete-repair). Compatibility in a repair system is the combination of properties between the repair material and the existing concrete substrate which ensures that the combined system withstands the applied stress and maintains its structural integrity (Hassan et al. 2001). Mangat and OFlaherty (2000) suggested that the relative stiffness of repair material and concrete substrate is the primary parameter for the design of efficient repair. They noted that repair applied with relatively stiff materials (higher elastic modulus compared to that of concrete substrate) will display effictive stress transfer to the substrate. Using polymeric and polymer modified concrete repair materials, Shambira and Nounu (2000) indicate that in the short-term both repair materials assist the repaired concrete column to carry load. Meanwhile, Hassan et al. (2001) proposed a simple model describing the modulus behaviour of combined repair and concrete materials and presented an experimental programme on the application of this model. Basically, the model is developed on the assumption that strain is constant over any cross section (iso-strain). In reality, this may not be tha case. Evaluation of compatibility between repair materials containing tyre fibers and concrete substrate by considering the differential strains (or elastic modulus) is the main focus of this research. The stress-strain relations of the repaired concrete (composite) under compressive stress were measured both on the existing concrete and on the patch repair materials. The

difference of strains observed on existing concrete and patch repair materials are used to evaluate their dimensional compatibility. A new model that takes into account those differential strains is proposed to describe elastic modulus behaviour of the composite system. This model is than used to estimate the stress distribution across section of patch repaired concrete. Comparison is made to asses the difference of stress distribution estimated by this model with that based on iso-strain. MODEL THEORY Elastic modulus behaviour of combined repair material and parent concrete based on assumption of isostrain has been suggested by Hassan et al. (2001). Fig. 1 ilustrates the combined system subjected to external stress (o), have modulus of elasticity Eo and Poissons ratio o . The corresponding properties of the two phases are shown in Fig. 1 with substrate concrete indicated by c and repair mortar by m. o

c Ec c

m Em m

0.5

0.5

Fig.1. Stress and strains of composite system The proposed model to compute elastic modulus of the combined system from the known elastic modulus of two phases is as follow:

Ec Em E o = 0 .5 (1 2 o ) 1 2 + 1 2 c m

(1)

According to Emberson and Mays (1996) the Poiaaons ratio has only second order effect on the stress distribution is patch repair. If the differences in Poissons ratios are neglected, i.e. 0=c=m, then Eq.1 becomes: (2) E = 0.5( E + E )
o c m

For the case of non-iso strain, the model is developed as follows: Let the strain over cross section of the combined system is shown as in Fig. 2. The observed

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strain due to applied external stress o on the surface of concrete and repair material is cs and ms , respectively while the strain in the interface or transition of repair material and concrete is t . The average strain in the concrete c and mortar m may be calculated using Eq. 3 and 4. . c = 0 .5 ( cs + t ) (3)

m = 0.5( ms + t )
For equilibrium of forces in the combined system:

(4) (5)

research is that of passing grading size of 4.75 mm. Meanwhile, the use of accelerator is necessary to increase hardening rate of repair material since in practice the repair material should adhere to the parent concrete and work as composite system as fast as possible. Table 2 summarises the proportions of the materials. A part from the repair materials, concrete having target strength of 30 MPa was also proportioned to represent substrate concrete which will eventually be repaired.

o x1 = c x 0 .5 + m x 0 .5
or

o = 0 .5 ( E c c + E m m )
Substituting Eqs. 3 and 4 into Eq. 6:

(6)

o = 0 . 25 [E c ( cs + t ) + E m ( ms + t ) ]

(7)

cs

Fig.3. Tyre fiber used in this research

ms
Grading size 4.75 2.36 1.18 0.85 Table 1. Tyre fiber grading Physical properties of fiber Cumulative Passing Length Diameter (mm) (mm) 66.6% 21.5 1.8 56.5 9.2 1.2 29.14 2.35 0.8 7.8 Table 2. Composition of repair materials Repair Material Fiber Composition

Fig.2. Asummed strain over cross section of combined specimen MATERIALS AND METHODS This research utilizes mortar containing various level of tyre fibers as patch repair materials. The properties of mortar is enhanced by the use of two admixtures i.e. superplasticizer and accelerator to modify its workability and hardening rate, respectively. Since the repair material should have comparable strength with that of parent concrete, the water/cement ratio has to be kept at a level that will produce mortar having strength in the range of 20-30 MPa. This range of strength is assumed to be that of normal concrete use in common old structural concrete. Trial investigation showed that this could be achieved when mortar was proportioned at 1:2.5 by weight of cement:sand with water/cement ratio of 0.50. The proportion of superplasticizer is determined at 2% by weight of cement. At this composition, 12 % of tyre fiber by volume of mortar is found to be the maximum level of fiber that can be added into mix to maintain workability of fresh repair material still suitable to be mixed, handled and applied manually. Fig. 3 and Table 1 ilustrate physical properties of tyre fiber used in this research. It is noted that tyre fiber used in this

M-0% 0% All repair materials have proportion: cemen: sand = 1: 2.5, w/c ratio = M-4% 4% 0.5, superplasticizer = 2%*, M-8% 8% M-12% 12% accelerator = 0.4%* (*by weight of cement) Cylindrical specimens having size 15 mm diameter and 300 mm height were cast for the purpose of determining elastic modulus. These cylindrical specimens include that of parent concrete specimens. The specimens were demolded after 24 hours and stored in the laboratory environment (27-32oC and 65-70% RH) before testing. All the specimens were tested under compressive stress (Fig.4). The stress was applied

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incrementally until reaching 30% of the ultimate strength of the specimen. The stress and the coressponding strain were recorded. For concrete specimens, testing was performed at the age of 28 days. Meanwhile, for repair materials testing was carried out at the age of 1 day.

Combined cylindrical specimens were cast as follow; First a half of cyllinder concrete specimens was cast (Fig. 5). After 24 hours, they are demolded and stored in the laboratory environment until 28 days. At this age, the half cylinder concrete specimens were placed again in their original moulds. The other halves of the moulds were cast with the different repair materials to produce combined specimens (Table 3). The specimens were compacted and kept in the mould for 24 hours before demoulding. The combined specimens were then tested under compressive stress similar to those of uncombined specimens. The stress and the coressponding strains on the surface of concrete substrate and repair materials were recorded. Table 3. Combined specimens identification Sample Combined specimen identification Combined specimen made of a half C-M0% concrete (C) and a half of repair C-M4% materials (M) with respective % of C-M8% fiber content C-M12%

RESULTS AND DISCUSSION The stress and corresponding strain of concrete substrate and all repair materials tested under compressive stress up to 30% of their respective ultimate strength are given in Fig.6. Each curve represents average of three specimens. Generally, it can be reckoned that concrete substrate is stiffer than those of repair materials. This is not surprising since stress-strain relationship of concrete substrate is determined at the age of 28 days while the corresponding repair materials determined at the age of 1 day. This difference in age of testing is intended to signify the difference in the age of damaged structural concrete and repair materials used to restore the damage. Furthermore, it is expected that repair materials should immediately contribute to carry load 24 hours after application. The results of this investigation imply that even though repair materials has been proportioned to have similar strength to that of concrete substrate, but at early age it has not yet developed its full potential properties and in turn, when it carries external compressive stress it will show higher deformation compared to that of concrete substrate. The difference in elastic deformation between concrete substrate and repair materials raise concern over it dimensional compatibility. From Fig.6, elastic modulus of the materials may be obtained from the gradient of these curves. The elastic moduli of materials determined in this way are presented

Fig.4. Testing of elastic modulus under compressive stress

Fig.5. Casting a half of combined cylinder

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in Table 4. These values of elastic modulus may further be analyzed to investigate the effect of fiber content. The result is presented in Fig.7. It is indicated from Table 4 that the elastic modulus of repair materials is in the range of 32-64% of the concrete substrate. Increasing fiber content tends to reduce the elastic modulus. From Fig. 6 it is clear that each addition of 4% fiber into repair material will reduce elastic modulus by about 17%. The reduction in elastic modulus by addition of fiber could be related to the fact that this material is softer compared to sand. At a given volume, repair material with higher fiber content will have lower fraction of sand. Hence, a higher fraction of softer ingredient in the repair materials causes these materials deform more under compressive stresss and vice versa.
9 8 7 6 S tre s s (M P a ) 5 4 3 2 1 0 0 50 100 150 200 250 300 350 400 450 Strain (10-6) Concrete substrate M-0% M-4% M-8% M-12%

Table 4. Elastic modulus of materials Specimen Elastic Modulus C (concrete substrate) 24.6 GPa M-0% 15.6 GPa M-4% 13.5 GPa M-8% 9.4 GPa M-12% 7.9 GPa

Fig.7. Effect of fiber content on elastic modulus of repair materials

Fig.6. Stress-strain relationships of concrete and repair materials

Fig. 8. Stress and corresponding strains on the concrete and repair materials phase of combined specimens

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Fig.8 shows the stress-strain relationships of combined specimens under compresive stress. All specimens confirm the different in strains observed on the surface of concrete substrate and repair materials. As the elastic modulus of repair materials is lower than that of concrete substrate, therefore when external stress applied to the combined specimens the strains observed on the repair materials tend to be higher than that of concrete substrate. To determine whether this difference in strain under short-term compressive stress is still within acceptable level or not, it is necessary to evaluate its effect on the stress distribution over cross section of combined specimen. If the stress distribution does not different with that calculated from the assumption of constant strain over any cross section of combined specimen (iso-strain), it is justified to state that the repair materials and concrete substrate still have dimensional compatibility. For a case of iso-strain any external load applied to combined specimen will produce constant strain over any cross section which is equal to the applied stress divided by the elastic modulus of combined specimen determined from Eq.2. The resulting strain is then used to calculate the stress distribution by considering the elastic modulus of each phase. It can be deduced that the external stress will produce ratio of stress distributed on repair material and concrete phase equals to the ratio of their respective elastic modulus. For the case of non-isostrain, the stress distribution is calculated as follows: First, the measured strain on each surface of concrete and repair material is determined from Fig. 8. Then Eq. 7 could be employed to calculate the strain in the interface between concrete substrate and repair material with elastic modulus data taken from Table 4. With the strain in the interface has been obtained, so the average of strain in concrete substrate and repair material can be calculated using Eq. 3 and 4, respectively. The resulting average strains are then used to compute the stress distribution by multiplying of the strains with the corresponding elastic modulus. The results of stress distribution calculation both for cases of iso-strain and non isostrain are presented in Fig. 9. As can be seen from this figure, the stress distributed in the repair material and concrete depends on the ratio of elastic modulus of repair material and concrete substrate. For a case of iso-strain the ratio of stress distributed on repair material and concrete substrate is exactly equal to the ratio of their respective elastic modulus. In the case of non iso-strain, a higher ratio of elastic modulus is required for the same level of stress distribution compared to that of iso-strain case. It means that for a

given repair materials, actual stress carried by the repair materials is less than that calculated by the asumption of iso-strain. This clearly confirms that dimensional incompatibility between repair material and concrete substrate will affect the capability of the repair material in assisting to carry load. The effect is to reduce its contribution to support external load, and the magnitude of its contribution is less than that expected from the iso-strain asumption.

100

Ratio of elastic modulus of repair material and concrete (%)

y = 0,8841x + 34,713 80

60 iso-strain 40 non iso-strain

y=x

20

0 0 10 20 30 40 50 60 70 Ratio stress in repair material and concrete (%)

Fig. 9. Relationship between ratio of elastic modulus of repair material and concrete substrate and ratio of their respective stress distribution. Fig. 9 also suggests that to expect repair material carrying external stress at 50% of that carrying by concrete substrate, the required elastic modulus elasticity must be at least 75% of the elastic modulus of concrete substrate. This is higher than that expected for the case of iso-strain which requires only 50%. CONCLUSIONS This research confirms that application of patch repair material requires consideration of dimensional compatibility. The difference of elastic modulus between repair material and concrete substrate result in uneven of strain across section of combined specimen. Consequently, the stress distributed over the repair material is less than that calculated based on iso-strain assumption. For patch repair material used in this research, inclusion of a higher fiber content reduces the elastic modulus of repair material, which in turn, lowering the contribution of the repair material in carrying compressive stress.

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REFERENCES Baluch, M.H., Rahman, M.K. and Al-Ghadib, A.H. (2002). Risks of cracking and delamination in patch repair. Journal of Material in Civil Engineering.14(4):294-302. Cabrera, J.G., Al-Hasan, A.S. (1997). Performance properties of concrete repair materials. Construction and Building Materials. 11(5-6):283-290. Hassan, K.E., Brooks, J.J. and Al-Alawi, L. (2001). Compatibility of repair mortars with concrete in a hot-dry environment. Cement and Concrete Composites. 23:93-101.

Mangat, P.S. and OFlaherty, F.J. (2000). Influence of elastic modulus on stress redistribution and cracking in repair patches. Cement and Concrete Research. 30:125-156. Morgan, D.R. (1996). Compatibility of concrete repair materials and system. Construction and Building Materials. 10(1):57-67. Robery, P. and Shaw, J. (1997). Materials for the repair and protection of concrete. Construction and Building Materials. 11(5-6):275-281. Shambira, M.V. and Nounu, G. (2000). Construction and Building Materials. 14:425-432.

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