Technical Bulletin No. 17 Epoxy Bonding Agents
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1 1.0 Design Considerations Technical Bulletin No Bond Line Thickness: A thin bond line is more desirable than a thick one as more time is available to assemble the components to be bonded and the strength of the bond is greater. In excessively thick bond lines, heat developed during cure may cause foaming with a reduction in strength. The optimum bond line thickness is between 1/32 to 1/ Service Temperature: Important physical properties of polymers gradually decrease with increasing temperature. As the temperature approaches the Heat Deflection Temperature (HDT) this decrease becomes more dramatic. Therefore, the HDT is an indicator of the service temperature limitations of polymers under load. (See Section 2.0, Material Considerations.) 1.3 Influence of Load: When loads are applied to polymers, their response is a combination of elastic and viscous strain (viscoelastic behavior). The viscous component of strain is time dependent, thus a sustained load may cause creep. The rate of creep in turn is dependent on the load magnitude and the temperature: an increase or decrease in either will result in an increase or decrease in creep. 1.4 Construction Sequence: Construction sequence will require a compromise between working and cure time. A fast curing product has a short working time but can be put into service sooner than a product with a slower cure and longer working time. 2.0 Material Considerations 2.1 Application Characteristics: All forms of epoxy adhesives, liquids, pastes, or gels, change their characteristics with the prevailing ambient temperature. At low temperature they become more viscous and more difficult to apply. High temperature causes a decrease in viscosity and a reduction in non-sag properties of pastes and gels. It is important to define the probable application temperature range and select a product with application characteristics suitable for this range. Use of more than one product may be required to accommodate a wide temperature range. 2.2 Curing Characteristics: Working time and cure time are affected by the ambient air and substrate temperature at the time the material is applied and during cure as follows: Working Time: Pot life and open time are the two elements which make up working time: Page 1 of 6
2 Pot life is the time a predetermined quantity of mixed product is workable in the mixing vessel. A high material temperature and/or a large volume of mixed material will shorten the pot life. Open time is the period between the application of the product and the expiration of the ability of the adhesive to bond. Use of fast curing products or high substrate temperature will result in short open times Cure Time: Cure rate increases with increasing temperature. There is a minimum temperature below which formulations will cease to cure. Many epoxy adhesives will resume curing when the temperature rises above this minimum. 2.3 Cured Characteristics 3.0 Estimating Quantities Bond Strength: In bonding concrete to concrete or other rigid materials, the bond is usually subjected to shear stresses. The common measure of bond strength is a slant shear test (ASTM C882) wherein the bond line is oriented 30 F from the vertical axis of a compression specimen Heat Deflection Temperature: Cross-linked polymers such as epoxy adhesives are characterized by a temperature at which they experience a transition from a rigid to a flexible state. Due to the nature of these polymers, the transition is gradual and occurs over a range. By convention, a close approximation of this temperature is obtained from ASTM D648 and is called Heat Deflection Temperature, which falls in the center of the range. The range typically extends 25 to 30 F above and below the HDT. A polymer will exhibit the physical characteristics desirable for structural bonding applications when the service temperature is within the rigid zone (at least 30 F below the HDT). 3.1 In bonding two hardened surfaces, the volume of the anticipated joint is determined and the additional volume required to fill surface irregularities is estimated. For squeeze out and waste 10% is usually added to the total calculated volume. 3.2 In bonding fresh concrete, the material requirement can be determined from the coverage recommendations in the Technical Bulletin for the specific product. Page 2 of 6
3 3.3 The coverage rate will vary with the surface texture of the concrete. Rough surfaces, with a chipped or broom finish, will require more bonding agent than smooth surfaces such as a screeded or steel troweled finish or a formed surface. The following coverage rates may be used for estimating purposes: Rough Smooth Surface Surface Gel 6 ft 2 /gallon 12 ft 2 /gallon Liquid 50 ft 2 /gallon 100 ft 2 /gallon 4.0 Surface Preparation 4.1 General: Surfaces to be bonded must be clean and sound, which in all cases requires some form of preparation. 4.2 Surface Evaluation: The following tests can be used to evaluate the condition of the substrate and the effectiveness of the surface preparation procedures Strength: The direct tensile strength of the surface can be determined by a pipe cap pull-off test (1) or a commercially available adhesion tester. (2) A pull-off strength of 200 psi is considered minimum for bonding applications Contaminants: The presence of grease, wax or oil may be detected by dropping a small amount of muriatic acid onto the surface. No reaction indicates that contaminants are present. If oil has penetrated into a concrete surface, it can be detected by raising the temperature of a small area about 150 F with a heat lamp. Presence of the contaminant is indicated if oil appears or the area becomes greasy to the touch. 4.3 Cleaning Procedures: Concrete Surfaces: Concrete surface profile should be in compliance with the International Concrete Repair Institute, Concrete Surface Profile, CPS 3 to Grease, wax and oil contaminants can be removed by scrubbing with an industrial grade detergent or degreasing compounds followed with mechanical cleaning. Page 3 of 6
4 Weak or deteriorated concrete must be removed to sound concrete by bush hammering, gritblasting, scarifying, waterblasting or other suitable mechanical means Dirt, dust laitance and curing compounds can be removed by gritblasting or etching with a 15% solution of hydrochloric acid. Acid etching is recommended only when there is no practical alternative and must be followed by scrubbing and flushing with copious amounts of clean water. When checked with moist ph paper, a reading of 10 or more will indicate that the acid has been removed Dust from mechanical cleaning is removed by vacuum cleaning. 4.4 Steel Surfaces: 5.0 Application Techniques A suitable industrial grade cleaning and degreasing compound will remove dirt, grease and oil Rust and mill scale can be removed by gritblasting to white metal. It is recommended to follow gritblasting with vacuuming or oil-free, dry airblast. 5.1 General Bonding: Deep surface irregularities in the face of the substrate can be filled with a 1:1 blend of sand and epoxy adhesive. After this fairing material has set or within 24 hours, the neat bonding agent is applied with a trowel in sufficient quantities to fill all gaps between the mated surfaces Ideally, a small amount of bonding agent is extruded from the joint when the surfaces are mated and pressure is applied. Surfaces must be mated within the open time of the epoxy adhesive A second coat of adhesive must be applied if the open time is exceeded. Should the adhesive have cured hard, the first coat must be roughened with an abrasive wheel or preferably light gritblasting and a second coat of adhesive applied prior to mating the surfaces to be bonded. Polymer adhesives are used throughout the construction industry in bonding a variety of construction materials The major advantage of bonding over other fastening methods, e.g., welding and bolting, is that stresses are distributed over a larger area, thus maintaining the integrity of the substrates Structural bonding materials are usually based on epoxy polymer systems because they have several important advantages over other polymer: Page 4 of 6
5 5.2 Low Shrinkage: Epoxy adhesives have lower curing shrinkage than most polymers. 5.3 Versatility: Epoxy adhesives have the ability to bond to most construction materials and under a wide range of environmental conditions, particularly to damp concrete and even under water. Epoxy bonding adhesives are available in many forms; such as low viscosity liquids, medium viscosity high-build liquids, and pastes or gels. When cured, they can be formulated to be relative stiffness (rigid) to relatively flexible. In this Bulletin, specific bonding applications will be described along with useful information to aid in engineering and application design, product selection, specification and use of epoxy adhesives. Technical Bulletins for the selected bonding agents give detailed application, physical property and performance information. Bonding Fresh Concrete Typical applications of bonding fresh concrete include: Bonding fresh concrete overlays and patches to existing concrete Bonding fresh concrete to permanent steel forms or decking to enhance composite action. Bonding Rigid Materials A number of applications fall into this category; all have similar performance requirements. The most common of these applications are: Bonding precast concrete segments Anchoring bolts, dowels and rebars into concrete Bonding external steel reinforcing plates or beams to concrete Bonding brick, stone and other masonry products Bonding dry wood itself Bonding Dissimilar Materials When joining materials which have different degrees of flexibility and/or coefficients of thermal expansion, it is desirable that the joining material be somewhat pliable. Applications which fall into this category are: Bonding rubber gaskets to steel or concrete Bonding plastic or foam to steel or concrete Bonding raised pavement markers Bonding waterstop in concrete Page 5 of 6
6 Disclaimer: PolyAmerica USA Technical Bulletins are developed in good faith for the sole purpose of assisting others with products, systems and industry standards. The information published herein is gathered from different sources that are thought to be reliable, but the reader should not assume that the information absolves the reader from validating information from other sources, such as listed below, before making a decision. Since information from others can change without notice, PolyAmerica USA cannot be held at fault if any of the information conveyed in good faith is deemed in error. Listed below is a number of Trade Association Organization that can provide additional assistance to the reader. Questions: Contact PolyAmerica USA PolyAmerica USA, LLC 5001 East Expressway 83, Suite 830 Mercedes, Texas Page 6 of 6
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