Permeability Compatibility Between

Concrete Repair Material and Concrete

Substrate – Scoping Study
Research and Development Office
Science and Technology Program
Final Report ST-2018-1863-01 (8530-2018-58)

U.S. Department of the Interior

Bureau of Reclamation
Research and Development Office September 2018
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Permeability Compatibility Between Concrete Repair Material and Concrete 18XR0680A1-RY15412018WI31863
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Concrete, Geotechnical, and Structural Laboratory
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13. SUPPLEMENTARY NOTES
14. ABSTRACT
The primary objective of this report is to develop a robust research program and to highlight the importance of research
related to freeze-thaw durability and repair material compatibility with existing concrete substrates. This report will identify
several organizations in the concrete industry that have identified better concrete durability as a key goal.
15. SUBJECT TERMS
Concrete repair, freeze thaw, compatibility
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BUREAU OF RECLAMATION
Research and Development Office
Science and Technology Program
Concrete, Geotechnical, and Structural Laboratory, 86-68530
Final Report ST-2018-1863-01 (8530-2018-58)

Permeability Compatibility Between Concrete

Repair Material and Concrete Substrate - Scoping
Study
SHANNON Digitally signed by SHANNON
HARRELL
HARRELL Date: 2018.09.25 10:15:34 -06'00'

Prepared/Technical Approval by: Shannon Harrell, P.E.

Civil Engineer, Concrete, Geotechnical, and Structural Laboratory Group, 86-68530

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Acronyms and Abbreviations
ACI American Concrete Institute

ARPA-E Advanced Research Projects Agency-Energy

ASTM ASTM International

DOE Department of Energy

ICRI International Concrete Repair Institute

SDC Strategic Development Council

Executive Summary
The discussion of repair material compatibility with the existing concrete substrate has been a
topic of discussion between concrete repair experts for many years. Most of the compatibility
discussions have been focused on dimensional compatibility between repair materials and
existing substrates, but there has not been much emphasis on permeability compatibility. When
permeability has been investigated, most studies looked at the repair material itself and not the
composite system. Many researchers have studied freeze-thaw durability of repair materials
using ASTM C666 [1], or the permeability as it relates to chloride ion penetration using ASTM
C1202 [2], which relates more to corrosion of embedded steel. There is one example of issues
with permeability between the concrete substrate and the repair material that has been cited in
several references. However, there is limited research into how a low permeability repair
material placed over a highly permeable concrete substrate will affect the long-term durability of
the repair in cold weather environments.

Water vapor transmission is the key compatibility issue that will be discussed in this report.
Water vapor transmission becomes an issue when a low permeability repair material placed over
an existing concrete substrate allows the transport of water vapor to the interface between the
repair material and the existing concrete substrate. If the repair is thin, the water vapor may
freeze and hydraulic pressure may cause the repair to disbond from the existing concrete, leading
to failure of the repair [3].

This scoping study came to the following conclusions:

• Concrete durability is one of the topics leading experts find important for the
development of the concrete industry.
o Both SDC and ARPA-E list concrete durability as goals for the concrete industry.
• There is limited guidance by ICRI for specifying concrete repair overlays that may be
subject to water vapor transmission passing through the existing concrete substrate.
• There has been little research on freeze-thaw durability of the composite system. Most
studies have looked only at freeze-thaw durability of the repair material.
• Typical guidance for specifying permeability of concrete repair materials has been to
specify a low permeability material because of its resistance to chloride penetration and
carbonation of the concrete.
• More applied research in the laboratory is recommended.
Contents
Executive Summary ........................................................................................................... vi
Abstract .............................................................................................................................8
Background ..........................................................................................................................8
Previous Work .....................................................................................................................8
Conclusions ..........................................................................................................................9
Discussion ............................................................................................................................9
Literature Review...............................................................................................................10
ICRI Recommendation [3].............................................................................................10
Strategic Development Council (SDC) [11] ..................................................................11
ARPA-E Workshop [13] ................................................................................................11
Recommendations for Next Steps......................................................................................12
Laboratory Research Strategy ........................................................................................12
References ..........................................................................................................................14

Figures
Figure 1. Freeze-thaw probability map from International Residential Code 2009 [8].....10
Figure 2. Concrete specimens used for bond failure investigation. ...................................13
Figure 3. Concrete specimens used for accelerated freeze-thaw deterioration investigation.
............................................................................................................................................13

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Permeability Compatibility Between Concrete Repair Material and Concrete Substrate - Scoping
Study

Abstract
The primary objective of this report is to develop a robust research program and to highlight the
importance of research related to freeze-thaw durability and repair material compatibility with
existing concrete substrates. This report will identify several organizations in the concrete
industry that have identified better concrete durability as a key goal.

Background
The discussion of repair material compatibility with the existing concrete substrate has been a
topic of discussion between concrete repair experts for many years. Most of the compatibility
discussions have been focused on dimensional compatibility between repair materials and
existing substrates, but there has not been much emphasis on permeability compatibility. When
permeability has been investigated, most studies looked at the repair material itself and not the
composite system. Many researchers have studied freeze-thaw durability of repair materials
using ASTM C666 [1], or the permeability as it relates to chloride ion penetration using ASTM
C1202 [2], which relates more to corrosion of embedded steel. There is one example of issues
with permeability between the concrete substrate and the repair material that has been cited in
several references. However, there is limited research into how a low permeability repair
material placed over a highly permeable concrete substrate will affect the long-term durability of
the repair in cold weather environments.

Water vapor transmission is the key compatibility issue that will be discussed in this report.
Water vapor transmission becomes an issue when a low permeability repair material placed over
an existing concrete substrate allows the transport of water vapor to the interface between the
repair material and the existing concrete substrate. If the repair is thin, the water vapor may
freeze and hydraulic pressure may cause the repair to disbond from the existing concrete, leading
to failure of the repair [3].

Previous Work
In 2017, the Bureau of Reclamation’s (Reclamation) Research and Development office through
the Science and Technology program funded the scoping study report number ST-2017-7103-01,
Development of Practical Guidelines to Achieve Compatibility in Concrete Repairs and
Overlays- Scoping Study. Through that project, the Concrete, Geotechnical, and Structural
Laboratory (CGSL) identified permeability as a concrete repair material compatibility issue that
required further investigation. There has been very little research focus on permeability as it
relates to water vapor transmission and bond failure between repair materials and existing
concrete substrates [4].

Reclamation’s involvement with the concept of concrete repair compatibility was started with the
Materials Engineering and Research Laboratory (MERL) report number MERL-2014-87,
Compatibility Issues in Design and Implementation of Concrete Repairs and Overlays which was
also funded by Reclamation’s Research and Development office through the Science and

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Technology program. The report identified 5 compatibility issues that require further study;
dimensional, permeability, electrochemical, chemical, and aesthetic compatibility [5].

MERL report number MERL-2014-87, referenced Vaysburd and Emmons [6] which discusses
the potential of encapsulating concrete through protective vapor barriers. The vapor barrier traps
moisture below the impermeable coating and can lead to freeze-thaw damage of the concrete.
MERL-2014-87 referenced Vaysburd, noting that further studies should be conducted to
determine what degree of permeability should be recommended for repair materials. The
question was raised: “Is a very low permeability or matching (with the existing concrete)
permeability more effective?” [5] [7].

Conclusions
• Concrete durability is one of the topics leading experts find important for the
development of the concrete industry.
o Both SDC and ARPA-E list concrete durability as goals for the concrete industry.
• There is limited guidance by ICRI for specifying concrete repair overlays that may be
subject to water vapor transmission passing through the existing concrete substrate.
• There has been little research on freeze-thaw durability of the composite system. Most
studies have looked only at freeze-thaw durability of the repair material.
• Typical guidance for specifying permeability of concrete repair materials has been to
specify a low permeability material because of its resistance to chloride penetration and
carbonation of the concrete.
• More applied research in the laboratory is recommended.

Discussion
The following literature review has been provided to highlight the lack of guidance as it pertains
to concrete repair material permeability. There has been very limited guidance on how to handle
specifying a concrete repair overlay in a concrete structure where the existing concrete may be
saturated prior to repair or may have a means of water vapor transmission through the existing
concrete. In general, the guidance is simply to consider that a low permeability repair material
may not be appropriate. The literature review also reinforces the author’s view that durability is
an issue throughout the concrete industry. Although dimensional, chemical, electrochemical, and
chemical compatibility are important to long lasting concrete repairs, permeability is just as
important in cold weather climates and should not be ignored. Many Reclamation projects fall in
this F/T affected exposure classification. Figure 1 below shows that many of Reclamation
facilities are in “severe weathering probability” zones.

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Permeability Compatibility Between Concrete Repair Material and Concrete Substrate - Scoping
Study

Figure 1. Freeze-thaw probability map from International Residential Code 2009 [8].

Literature Review
ICRI Recommendation [3]
The International Concrete Repair Institute (ICRI) has numerous technical guides to educate the
concrete repair industry on specifying repair materials, appropriate surface conditions and
preparation of the existing concrete substrate, concrete removal and repair material application
methods, and many more. One of these technical guides, Guide for Selecting and Specifying
Materials for Repair of Concrete Surfaces (Guideline No. 320.2R-2009) [3] discusses the
properties that should be specified as it relates to a durable repair. However, when it comes to
permeability, the recommendation in section 3.3.1 is a low permeability repair material to resist
chloride ion penetration and carbonation of the concrete. There is no discussion as to how a low
permeability repair material placed over a highly permeable and saturated concrete substrate may
affect freeze-thaw damage potential.

Freezing and thawing resistance is also discussed in ICRI Guideline No. 320.2R-2009 [3] in
section 3.3.3, but the recommendation is based on freeze-thaw resistance of the repair material
and not necessarily the composite section.

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Water vapor transmission through the repair material is discussed in the ICRI Guideline No.
320.2R-2009 [3] as being an issue if water vapor is transmitted through the substrate and trapped
below a low permeability repair material. ASTM E96 [9] is the recommended test method to
determine the water vapor transmission of the material. However, many major repair material
manufacturers either do not test their products using ASTM E96 [9] or do not publish the results
in their technical data sheets. In addition, Guideline No. 320.3R-2012 [10], Guideline for
Inorganic Repair Material Data Sheet Protocol, does not recommend ASTM E96 [9] as a test
method that should be conducted or reported by the repair material manufacturers [10]. Without
the publication of this information by the manufacturer, it is difficult to know if the repair
material will be compatible with the existing substrate when it comes to water vapor
transmission. Furthermore, there is uncertainty in what the range of values ASTM E96 [9] gives
and what limits truly affect the bond.

Strategic Development Council (SDC) [11]

The Strategic Development Council (SDC) is a council of the ACI Foundation which was
formed to facilitate and accelerate the acceptance of new technologies. SDC has developed a
Concrete 2029 initiative where one of their goals is durability roadmapping. SDC has been
holding numerous Concrete 2029 workshops during the biannual technology forums. The 2017
Spring workshop held in Dallas, TX focused the discussion on durability design and what
improvements need to be made in the U.S. to achieve better concrete durability in the future.

An overview of International codes and how they approach durability was highlighted. The
biggest takeaway was the emphasis on expected design service life. The Japan Society of Civil
Engineers have a chapter on verification of durability to determine if steel corrosion, freeze-thaw
damage, or chemical attack will affect the required performance of the structure. ACI 318 has no
reference to design service life [12].

ARPA-E Workshop [13]

Advanced Research Projects Agency-Energy (ARPA-E) was established as an advanced research
project agency within the Department of Energy (DOE) to “identify the most urgent challenges
the U.S. faces in maintaining leadership in key areas of science and technology.” ARPA-E funds
research on energy technologies to foster the United States’ economic and energy security.

In April 2018, ARPA-E held an Extremely Durable Cementitious Materials Workshop which
brought together leading experts in the concrete industry. The workshop included representatives
from government, academic, and private sector industries. The purpose of the workshop was to
“identify innovation which significantly improves durability, lowers its energy footprint, and
results in next generation, cost-effective materials to address our current infrastructure
challenges.”

One of the themes that routinely arose during the discussions was the need for more durable
concrete. These discussions also focused on the gaps in the industry for long term durability and
how the U.S. has fallen behind in defining exposure conditions and requiring that durability be a
focus during design. This was also highlighted in the SDC workshop discussed above.

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Permeability Compatibility Between Concrete Repair Material and Concrete Substrate - Scoping
Study

The workshop challenged the attendees to have an open discussion about the following goals and
how they could be achieved:

1. Double concrete durability with two times longer service life.

2. Halve O&M expenses.
3. Use of existing facilities.
4. Lower concrete costs.

Reclamation was a part of this workshop to bring to the table how concrete durability (or lack
thereof) affects our infrastructure. We discussed the importance of durable concrete due to our
mission of reliably delivering water and power to the 17 western states.

Recommendations for Next Steps

Laboratory Research Strategy
Laboratory research should be conducted to answer the following questions:

1. Will a low permeability repair material placed over a highly permeable and saturated
existing concrete substrate lead to bond failure of the concrete after cycles of freezing
and thawing due to trapping water vapor below the concrete repair material?
2. Will a low permeability repair material placed over a highly permeable and saturated
existing concrete substrate lead to an acceleration of freeze-thaw deterioration of the
existing concrete substrate due to trapping water vapor below the concrete repair
material?

Bond Failure Investigation

Investigation of the bond failure between a low permeability repair material and highly
permeable and saturated existing concrete substrate will be tested in the lab by first casting
specimens that are highly permeable. The slabs will be saturated to different levels to determine
if there is a degree of saturation at or beyond which bond failure is likely to occur. A low
permeability repair material will be cast on top of the highly permeable specimens. Bond testing
of the specimens utilizing the pull-off test per ASTM C1583 [14] will be used to set a baseline of
the bond strength that is expected for each degree of saturation. The specimens will then be
subjected to freeze-thaw testing per ASTM C666 [1] and retested for bond strength per ASTM
C1583 [14] at the completion of the ASTM C666 procedure. Figure 2 shows the configuration of
the concrete specimens for the bond failure investigation.

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Figure 2. Concrete specimens used for bond failure investigation.

Acceleration of Freeze-thaw Deterioration Investigation

Highly permeable concrete specimens without low permeability concrete overlays will be cast at
the same time as the specimens for the bond failure investigation. The specimens will be
subjected to freeze-thaw testing per ASTM C666 [1] at the same time as the bond failure
specimens.

At the end of testing, a petrographic examination will be conducted to compare the degree of
deterioration of highly permeable specimens with low permeability concrete overlays to highly
permeable specimens without an overlay. Figure 3 shows the two different specimens that will
be used for this portion of the investigation.

Figure 3. Concrete specimens used for accelerated freeze-thaw deterioration investigation.

Further Studies
Successful outcomes from the laboratory research outlined above could lead to the following
additional investigations:

• Field study to determine if results are similar to those observed in the laboratory study.
• Development of guidance for specifying concrete repair overlays in freeze-thaw prone
locations.

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Permeability Compatibility Between Concrete Repair Material and Concrete Substrate - Scoping
Study

References

[1] ASTM, ASTM C666/C666M - Standard Test Method for Resistance of Concrete to Rapid
Freezing and Thawing, West Conshohocken, PA: ASTM International, 2015.

[2] ASTM, ASTM C1202 - Standard Test Method for Electrical Indication of Concrete's
Ability to Resist Chloride Ion Penetration, West Conshohocken, PA: ASTM International,
2017.

[3] International Concrete Repair Institute (ICRI), "Guide for Selecting and Specifying
Materials for Repair of Concrete Surfaces (Guideline No. 320.2R-2009)," International
Concrete Repair Institute, Des Plaines, IL, May 2009.

[4] S. Harrell, "Development of Practical Guidelines to Achieve Compatibility in Concrete

Repairs and Overlays - Scoping Study," Bureau of Reclamation, Research and
Development Office, Denver, CO, 2017.

[5] A. M. Vaysburd, B. Bissonnette and K. F. von Fay, "Compatibility Issues in Design and
Implementation of Concrete Repairs and Overlays- MERL-2014-87," U.S. Department of
the Interior, Bureau of Reclamation, Denver, CO, 2014.

[6] P. H. Emmons and A. M. Vaysburd, "Factors Affecting Durability of Concrete Repair -

The Contractor's Viewpoint.," in Proceedings of the Fifth International Conference on
Structural Faults and Repair, 253-268, Edinburgh, UK, 1993.

[7] A. M. Vaysburd, "Holistic System Approach to Design and Implementation of Concrete

Repairs," Cement and Concrete Composites, vol. 28, no. 8, pp. 671-678, 2006.

[8] International Code Council, International Residential Code, Country Club Hills, IL:
International Code Council, Inc., 2009.

[9] ASTM, ASTM E96 - Standard Test Method for Water Vapor Transmission of Materials,
West Conshohocken, PA: ASTM International, 2016.

[10] International Concrete Repair Institute (ICRI), "Guideline for Inorganic Repair Material
Data Sheet Protocol (Guideline No. 320.3R-2012)," International Concrete Repair Institute,
Rosemont, IL, 2012.

[11] ACI Foundation Strategic Development Council (SDC), "Concrete 2029," Dallas, TX,
2017.

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[12] T. D. Marcotte, "Durability Design International Codes," in SDC Technology Forum #41,
Dallas, TX, 2017.

[13] ARPA-E, "Extremely Durable Cementitious Materials," Dallas, 2018.

[14] ASTM, ASTM C1583 - Standard Test Method for Tensile Strength of Concrete Surfaces
and the Bond Strength or Tensile Strength of Concrete Repair and Overlay Materials by
Direction Tension (Pull-off Method), West Conshohocken, PA: ASTM International, 2013.

15
 Data Sets that Support the Final Report
If there are any data sets with your research, please note:

Share Drive folder name and path where data are stored: \\bor\do\ENGRLAB\MERL\Science
and Technology\FY18\Harrell\Permeability\references

Point of Contact name, email, and phone: Shannon Harrell, [email protected], 303-445-2370

Short description of the data: Literature references used in this study.

Keywords: ASTM, Concrete repair, compatibility.

Approximate total size of all files:13.5MB (folder size)