BIO-BASED MORTAR FOR CONCRETE REPAIR

M G Sierra-Beltran & H M Jonkers

Delft University of Technology
Faculty of Civil Engineering and Geosciences
Microlab, M & E
P.O. Box 5048
2600 GA Delft
The Netherlands
m.g.sierrabeltran@tudelft.nl

KEYWORDS: Concrete repair, Bio-based agent, Fibre-reinforced mortar, Shrinkage

ABSTRACT
Compatibility between the repair material and the concrete substrate ensures that the
repair system will stand the stresses induced by restrained shrinkage as well as
chemical changes. In this research, a cement-based mortar reinforced with a low
percentage of polymer fibres is studied. Under tension stress this material behaves
ductile and develops multiple micro-cracks before failure. A bio-based agent, present
in the mortar, will improve the durability of the repair system by promoting crack
healing and improving the bonding with the concrete substrate. The bio-based agent
consists of bacteria that are compatible with concrete and organic compounds that
serve as food for the bacteria. Previous research has shown the capacity of this biobased agent to produce calcite-based minerals, filling up cracks and reducing the
concrete permeability.
INTRODUCTION
Currently available concrete repair systems are often not compatible with the original
concrete material, which translate into early detachment and poor durability.
Additionally, these systems are largely based on environmental unfriendly materials
such as epoxy systems, acrylic resins or silicone-based polymers. This paper focus on
the development of a concrete compatible and fully sustainable bio-based repair
system, that features better bonding and improved durability and sustainability
characteristics when compared to existing repair systems.
A special type of high performance fibre reinforced cementitious composite (HFRCC)
called Engineered Cementitious Composite (ECC) has been studied as repair material
for concrete structures (Li 2009, Zhou 2011) because of its capability to deform to
high tensile strains under load. As a repair material, ECC cracks when subjected to
differential shrinkage but it is capable of carrying more tensile load and to
accommodate larger tensile strain than other repair systems (Zhou 2011).
ECC was micromechanically designed to have large values of strain capacity with a
low percentage of randomly distributed polymer fibres (Li 1993). Because of the
presence of fibres ECC develops multiple micro-cracking prior to failure. The crack
width remains below 1 millimetre (Li 2002). Conventional ECC is designed without
coarse aggregates and with only a small amount of fine sand, in order to control the
fracture toughness of the matrix (Li 1993). This characteristic leads to a higher
cement and binder ratio and eventually to a high value of shrinkage (Buffenbarger et
al. 1998). Li (2009), Yang et al. (2007) reported drying shrinkage values of 1200x106
to 1800x106 for conventional ECC. In similar drying conditions of 20C and 60%

relative humidity, normal concrete has a drying shrinkage strain of 400x106 to

600x106 (Neville 1995).
To improve the durability of the concrete repair system as well as to improve the
bonding with the concrete substrate, this paper proposes a bio-based agent to be
included in the mortar mix. The bio-based agent consists of alkali-resistant bacteria
and a food source for the bacteria. When applied in concrete, this bio-based agent has
the capacity to produce calcite-based minerals inside cracks reducing the permeability
of the concrete (Jonkers 2011, Wiktor and Jonkers 2011). The first steps into the
development of the bio-based mortar repair systems are presented in this paper.
EXPERIMENTAL PROGRAM
In this paper the experimental program covers two parts of the research investigation.
In the first part, four different ECC-type mixtures are characterized by their
mechanical properties and drying shrinkage. Based on these results, two mixtures are
chosen for further investigation as bio-based mortars. In the second part, the influence
of the healing-agent in the mechanical properties of the mortars was investigated.
Materials
The materials used are cement type CEM I 42.5N, blast furnace slag (BFS), fly ash
(FA), limestone powder (LP), sand, poly-vinyl-alcohol (PVA) fibres, and
superplasticizer (SP). BFS and fly ash have a potential of pozzolanic reaction and
these reactions need to be activated by the hydration products of Portland cement. In
the mix design, BFS, FA and Portland cement were considered as cementitious
materials, and the limestone powder was considered as inert filler material. Table 1
gives the mix proportion of the ECCs.
Table 1 Mixture compositions of ECCs
Mix ID
Mix 1
Mix 2
Mix 3
Cement, kg/m3
233
440
526
3
BFS, kg/m
543
132
FA, kg/m3
560
631
LP, kg/m3
775
Sand, kg/m3
440
405
Water, kg/m3
416
374
365
3
SP, kg/m
8
16
16
PVA fibres, kg/m3
26
26
26
0.27
0.33
0.33

Mix 4
516
620
413
384
10
26
0.25

The sand has an average and maximum grain size of 250 m and 500 m respectively.
The maximum particle size in Mix 2 and 3 correspond to the maximum particle size
of the sand. In Mix 1, the maximum particle size is 150 m, corresponding with the
maximum particle size of the cement and LP. The maximum particle size in Mix 4 is
200 m corresponding to the FA.
The PVA fibres have a diameter of 39 m and a length of 8 mm. The fibres have a
tensile strength of 1620 MPa, elastic modulus of 42.8 GPa and a maximum elongation
of 6.0%. The fibres have been coated with a proprietary oiling agent 1.2% by mass.
The superplasticizer Cretoplast SL-01 was used in this research. The amount of
superplasticizer was adjusted for each mixture to achieve consistent rheology
properties for proper fibre distribution and workability. The use of limestone powder

with Portland cement has many advantages, including durability and workability
(Tsivilis et al. 2002). Thus, in Mixes 1 and 4 prepared with LP, a lower water-tobinder ratio () and smaller amount of superplasticizer were necessary.
The healing agent considered for this research is an alkali-resistant spore-forming
bacteria and calcium lactate as a nutrient source for the bacteria. Lightweight
aggregates (LW) were impregnated with the bacteria and food. The LW particles have
sizes ranging between 0.25 and 2 mm.
Test methods
For each mixture, fresh state ECC was cast into prisms with dimensions 40x40x160
mm3 and thin beams with dimensions 240x60x10 mm3. The specimens were
demolded after 24 hours and moist cured in plastic bags at 95% relative humidity
(RH), 25C for 7, 28 and 60 days. Some of the prisms were cut into 40-mm cubic
specimens for compression tests and the thin specimens were cut into thin beams of
120x30x10 mm3 for four-point bending tests.
The four-point bending tests were performed under displacement control at a loading
rate of 0.01 mm/s. The span length of the flexural loading was 110 mm with a 30 mm
centre span length. During flexural test, the load and mid-span deflection were
recorded.
Drying shrinkage measurements were made on all mixtures. The drying shrinkage of
three prism specimens was measured up to 120 days after an initial one day curing in
the mould. The drying shrinkage specimens were stored in a drying room at 191C
and 522% RH.
RESULTS AND DISCUSSION
Compressive strength
Figure 1 shows the average of the compressive strength as determined from four cubic
specimens at the age of 28 days. The compressive strength of Mix 1, the mix with
considerably lower cement content, is as expected lower than for the other mixes.
This material fulfils the compressive strength requirements for repair material of
concrete structures Class R3 according to the standards NEN 1504-3. The other three
mixes have compressive strengths higher than 45 MPa, fulfilling the requirement for
Class R4 in the same standard.

Compressive strength, MP

60
50
40
30
20
10
0
Mix 1

Mix 2

Mix 3

Mix 4

Fig. 1 Average compressive strength (MPa) of ECCs at 28 days.

3

Flexural performance
The flexural test results at different ages are summarized in Table 2. The table
presents the average flexural strength (modulus of rupture) and the ultimate mid-span
deflections at the peak stress for each mixture. Each result in this table is the average
of four tests.

Mix ID
Mix 1
Mix 2
Mix 3
Mix 4

Table 2 Flexural strength and ultimate deflection of ECCs

Flexural strength, MPa
Ultimate deflection, mm
7 days
28 days 60 days
7 days
28 days 60 days
9.6
10.6
13.8
6.9
4.6
4.1
7.8
9.5
10.1
6.0
5.6
3.7
8.5
11.5
10.5
6.7
4.8
4.8
8.4
10.2
10.4
5.3
6.6
5.0

The flexural strength increases with increasing age, apart from Mix 3, as shown in
Table 2. For Mix 3, the test results after 28 days show a decrease of flexural strength.
Specimens of this mix were tested at 90 days to confirm this tendency. At this age, the
average flexural strength was 9.9 MPa, a lower value than the average strength at age
60 days, 10.5 MPa.
The ultimate deflection capacities of Mixes 1, 2 and 3, decrease with increasing age.
Similar behaviour has been observed in other ECC type materials (Sierra-Beltran
2011, Yang et al. 2007, Lepech and Li 2006). Mix 4 exhibited a maximum deflection
capacity at 28 days.
Figure 2 shows the typical flexural strength-deflection curves at 28 days for each of
the mixtures. As can be seen in these figure, all ECC thin beams have similar
behaviour under blending load, they deform similarly to a ductile metal plate through
plastic deformation. In all the specimens, the first crack started within the mid-span at
the tensile face. As presented in Figure 2, the slope of the load-deflection curves is
similar for all mixes. This slope represents the stiffness of the thin beams.
14

Flexural Strength (MPa

12
10
8
6
Mix 1

Mix 2

Mix 3
Mix 4

0
0

Mid-Span Deflection (mm)

Fig. 2 Typical flexural strength-deflection curves of ECCs at 28 days.

Drying shrinkage
The drying shrinkage measurements for all mixes are shown in figure 3. Each value in
this figure represents the average measurements of three specimens.
4

Mix 1 has the highest shrinkage, while mixes 3 and 4 have the lowest. The presence
of sand particles in mixes 2 and 3 contributes to reduce the drying shrinkage. In Mix 4,
it is possible that unhydrated fly ash particles serve as fine aggregates that restrain the
shrinkage, thus contributing to a lower shrinkage compare to the other mixes
(Sahmaran et al. 2007).
Age (days)
0

20

40

60

80

100

120

0
Drying shrinkage (x10-6

Mix 1
-500

Mix 2

-1000

Mix 3
Mix 4

-1500
-2000
-2500
-3000
-3500

Fig. 3 Drying shrinkage strain versus drying shrinkage time for ECCs.
Mechanical properties of bio-based mortar
Based on the laboratory tests results discussed above, mixes 2 and 4 were chosen to
further develop the bio-based repair mortar systems. These mixes developed low
drying shrinkage while exhibiting the higher compressive strength. The flexural
behaviour of these mixes is comparable in strength and deflection capacity to the
other mixes.
In Mix 2 the sand was partially replaced by the lightweight (LW) particles containing
the healing agent. In Mix 4, the limestone powder was partially replaced by the
particles with healing agent. In both mixes a higher amount of water and
superplasticizer was necessary to achieve consistent rheology properties. The mixture
compositions with and without healing agent are presented in Table 3.
Table 3 Mixture compositions of selected ECCs with and without healing agent
Mix ID
Mix 2
Mix 2 H
Mix 4
Mix 4 H
Cement, kg/m3
440
420
516
479
3
BFS, kg/m
132
126
FA, kg/m3
560
532
620
575
LP, kg/m3
413
323
3
Sand, kg/m
440
361
LW with healing agent,
59
60
kg/m3
Water, kg/m3
374
374
384
389
3
SP, kg/m
16
16
10
14
PVA fibres, kg/m3
26
26
26
26
0.33
0.35
0.25
0.28

Specimens of Mixes 2 H and 4 H were prepared, casted and tested in the same way as
the samples without healing agent, as described above under the Test method section.
The LW particles are evenly distributed within the samples, as was observed with the
5

stereomicroscope and the Environmental scanning electron microscope (ESEM).

Figure 4 presents a microscopic image of a Mix 4H sample where the LW particles
can be seen.

Fig. 4 Lightmicroscopic image of LW particles with healing agent distributed through

a Mix 4H sample.
The average compressive strength at 28 days of the mixes with healing agent is higher
than the average compressive strength of the mixes without healing agent, as shown in
figure 5. This may be an effect of the presence of calcium lactate in the healing agent.
Jonkers and colleagues (2009) reported the same effect.

Compressive strength (MP

60
50

Without LW
With LW

40
30
20
10
0
Mix 2

Mix 4

Fig. 5 Average compressive strength (MPa) of selected ECCs with and without
bacteria, at 28 days.
The presence of LW particles with healing agent has an effect on the flexural
behaviour of ECC. Figures 6 and 7 present typical flexural strength-deflection curves,
at 28 days, of Mixes 2 and 2 H and Mixes 4 and 4 H, each. The flexural strength of
Mix 2 H, 9.3 MPa, is slightly lower than that for Mix 2, 9.5 MPa. In a similar way, the
flexural strength of Mix 4 H, 9.6 MPa, is lower than that of Mix 4, 10.2 MPa. These
reductions are attributed to several factors. In the first place, the mixes with healing
agents have higher water-to-binder ratio and higher amount of superplasticizer. In the
second place, the small particle size of limestone powder (mean particle size 7.78 m)

and sand (mean particle size 250 m) compared to the size of the LW particles (mean
particle size 900 m). The smaller particle sizes contribute to a better packing of the
cement-based matrix around the fibre, and a better packing leads to an improvement
of the fibre-matrix interface properties and the ductility of the composites without
healing agent. Nevertheless, the flexural behaviour of both Mix 2 H and mix 4 H
containing healing agent, remain acceptable for an ECC type material. Both mixes
developed multiple cracking prior to failure and exhibited a mid-span deflection of
more than 5 mm which is considerably greater than the ductility of conventional
concrete.

Flexural Strength (MPa

12
10
8
6
4
2

Mix 4
Mix 4 H

0
0

Mid-Span Deflection (mm)

Fig. 6 Typical flexural strength-deflection curves of Mix 4 and Mix 4H.

Flexural Strength (MPa

12
10
8
6
4
2

Mix 2
Mix 2 H

0
0

Mid-Span Deflection (mm)

Fig. 7 Typical flexural strength-defection curves of Mix 2 and Mix 2H.

CONCLUSIONS
This paper presents the first results in the development of a bio-based mortar for
concrete repair. The proposed material is cement-based; it is reinforced with polymer
fibres and includes lightweight aggregates impregnated with a healing agent.
Initially, four different ECC-type materials were studied and based on their
mechanical properties and drying shrinkage capacity, two of them were chosen for
further studies. Both materials fulfil the compressive strength requirements of the
standards NEN 1504-3 for repair materials for concrete structures Class R4.
7

In the chosen materials the filler, either limestone powder or sand, was partially
replaced with lightweight aggregates impregnated with a healing agent consisting of
alkali-resistant bacteria and a food source. The presence of the healing agent resulted
in an increase of compressive strength of the mixtures. The flexural strength and
deflection capacity, on the other hand, decreased slightly when the healing agent was
included. Nevertheless, the composites with healing agent exhibited acceptable
strength and ductility for an ECC type material.
Currently, the drying shrinkage capacities of the two bio-based mortar repair mixtures
are being measured. Further research in this ongoing development also includes the
assessment of healing capacity of the bio-based mortar and the bonding properties
with aged concrete.
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