8/1/2017 Bonding Old-to-New Concrete, Epoxy Concrete Bonding

Featured Products Bonding Old-to-New Concrete

CCS Bonders
CCS Injection
Bonding Fresh Concrete to Existing Concrete Surfaces
CCS Grouts
CCS Coatings Overlays or patching materials of new Portland Cement
Concrete (PCC), terrazzo, mortar, grout and extruded
CCS Binders
curb based on Type I through Type V cements or White
Coating and Crack Cement may be structurally bonded with liquid epoxy
Quantity Calculator adhesives to existing concrete surfaces. Most
Product Spec Template cementitious admixtures in Types A through E defined
in ASTM C-494 are compatible with epoxy when
employed in normal concentrations. The existing
surface may be lightweight or dense portland cement
concrete, asphaltic concrete (AC), steel, stone, wood
Projects or composite combinations of these materials. The
Tech Links bond line may be vertical, oblique or horizontal and can
be on or below grade. The American Concrete Institute
- FAQ's
recently issued a similar set of recomendations: ACI
- Structural Concrete Repair 548.13-14.
- Crack Injection Specification
- Surface Preparation Estimated coverage
> Bonding Old-to-New
Concrete Using liquid epoxies in the viscosity range of 2000-
- Intro to Construction 6000 cps, apply 15 mils minimum adhesive thickness
Polymers over entire area of the hardened concrete to be
bonded. Lightweight concrete or other porous substrates may require a second coat. A
- Plate Bonding
one-gallon liquid epoxy mix yields approximately 100 square feet on a smooth surface and
- Coating Guide 50-75 square feet on a rough or chipped surface. As the temperature drops below 55F,
the material becomes thicker and more difficult to spread with a resulting decrease in the
yield.

Ambient curing epoxies have short working times and cure quickly in hot weather and cure
slowly in cold weather. Cure almost ceases at freezing temperatures. Regular grades
(SWL) of ChemCo concrete bonding agents should not be used at temperatures below
40F and long pot life (LWL) grades should not be used below 50F. The workhorse
products for this application are the liquid bonders: CCS Bonder Liquid LWL, followed by
CCS Bonder Liquid SWL (for colder environment uses or faster cure strength) and the
paste bonders: CCS Bonder Paste LWL, followed by CCS Bonder Paste SWL (for colder
uses).

In cold weather, store unmixed containers of Part A and Part B inside at 60F or above.
DO NOT ADD SOLVENTS OR WATER TO THIN THE MIX. The containers may be heated
by electric pail or drum heaters to reduce viscosity. If unmixed components have been
exposed to the sun and are hot, working life (pot life) will be shortened. Immerse but do
not submerge sealed containers in cold or ice water to cool or keep them in the shade.

Epoxy bonding adhesives must be tacky or wet prior to placement of plastic concrete. Use
long pot life grades on surfaces over 90F or scale down the area to be covered to insure
retention of tack prior to concrete placement.

Surface preparation

http://chemcosystems.com/tech_bondingcon.html 1/3
8/1/2017 Bonding Old-to-New Concrete, Epoxy Concrete Bonding
Contaminants, such as oil, grease, tar, asphalt, paint, wax, curing compounds and surface
impregnants, such as linseed oil, should be removed; so should dust, laitance and weak or
loose concrete. When bonding to asphalt, the surface should be roughened so that
clean aggregate is exposed. Do not apply epoxy adhesives in the rain or in the presence
of standing water. An applicable industry standard for the surface preparation is ASTM
D5258.

Two methods of surface preparation in order of their preference are:

A. Mechanical

1. Removal of surface by grinding

2. Sandblasting
3. Heavy mechanical scarification (for example, by Tennant machine).
4. Chipping
5. Roto-milling

B. Chemical

1. Acid etching with 15% by weight hydrochloric acid solution followed by thorough
flushing with a high pressure stream of water.

The use of epoxy adhesives will allow feather edging of the concrete mix for areas other
than joints, edges or corners. A preferred edge should be 1/4" minimum in thickness. The
edges of the deteriorated area should be saw cut to eliminate edge spalling. As an
alternate, the sides of the spall should be chipped as steeply as possible. Cut well back
into sound concrete.

Proportioning and mixing

Both A and B components should be poured into a disposable container for mixing.
Calibrate two containers in the volume mix ratio given on the data sheet. Scrape the
containers used for proportioning to insure accuracy. Removing the rims of gallon cans
with a twist-type can opener greatly assists this operation.

Mix the contents with a paint stirrer (e.g., a Jiffy paddle, Jiffy Mixer Co.) attached to a low
speed (400-600 rpm) electric or pneumatic drill for about 3 minutes. Move the stirrer up
and down and around the sides until an even streak-free color is obtained. Avoid making
the mix frothy by whipping in an excessive amount of air.

If power is not available, use a steel pallet knife cut off at the tip to give a flat end to reach
into corners of the can and mix vigorously by hand for at least 5 minutes. A stick will not
provide good mixing.

Do not mix more epoxy concrete bonding agent than can be used within the pot life
of the product. An end to the pot life is indicated by heat build up in the mixture, followed
by solidification (gelation). Spreading the material in a flat shallow container will extend the
working life.

Application
ChemCo Systems epoxy adhesives for bonding new concrete to existing surfaces may be
applied and distributed by broom, brush, roller, notched trowel, squeegee or spray gun
depending upon the nature of the surface, the size of the area, and the scheduling of the
concrete placement.

Patches and Vertical Joints

Medium stiff nylon bristle paint brushes.

Overlays on Rough Surfaces

Spread with rubber, PVC or polyethylene squeegee or 1/16" notched trowels. Work into
surface with stiff bristle street brooms.

Overlays on Flat Smooth Areas

Short nap paint roller fitted with long handle or squeegee.

http://chemcosystems.com/tech_bondingcon.html 2/3
8/1/2017 Bonding Old-to-New Concrete, Epoxy Concrete Bonding
Sandblasted Dry Steel

Medium stiff nylon bristle paint brushes.

Large Areas

Spray gun with selective brooming in rough spots. Spray apparatus may be two-
component equipment that meters, mixes and applies or conventional single component
where large batches may be premixed (long pot life types). Airless type spray equipment
minimizes overspray and wasted material. Equipment providing internal heating of A and B
components is most useful in very cold weather since solvents should not be employed for
thinning. Manufacturers of suitable spray equipment are Graco, Inc., Binks Mfg. Co., Pyles
Industries, Inc., and Spee Spray.

CAUTION

Where the bond coat has lost its tack but not become hard, a second coat of epoxy must
be applied immediately prior to placement of concrete. Should the epoxy have cured hard,
the first coat must be roughened with a wire brush, abrasive wheel or preferably light
sandblasting and a second coat of epoxy applied prior to concrete placement. Fresh
epoxy will not bond to unroughened cured epoxy. Tack free or cured epoxy will not provide
a structural bond to fresh PCC.

Placement and curing of concrete

Concrete Mix

The plastic PCC should be a relatively dry mix with a standard slump of between 0-1/2".
Where feather edging is required, the aggregate grading should be adjusted accordingly.
Best results are achieved with a minimum 1" overlay.

Vibrating Concrete

When vibrating epoxy bonded concrete, care should be taken to keep the head of the
vibrator sufficiently away from the bond line to avoid wiping the epoxy from the old surface.

Finishing Concrete

Normal finishing methods are employed for epoxy bonded concrete.

Curing Concrete Overlays

Thin overlays, such as terrazzo or cement mortar, must be kept moist with burlap,
polyethylene sheeting or a good curing compound for 5-7 days. Under normal temperature
conditions, Type III concrete bonded with epoxy should not receive heavy traffic for at least
two days.

Admixtures

The moderate use of most admixtures for air-entrainment, water reduction or acceleration
and retardation of hardening rate do not appear to affect compatibility of PCC with epoxy
bonding agents. Synthetic latex admixtures based on polymers other than epoxy (e.g.,
acrylic, PVA, styrene-butadiene) should be tested first for compatibility.

References

Old-to-new concrete bonding specifications include ASTM C881 Type II and ASTM
C881 Type V. For applicable products, see our ASTM C881 product listing.

The epoxy adhesive bonder products described above are 0 VOC.

Top of page

CCS PRODUCTS | KEMKO APPLICATORS | EPOXY ASPHALT | SERVICES | EQUIPMENT & PARTS | WHAT'S NEW | COMPANY | CONTACT | HOME

Toll Free: 800.757.6773 Tel: 650.261.3790 Email: email link

http://chemcosystems.com/tech_bondingcon.html 3/3