ACI 548.

11R-12

Guide for the Application of

Epoxy and Latex Adhesives for
Bonding Freshly Mixed and
Hardened Concretes

Reported by ACI Committee 548

 First Printing
September 2012

Guide for the Application of Epoxy and Latex Adhesives for Bonding
Freshly Mixed and Hardened Concretes

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American Concrete Institute

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U.S.A.
Phone: 248-848-3700
Fax: 248-848-3701
www.concrete.org
ISBN 978-0-87031-774-3
 ACI 548.11R-12

Guide for the Application of Epoxy and Latex

Adhesives for Bonding Freshly Mixed
and Hardened Concretes
Reported by ACI Committee 548
Bradley Nemunaitis, Chair Mahmoud M. Reda Taha, Secretary

Ashraf I. Ahmed Donald A. Schmidt Craig A. Ballinger Henry N. Marsh, Jr.

Mohammad A. Alhassan Raymond J. Schutz John J. Bartholomew Peter Mendis
Milton D. Anderson Qizhong Sheng Shashi P. Bhatnagar Peter J. Moss
Jacques A. Bertrand Joe Solomon Zhi-Yuan Chen Yoshihiko Ohama
Constantin Bodea Michael M. Sprinkel Inz Lech Czarnecki Kelly M. Page
Timothy Bower Michael S. Stenko Harold (Dan) R. Edwards Jerzy Pictrzykowski
David W. Fowler Donald P. Tragianese Larry J. Farrell Richard C. Prusinski
Robert W. Gaul Wafeek S. Wahby Jack J. Fontana Hamid Saadatmanesh
Quentin L. Hibben David White George Horeczko Donald A. Schmidt
Albert O. Kaeding David P. Whitney David P. Hu Meyer Steinberg
John R. Milliron Richard E. Wollmershauser Bert Paul Kreikemans Harold H. Weber, Jr.
Myles A. Murray Deon Kruger
Joseph A. Nuciforo, Jr. Consulting Members William Lee
John R. Robinson Lu Anqi Troy D. Madeley

This guide provides information, requirements, and procedures for CONTENTS

bonding freshly mixed and hardened concretes by using epoxy
or latex adhesives. This guide covers evaluation of hardened Chapter 1Scope, p. 2
concrete, selection of suitable epoxy or latex adhesive and
application methods.
Chapter 2Definitions, p. 2
Keywords: adhesives; bonding; epoxy adhesives; evaluation; latex
adhesive; preparation. Chapter 3Hardened concrete evaluation, p. 2

Chapter 4Removal of unsound concrete, p. 2

Chapter 5Surface preparation, p. 2

Chapter 6Use of epoxy adhesives, p. 3

ACI Committee Reports, Guides, and Commentaries are
intended for guidance in planning, designing, executing, and
inspecting construction. This document is intended for the use
of individuals who are competent to evaluate the significance
and limitations of its content and recommendations and who
will accept responsibility for the application of the material it
contains. The American Concrete Institute disclaims any and
all responsibility for the stated principles. The Institute shall
not be liable for any loss or damage arising therefrom.
Reference to this document shall not be made in contract
documents. If items found in this document are desired by
the Architect/Engineer to be a part of the contract documents,
they shall be restated in mandatory language for incorporation
by the Architect/Engineer.
6.1Selection of epoxy adhesive
6.2Mixing of epoxy adhesive
6.3Application of epoxy adhesive
ACI 548.11R-12 supsersedes ACI 503.6R-97(03) and became effective September 6,
2012.
Copyright 2012, American Concrete Institute.
All rights reserved including rights of reproduction and use in any form or by any
means, including the making of copies by any photo process, or by electronic or
mechanical device, printed, written, or oral, or recording for sound or visual repro-
duction or for use in any knowledge or retrieval system or device, unless permission
in writing is obtained from the copyright proprietors.

1
2 APPLICATION OF EPOXY AND LATEX ADHESIVES FOR BONDING (ACI 548.11R-12)
Chapter 7Use of latex adhesives, p. 3
7.1Selection of latex adhesive
7.2Application of latex adhesive
Chapter 8References, p. 4
CHAPTER 1SCOPE
This guide provides information, requirements, and
procedures for bonding freshly mixed and hardened concretes
by using epoxy or latex adhesives. This information will be
of particular use to contractors.
This guide consists of:
a) Evaluation of hardened concrete to determine proper
preparation and surface conditioning before application of
adhesives
b) Selection of suitable epoxy or latex adhesive depending
on the expected performance and environmental conditions
(ACI 503.5R)
c) Application methods
CHAPTER 2DEFINITONS
2.1Definitions
ACI provides a comprehensive list of definitions through
an online resource, ACI Concrete Terminology, http://
terminology.concrete.org.
CHAPTER 3HARDENED
CONCRETE EVALUATION
Contaminated and deteriorated concrete can be detected
by visual inspection; however, in many cases, visual
determination of the soundness of the concrete is not
sufficient to select the repair and preparation methods. It is
necessary to determine the extent and cause of deterioration,
and if that cause is active. For guidance on surveys for these
determinations, refer to ACI 201.1R, ACI 364.1R, and
ASTM C823/C823M.
Methods common for evaluating and determining
concrete condition include sounding with a hammer
or chain drag, ultrasonic pulse velocity, petrographic
analysis, infrared thermography, radar detection, core
evaluation, impact echo, measurement of chloride ion
content, and bond tests as described in ACI 228.1R and
ASTM C1583/C1583.
Proper preparation, as described in Chapter 5, of any
concrete to receive an adhesive is of primary importance.
Inadequate preparation may result in bond failure at the
adhesive interface.
The surface conditions required for different types of
adhesive are described in Chapters 4 and 5.
CHAPTER 4REMOVAL
OF UNSOUND CONCRETE
The removal of unsound or damaged concrete prior to
placing an adhesive and before placement of the freshly mixed
concrete is a necessary part of the rehabilitation of structures.
The first step involves saw cutting the periphery of the
removal area to a depth of 1 in. (25 mm) or to a lesser depth
American Concrete Institute Copyrighted Materialwww.concrete.org
necessary to clear the reinforcing steel (VDOT 2007). This
saw cutting delineates the repair area and reduces edge
spalling and weakness introduced by outlining the area using
other methods. Saw cutting also provides a shoulder against
which the repair materials can be placed and finished,
resulting in a neater appearance. The saw-cut line should
be located outside of the determined limits of the defect to
ensure that all defective concrete is removed and that the
fresh material is bonded to sound concrete.
Several types of systems are available to remove unsound
concrete.
a) Scabblers or bush hammers are tools with several points
that remove concrete by pulverizing or fracturing the surface
b) Scarifiers have wheels with several points that are
tipped with carbide, tungsten, or diamonds. This equipment
removes concrete by scraping or impacting the surface
c) Water blasting (hydrodemolition) removes concrete by
projecting jets of potable water
d) Jackhammers remove concrete by impacting the surface
CHAPTER 5SURFACE PREPARATION
After the concrete has been removed by one or more of the
aforementioned methods (USACE 1995), except for water
blasting, all newly exposed surfaces should be abrasive
blasted and washed thoroughly with a water jet that has a
pressure of at least 1500 psi (10 MPa). The surface should
then be dried with oil-free compressed air or vacuumed to
remove any residual debris.
Surfaces or parts of surfaces not requiring removal
of concrete should be cleaned to remove all surface
contaminants detrimental to the bond of the adhesive. Such
contaminants may include laitance, curing membranes,
surface coatings, treatments, oil, grease, rust stains, and dust.
These methods are commonly used to remove contaminants
a) Shot blasting, which projects metal balls of varying size
at high velocity to impact and abrade the surface
b) Abrasive blasting, which projects particles of varying
size to impact and abrade the surface. The particles may be
carried by air or water
c) Scabbling, which uses bush hammers
d) Scarification
e) Water blasting
One or more of these methods may be required for
preparation. For guidance, refer to ASTM D4258 and D4259
and ICRI No. 310.1R, No. 310.2R, and No. 310.3R.
Regardless of surface preparation method, the results
should be such that the surface is abraded to expose the
coarse aggregate in the surface with a maximum surface
texture of 0.01 in. (0.254 mm) measured in accordance
with ASTM E965. Heavier textures require the use of
excessive adhesive.
To determine if surface preparation is adequate for
bonding, test for pulloff strength in accordance with
ASTM C1583/C1583. If 250 psi (1.7 MPa) is achieved, then
the surface preparation and concrete quality is adequate. If
the pullout value is less than 250 psi (1.7 MPa) and 50 percent
or more of the failure area is in the concrete at a depth of
0.236 in. (6 mm) or greater, then the surface preparation
 APPLICATION OF EPOXY AND LATEX ADHESIVES FOR BONDING (ACI 548.11R-12)
is adequate, but the concrete quality may not be adequate.
In this case, an additional evaluation in accordance with
Chapter 3 may be necessary.
CHAPTER 6USE OF EPOXY ADHESIVES
To ensure adequate bonding using epoxy adhesives, the
following requirements should be met.
a) The concrete surface should be strong, dense, and sound
as determined by the methods in Chapter 5.
b) The concrete surface should be clean and free from
contaminants and prepared as described in Chapter 5.
c) In addition to other considerations, the selection of
epoxy adhesive should consider the anticipated ambient and
concrete temperatures. The ease of use and final properties of
epoxy application are influenced by the surface temperature.
Refer to ASTM C881/C881M for a list of epoxies for use at
different temperatures.
d) Surface moisture and vapor can interfere with the
bond of the adhesive. Surface moisture and vapor leaving
the concrete surface should be recognized as potential
impediments to proper bond. Efforts should be made
to dry the surface. Moisture vapor transmission may be
detected by covering the surface tightly with a 4 x 4 ft (1.2
x 1.2 m) transparent plastic film, following the procedure
in ASTM D4263. If moisture has not accumulated under
the film after 6 to 8 hours, or within the time required
for the adhesive to cure and the concrete to set, capillary
moisture or out-gassing vapors are insufficient to
adversely affect the bond. The exposure time should be
extended 50 percent under the film if temperatures are
below 40F (4C) or if the site is under cloud cover.
6.1Selection of epoxy adhesive
The epoxy adhesive should meet the requirements of
ASTM C881/C881M, Type II and V, Grade 2 and 3, Class A,
B, or C. In addition, unless otherwise recommended by
the adhesive manufacturer, apply sufficient adhesive
to cover the entire prepared surface without leaving
excessive adhesive in the low areas. Apply adhesive
to horizontal, vertical, and overhead surfaces prior to
placing the freshly mixed concrete. Type II adhesives are
used in non-load-bearing applications, whereas Type V are
for load-bearing uses. Grade 1 materials are low viscosity.
Grade 2 materials are medium viscosity. Grade 3 materials
have a nonsagging consistency. Class A materials are used
when temperatures are below 40F (4C), Class B materials
are used when temperatures are typically between 40 and
60F (4 and 16C), and Class C materials are used when
temperatures are above 60F (16C) with upper limits set
by the manufacturer.
6.2Mixing of epoxy adhesive
Epoxy adhesives are supplied as two-part systems. One
part contains the epoxy resin and the other part contains the
hardener or curing agent.
Epoxy and substrate temperatures directly affect the
performance of the epoxy compound. The quantity and
temperature of the adhesive at time of mixing influence the
American Concrete Institute Copyrighted Materialwww.concrete.org
3
working time. Elevated temperatures reduce the viscosity
of the epoxy. This makes it easier to mix and apply and
shortens the working time in the container. Less open time
before early polymerization affects the bonding ability
of the epoxy compound. Cooler temperatures increase
the viscosity of the epoxy. This makes thorough mixing
difficult, lengthens the working time in the container,
and extends the open time before concrete placement.
The quantity of adhesive to be mixed should not exceed
the amount that can be readily applied within the pot life
or working time of the specific adhesive.
For best results, condition the components from 65 to
85F (18 to 29C) or as recommended by the manufacturer.
Before mixing, premix each component separately.
Mechanical mixing of the two components is necessary,
except for mixing volumes of less than 1 qt (1 L). A
mixing container should have a flat bottom and a capacity
approximately two times the batch size. Dry, clean, plastic
pails are suitable because the sides can be scraped during
mixing, allowing for easy clean up. A cage or propeller-type
mixing paddle driven by a low-speed electric or air-powered
drill is recommended for mixing. Mixing may take 3 to
5 minutes. Thorough mixing of both components provides
optimum results.
Preportioned or prepackaged units are usually supplied by
the manufacturer so that the entire contents of both containers
are mixed together. If smaller quantities are required, the
specific proportioning ratio should be accurately measured
by mass or volume.
For large volumes of mixed adhesive, automatic
metering and mixing equipment that dispense the properly
proportioned and mixed material is recommended. Such mixers
are available commercially. Mixed adhesive is applied to the
repair area through a spray gun or extruding nozzle.
6.3Application of epoxy adhesive
The adhesive can be applied to the properly prepared
surface using brushes, rollers, squeegees, or spray
equipment. Use stiff bristle brushes in a scrubbing
motion to ensure all surface irregularities and pores are
coated. Epoxy adhesive provides satisfactory adhesion if
the freshly mixed concrete is placed 5 to 10 minutes after
applying the adhesive. This is to allow the adhesive to
wet the existing surface before contact with the freshly
mixed concrete. The freshly mixed concrete should be
placed while the adhesive is tacky. If the epoxy bond
coat has reached a tack-free stage before placement of
the freshly mixed concrete, a second coat of the bonding
epoxy should be applied before placement of the freshly
mixed concrete. If more than 5 hours elapse, the semi-
cured or cured epoxy should be brush blasted to provide
a bondable surface for the second coat of epoxy.
CHAPTER 7USE OF LATEX ADHESIVES
To ensure adequate bonding using latex adhesives, the
following requirements should be met.
a) The concrete surface should be strong, dense, and sound
as determined by methods in Chapter 3.
4 APPLICATION OF EPOXY AND LATEX ADHESIVES FOR BONDING (ACI 548.11R-12)
b) The concrete surface should be clean and free from
such contaminants as described in Chapter 5.
c) Latex adhesives need to be applied to a damp surface
to ensure adequate wetting. The moisture content should
be such that newspaper should become damp when placed
on the surface. The newspaper should be removed before
placing the latex adhesive.
7.1Selection of latex adhesive
Type I latex adhesives are redispersible, one-component
systems used as supplied. They are restricted for interior work
not subject to water immersion or relative humidity greater
than 90 percent. Typically, Type I latex adhesives are vinyl
acetate homopolymers or copolymers, with the comonomer
being ethylene or an acrylic ester. The vinyl acetate
homopolymers may be plasticized.
Type II latex adhesives are nonredispersible and may
be mixed with hydraulic cements. They are suitable for
interior and exterior work and may be used in areas subject
to water immersion or high humidity. Typically, they are
styrene-butadiene copolymers or acrylic ester copolymers
with a solids content of approximately 50 percent by weight.
Latex-to-cement ratios are typically one-to-one by
volume or one-to-two by mass. The pot life of two-part
adhesives is 10 to 120 minutes. Pot life depends on the
type of hydraulic cement and environmental conditions
such as temperature and relative humidity. For
information on Type I and Type II latex adhesives, refer
to ASTM C1059/C1059M.
7.2Application of latex adhesive
Type I latex adhesives, stabilized with polyvinyl
alcohol, are not suited for spray application and should
be applied by brush or roller. Type II latex adhesives are
applied by brushing, rolling, or spraying.
The prepared surface of the hardened concrete should
be dampened before application of the adhesive to ensure
good contact.
Typical rates of application are 200 ft2/gal. (5 m2/L)
for Type I adhesives and 55 ft2/gal. (1.4 m2/L) for Type II
adhesives. Follow the manufacturers recommendations
for rate of application.
For Type II adhesives, it is essential that the freshly mixed
concrete is applied before the adhesive has dried or set up. If
the Type II adhesive has dried or set up, the adhesive should
be removed and the surface should be prepared to meet the
conditions described in Chapter 7 (a, b, and c). Because
Type I adhesives are redispersible, timing the application of
the freshly mixed concrete is not critical, but it should be
placed before the adhesive becomes contaminated. If such
contamination occurs, the surface should be cleaned by wet
brushing or water spray and the Type I adhesive reapplied.
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CHAPTER 8REFERENCES
8.1Referenced standards and reports
Committee documents are listed first by document number
and year of publication followed by authored documents.
American Concrete Institute
ACI 201.1R-08Guide for Conducting a Visual Inspection
of Concrete in Service
ACI 228.1R-03In-Place Methods to Estimate
Concrete Strength
ACI 364.1R-07Guide for Evaluation of Concrete
Structures before Rehabilitation
ACI 503.5R-92Guide for the Selection of Polymer
Adhesives with Concrete (Reapproved 2003)
ASTM International
ASTM C823/C823M-12Standard Practice for Examination
and Sampling of Hardened Concrete in Constructions
ASTM C881/C881M-10Standard Specification for
Epoxy-Resin-Base Bonding Systems for Concrete
ASTM C1059/C1059M-99(2008)Standard Specification
for Latex Agents for Bonding Fresh to Hardened Concrete
ASTM C1583/C1583-04Standard Test Method for
Tensile Strength of Concrete Surfaces and the Bond
Strength or Tensile Strength of Concrete Repair and
Overlay Materials by Direct Tension (Pull-off Method)
ASTM D4258-05(2012)Standard Practice for Surface
Cleaning Concrete for Coating
ASTM D4259-88(2012)Standard Practice for Abrading
Concrete
ASTM D4263-83(2012)Standard Test Method for
Indicating Moisture in Concrete by the Plastic Sheet Method
ASTM E965-95(2006)Standard Test Method for
Measuring Pavement Macrotexture Depth Using a
Volumetric Technique
International Concrete Repair Institute
310.1R-1997Guide for Surface Preparation for the
Repair of Deteriorated Concrete Resulting from Reinforcing
Steel Corrosion (formerly No. 03730)
310.2R-1997Selecting and Specifying Concrete Surface
Preparation for Sealers, Coatings, and Polymer Overlays
(formerly No. 03732)
310.3R-2004Guide for the Preparation of Concrete
Surfaces Using Hydrodemolition Methods
USACE, 1995, Evaluation and Repair of Concrete
Structures, EM 1110-2-2002, United States Army Corps of
Engineers, Washington, DC, 185 pp.
VDOT, 2007, Road and Bridge Specifications, Section
412.03, Virginia Department of Transportation, Richmond, VA.
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American Concrete Institute

38800 Country Club Drive
Farmington Hills, MI 48331
U.S.A.
Phone: 248-848-3700
Fax: 248-848-3701
www.concrete.org
 Guide for the Application of Epoxy and Latex
Adhesives for Bonding Freshly Mixed
and Hardened Concretes

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