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Journal of Adhesion Science and

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Adhesion of an acrylic paint

coating to a concrete substrate
a b
V. Saraswathy & N.S. Rengaswamy
a
Central Electrochemical Research Institute,
Karaikudi-630006, Tamil Nadu, India
b
Central Electrochemical Research Institute,
Karaikudi-630006, Tamil Nadu, India

Version of record first published: 02 Apr 2012.

To cite this article: V. Saraswathy & N.S. Rengaswamy (1998): Adhesion of an acrylic paint
coating to a concrete substrate, Journal of Adhesion Science and Technology, 12:7, 681-694

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 Adhesion of an acrylic paint coating to a concrete substrate
- some observations
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V. SARASWATHY and N. S. RENGASWAMY*

Central Electrochemical Research Institute, Karaikudi-630006, TamilNadu, India

Received in final form 20 December 1997

Abstract-It is now widely accepted that the inherent chemical resistance of concrete is limited and
that the concrete surface needs additional barrier protection when exposed to aggressive environments.
Unlike a metallic substrate, the concrete substrate is heterogeneous and porous in nature. Since
adhesion is one of the important parameters influencing the durability of any surface coating, the
influence of various characteristics of the concrete substrate on coating adhesion has been investigated.
It is shown that the adhesion strength of a coating on a concrete substrate depends on the surface
strength of the substrate itself. It was found that the cement content of the substrate has a significant
influence on the surface strength. Surface strength, like compressive strength, is a function of the
hardening process. There is a linear relationship between the surface strength and curing time. The
adhesion strength of an acrylic paint coating was found to be slightly higher than the surface strength
of the substrate, even though the values lie in the same range.

Keywords:Coating; pull-off test; adhesion strength; surface strength; moisture content; resistivity.

1. INTRODUCTION

It is well known that the inherent chemical resistance of concrete is limited. It is

sufficiently permeable to oxygen, water, chloride, and other aggressive salts which
can promote the rapid corrosion of embedded steel. Regardless of its strength
and quality, concrete can undergo chemical deterioration such as acid corrosion,
leaching action, and sulphate swelling when exposed to industrial and marine
environments [ 1 ]. A chemically more resistant and less permeable coating on the
concrete surface would supplement the barrier effect and prevent further ingress
of corrosive agents. Protective barrier systems protect concrete from degradation
by chemicals and subsequent loss of structural integrity, prevent the staining of
concrete, and protect liquids from being contaminated by the concrete. The quality
of the concrete influences the performance of the system. A major factor affecting

*To whom correspondence should be addressed. E-mail: Cecrik@Cscecri.ren.nic.in

 682

performance is the bond between the coating and concrete. During the last two
decades, numerous organic and inorganic coatings have been suggested for the
concrete surface [2, 3 ]. One of the important parameters to be considered with
regard to the durability of any surface coating is the adhesion between the surface
coating and the concrete substrate. The concrete substrate is heterogeneous in
nature, since it is composed of cement, sand, and stone aggregates of different
sizes and shapes. Concrete is also significantly porous and its porosity depends
on various factors such as the water-cement (W/C) ratio, the cement-aggregate
(C/A) ratio, the method of compaction, the degree of curing, etc. The moisture
content in concrete is another variable parameter which can influence the adhesion
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of the surface coating.

A critical examination of the available literature information revealed that not
many in-depth studies have been made on this particular aspect. Even the proceed-
ings of an international symposium organized by RILEM in Paris during 1986 on
the adhesion between polymers and concrete does not shed much light in this direc-
tion [4].
The present investigation was therefore undertaken to elucidate information on
various factors which can influence the coating adhesion. Studies were carried out
in two parts. In one series, the surface strength of concrete substrate as influenced
by the cement content, the W/C ratio, and the curing time was studied. In another
series, the adhesion strength of an acrylic resin-based coating as influenced by the
substrate surface condition and moisture content was assessed.

2. EXPERIMENTAL

2.1. Materials

The following materials were used: ordinary portland cement conforming to

IS specification 269-1976 (passing through a 90 pm sieve) [5]; river sand con-
forming to grading zone III of IS specification 383-1980 (fineness modulus of sand
2.6-2.9) [6]; and locally available stone aggregates less than 10 mm in size. A
two-pack methyl methacrylate resin-based paint coating system was used to study
the adhesion strength of coating.

2.2. Methods

2.2.1. Specimen preparation. Cylindrical specimens 50 mm in diameter and

75 mm long were cast using either pure cement paste, or cement sand mortar, or
cement-sand aggregate concrete mixes of different proportions. Deionized water
was used for mixing and the W/C ratio was one of the parameters studied. A
threaded mild steel cylindrical specimen 25 mm in diameter and 55 mm long was
centrally embedded in each specimen with the projecting end serving as the adapter
for fixing the specimen in the testing machine. Specimens were cured in deionized
 683

water for specified test periods. The projecting mild steel end was suitably protected
during the curing of specimens. After curing, specimens were removed from water
and air-dried for 60 =b 12 h.
For studies on the surface strength, the concrete substrate was lightly sand-blasted
and after the surface had been cleaned with a hot air blower, a cylindrical mild steel
specimen 25 mm in diameter and 55 mm long was glued onto the sand-blasted
surface using a two-pack epoxy adhesive (Araldite, a Ciba-Geigy product). The
joint was kept under compression and air-cured for 12 h before testing.
For studies on the adhesion strength of the coating, a first coat of the acrylic-
based paint system was brush-applied over the concrete and air-cured for 48 h.
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Then a second coat of the same system was applied and the same was air-cured
for 72 h. A cylindrical mild steel specimen was then glued onto the painted surface
using a commercially available two-pack epoxy adhesive. The joint was kept under
compression and air-cured for 12 h before testing.
To study the influence of the moisture content in the substrate on the adhesion
of paint, another series of specimens were cast. At the end of the specified curing
period, the specimens were removed from water and air-dried for specified periods,
say 2, 4, 8, 16, and 24 h. Simultaneously, companion specimens of dimensions
10 x 10 x 10 cm were cast and subjected to the same curing time and air-drying
time. To assess the degree of dryness, electrical resistivity measurements were taken
on the companion specimens using the four-probe technique [7].

2.2.2. Pull-off test. A Monsanto Tensometer Model 2000 was used for carrying
out the pull-off tests. The arrangement of the specimen is shown in Fig. 1. One end
of the specimen was kept fixed and the other end containing the glued steel specimen
was pulled at a uniform rate and the load vs. crosshead movement was recorded up
to the stage of complete failure. The accuracy of the load 0.005 kN and the
readable accuracy of the crosshead movement was 0.125 mm. For each experiment,
six specimens were used. In all the samples, the failure was observed to be cohesive

Figure 1. Arrangement for the pull-off test.

 684

in nature, i.e. the failure occurred in the concrete core itself and not at the interface
between the substrate and the paint film.

3. RESULTS AND DISCUSSION

3.1. Surface strength

The surface strength values for cement paste substrates of different W/C ratios and
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different curing periods are given in Table 1. It can be seen that the surface strength
increases with the curing time and decreases with the W/C ratio. Figure 2 shows
a linear relationship between the surface strength and the curing time. It is also
seen that the slope is almost the same for all the different W/C ratios except the
0.40 ratio. The slope is either 0.07 or 0.08 N/mm? days.
Data for cement mortar substrates of different mix ratios, W/C ratios, and curing
times are given in Table 2. Here also, the surface strength increases with the curing
time. The strength decreases with the W/C ratio as well as with an increase in the
sand content. It is also seen from Figs 3-5 that the strength increases linearly with
the curing time. Interestingly, the slopes are not significantly different and the value
is either 0.06 or 0.07 N/mm days.
Values for concrete substrates of different mix ratios, W/C ratios, and curing
times are given in Table 3. Here again, the surface strength increases with the curing
time. With an increase in the W / C ratio, as well as with an increase in the aggregate
ratio, the strength decreases. Figure 6 shows that the strength increases linearly with
the curing time. Here again the slopes are not very different in the majority of cases
and lie in the range 0.04-0.07 N /mm days.
A comparison of Tables 1, 2, and 3 indicates that the surface strength depends
on the cement content in the substrate. The values are generally higher in the case
of cement paste, compared with mortar and concrete, and the concrete substrate
invariably shows a lower strength.

Table 1.
Effect of the W/C ratio on the surface strength (N/mm2) of cement paste for different curing periods
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Figure 2. Surface strength vs. curing time for cement paste of different W /C ratios.

Figure 3. Surface strength vs. curing time for cement mortar of W/C ratio 0.35.

3.2. Adhesion strength

The adhesion strength of a typical coating onto the sand-blasted substrate was
assessed for cement paste (Table 4a), cement mortar (Table 4b), and concrete
(Table 4c) specimens prepared with different W/C ratios. The curing time was
 688
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Figure 4. Surface strength vs. curing time for cement mortar of W/C ratio 0.40.

Figure 5. Surface strength vs. curing time for concrete of W/C ratio 0.45.

30 days. It can be seen from the tables that as in the case of surface strength, here
also the cement paste offers the highest adhesion strength followed by mortar.
The concrete substrate shows the lowest adhesion strength. Figures 7-9 show
that the adhesion strength decreases linearly with the W/C ratio. Like the surface
strength, the slopes are not significantly different, as can be seen in Fig. 8 for
different mortar mixes and in Fig. 9 for different concrete mixes. The slopes lie
in the range 0.06-0.08 N/mm? days. Obviously, the adhesion strength of the paint
coating depends on the surface strength of the substrate. Table 5 gives a comparison
 689
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Figure 6. Surface strength vs. curing time for cement paste of W/C ratio 0.60.

Table 4a.
Adhesion strength (N/mm2) of paste for different W/C ratios at the end of 30 days
 690
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Figure 7. Effect of the W/C ratio on the adhesion strength of cement paste.

Figure 8. Effect of the W/C ratio on the adhesion strength of cement mortar.

between the two strengths. When the adhesion strength and the surface strength are
compared, the adhesion strength of the acrylic coating appears to be slightly higher
than the surface strength of the substrate, even though the values lie in the same
range.
It has been reported that the adhesion strength of the barrier should be at least
equal to the tensile strength of the concrete at the surface and it should have a low
modulus of elasticity to prevent stress from being greater than the tensile strength
of concrete [8].
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Figure 9. Effect of the W/C ratio on the adhesion strength of concrete.

3.3. Influence of the moisture content

It is known that the presence of moisture in the substrate and the presence of
contaminants on the surface adversely affect the adhesion of a coating. The concrete
surface should be free of loose particles, dirt, dust, oil, waxes, and other chemicals
that prevent adhesion. Moisture within the concrete may also affect the adhesion. A
dry surface is normally preferred. It is often difficult, however, to assess the degree
of dryness, particularly on large concrete structures. Measurement of the electrical
resistivity is a useful tool for assessing the degree of dryness.
Since the electrical resistivity of concrete is influenced by the moisture content,
the measurement of resistivity will indicate the degree of dryness of concrete
structures. The higher the resistivity, the lower the moisture content; and the lower
the resistivity, the higher the moisture content. Hence the measurement of resistivity
with air drying time, particularly during the summer, will help in assessing the
degree of dryness. It is pertinent to point out here that paint coating systems should
preferably be applied only during the dry season. Some interesting data in this
regard are presented in Table 6.

3.3.1. Concrete substrate. It can be seen from Table 6 that in the case of the
concrete substrate, with an increase in the air-drying time (in h), the adhesion
strength also increases. However, it appears to be stabilized after 8 h of air-drying.
With regard to resistivity, it can be seen that resistivity also increases with the air-
drying time. However, there is a distinct increase in resistivity at the end of 8 h of
air-drying. This indicates that air-drying for a minimum of 8 h is needed for the
concrete substrate, so as to avoid the adverse influence of any moisture content.

3.3.2. Mortar substrate. It can be seen from Table 6 that in the case of the
mortar substrate, with an increase in the air-drying time (in h), the adhesion strength
 692

Table 5.
Adhesion and surface strengths for paste, mortar, and concrete for different W/C ratios at the end of
30 days
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increases. However, the increase in resistivity is negligible up to 4 h of air-drying

and then there is a distinct rise in resistivity at the end of 6 h. This indicates that
air-drying for a minimum of 6 h is required for the mortar substrate.

3.3.3. Paste substrate. It can be seen from Table 6 that in the case of the mortar
paste substrate, the same trend is also observed.
Lindberg [9], after studying the influence of different mechanical and chemical
surface treatments, reported that concrete with a low W/C ratio and a smooth
surface cast against a mould showed a high surface strength of the order of
2.9 N/mm2. His studies showed that an acid-etched surface had a poor surface
strength; however, in the present work, a uniformly sand-blasted substrate was
 693

Table 6.
Effect of the air-drying time on the adhesion strength (N/mm2) and resistivity (kQ cm)
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studied. Our studies have shown that the cement content of the substrate has a
strong influence on the surface strength and a cement-rich layer at the surface will
have a beneficial effect. Since the binding action of concrete substrate is due to
the reaction between cement and water, a higher cement concentration and a lower
W/C ratio will lead to stronger binding action and consequently a higher surface
strength. Since aggregates are inert fillers and have no binding action of their own,
an increase in their content at the substrate will lead to weaker binding action. A
linear increase in the surface strength with the curing time indicates that the surface
adhesion, like the compressive strength, is a function of the hardening process. The
fact that the slope of the curve is more or less the same for different mix ratios and
W/C ratios indicates that the rate of the increase in surface strength with curing
time is mainly related to the hardening of cement gel.
 694

4. CONCLUSIONS

From the present investigation, the following general conclusions can be drawn with
regard to the adhesion of a coating to a concrete substrate:
(i) The surface strength of the concrete substrate is an important parameter
influencing the adhesion strength of an acrylic coating.
(ii) Like the compressive strength, the surface strength is a function of the
hardening process and the cement content has a major influence.
(iii) There is a linear relationship between the surface strength and the curing time.
(iv) A linear relationship between the adhesion strength of an acrylic coating and
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the W/C ratio of the concrete substrate was found.

(v) The adhesion strength of the acrylic coating is also influenced by the degree
of dryness of the concrete substrate at the time of application. A minimum of
6-8 h air-drying is required. Under field conditions, monitoring the electrical
resistivity of the concrete substrate can indicate the ideal air-drying time
needed for effective adhesion.

REFERENCES
1.I. Biczok, Concrete Corrosion and Concrete Protection. Bergamen Press, Akademiaikiado,
Budapest (1972).
2. R. E. Foscante and H. H. Kline, Mater. Perform. 27, 34 (1988).
3. M. S. Eglinton, Concrete and its Chemical Behaviour. Thomas Telford, London (1987).
4. H. R. Sasse, Adhesion Between Polymers and Concrete. University Press, London (1986).
5. IS 269-1976, Specification for ordinary, rapid hardening and low heat portland cement. Indian
Standards Institution, New Delhi ( 1990).
6. IS 383-1980, Specification for coarse and fine aggregates from natural sources for concrete.
Indian Standards Institution, New Delhi (1990).
7. N. S. Rengaswamy, S. Srinivasan, Y. Mahadeva Iyer and R. H. Suresh Babu, Indian Concrete J.
60, 23-26 (1986).
8. ACI 151-IR 79, A guide to the use of waterproofing, damp-proofing, protective and decorative
barrier systems for concrete. American Concrete Institute (1984).
9. B. Lindberg, J. Oil Colour Chem. Assoc. 57, 100-113 (1974).