materials

Article
Mechanical Properties of Epoxy Resin Mortar with
Sand Washing Waste as Filler
Dinberu Molla Yemam, Baek-Joong Kim, Ji-Yeon Moon and Chongku Yi *
School of Civil, Environmental and Architectural Engineering, Korea University, Anam-dong, Seongbuk-gu,
Seoul 02841, Korea; yaatdg@gmail.com (D.M.Y.); kaka790905@korea.ac.kr (B.-J.K.); yeon414@korea.ac.kr (J.-Y.M.)
* Correspondence: chongku@korea.ac.kr; Tel.: +82-2-3290-3329

Academic Editor: Jorge de Brito

Received: 12 January 2017; Accepted: 22 February 2017; Published: 28 February 2017

Abstract: The objective of this study was to investigate the potential use of sand washing waste as
filler for epoxy resin mortar. The mechanical properties of four series of mortars containing epoxy
binder at 10, 15, 20, and 25 wt. % mixed with sand blended with sand washing waste filler in the
range of 0–20 wt. % were examined. The compressive and flexural strength increased with the
increase in epoxy and filler content; however, above epoxy 20 wt. %, slight change was seen in
strength due to increase in epoxy and filler content. Modulus of elasticity also linearly increased with
the increase in filler content, but the use of epoxy content beyond 20 wt. % decreased the modulus
of elasticity of the mortar. For epoxy content at 10 wt. %, poor bond strength lower than 0.8 MPa
was observed, and adding filler at 20 wt. % adversely affected the bond strength, in contrast to the
mortars containing epoxy at 15, 20, 25 wt. %. The results indicate that the sand washing waste can be
used as potential filler for epoxy resin mortar to obtain better mechanical properties by adding the
optimum level of sand washing waste filler.

Keywords: epoxy resin mortar; polymer binder; filler; mechanical properties

1. Introduction
Concrete structures were assumed to be durable and maintenance free; however, in the past few
decades, sign of degradation are becoming apparent [1,2] for various reasons, such as environmental
loads, faulty material, construction, and design errors which have caused the deterioration of the
structures [3–5]. The current practice of the construction industry is inclined towards the repair
and retrofit of these deteriorated structures rather than demolition [1,6]. In the United States alone,
a significant amount of money is expended in the repair of concrete structures every year [7].
Various materials from conventional Portland cement to polymer binders have been used to
perform the repair of concrete structures. Ordinary Portland cement (OPC) is by far the most widely
consumed material for the repair and restoration of concrete structures. Despite their vast consumption,
OPC-based composites present different shortcomings, such as longer curing time, weak flexural
strength, poor bond strength, high shrinkage, low resistance to aggressive environment, and durability
problems. These problems of OPC have instigated the use of polymer-based materials as a repair
material, which resulted in the introduction of epoxy resin mortar in the repair industry [8].
Epoxy resin mortar has been used as a repair material for the past couple of decades [1,9–12];
however, their consumption did not grow as anticipated due to the high cost of the epoxy resin and
the different properties of the epoxy binder and the substrate concrete which caused compatibility
problems [11,13,14]. The properties of the epoxy resin mortar depend on the constituents of the mortar.
Hence, it is necessary to optimize the mix proportion of the epoxy resin mortar for feasible repair
scheme and to avoid or reduce a mismatch in the properties of the repair mortar and the substrate

Materials 2017, 10, 246; doi:10.3390/ma10030246 www.mdpi.com/journal/materials

Materials 2017, 10, 246 2 of 11

concrete [15–19]. Different studies used fillers such as fly ash to reduce the epoxy resin dosage and
Materials 2017, 10, 246 2 of 11
make it more economical [20–23].
The recycling
concrete [15–19].ofDifferent
industrial wastes
studies used such
fillersas sand
such washing
as fly wastethe
ash to reduce is epoxy
important for sustainable
resin dosage and
development
make it more in the construction
economical [20–23].industry. Sand washing waste is a waste product of the sand
production Theprocess,
recycling and
of creates
industriala landfill problem.
wastes such as sandThe potential
washing reuse
waste of sand washing
is important waste as a
for sustainable
development
supplementary in the for
material construction industry.for
sand is beneficial Sand washing
reducing thewaste is a waste
depletion product
of natural sandof[24,25].
the sand Hence,
production
a sand washing process,
waste was andutilized
creates ainlandfill problem.
this study Thefor
as filler potential
epoxy reuse
resin of sand washing
mortar. waste as
Experimental a
study of
supplementary material for sand is beneficial for reducing the depletion
the effect of the filler on the mechanical properties of epoxy resin mortar was performed. of natural sand [24,25].
Hence, a sand washing waste was utilized in this study as filler for epoxy resin mortar. Experimental
study of the effect of the filler on the mechanical properties of epoxy resin mortar was performed.
2. Experiment
In this study, a mortar was prepared by using epoxy resin, sand, and filler; the mechanical
2. Experiment
propertiesInofthis
thestudy,
mortars with different mix proportions were investigated.
a mortar was prepared by using epoxy resin, sand, and filler; the mechanical
properties of the mortars with different mix proportions were investigated.
2.1. Materials
2.1.two-part
A Materials epoxy having a Grade 1 viscosity as per ASTM C881 [26] was used as a binder for
manufacturing the mortars
A two-part in thisa study.
epoxy having Grade Table 1 shows
1 viscosity the
as per detailed
ASTM C881properties of the
[26] was used as aepoxy
binderresin
for and
its hardener.
manufacturing the mortars in this study. Table 1 shows the detailed properties of the epoxy resin
and its hardener.
Table 1. Properties of epoxy resin and its hardener.
Table 1. Properties of epoxy resin and its hardener.
Type Epoxy Resin Hardener
Type Epoxy Resin Hardener
Mixing
Mixingproportion
proportion 3 3 1 1
Specific
Specificgravity
gravity ± 0.1
1.141.14 ± 0.1 1.02 ± 0.1
1.02 ± 0.1
Color Colorless Brown
Color Colorless Brown
Viscosity (mPa·s) 550 ± 50
Viscosity (mPa·s) 550 ± 50
Pot life (min) 30 ± 10 at 23 ◦ C
Pot lifetime
Hardening (min)(h) 30 ± 10 23
24–36 at at ◦23
C °C
Hardening time (h) 24–36 at 23 °C

SandSand
usedused
in this study
in this waswas
study purchased from
purchased froma local store.
a local The
store. Thephysical
physicalproperties
propertiesof
ofthe
thesand
sand were
were characterized
characterized according according
to ASTM to ASTM C128and
C128 [27] [27]ASTM
and ASTMC29 C29
[28];[28];
thethe
sandsand was
was foundtotohave
found have aa bulk
bulk
density ofdensity
1.52 g/cm 3 , water
of 1.52 g/cm3,absorption
water absorption of 0.41%,
of 0.41%, a specific
a specific gravity
gravity at oven
at oven drydry conditionofof2.6,
condition 2.6,and a
and a void fraction of 41.28%. Since the epoxy resin mortar was also prepared to repair
void fraction of 41.28%. Since the epoxy resin mortar was also prepared to repair cracks with small cracks with
small widths, a fine-graded sand with high percentage of particle size less than 600 µm was used.
widths, a fine-graded sand with high percentage of particle size less than 600 µm was used. In order to
In order to accurately determine the particle size of the sand, a consistent method to that of sand
accurately determine the particle size of the sand, a consistent method to that of sand washing waste
washing waste (laser diffraction technique) was utilized, and Figure 1 presents the particle
(lasersize
diffraction technique) was utilized, and Figure 1 presents the particle size distribution.
distribution.

Figure 1. Particle size distribution of sand.

Figure 1. Particle size distribution of sand.
Materials 2017, 10, 246 3 of 11
Materials 2017, 10, 246 3 of 11
The filler used in this investigation was a sand washing waste that was collected from an
The
The
aggregates filler used inplant
producing investigation
this located
investigation was a sand
was
in Gyeonggi-do, washing
Korea; wastematerial
waste
the sludge that waswas collected
collected
a wastefrom an
product
aggregates producing plant
producingprocess.
of a sand washing located
plant located in Gyeonggi-do,
in Gyeonggi-do,
The collected sludge wasKorea;
Korea; the sludge
the sludge
dried material
at 110 material was a waste
was a waste
°C to remove product of
product
any moisture,
acrushed
sand washing process. The collected sludge was dried atdried
110 C◦
of a sand towashing
break offprocess.
clusters, The
andcollected
sieved tosludge
remove was
any at to110
clusters. remove
The °C
sandtoany moisture,
remove
washing any crushed
waste to
moisture,
used as
break
crushed offtoclusters,
break and
off sieved
clusters, to
andremove
sievedany
to clusters.
remove The
any sand washing
clusters. The
filler (Figure 2) had a bulk density of 1.03 g/cm and specific gravity at oven dry condition of
3 waste
sand used
washingas filler
waste (Figure
used 2)
as
had a bulk density of 1.03 g/cm 3 and specific gravity at oven dry condition of 2.69 according to ASTM
filler (Figure 2) tohad
2.69 according a bulk
ASTM C29density
and ASTM of 1.03 g/cm
D854 3
[29].andThespecific gravity size
filler particle at oven dry condition
distribution of
was also
C29
2.69 and ASTM
according D854
to ASTM[29]. The
C29 filler
and particle
ASTM size
D854 distribution
[29]. The was
filler also
particledetermined
determined by using LA-950 laser scattering particle size analyzer manufactured by Horiba, Japan, size by using
distribution wasLA-950
also
laser scattering
determined
as presented by particle
in using 3.size analyzer
FigureLA-950 manufactured
laser scattering particlebysize
Horiba, Japan,
analyzer as presentedby
manufactured in Horiba,
Figure 3.Japan,
as presented in Figure 3.

Figure 2. Sand washing waste used as filler for epoxy resin mortar in this study.
Figure 2. Sand washing waste used as filler for epoxy resin mortar in this study.
Figure 2. Sand washing waste used as filler for epoxy resin mortar in this study.

Figure 3. Particle size distribution of filler.

Figure 3. Particle size distribution of filler.
Figure 3. Particle size distribution of filler.
Based on the particle size distribution of the sand and the filler, the specific surface area and the
meanBased on the
size were particle size
calculated. Thedistribution of the
specific surface areasand and the
of sand andfiller,
fillerthe
werespecific
foundsurface area and
to be 1965.57 m2the/m3
mean Based on
size were m the particle
calculated. size
2/m3, and The
distribution
specific of
surface the sand
area ofµm and
sand the
and filler,
filler the
were specific surface area and the3
and 140,625.65 the mean size was 450.83 and 21.12 µm. Thefound
chemicalto becomposition
1965.57 m /m 2
2 /m of3
mean
and size were
140,625.65 calculated.
m The specific surface area of sand and filler were found
2/m3, and the mean size was 450.83 µm and 21.12 µm. The chemical composition of to be 1965.57 m
the filler and the 2sand3 examined using X-ray Fluorescence manufactured by Horiba, Japan is given
andfiller
the 140,625.65
and them sand
/m ,examined
and the mean usingsize wasFluorescence
X-ray 450.83 µm and 21.12 µm. The
manufactured chemical composition of
in Table 2. The filler showed a comparable chemical composition as that by Horiba,
of fly ash usedJapan asisfiller
given to
the
in filler and
Table polymer the sand
2. The filler examined
showed using
a comparable X-ray Fluorescence
chemical manufactured
composition as that by Horiba,
of fly ash Japan is given
used content.
as filler toin
prepare concrete in previous studies [22], and the sand has a majority of silica In
Table 2. The
prepare filler showed ain
comparable chemical[22],
composition as that ofafly ash used as fillercontent.
to prepare
addition,polymer
the X-ray concrete
diffraction previous studies
(XRD) spectra and the using
was recorded sand has
a D/MAX majority
2200 ofVPCsilica
manufactured In
polymer
addition, concrete in previous studies [22], and the sand has a majority of silica content. In addition,
by Sciencethe ofX-ray
Japandiffraction
Inc. with a(XRD) spectra
continuous was recorded
scanning using
speed of 2°/mina D/MAX
across 2200 VPC manufactured
a 2θ range of 5°–80° and
theScience
by X-ray diffraction
of Japan (XRD)
Inc. withspectra
a was recorded
continuous scanningusing a D/MAX
speed of 2°/min2200across
VPC manufactured
a 2θ range of by Science
5°–80° and
a Cu/Kα1 target (λ = 1.54059 Å), U = 40 kV, and I = 200 mA. The XRD data is shown
◦ /min in◦Figure
◦ –80 4, which
of Japan
aidentifies Inc.
Cu/Kα1 target with
(λ a
= continuous
1.54059 Å), scanning
U = 40 kV, speed
and I of
= 2
200 mA. across
The XRD a 2θ range
data is of
shown5 in and
Figure a 4,
Cu/Kα
which 1
the main crystalline phases in the filler as being quartz, albite, and muscovite.
target (λ = 1.54059 Å), U = 40 kV, and I = 200 mA. The XRD data is shown
identifies the main crystalline phases in the filler as being quartz, albite, and muscovite. in Figure 4, which identifies
the main crystalline phases in the filler as being quartz, albite, and muscovite.
Materials 2017, 10, 246 4 of 11

Materials 2017, 10, 246 4 of 11

Table 2. Chemical composition of sand and filler (wt. %).
Table 2. Chemical composition of sand and filler (wt. %).
Chemical Composition SiO2 Al2 O3 K2 O Fe2 O3 TiO2 MnO2 CaO
Chemical Composition SiO2 Al2O3 K2O Fe2O3 TiO2 MnO2 CaO
Sand 87.720 5.915 6.277 - - - -
Sand 87.720 5.915 6.277 - - - -
Filler 70.993 18.070 1.792 6.450 0.805 0.282 1.607
Filler 70.993 18.070 1.792 6.450 0.805 0.282 1.607

Figure 4. XRD spectra of filler.

Figure 4. XRD spectra of filler.
2.2. Mix Proportions
2.2. Mix Proportions
Four mortar groups were prepared with epoxy content at 10%, 15%, 20%, and 25% by weight
Four mortar
fraction of thegroups
mortar. were prepared epoxy
The minimum with epoxy
contentcontent at %
of 10 wt. 10%,
was15%, 20%,from
selected and workability
25% by weight
condition,
fraction of theand the maximum
mortar. content was
The minimum limited
epoxy to 25 of
content wt.10
% due
wt. to%segregation of the
was selected epoxy
from from
workability
the mortar mixture. Filler was added to the mortar mix at 10 and 20 wt. % as sand
condition, and the maximum content was limited to 25 wt. % due to segregation of the epoxy from replacement.
The detailed
the mortar mix proportion
mixture. Filler wasofadded
the samples
to theinvestigated
mortar mix in this
at 10study
andis20
presented
wt. % as in Table
sand 3.replacement.
The detailed mix proportion of the samples investigated in this study is presented in Table 3.
Table 3. Mix proportion by weight percent (wt. %) and specimen notation.

TableSpecimen * Epoxy by
3. Mix proportion (E) weight
Sand percent
(S) Sand Washing
(wt. %) andWaste Fillernotation.
specimen (F)
E10-F0 10.00 90.00 0.00
E10-F10 10.00 80.00 10.00
Specimen * Epoxy (E) Sand (S) Sand Washing Waste Filler (F)
E10-F20 10.00 70.00 20.00
E10-F0
E15-F0 10.00
15.00 90.00
85.00 0.000.00
E10-F10
E15-F10 10.00
15.00 80.00
75.00 10.00
10.00
E10-F20
E15-F20 10.00
15.00 70.00
65.00 20.00
20.00
E15-F0
E20-F0 15.00
20.00 85.00
80.00 0.000.00
E15-F10
E20-F10 15.00
20.00 75.00
70.00 10.00
10.00
E15-F20
E20-F20 15.00
20.00 65.00
60.00 20.00
20.00
E20-F0
E25-F0 20.00
25.00 80.00
75.00 0.000.00
E20-F10
E25-F10 20.00
25.00 70.00
65.00 10.00
10.00
E20-F20
E25-F20 20.00
25.00 60.00
55.00 20.00
20.00
E25-F0 includes25.00
* Specimen notation two parts. The75.00 0.00
first part is used to identify the epoxy/mortar ratio by
weight, andE25-F10
the other is used25.00
to identify the65.00 10.00
filler/mortar ratio by weight. For example, E20-F10 is a
E25-F20
specimen having epoxy/mortar25.00 55.00
= 20% and filler/(sand + filler) = 10%. 20.00
* Specimen notation includes two parts. The first part is used to identify the epoxy/mortar ratio by weight,
and the other is used to identify the filler/mortar ratio by weight. For example, E20-F10 is a specimen having
epoxy/mortar = 20% and filler/(sand + filler) = 10%.
Materials 2017, 10, 246 5 of 11

2.3. Test Method

Materials 2017, 10, 246 5 of 11
Specimens were prepared to study the effect of filler on the compressive strength, flexural strength
2.3. Test of
and modulus Method
elasticity, and bond strength of epoxy resin mortar. The sample preparation was
performed as follows.
Specimens
Materials 2017, Except
10, 246were for control
prepared specimens,
to study the effectfirst dry mixing
of filler of sand andstrength,
on the compressive filler was 5 ofperformed
flexural
11
strength
for 2 min usingand anmodulus
automatic of elasticity,
mortarand bondtostrength
mixer ensureofaepoxy uniform resin distribution
mortar. The sample
of the preparation
sand and filler.
Epoxy 2.3.
wasTest
resin Method
performed
and as follows.
its hardener wereExcept for control
manually specimens,
mixed for 1 min firstin dry mixing ofbowl
a separate sand and
and filler
werewas added to
performed for 2 min using an automatic mortar mixer to ensure a uniform distribution of the sand
Specimens were prepared to study the effect of filler on the
the mortar mixer. Mixing was continued for another 2 min, and the mortar mixture was casted as per compressive strength, flexural
and filler.
strength Epoxy
and modulusresinofand its hardener
elasticity, werestrength
andperformed
bond manually mixedresin
of epoxy for 1mortar.
min in aThe
separate
samplebowl and were
preparation
KS F 4043 [30].to
added Before
the de-molding
mortar mixer. was
Mixing was continued after
for 24 h, the
another 2 molded
min, and specimens
the mortar were stored
mixture was in a
was performed as follows. Except for ◦control specimens, first dry mixing of sand and filler was
controlled environmental
casted as per chamber at 23 C and 50% RH, and continued curing of the specimen in the
performed for KS
2 minF 4043
using[30]. Before de-molding
an automatic was to
mortar mixer performed after 24 h,
ensure a uniform the molded
distribution specimens
of the sand
same condition
were
and filler. was
stored
Epoxyin performed
aresin
controlled for 6 more
and itsenvironmental
hardener days.
were chamber
manuallyatmixed
23 °Cfor and 50%in
1 min RH, and continued
a separate bowl and curing
wereof
Thethe specimen
compressive in the same
test of condition
the epoxy was performed
resin mortar for 6
wasmore days.
conducted
added to the mortar mixer. Mixing was continued for another 2 min, and the mortar mixture was according to KS F 4043/EN
12190 [31].
casted The
Three compressive
as percompressive test
KS F 4043 [30]. of the epoxy
strength resin mortar
samples with
Before de-molding was
wasthe conducted
dimensions
performed according
40 h,
after 24 to
mm KS
the× F 4043/EN × 160[31].
12190
40 mmspecimens
molded mm were
Three
wereFirst,compressive
storedthe in asample strength
controlled samples with
environmental the dimensions 40 mm × 40 mm × 160 mm were prepared.
prepared. that was curedchamber
for sevenat 23days°C andwas50% RH, and
broken continued
into halves curing
through of flexure
First,
the the sample
specimen in thethat
samewascondition
cured forwasseven days was
performed forbroken
6 more into
days.halves through flexure and then the
and then the compressive
compressive strength
strength test was performed on the broken halvesusing
of thea universal
samples using
The compressive testtest was
of the performed
epoxy on the
resin mortar wasbroken
conducted halves of the to
according samples
KS F 4043/EN 12190 [31].
a universal testing
testing machine machine
(UTM) at (UTM) at arate
a loading loading
of 800 rate
N/min of(Figure
800 N/min 5A). (Figure 5A).
Three compressive strength samples with the dimensions 40 mm × 40 mm × 160 mm were prepared.
First, the sample that was cured for seven days was broken into halves through flexure and then the
compressive strength test was performed on the broken halves of the samples using a universal
testing machine (UTM) at a loading rate of 800 N/min (Figure 5A).

Figure 5. (A) Compressive strength and (B) Flexural strength and modulus of elasticity through
5. (A) Compressive
Figure three-point strength and (B) Flexural strength and modulus of elasticity through
bending tests.
three-point bending tests.
The flexural
Figure strength and
5. (A) Compressive modulus
strength of Flexural
and (B) elasticity of three
strength andepoxy resin
modulus mortarsthrough
of elasticity of each mix
The flexural strength and modulus of elasticity of three epoxy resin mortars of eachofmix
proportion were
three-point evaluated
bending tests. in accordance to ASTM C580 [32]. Continuous measurements the proportion
load
applied and the corresponding deflection that occurred at the mid span were recorded. The maximum
were evaluated in accordance to ASTM C580 [32]. Continuous measurements of the load applied
loadThe
wasflexural
used to determine
strength and the modulus
flexural strength, and the
of elasticity of tangent
three epoxymodulus
resinwas determined
mortars of eachfrommixthe
and the corresponding deflection that occurred at the mid span were recorded. The maximum load
load versus
proportion deflection
were evaluatedcurve. KS F 4043topull-off
in accordance ASTM C580 test method was adopted
[32]. Continuous to measure
measurements theload
of the bond
was used to determine
strength
applied of the
and the resin
flexural
the corresponding
epoxy strength,
mortar thatand
to ordinary
deflection the tangent
Portland
occurred cement
at the midmoduluswerewas
concrete.
span determined
Three
recorded.specimens from
The maximumof eachthe load
versus load
deflection
mix was curve.
proportion KS
tested F 4043
consisted pull-off
of a test
concrete method
of was
dimensions adopted
100 mm to measure
diameter
used to determine the flexural strength, and the tangent modulus was determined from theand the
70 mmbond strength
thickness of
the epoxy resin mortar to ordinary Portland cement concrete. Three specimens of each mix proportion
as
loadsubstrate,
versus with
deflection28-day
curve.compressive
KS F 4043 strength
pull-off of
test50 MPa
method (Figure
was 6A).
adopted The
to procedure
measure shown
the bond in
strength
Figure 5of
tested consisted wasthea
of epoxy
used
concreteresinofmortar
to prepare to ordinary
the specimens
dimensions and
100 Portland
mm perform cement
diameter concrete.
the test.
and 70 mm Three specimens
thickness of each
as substrate, with
mix proportion tested consisted of a concrete of dimensions 100 mm diameter and 70 mm thickness
28-day compressive strength of 50 MPa (Figure 6A). The procedure shown in Figure 5 was used to
as substrate, with 28-day compressive strength of 50 MPa (Figure 6A). The procedure shown in
prepareFigure
the specimens and perform the test.
5 was used to prepare the specimens and perform the test.

(A) Concrete substrate preparation (B) Casting of epoxy resin mortar on surface of the substrate

Figure 6. Cont.

(A) Concrete substrate preparation (B) Casting of epoxy resin mortar on surface of the substrate

Figure 6. Cont.
Figure 6. Cont.
 Materials 2017, 10, 246 6 of 11
Materials 2017, 10, 246 6 of 11
Materials 2017, 10, 246 6 of 11

(C) Steel stud was attached on top surface of the epoxy resin
(C) Steel stud was attached on top surface of the epoxy resin (D) Pull-off test set up using universal testing machine
mortar using adhesive (D) Pull-off test set up using universal testing machine
mortar using adhesive
Figure 6. Pull-off test method.
Figure Pull-off
6. 6.
Figure test
Pull-off method.
test method.
3. Results and Discussion
3.3.Results
Resultsand
andDiscussion
Discussion
3.1. Compressive Strength
3.1.
3.1.Compressive
CompressiveStrength
Figure Strength
7 presents the compressive strength versus filler content results obtained from mortars
prepared with three different filler weight fractions at four various epoxy contents. The results
Figure
Figure 7 7presents
presents thethe compressive
compressive strength versus filler content results obtained from mortars
illustrate that the compressive strengthstrength versus
of the mortar wasfiller content
affected results
by both obtained
its epoxy and from
filler mortars
prepared
prepared with three different filler weight fractions at four various
content. For mortars prepared with epoxy at 10 wt. %, the compressive strength increased upThe
with three different filler weight fractions at four various epoxy
epoxy contents.
contents. The to results
results
illustrate that
wt. %theof compressive
filler content strength
then leveled of
offthe mortar
between 10 was
wt. % affected
illustrate that the compressive strength of the mortar was affected by both its epoxy and filler
10 and 20 by
wt. %, both
while itsforepoxy
mortarsand filler
prepared content.
For mortars
content.with Forprepared
epoxy at 15,with
mortars 20, epoxy
and
prepared 25 wt.at %,
with10epoxy
wt.compressive
the %,at the10compressive
wt.strength strength
%, theincreased
compressiveup increased wt. %up
to 20strength towith
10 wt.
butincreased a % upofto
filler decreasing
content rate of increase between filler content of 10 wt. % and 20 wt. %. The mortars showed an
10 wt. % of then
filler leveled
contentoff then between
leveled10offwt. % and 10
between 20 wt. % %,and
while 20 for
wt.mortars
%, whileprepared
for mortars withprepared
epoxy
average improvement in compressive strength of 24.46% for epoxy at 10 wt. %, 65.15% for epoxy at
atwith
15, 20,
epoxyand at 2515,wt.20, %,andthe 25 compressive
wt. %, the strength
compressive increased
strength up increased
to 20 wt. % upbut with
to 20 wt.a% decreasing
but with a
15 wt. %, 15.28% for epoxy at 20 wt. %, and 8.60% for epoxy at 25 wt. % due to incorporation of filler
rate of increase
decreasing rate between
of increasefiller content
between of
filler10 wt.
content % and
of 1020wt.wt.% %.
and The
20
when compared to the control group. The increase in epoxy content also enhanced the compressive
mortars
wt. %. Theshowed
mortars an averagean
showed
improvement
average in compressive strength of 24.46% for epoxy at 10 wt. %, 65.15%
strength of the mortar composite, but the rate of increase diminished at epoxy content of 20 wt. % epoxy
improvement in compressive strength of 24.46% for epoxy at 10 wt. for
%, epoxy
65.15% at
for15 wt. %,at
15.28% for
15 wt.and epoxy
%, 15.28%
25 wt. %. at 20 wt.
forThese
epoxy %,
canatbeand 8.60%
20attributed
wt. %, and for epoxy
8.60%
to the at 25
for epoxy
decrease wt.
in the at% due
25 wt.
void to incorporation
% due
content of the sand with the when
of
to incorporationfiller of filler
compared incorporation
when comparedto the control of the filler
to thegroup. in
controlThe addition
increase
group. to the
The in epoxy binder
epoxy content
increase [22].
in epoxyalso Furthermore,
enhanced
content it can be noticed
the compressive
also enhanced thatstrength
the compressive
ofstrength except composite,
the mortar for the control group, the increase of epoxy content beyond 15 wt. % appearsof 20towt.
enhance
% andthe
of the mortar but the rate
composite, of
butincrease
the ratediminished
of increaseatdiminished
epoxy contentat epoxy content of2520wt.
wt.%.%
compressive strength of the mortar insignificantly.
These
and can
25 wt. be attributed
%. These to canthe bedecrease
attributed in the voiddecrease
to the content of in the
the sand
voidwith content the incorporation
of the sand with of the
the
filler in additionoftothe
incorporation thefiller
epoxy in binder
addition [22].to Furthermore,
the epoxy binder it can be noticed
[22]. Furthermore, that except
it canfor be the control
noticed that
group,
exceptthe forincrease
the controlof epoxy
group, content beyondof
the increase 15epoxy
wt. % content
appearsbeyondto enhance 15 wt.the % compressive
appears to strength
enhance of the
the mortar insignificantly.
compressive strength of the mortar insignificantly.

Figure 7. Relationship of compressive strength vs. filler content at different amount of epoxy (10 wt. %,
15 wt. %, 20 wt. %, and 25 wt. %).

Figure 7. Relationship of compressive strength vs. filler content at different amount of epoxy (10 wt. %,
Figure 7. Relationship of compressive strength vs. filler content at different amount of epoxy (10 wt. %,
15 wt. %, 20 wt. %, and 25 wt. %).
15 wt. %, 20 wt. %, and 25 wt. %).
Materials 2017, 10, 246 7 of 11
Materials 2017, 10, 246 7 of 11

Thecompressive
The compressivestrength
strengthisisaatraditionally
traditionallyexamined
examinedproperty
propertyof ofrepair
repairmaterial
materialfor
forconcrete
concrete
structures.Mostly
structures. Mostlyititisisexpected
expected that
that thethe ratio
ratio of of
thethe compressive
compressive strength
strength of repair
of repair mortar
mortar to that
to that of theof
substrate concrete should be equal to or higher than one. Furthermore, KS F 4043 suggests a minimuma
the substrate concrete should be equal to or higher than one. Furthermore, KS F 4043 suggests
minimum compressive
compressive strength of 40strength
MPa forof 40 MPa
epoxy resinfor epoxyused
mortars resin
formortars
repair ofused for structures.
concrete repair of concrete
All the
structures.
samples All E10-F0
except the samplesshowedexcept E10-F0 showed
a compressive a compressive
strength above 40 MPa.strength above 40 MPa.

3.2.
3.2.Flexural
FlexuralStrength
Strength
The
Theflexural
flexuralstrength
strengthofofmortar
mortarmixes
mixesprepared
preparedwith withvarying
varyingfiller
fillercontent
contentatatgiven
givenamount
amountofof
epoxy
epoxyisispresented
presentedinin Figure
Figure8. 8.
The flexural
The strength
flexural strengthof the mortar
of the altered
mortar withwith
altered respect to thetofiller
respect and
the filler
epoxy content.
and epoxy EvenEven
content. though the rate
though of increase
the rate of increaseslightly decreased
slightly decreasedbetween
between 1010
wt.
wt.%%and
and20 20wt.
wt.%,
%,
aamore linear increase in flexural strength with R2 value of 0.942 and 0.957 was
more linear increase in flexural strength with R2 value of 0.942 and 0.957 was observed for mortarobserved for mortar
containing
containingepoxy
epoxyatat10 10wt.
wt.%%andand1515wt.
wt.%.
%.For
Formortars
mortarsprepared
preparedwithwithepoxy
epoxyatat20 20wt.
wt.%%and
and25 25wt.
wt.%,
%,
the
theflexural
flexural strength increased linearly
strength increased linearlyup uptoto2020wt.
wt.%%ofoffiller
filler content
content withwith
thethe
R2 R2 values
values of 0.995
of 0.995 and
and 0.999,
0.999, respectively.
respectively. TheThe mortars
mortars showed
showed anan averagerise
average riseininflexural
flexuralstrength
strength ofof 44.6% for
for epoxy
epoxyatat
10
10wt.
wt.%,%,65.78%
65.78%for
forepoxy
epoxyatat1515wt.
wt.%,
%,17.61%
17.61%for forepoxy
epoxyatat2020wt.
wt.%,
%,and
and19.51%
19.51%forforepoxy
epoxyatat25 25wt.
wt.%%
due
duetotoincorporation
incorporationofoffiller
fillerwhen
whencompared
comparedtotothe thecontrol
controlgroup.
group.The
Theflexural
flexuralstrength
strengthofofthe
themortar
mortar
seems
seemstotobe beslightly
slightlybeyond
beyond15 15wt.
wt.%%ofofepoxy
epoxycontent.
content.InIngeneral,
general,ititcan
canbe beconcluded
concludedthat
thataalinearly
linearly
proportional
proportionalrelationship
relationshipwas wasexhibited
exhibitedbetween
betweenflexural
flexuralstrength
strengthandandthe
thefiller
fillercontent
contentupuptoto2020wt.
wt.%%
ofofthe epoxy resin mortar.
the epoxy resin mortar.

Figure 8. Relationship of flexural strength vs. filler content at different amounts of epoxy (10, 15, 20,
Figure 8. Relationship of flexural strength vs. filler content at different amounts of epoxy (10, 15, 20,
and 25 wt. %).
and 25 wt. %).

The strength of repair materials to withstand a bending load is stated as flexural strength.
The strength
Generally, ofofrepair
the ratio materials
the flexural to withstand
strength a bending
of the repair loadthe
mortar and is substrate
stated as concrete
flexural should
strength.
be
Generally, the ratio of the flexural strength of the repair mortar and the substrate
higher than one, whereas KS F 4043 specifies 10 MPa as the minimum flexural strength value concrete should
for
be higher
epoxy thanmortars
resin one, whereas
used forKS Frestoration
4043 specifies 10 MPa as
of concrete the minimum
structures. In ourflexural
study,strength value
all mortar for
mixes
epoxy resinexhibited
prepared mortars used for restoration
a flexural of concrete
strength much higher structures. In our study, all mortar mixes prepared
than 10 MPa.
exhibited a flexural strength much higher than 10 MPa.
3.3. Modulus of Elasticity (MoE)
3.3. Modulus of Elasticity (MoE)
The tangent modulus of elasticity of the epoxy resin mortars was determined from the load
The tangent modulus of elasticity of the epoxy resin mortars was determined from the load versus
versus deflection relation obtained via three-point bending test. Figure 9 shows the influence of filler
deflection relation obtained via three-point bending test. Figure 9 shows the influence of filler content
content on the MoE of the mortars prepared with different epoxy content (10 wt. %, 15 wt. %, 20 wt. %,
on the MoE of the mortars prepared with different epoxy content (10 wt. %, 15 wt. %, 20 wt. %, and
and 25 wt. %). It can be noticed that a linear trend was observed as that of flexural strength results
25 wt. %). It can be noticed that a linear trend was observed as that of flexural strength results between
between MoE and filler content with R2 value of 0.998, 0.999, 0.966, and 0.999 for epoxy content at 10,
15, 20, and 25 wt. %, respectively. The addition of filler resulted in an average increase in MoE of
Materials 2017, 10, 246 8 of 11

Materials 2017, 10, 246 8 of 11

Materials 2017, 10, 246 8 of 11
MoE and filler content with R2 value of 0.998, 0.999, 0.966, and 0.999 for epoxy content at 10, 15, 20,
51.5% 25for
and 51.5% wt.epoxy
for
at 10atwt.
%, epoxy
respectively. %, 54.47%
10 wt.The
for epoxy
%, addition
54.47% for ofepoxy at resulted
filler 15 wt. %,%,11.10%
at 15 wt. in an for
average
11.10%
epoxy atat20
increase
for epoxy in wt.
20 MoE %, and
wt. %,ofand
7.29%
51.5% for
7.29%
for
epoxyepoxy at
foratepoxy 25 wt.
10 wt.at%, % when
25 54.47% compared
for epoxy
wt. % when to the
at 15 wt.
compared control
%,control
to the group.
11.10%group. Besides
for epoxy the
at 20the
Besides substantial
wt.substantial
%, and 7.29%improvement
for epoxyin
improvement in
at
the MoE
25 wt. of
the%MoE mortar
when containing
compared
of mortar epoxy
to the
containing at 10
control
epoxy wt.wt.
atgroup.
10 % Besides
and
% and 1515 wt.
wt.%,
the %,a ahigher
higherrate
substantial rateof
ofincrease
increaseinin
improvement MoE
inthe
MoE MoEwith
withof
the increase
mortar in filler
the containing
increase content
in epoxy
filler was
at 10
contentwt.observed
was and 15when
%observed wt. %,
when compared
higher to
acompared tomortars
rate containing
of increase
mortars in MoEepoxy
containing at
at 20
with the
epoxy 20 wt. %%
increase
wt.
and 25
in filler wt. %.
andcontent The
25 wt. %. increase
was
Theobserved in MoE
when
increase in can be
MoEcompared attributed to
to mortars
can be attributed the increased
containing
to the stiffness
increasedepoxy of
at of
stiffness the
20the mortar
wt.mortar when
% andwhen the
25 wt.the
%.
filler is added.
filler
The increase is added.
in MoE can be attributed to the increased stiffness of the mortar when the filler is added.

Figure 9. Effect of filler content on the modulus of elasticity of epoxy resin mortars at different
9. Effect
Figure 9.
Figure
amountEffect ofoffiller
of epoxy
content
filler content
(10, 15,
onon
thethe
20, and
modulus of elasticity
25 wt.modulus
%).
of epoxy
of elasticity resin mortars
of epoxy at different
resin mortars amount
at different
of epoxy (10, 15, 20, and 25 wt. %).
amount of epoxy (10, 15, 20, and 25 wt. %).
The density of the epoxy resin mortar three-point bending test beams were determined by
The
The density
density
measuring ofmass
theof the epoxy
the epoxy resin mortar
resin
and volume mortar
in three-point
orderthree-point
to understand bending
bending test beams
test
the relation beams were
were
between determined
thedetermined
MoE and the by
by
measuring
densitythe
measuring the mass
mass
of the and
andvolume
hardened beam in
volume order
in to
order
samples. understand
to understand
Figure the relation
10 indicates the ofbetween
relation
a plot theand
between
the density MoEthe and
MoEMoE theand
versusdensity
the
filler
of the
densityhardened
content
of thefor beam
the
hardened samples.
mortarsbeamwith Figure 10
different
samples. indicates
epoxy
Figure a plotThe
10content.
indicates ofathe density
density
plot andsamples
MoE
of density
of the the andversus filler
showed
MoE a content
versussimilar
filler
trend
for the
content forwith
the the
mortars withincrease
mortars in filler
different
with epoxy content
differentcontent.
epoxyas that
The of theThe
MoE.
density
content. Thesamples
ofdensity
the results
of theshow thataasimilar
showed
samples linear correlation
showed trend with
a similar
with R
the increase 2 value of 0.919 exists between the MoE and the density of the samples.
in filler content as that of theasMoE. 2
trend with the increase in filler content that The results
of the MoE.show that a linear
The results showcorrelation
that a linearwith R value
correlation
of 0.919
with existsof
R2 value between the MoE
0.919 exists and the
between the density
MoE and of the
the density
samples.of the samples.

Figure 10. Relationship between modulus of elasticity (MoE) and density of sample.

Figure
Figure 10.
10. Relationship
Relationshipbetween
between modulus
modulus of
of elasticity
elasticity (MoE)
(MoE) and
and density
density of
of sample.
sample.
Materials 2017, 10, 246 9 of 11
Materials 2017, 10, 246 9 of 11

3.4.
3.4.Bond
BondStrength
Strength
TheThe bond
bond strength
strength ofof
epoxy
epoxy resin
resinmortar
mortar totosubstrate
substrate concrete
concrete waswas determined
determined using
using a pull-off
a pull-off
test.
test.AAhigh highstrength
strengthconcrete
concretewith witha a28-days
28-dayscompressive
compressivestrength strengthofof5050MPa MPawas wasprepared
preparedasasa a
substrate
substratetoto execute
executethis thistest.
test.Depending
Dependingononwhich whichsection
sectionisisthe theweakest,
weakest,one oneofofthethethree
three modes
modesofof
failures
failures (de-bonding)
(de-bonding) (failure
(failure ininthe
the epoxy
epoxyresin
resinmortar,
mortar, failure
failure atat
the interface
the interface ofof
epoxy
epoxy resin
resin mortar
mortar
and substrate concrete, and failure in the concrete substrate) could occur
and substrate concrete, and failure in the concrete substrate) could occur when the pull-off test when the pull-off test on theon
epoxy resin mortar-bonded
the epoxy resin mortar-bonded concrete is performed.
concrete is performed.
Figure
Figure 1111indicates
indicates the pull-off
the pull-off test results
test resultsofofconcrete
concrete bonded
bonded with
withepoxy
epoxy resin
resinmortar
mortar containing
containing
varying
varying weight fractions of filler at four different epoxy amounts. For epoxy at 10 wt. %,allallthe
weight fractions of filler at four different epoxy amounts. For epoxy at 10 wt. %, the
failures
failures occurred
occurred at at
thethemortar/substrate
mortar/substrateconcrete concreteinterface,
interface,and andthethebond
bondstrength
strengthseemed
seemedtotoslightly
slightly
increase
increase with
withthethe addition
addition ofof1010 wt.
wt.%;%;however,
however, thethebond
bond strength
strength considerably
considerably dropped
dropped atat2020
wt.
wt.%%
ofoffiller content
filler contenttotothe theextent
extentthat thatfailure
failureofofthethebond
bond between
betweenthe theepoxy
epoxyresin
resin mortar
mortar andand concrete
concrete
occurred
occurred byby anan insignificant
insignificant loadloadapplication.
application.Hence,
Hence,the thebond
bondstrength
strengthofof E10-F20
E10-F20was was specified
specifiedasas
zero. The mortars prepared with epoxy at 15 wt. % showed two
zero. The mortars prepared with epoxy at 15 wt. % showed two modes of failure: all the samples modes of failure: all the samples
except
except those
those containing
containing filler atat
filler 2020wt.wt.%% exhibited
exhibited a afailure
failure ininthe
theinterface
interface ofofepoxy
epoxyresinresin mortar
mortar and
and
substrate
substrate concrete,
concrete, whereas
whereas thethesamples
samples prepared
preparedwithwith
fillerfiller
at 20atwt.
20 % wt.demonstrated
% demonstrated a failure in thein
a failure
substrate concrete.
the substrate The bond
concrete. strength
The bond of the of
strength mortar at 15 wt.
the mortar at 15% showed
wt. % showeda lineara increase with filler
linear increase with
content up to 20up
filler content wt.to%. 20For
wt.epoxy
%. Foratepoxy20 andat2520wt.and%,25 allwt.
the %,failure occurred
all the failurein the substrate
occurred in theconcrete;
substrate
the failuresthe
concrete; seems to occur
failures seems in the interfacial
to occur in thetransition
interfacialzone of the zone
transition coarse ofaggregate
the coarseinaggregate
the substrate
in the
concrete.
substrate Hence,
concrete.the effect
Hence, of the
filler content
effect on the
of filler adhesion
content on theproperty
adhesion of epoxy
propertyresinofmortar
epoxy to concrete
resin mortar
was
to not clearly
concrete wasunderstood,
not clearly because the failure
understood, was mainly
because the failuregoverned by the governed
was mainly intrinsic property of the
by the intrinsic
concrete
property [33,34].
of the concrete [33,34].

Figure 11. Effect of filler content on the bond strength of epoxy resin mortar at different amounts of
Figure 11. Effect of filler content on the bond strength of epoxy resin mortar at different amounts of
epoxy (10, 15, 20, and 25 wt. %) to substrate concrete.
epoxy (10, 15, 20, and 25 wt. %) to substrate concrete.

Bond strength of repair material is an important property that holds the repair mortar and the
substratestrength
Bond concreteofbonded
repair material
as a unit. is an important
Hence, property
in order to havethata holds
durabletherepair
repairwork
mortarofand the
concrete
substrate concrete bonded as a unit. Hence, in order to have a durable repair
structures, the mortars used should have adequate adhesion to avoid bond failure between the work of concrete
structures,
repair andthethe
mortars used because
substrate should have adequate
of the stresses adhesion to avoid
developed due bond failure between
to internal the repair
and external loads.
and the substrate because of the stresses developed due to internal and external
KS F 4043 suggests a minimum of 1.5 MPa bond strength of the epoxy resin mortar used for the loads. KS F 4043
suggests a minimum
maintenance of 1.5 MPa
of concrete bond In
structure. strength of the the
this study, epoxy resinresin
epoxy mortar usedprepared
mortar for the maintenance
with 10 wt.of%
concrete structure.
epoxy showed In this
poor bondstudy, the epoxy
strength resin0.8
lower than mortar
MPa.prepared
Whereas with 10samples
all the wt. % epoxy showed
with epoxy at poor
15, 20,
bond strength lower than 0.8 MPa. Whereas all the
and 25 wt. % showed a bond strength higher than 1.5 MPa. samples with epoxy at 15, 20, and 25 wt. % showed
a bond strength higher than 1.5 MPa.
Materials 2017, 10, 246 10 of 11

4. Conclusions
This study investigated the effect of filler on the mechanical and adhesion properties of epoxy
resin mortar. The following conclusions were drawn based on the experimental results obtained.

(1) The compressive strength, flexural strength and modulus of elasticity value of epoxy mortar
containing filler up to 20 wt. % improved by an average of 1.08–1.66, 1.18–1.66, and
1.07–1.54 times, respectively, at different weight fraction of epoxy in the range of 10–25 wt. %
when compared to the control specimens.
(2) It was observed that when filler is used at optimum level, it can improve bond strength; all the
mortars except those prepared with epoxy at 10 wt. % showed a good bond strength higher than
1.5 MPa.
(3) It can be established that sand washing waste can be used as potential filler for epoxy resin mortar
to obtain better compressive, flexural, stiffness, and bond strength.
(4) This study does not cover all the parameters required to examine repair materials for concrete
structures; further investigations on compatibility issues such as dimensional change stability of
the epoxy resin mortar containing sand washing waste filler is required.

Acknowledgments: This research was supported by Basic Science Research Program through the National
Research Foundation of Korea (NRF) funded by the Ministry of Education (2015R1D1A1A01060892).
Author Contributions: Chongku Yi conceived and designed the experiments; Ji-Yeon Moon and
Dinberu Molla Yemam performed the experiments; Dinberu Molla Yemam and Baek-Joong Kim analyzed the data;
Dinberu Molla Yemam wrote the paper. Authorship must be limited to those who have contributed substantially
to the work reported.
Conflicts of Interest: The authors declare no conflict of interest. The founding sponsors had no role in the design
of the study; in the collection, analyses, or interpretation of data; in the writing of the manuscript, and in the
decision to publish the results.

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