Microstructure and durability of rapid repair mortar with self-emulsifying waterborne epoxy polymer

Due to the low hydration rate of ordinary Portland cement (OPC), it cannot meet the requirements of rapid repair, especially in negative temperature environments. Simultaneously, facing the harsh marine environment, repair materials urgently need high durability. In this paper, a self-emulsifying waterborne epoxy polymer (WEP) suitable for cement systems was combined with sulfoaluminate cement (SAC) to prepare repair materials. The effect of the WEP on the development of microstructure, auto-drying shrinkage and durability was investigated by nuclear magnetic resonance, XRD and SEM methods. Results showed that a continuous interpenetration polymer network (IPN) was intricately woven within the multiphase composites, using the macromolecular network structure formed by -OH groups in WEP and Ca2+ and Al3+ in cement as a bridge. The resistance to chloride migration and water absorption exhibited an increase followed by a decrease. In particular, the resistance to chloride migration was improved by 45 %. Similar trends were observed for the carbonation resistance. Due to the lower porosity and capillary pressure caused by IPN, leading to a decrease in auto-drying shrinkage. Nevertheless, the larger percentage of capillary pores in a mortar with a P/C of 15 % increased the auto-drying shrinkage. The WEP decreased the availability of pores of critical diameter (14 nm) of mortar exposed to water freezing, leading to an increase in the freeze-thaw resistance. The change in P/C hardly affected the resistance to sulfate attack. Under - 10 degrees C, at 2 hours, the compressive strength of CSA-based mortar satisfied the load requirements for vehicular operations. This research provides theoretical and practical implications for the repair work of large-scale projects serving in harsh environments.