Mechanical properties and microstructure of waterborne polyurethane-modified cement composites as concrete repair mortar

With the increase in service life, the durability of a large number of concrete structures deteriorates year by year under the influence of the external environment, requiring urgent repair and reinforcement. Ordinary cement concrete materials have disadvantages such as high brittleness, low tensile strength, poor bonding ability, and insufficient durability, making it difficult to meet the repair needs of high-quality building structures. Therefore, self-synthesized anion WPU was used to study its effect on the mechanical properties of cement-based repair mortar. The research found that waterborne polyurethane (WPU)-modified cementitious composite repair materials exhibit better bonding strength with old concrete substrates compared to traditional cement-based materials. Additionally, the incorporation of WPU significantly reduces the brittleness of the repair material, ensuring enhanced efficiency in the repair process. However, according to the hydration heat test results, the addition of WPU delays the hydration process of the composite repair materials. In addition, the addition of WPU enhances the flexibility and bonding ability of the materials, with flexural strength and tensile strength at the age of 28 days reaching 13 MPa and 6 MPa, respectively. Through stress‒strain curve analysis, it was found that the maximum strain amplification of WPU cement mortar can reach 134 %. Combined with SEM testing, it was observed that cured WPU films were present in specimens aged 28 days with P/C ratios of 10 % and 15 %. WPU and cement hydration products permeate each other, forming a three-dimensional polymer network structure, improving the pore structure, and fully exerting the flexibility of WPU. This also validates the experimental results of increased ultimate tensile strain. WPU cement-based composite repair materials have higher bonding strength at a high P/C ratio (15 %), and WPU alone, used as an interface agent for pretreating the interface of old concrete, can improve the interface bonding strength, up to twice that of the group without the surface agent.