1.

Elastomeric Coatings
2. Anti-carbonation Paints
3. Painting of Concrete
 Concrete and carbonation
• Concrete consist of mixture of cement, sand and aggregates while cement is largely
a mixture of tricalcium silicate, dicalcium silicate and tricalcium aluminates. The
result is a mass of interlocking crystals of hydrated silicates and aluminates which,
in admixture with sand and aggregates, produces concrete. At the same time some
calcium hydroxide is formed and this is responsible for the high alkalinity (pH- 11 to
12) of new concrete.
• Carbonation reaction : On exposure to air, the outermost layers react slowly with
atmospheric carbon dioxide to produce calcium carbonate and these result in fall in
a pH value to about 8-9. Concrete is attacked also by soluble sulphates and
atmospheric sulphur dioxide with formation of the sparingly soluble calcium
sulphate whilst chlorides (often in the form of sodium chloride) produce the
soluble calcium chloride which is leached from the film.
• The ‘carbonation’ process extends gradually into the concrete mass by penetration
of the micropores by carbon dioxide and can exert a damaging effect when the
concrete contains steel reinforcing rods. These rods are protected from corrosion
by the highly alkaline concrete surrounding them. If the process of carbonation
reaches the concrete immediately surrounding the rods, the pH will fall to a point
when corrosion can result. Then the more voluminous rust exerts pressure on the
concrete and cracking or spalling can result.
 Bre’s equation:
d = k √t, Where,
d is the depth of
carbonation, t is
the time of
exposure, k is a
coefficient.

Corrosion of steel reinforcement due to carbonation in a bridge

The values of k which influences the
rate of carbonation are as follows: < 3
mm/year ½ : Less ; 3 mm – 6 mm /year
½ : Moderate; > 6 mm/year ½ : Severe
Brown’s equation: d = k (√t/S) ---
Where S is the compressive strength of
• The process is represented by the reaction below,
CO2 + H2O ------> H2CO3
H2CO3 + CaO ------> CaCO3 + H2O[2].
• Dissolution of CO2 in the pore solution of cement paste:
CO2 + 2 OH = CO32- + H2O ----------------- (1)
• Dissolution of Ca (OH)2:
Ca (OH)2 = Ca2++ 2 OH- --------------- (2)
• Decomposition of hydrated silicate and
aluminate phases, viz.:
x CaO.SiO2 (aq) + z H2O = y Ca2+ + 2y OH- + (x-y) CaO.SiO2 (aq)
------------------------ (3)
• Reaction to form Carbonate:
Ca2+ + CO32- = CaCO3 --------------------- (4)[1].
 Anti-carbonation coatings
• The object of these coatings is the provision of a barrier to
carbon dioxide penetration whilst, at the same time,
allowing the passage of the moisture. Furthermore, such
coatings must retain these properties as the film weathers.
• Work by K. Klopfer in Germany has led to the establishment
of ‘minimum acceptance criteria’ for anticarbonation
coatings. These criteria involve a ‘carbon dioxide diffusion
resistance coefficient’ and coating thickness.
• A minimum dry film thickness of 150 µm is essential in an
efficient anti-carbonation coating. Among coating which
have shown good test results are high build and textured
forms of acrylic and vinyl copolymer emulsion paints.
• The protective coating fills surface pores and bridges fine
cracks & form a barrier to the movement of carbon
dioxide. It is measured by carbon dioxide diffusion, which
is defined as ability of the coating to resist the ingress of
carbon dioxide and to stop the carbonation of the
concrete.
• The CO2 diffusion coeffcient (D) are described in meters
of equivalent air layer thickness(R). These values indicate
how much more impermeable to CO2 is the coating
compared to air. Diffusion coefficient is typically around
7x 10–8 cm2/sec.
• The equivalent air layer thickness (R) is the product of
CO2 diffusion coefficient (D) and thickness of the coating
(S) : R = μ x S meters
• A value of R in excess of 50 m is normally considered to be
adequate. The R-value used in the design of coating system
is to prevent the carbonation front reaching the steel
reinforcement in a 60 year life cycle, assuming the cover is
not less than 25 mm otherwise, for less cover, R values need
to be increased. Also the R value remains same for old and
new concrete of grade M 45 and above.
• The other way of expressing carbon dioxide diffusion is
equivalent thickness of concrete (Sc): Sc = R/μ concrete
where, μ of concrete is taken as 400 which is an average
value for concrete of strength 30N/mm2.
• Sc gives the equivalent concrete layer, which has the same
resistance of CO2 diffusion as the given thickness of coating.
Typically, a high quality solvent based anti-carbonation
system at 150 microns will have an equivalent concrete
thickness of 700 mm. Hence for carbon diffusion a
minimum thickness of 150 µm is required.
 Properties to be calculate:
 CO2 Concentration in environment

 Carbon Dioxide diffusion rate

 Carbon dioxide permeability

 Diffusion resistance

 Carbonation coefficient.
• The carbon dioxide transmission rate or carbon dioxide
diffusion flux is measure of the amount of carbon dioxide
diffusing in unit time through unit area of the coating.

……………………….(A)[2]
• Where,
i = Diffusion flux of CO2
∆m = Amount of CO2 diffusing in unit time through unit
area (gm)
A = area (m2)
∆T = time (days).
• Carbon Dioxide permeability (ρ)

…………………………..(B)

Where,
S = thickness of the sample
∆P = P1 - P2, the partial pressure difference between the two
surfaces.
• The reciprocal of permeability is called diffusion resistance(µ).

• …………………………………………….(C)

• Where,
ρ = permeability of CO2 in the coating
ρL = permeability of CO2 in air
• diffusion –equivalent air layer thickness Sd (m) is the thickness of a static air
layer that possess, under the same carbon dioxide permeability as the coating.
Sd = µ. S ......................................(D)[2].
• Depth of Carbonation:
• Bre’s Equation :
d = k √t ..........................................................(E)
Note: Some papers showed depth of carbonation as a “x”.
where,
d = depth of carbonation
k = carbonation coefficient
t = time of exposure
• Brown’s equation :
d = k (√t/S) ................................................(F)
S = compressive strength
• The value of carbonation coefficient k can be calculated
as……………
k = (2 ⋅ D ⋅ C / M)½.............................(G)
Where,
D = Carbon Dioxide’s diffusion coefficient
C = Carbon Dioxide concentration in environment
M = equivalent concentration of the hydrated calcium oxide
in cement paste.[3]
The values of k which influences the rate of carbonation.............
< 3 mm/year ½ : Less
3 mm – 6 mm /year ½ : Moderate
> 6 mm/year ½ : Severe
Water vapor permeability- It is a desirable property to allow water vapors to
escape from the substrate[2].
 Elastomeric Wall Coating (EWC)
• Elastomeric wall coatings are designed for exterior masonry surfaces like
concrete, stucco and concrete block.
The main requirements of suitable systems are:
• High elasticity even at low temperature – capable of bridging cracks (low Tg
system)
• Low dirt pick up tendency (high Tg system)
• Protective – barrier against salts and atmospheric gases.
• High-build – masking imperfections in substrates.
• Waterproof – protects concrete from waterborne salts.
Criteria for Elastomeric Binder : polymers must exhibit Long Term Flexibility
upon extended exterior exposure.
Elastomeric Roof Coating : an exterior coating that resists carbonation and
prevents chloride ion ingress. Water based elastomeric coatings are easy to
use and clean up. Solvent based elastomeric coatings provide greater ponding
water resistance and is commonly used over flat roofs.
•An elastomeric roof coating is applied thicker than paint.
 Types of Elastomeric Roof Coating
•Acrylic Coating:
•Generally acrylic latex masonry paints designed to be applied in very
thick films (about 10 times as thick as regular paints); they are tough
and flexible, and stretch as cracks underneath open and close, thus
bridging the cracks and keeping wind driven rain out while maintaining
a nice appearance.
•They can be tinted to a light color. The EWC should be applied after
cracks more than 1/16" are caulked with a quality acrylic or siliconized
(not SILICONE) caulk.
•If the stucco is particularly porous, a masonry primer or paintable
sealer should be applied first.
•Applications of the EWC is usually at about 50 - 60 square feet/gallon,
and two coats should be applied.
• Polyurethane Coating:
Single component, solvent-based, moisture cure polyurethane
roof coating. Ponding water resistant. Excellent topcoat is
needed for Aromatic PU Coating for improved UV-resistance
and reflectivity.
• Silicon Coating:
Permeability, superior weatherability and ponding water
resistance. Again it has good hydrophobicity so during rainy
time, water will easily flow down and thus water spotting can
be avoided.
 References
[1] http://www.drfixitinstitute.com/download/anticarbonation%20coating.pdf.
[2] Dr. Satish Gaonkar, Sarjerao Kasbekar BASF India Ltd. “Anti carbonation
Coating”, The Masterbuilder-December 2013-www.masterbuilder.co.in, (2014),
p.160-166.
[3] E.I. Moreno, C.Vinajera-Reyna, A. Torres-Acosta, J.Perez-Quiroz, M.
Martinez-Madrid, F. Almeraya-Calderon, C. Gaona-Tiburcio, P. Castro-Borges, M.
Balancan-Zapata, T. Perez-Lopez, M. Sosa-Baz, E. Lopez-Vazquez, E. Alonso-
Guzman, W. Martinez-Molina, J.c. Rubio-Avolos, L.Ariza-Aguilar, B. Valdez-
Salas, D. Nieves-Mendoza, M. Baltazar, O. Troconis-Rincon, “Effect of
environmental parameters on concrete carbonation. DURACON collaboration
(Mexican results)”, concrete Repair, concrete Repair, rehabilitation II-Alexander et
al (eds), p.365-371.