Experimental Investigations on Influence of Epoxy and Alccofine in Concrete: A Potentially Sustainable Approach

This study presents a systematic investigation into the synergistic effects of a water‐miscible epoxy resin (EL‐Monobond‐200) and the microfine cementitious material Alccofine 1108 on the mechanical and durability performance of microconcrete repair mortars. Evaluating ordinary Portland cement (OPC) 43 grade as a baseline, the research contrasts conventional mortar performance against hybrid mixes incorporating Alccofine 1108 and water‐miscible epoxy resin at dosages ranging from 0% to 2.5% by weight of cementitious materials. Standardized tests were conducted in accordance with IS and ASTM protocols to measure mechanical properties, including compressive, split‐tensile, and flexural strengths at 1, 3, 7, and 28 days, and durability characteristics, such as sorptivity (ASTM C1585), rapid chloride migration (NT Build 492), carbonation depth, acid resistance (ASTM C267), and thermal stability. The observed improvements in strength and durability suggest matrix densification and improved interfacial characteristics, plausibly attributable to the combined effects of Alccofine reactivity and epoxy film formation. The findings depict that standard OPC 43 grade mortar is insufficient for high‐performance repair applications, necessitating the use of microfine cementitious systems. A 1% epoxy dosage was selected as the practical dosage because it provided the best balance among strength development, workability, consistency, setting‐related behavior, and practical applicability; higher epoxy dosages produced higher compressive strengths but were less favorable in terms of the overall working and setting characteristics. The observed improvements in strength and durability suggest a denser matrix and improved interfacial characteristics, plausibly attributable to the combined effects of Alccofine reactivity and epoxy film formation. The novelty of this research lies in its first comprehensive evaluation of a water‐miscible epoxy Alccofine hybrid cementitious system, a combination previously undocumented in literature. By establishing the synergistic role of polymer film‐forming ability and ultra‐fine pozzolanic activity, this work presents a water‐miscible epoxy Alccofine repair material with potential sustainability benefits, particularly for structural repair and retrofitting applications, particularly under aggressive environmental conditions where conventional curing is challenging.