The Influence of Multi-Walled Carbon Nanotubes on the Pull-Off Strength of Polymer Concrete Overlays on Concrete Substrates with Sulfate Exposure

Polymer concrete (PC) is recognized for its lightweight nature, wear resistance, and rapid curing, making it well-suited for the repair of deteriorated infrastructure. This research critically addresses the challenge of enhancing overlay adhesion to compromised substrates by uniquely evaluating the role of pristine versus functionalized multi-walled carbon nanotubes (MWCNTs) in improving polymer concrete (PC) bond strength, particularly on concrete deteriorated by sulfate attack. PC mixtures containing varying concentrations of MWCNTs (0%, 0.25%, and 0.5% by weight) were prepared and tested for their mechanical properties, including compressive strength, modulus of rupture, and pull-off strength. Pull-off tests were conducted to assess the bond between PC overlays and Portland cement concrete (PCC) substrates. To examine the effects of substrate deterioration, PCC specimens were cured under two conditions: standard and sulfate-exposed environments. The results showed that neat polymer concrete (PC-Neat) achieved a high average pull-off strength of 2.82 MPa under normal conditions. Incorporating 0.25% pristine MWCNTs (PC-P25) significantly reduced the bond strength to 0.039 MPa. In contrast, improved performance was observed with functionalized MWCNTs. The addition of 0.5% COOH-functionalized MWCNTs (PC-FC50) yielded a pull-off strength of 2.22 MPa under normal conditions and 1.65 MPa in sulfate environments. Notably, under sulfate exposure, functionalized MWCNTs enhanced the bond strength by up to 15% compared to PC-Neat, highlighting their potential in aggressive environments. This distinct improvement in bond strength presents a significant finding, demonstrating a novel pathway for developing more resilient repair materials for infrastructure exposed to aggressive chemical environments.