Blistering of Reactive Resin Coatings on Concrete: New Insights

The formation of blisters in reactive resin coatings on concrete is a widely known phenomenon that is also a subject of debate in the literature. In particular, blisters forming after curing of the coating can lead to extensive damage. This study was focused on the investigation of blistering between the concrete substrate and the resin coating. The hypothesis is that the cementitious material and the overlying reactive resin coating form a system that leads to damage under certain boundary conditions regarding material composition, as well as moisture and mass transport. Systematic investigations were carried out in an extensive testing program with various substrate mortars that differ in cement type, water–cement ratio, and aggregate. As coating systems, two different EP primers were used with a transparent EP topcoat. The long-term testing was conducted on potential blistering of composite test specimens stored under various (practically relevant) conditions prior and after the coating. It was found that a higher moisture content of the substrate reduces blistering of the EP coating system. EP systems containing benzyl alcohol do not automatically tend to blister. Furthermore, condensation in the substrate provides sufficient amounts of water to cause blistering and ASR can contribute to blister formation.