Mechanical performance of statically loaded flat face epoxy bonded concrete joints

One of the main challenges in the offshore renewable energy industry is the reduction in the levelised cost of energy of wind, wave and tidal devices. The use of concrete as the primary construction material in such devices presents a low unit cost, high marine durability alternative to steel, however, to maximise material efficiency factors such as mix constituent design, structural detailing and manufacturing processes have to take into account the specific conditions of the marine environment. Pre-cast segmental construction can be considered as one of the fastest and cheapest construction options. However the challenges regarding performance of epoxy bonded concrete in marine environment should be taken into account. This paper presents the results of an experimental programme on the performance of shear and tensile capacity of flat face concrete joints, focussing on the effect of substrate surface preparation, joint thickness, properties of epoxy resins, exposure to seawater and presence of joint defects on the ultimate failure load. The ultrasonic pulse velocity (UPV) method for detection of defects in the adhesive layer was examined and digital image correlation is used to observe the surface strain flow through the joint. The results indicate that the epoxy joints behave monolithically and remain undamaged under different types of static loading. The joints do not significantly interrupt the flow of strain but can locally affect the distribution of strain (and thus stiffness and stresses) in a structure. An increase in the density of the epoxy (and the filler content) leads to the increase in the joint strength and thicker joints are less affected by small defects in the bonding layer. The majority of tested specimens failed by cracking of concrete rather than by debonding of the joint, whilst compressive stresses acting on the joint can help to augment its shear strength. Sandblasting of bonded surfaces can improve performance of joints, whereas UPV testing may be used for quality control of epoxy-bonded joints.