Impact of Freeze–Thaw Cycling on the Mechanical and Durability Properties of Rapid Repair-Based Overlay Systems

Rapid repair materials (RRMs) have been used in concrete overlay systems to rehabilitate infrastructure for many years. The bond performance between RRMs and a concrete substrate is crucial for maintaining the desired performance and can deteriorate due to freeze–thaw action. In the case of partial depth repairs (PDRs), the mechanical and durability properties at the interface between the substrate and repair materials have not been thoroughly studied resulting in frequent failures. There is limited research on the freeze–thaw durability of RRM overlay–substrate interface, and no standardized test methods exist for evaluating the performance under freeze–thaw cycling. The proposed experimental procedure combines freeze–thaw cycling of an overlay–substrate specimen with pull-off testing of the overlay. Three RRM overlay systems were used consisting of calcium sulfoaluminate cement and ordinary Portland cement (PC), and a ternary blend of PC, calcium aluminate cement, and calcium sulfate cement. A correlation between tensile bond strength and fundamental transverse frequency in composite specimens was observed, and the results demonstrated that RRMs can maintain robust adhesion following 300 cycles of freeze–thaw exposure. Furthermore, the employed testing methodology elicited bond-only failures, underscoring the necessity for continued investigation into optimal conditioning intervals and substrate integrity to enhance the durability of repair systems.