IPDI-Core/Polyurethane-Shell Microcapsules: Synthesis and Application in Self-Healing Concrete

Cementitious materials are naturally brittle, which makes them prone to cracking. This study effectively employs autogenous healing techniques using microcapsules to solve this issue. The goals were twofold: first, to microencapsulate isophorone diisocyanate (IPDI) as a catalyst-free healing agent; and second, to evaluate how these microcapsules improve the healing abilities of cementitious materials. Polyurethane (PU) prepolymer with an NCO content of 19.8% was successfully created. Using interfacial polymerization, smooth, spherical microcapsules of IPDI with an average diameter of 38 to 62 micrometers were produced. The elastic modulus of the microcapsules ranged from 0.23 to 0.18 GPa, while their hardness varied between 5.29 and 4.15 MPa. Over six months, the microcapsules showed a weight loss of 9.72% to 12.47%, depending on their size, under ambient conditions. Specimens containing 3% of fabricated microcapsules demonstrated the ability to seal cracks less than 100 µm wide by up to 70%. Specimens that incorporated 3% of their cement weight in IPDI microcapsules achieved an impressive 74% recovery rate in compressive strength. In contrast, control mortars without microcapsules showed a recovery rate of less than 50%. Analysis using Energy Dispersive Spectroscopy (EDS) revealed a significant presence of carbon in areas where the microcapsules had ruptured and the cracks had healed. This confirms the effectiveness of the healing process, consistent with established self-healing theories. The water tightness recovery trace showed a recovery rate of up to 61%. Additionally, the specimens containing microcapsules exhibited higher initial compressive strength than the control specimens. However, this also indicates that some microcapsules may have ruptured unintentionally during preparation and molding. Therefore, further research on the mechanical properties of microcapsules, especially their stiffness in cementitious composites, is necessary.