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Polymer Concrete

Introduction

  • Polymer Concrete is a material made up of different types of aggregates adhered by polyester resins. This material is a lightweight in nature, and its practically zero percentage of water absorption guarantees complete water tightness.
  • Polymer concrete is a versatile, durable, composite material produced by mixing a variety of mineral fillers with a natural resin binding agent.

Types of Polymer Concrete

  1. Latex-Modified Concrete (LMC): It also known as Polymer Portland Cement Concrete. Conventional concrete made by replacing part of mixing water with a latex.
  2. Polymer Impregnated Concrete (PIC): It produced by impregnating or infiltrating a hardened concrete with a monomer and subsequently polymerizing the monomer in situ.
  3. Polymer Concrete (PC): It formed by polymerizing a mixture of a monomer and aggregate.

Significance

  • Depending upon the materials employed, PC can develop compressive strengths of the order of 140 MPa within hours or even minutes.
  • LMC possess excellent bonding ability to old concrete, and high durability to aggressive solutions; it has therefore been used mainly for overlays in industrial floors, and for rehabilitation of deteriorated bridge decks.
  • In the case of PIC, by effectively sealing the micro cracks and capillary pores.

Properties of PC

  • Commercial products are available with a variety of formulations, some capable of hardening to 105MPa (15,000 psi) within a few minutes without thermal treatment.
  • Epoxy resins are higher in cost but offer advantages such as adhesion to wet surfaces.
  • Styrene monomer, and methyl methacrylate with benzoyl peroxide catalyst and an amine promoter are often used.

Material Features

  • High resistance to chemical and biological attack.
  • Lightweight compared to cement concrete products.
  • Excellent noise and vibration absorption.
  • Excellent dielectric properties.
  • Good weathering and UV resistance.
  • Zero water absorption.
  • Can be cut with masonry drills and grinders.
  • Approximately 4 times the flexural strength of cement concrete.
  • Good thermal properties and stability.
  • Ultra smooth finish which encourages efficient hydraulic flow.

Benefits of Polymer Concrete

  • Strength
  • Durability
  • Fire and heat resistance
  • Lower absorbency
  • Less chalking in outdoor exposure
  • Chemical resistance
  • Abrasion resistance
  • Temperature stability
  • Mold ability
  • Machinability

Applications

  • Used for pump bases, flooring blocks, chemical containment, trenches drains and more.
  • Solid surface  countertops for modern kitchens and baths.
  • With its decorative finishes and excellent resilience, polymer concrete is ideal for many ornamental applications including park benches, outdoor furniture, and waste  containers.
  • Commonly used in areas subject to heavy wear and high loadings such as car parks, roadways and industrial areas.

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