Polymer concrete

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Polymer concrete is a type of concrete that uses a polymer to replace lime-type cements as a binder. One specific type is epoxy granite, where the polymer used is exclusively epoxy. In some cases the polymer is used in addition to portland cement to form Polymer Cement Concrete (PCC) or Polymer Modified Concrete (PMC). [1] Polymers in concrete have been overseen by Committee 548 of the American Concrete Institute since 1971.

Contents

Composition

In polymer concrete, thermoplastic polymers are often used, [2] but more typically thermosetting resins are used as the principal polymer component due to their high thermal stability and resistance to a wide variety of chemicals. Polymer concrete is also composed of aggregates that include silica, quartz, granite, limestone, or other material. The aggregate should be of good quality, free of dust and other debris, and dry. Failure to fulfill these criteria can reduce the bond strength between the polymer binder and the aggregate. [3]

Uses

Polymer concrete may be used for new construction or repairing of old concrete. The adhesive properties of polymer concrete allow repair of both polymer and conventional cement-based concretes. The corrosion resistance and low permeability of polymer concrete allows it to be used in swimming pools, sewer structure applications, drainage channels, electrolytic cells for base metal recovery, and other structures that contain liquids or corrosive chemicals. It is especially suited to the construction and rehabilitation of manholes due to their ability to withstand toxic and corrosive sewer gases and bacteria commonly found in sewer systems. Unlike traditional concrete structures, polymer concrete requires no coating or welding of PVC-protected seams. [4] It can also be used as a bonded wearing course for asphalt pavement, for higher durability and higher strength upon a concrete substrate, and in skate parks, as it is a very smooth surface.[ citation needed ]

Polymer concrete has historically not been widely adopted due to the high costs and difficulty associated with traditional manufacturing techniques. However, recent progress has led to significant reductions in cost, meaning that the use of polymer concrete is gradually becoming more widespread. [4] [5]

Polymer concrete in the form of epoxy granite is becoming more widely used in the construction of machine tool bases (such as mills and metal lathes) in place of cast iron due to its superior mechanical properties and a high chemical resistance.[ citation needed ]

Properties

The exact properties depend on the mixture, polymer, aggregate used etc. [6] Generally speaking with mixtures used:

Specifications

Following are some specification examples of the features of polymer concrete:

MaterialDensity
kg/m3
Compressive strength
Urea formaldehyde polymer concrete2260 [7] 37 MPa (5,400 psi) [8]
Polyester concreteN/A95 MPa (13,800 psi) [9]
Epoxy concreteN/A58 MPa (8,400 psi) [10]
Polymer Modified ConcreteN/A31 MPa (4,500 psi) [11]

Related Research Articles

<span class="mw-page-title-main">Concrete</span> Composite construction material

Concrete is a composite material composed of aggregate bonded together with a fluid cement that cures to a solid over time. Concrete is the second-most-used substance in the world after water, and is the most widely used building material. Its usage worldwide, ton for ton, is twice that of steel, wood, plastics, and aluminium combined.

<span class="mw-page-title-main">Reinforced concrete</span> Concrete with rebar

Reinforced concrete, also called ferroconcrete, is a composite material in which concrete's relatively low tensile strength and ductility are compensated for by the inclusion of reinforcement having higher tensile strength or ductility. The reinforcement is usually, though not necessarily, steel reinforcing bars and is usually embedded passively in the concrete before the concrete sets. However, post-tensioning is also employed as a technique to reinforce the concrete. In terms of volume used annually, it is one of the most common engineering materials. In corrosion engineering terms, when designed correctly, the alkalinity of the concrete protects the steel rebar from corrosion.

<span class="mw-page-title-main">Epoxy</span> Type of material

Epoxy is the family of basic components or cured end products of epoxy resins. Epoxy resins, also known as polyepoxides, are a class of reactive prepolymers and polymers which contain epoxide groups. The epoxide functional group is also collectively called epoxy. The IUPAC name for an epoxide group is an oxirane.

<span class="mw-page-title-main">Terrazzo</span> Cementitious composite material, usually used in flooring

Terrazzo is a composite material, poured in place or precast, which is used for floor and wall treatments. It consists of chips of marble, quartz, granite, glass, or other suitable material, poured with a cementitious binder, polymeric, or a combination of both. Metal strips often divide sections, or changes in color or material in a pattern. Additional chips may be sprinkled atop the mix before it sets. After it is cured it is ground and polished smooth or otherwise finished to produce a uniformly textured surface. "Terrazzo" is also often used to describe any pattern similar to the original terrazzo floors. Modern forms of terrazzo include polished concrete.

<span class="mw-page-title-main">Mortar (masonry)</span> Workable paste that hardens to bind building blocks

Mortar is a workable paste which hardens to bind building blocks such as stones, bricks, and concrete masonry units, to fill and seal the irregular gaps between them, spread the weight of them evenly, and sometimes to add decorative colours or patterns to masonry walls. In its broadest sense, mortar includes pitch, asphalt, and soft clay, as those used between bricks, as well as cement mortar. The word "mortar" comes from the Old French word mortier, "builder's mortar, plaster; bowl for mixing." (13c.).

<span class="mw-page-title-main">Grout</span> Building material

Grout is a dense substance that flows like a liquid yet hardens upon application, and it gets used to fill gaps or as reinforcement in existing structures. Grout is generally a mixture of water, cement, and sand, and it frequently gets employed in efforts such as pressure grouting, embedding rebar in masonry walls, connecting sections of precast concrete, filling voids, and sealing joints such as those between tiles. Common uses for grout in the household include filling in tiles of shower floors and kitchen tiles. It is often color tinted when it has to be kept visible and sometimes includes fine gravel when being used to fill large spaces. Unlike other structural pastes such as plaster or joint compound, correctly mixed and applied grout forms a water-resistant seal.

A binder or binding agent is any material or substance that holds or draws other materials together to form a cohesive whole mechanically, chemically, by adhesion or cohesion.

Engineered Cementitious Composite (ECC), also called Strain Hardening Cement-based Composites (SHCC) or more popularly as bendable concrete, is an easily molded mortar-based composite reinforced with specially selected short random fibers, usually polymer fibers. Unlike regular concrete, ECC has a tensile strain capacity in the range of 3–7%, compared to 0.01% for ordinary portland cement (OPC) paste, mortar or concrete. ECC therefore acts more like a ductile metal material rather than a brittle glass material, leading to a wide variety of applications.

<span class="mw-page-title-main">Structural steel</span> Type of steel used in construction

Structural steel is a category of steel used for making construction materials in a variety of shapes. Many structural steel shapes take the form of an elongated beam having a profile of a specific cross section. Structural steel shapes, sizes, chemical composition, mechanical properties such as strengths, storage practices, etc., are regulated by standards in most industrialized countries.

<span class="mw-page-title-main">Ground granulated blast-furnace slag</span> Granular slag by-product of iron and steel-making used as supplementary cementitious material

Ground granulated blast-furnace slag is obtained by quenching molten iron slag from a blast furnace in water or steam, to produce a glassy, granular product that is then dried and ground into a fine powder. Ground granulated blast furnace slag is a latent hydraulic binder forming calcium silicate hydrates (C-S-H) after contact with water. It is a strength-enhancing compound improving the durability of concrete. It is a component of metallurgic cement. Its main advantage is its slow release of hydration heat, allowing limitation of the temperature increase in massive concrete components and structures during cement setting and concrete curing, or to cast concrete during hot summer.

<span class="mw-page-title-main">Pozzolan</span> Siliceous volcanic ashes commonly used as supplementary cementitious material

Pozzolans are a broad class of siliceous and aluminous materials which, in themselves, possess little or no cementitious value but which will, in finely divided form and in the presence of water, react chemically with calcium hydroxide (Ca(OH)2) at ordinary temperature to form compounds possessing cementitious properties. The quantification of the capacity of a pozzolan to react with calcium hydroxide and water is given by measuring its pozzolanic activity. Pozzolana are naturally occurring pozzolans of volcanic origin.

Fiber-reinforced concrete or fibre-reinforced concrete (FRC) is concrete containing fibrous material which increases its structural integrity. It contains short discrete fibers that are uniformly distributed and randomly oriented. Fibers include steel fibers, glass fibers, synthetic fibers and natural fibers – each of which lend varying properties to the concrete. In addition, the character of fiber-reinforced concrete changes with varying concretes, fiber materials, geometries, distribution, orientation, and densities.

Biogenic sulfide corrosion is a bacterially mediated process of forming hydrogen sulfide gas and the subsequent conversion to sulfuric acid that attacks concrete and steel within wastewater environments. The hydrogen sulfide gas is biochemically oxidized in the presence of moisture to form sulfuric acid. The effect of sulfuric acid on concrete and steel surfaces exposed to severe wastewater environments can be devastating. In the USA alone, corrosion causes sewer asset losses estimated at $14 billion per year. This cost is expected to increase as the aging infrastructure continues to fail.

<span class="mw-page-title-main">Filler (materials)</span> Particles added to improve its properties

Filler materials are particles added to resin or binders that can improve specific properties, make the product cheaper, or a mixture of both. The two largest segments for filler material use is elastomers and plastics. Worldwide, more than 53 million tons of fillers are used every year in application areas such as paper, plastics, rubber, paints, coatings, adhesives, and sealants. As such, fillers, produced by more than 700 companies, rank among the world's major raw materials and are contained in a variety of goods for daily consumer needs. The top filler materials used are ground calcium carbonate (GCC), precipitated calcium carbonate (PCC), kaolin, talc, and carbon black.

<span class="mw-page-title-main">Epoxy granite</span> Mixture of epoxy and granite

Epoxy granite, also known as synthetic granite, is a polymer matrix composite and is a mixture of epoxy and granite commonly used as an alternative material for machine tool bases. Epoxy granite is used instead of cast iron and steel for improved vibration damping, longer tool life, and lower assembly cost, and thus better properties for stabilizing and housing machines.

<span class="mw-page-title-main">Types of concrete</span> Building material consisting of aggregates cemented by a binder

Concrete is produced in a variety of compositions, finishes and performance characteristics to meet a wide range of needs.

<span class="mw-page-title-main">Concrete degradation</span> Damage to concrete affecting its mechanical strength and its durability

Concrete degradation may have many different causes. Concrete is mostly damaged by the corrosion of reinforcement bars due to the carbonatation of hardened cement paste or chloride attack under wet conditions. Chemical damage is caused by the formation of expansive products produced by chemical reactions, by aggressive chemical species present in groundwater and seawater, or by microorganisms Other damaging processes can also involve calcium leaching by water infiltration, physical phenomena initiating cracks formation and propagation, fire or radiant heat, aggregate expansion, sea water effects, leaching, and erosion by fast-flowing water.

Concrete has relatively high compressive strength, but significantly lower tensile strength. The compressive strength is typically controlled with the ratio of water to cement when forming the concrete, and tensile strength is increased by additives, typically steel, to create reinforced concrete. In other words we can say concrete is made up of sand, ballast, cement and water.

Sulfur concrete, sometimes named thioconcrete or sulfurcrete, is a composite construction material, composed mainly of sulfur and aggregate. Cement and water, important compounds in normal concrete, are not part of sulfur concrete. The concrete is heated above the melting point of elemental sulfur at ca. 140 °C (284 °F) in a ratio of between 12% and 25% sulfur, the rest being aggregate.

References

  1. 1 2 3 4 Composite Structures for Civil and Architectural Engineering By D-H Kim
  2. Figovsky, Oleg; Beilin, Dmitry (2013-12-11). Advanced Polymer Concretes and Compounds. CRC Press. ISBN   9781466590328.
  3. L J Daniels, PhD Thesis, University of Lancaster, 1992 Polymer Modified Concrete
  4. 1 2 "Polymer Concrete Manholes & Precast Concrete | Armorock". Genevapolymerproducts.com. 2020-03-23. Retrieved 2022-04-15.
  5. "Home". napsco.co.
  6. Concrete admixtures handbook : properties, science, and technology. V. S. Ramachandran (2nd ed.). Park Ridge, N.J., U.S.A.: Noyes Publications. 1995. ISBN   1-59124-038-7. OCLC   49708378.{{cite book}}: CS1 maint: others (link)
  7. Suh, Jung Do; Lee, Dai Gil (2008). "Design and manufacture of hybrid polymer concrete bed for high-speed CNC milling machine". International Journal of Mechanics and Materials in Design. 4 (2): 113–121. doi:10.1007/s10999-007-9033-3. S2CID   135832609.
  8. Alzaydi, A. A.; Shihata, S. A.; Alp, T. (1990). "The compressive strength of a new ureaformaldehyde-based polymer concrete". Journal of Materials Science. 25 (6). in table Properties of polymer concrete. Bibcode:1990JMatS..25.2851A. doi:10.1007/BF00584892. S2CID   137295866.
  9. Ohama, Y. (1997-04-10). Polymers in Concrete. CRC Press. ISBN   9780419223306.
  10. "Power-Patch Concrete Epoxy Kit (Grey)". Interstate Products Inc. Retrieved 2021-06-04.
  11. "10 Minutes Concrete Mender". Concrete Repair. Retrieved 2024-06-21.

Further reading