An increasingly common material in building projects is polymer concrete, which is robust and adaptable. It’s a composite material that creates a robust, long-lasting product by mixing polymer resins with conventional aggregates. This special blend is a popular option for many applications because it has several advantages over traditional concrete.
The increased durability of polymer concrete is one of its key advantages. It is perfect for use in harsh environments because it is much more resistant to weathering, abrasion, and chemicals than regular concrete. Furthermore, polymer concrete can be used to build structures that are lighter and thinner without compromising strength, which is a big benefit in a lot of construction scenarios.
It’s also very possible to make your own polymer concrete. This sturdy material can be made at home with the correct supplies and a little bit of expertise. Aggregates, such as sand or gravel, are combined with a polymer binder, usually a kind of resin, in this process. This mixture produces a high-strength material that can be molded into different sizes and shapes to fit the requirements of your project.
We will go into great detail about the properties and makeup of polymer concrete in this article. For do-it-yourself projects, we’ll also offer a comprehensive guide on how to make your own polymer concrete. Polymer concrete provides a variety of options for enhancing the longevity of your constructions or experimenting with novel building materials.
Characteristics
Concrete made of polymer is resistant to both mechanical and moisture factors. It responds to temperature variations normally. The composition adheres well to any base and hardens quickly. The fabric is permeable and elastic. Chemical agents do not react with it.
Environmental safety is the primary feature of the polymer cement mixture.
Polymer concrete doesn’t release any chemicals that are harmful to the environment or human health. The mixture can be utilized in the building of venues for public catering.
Polymer concrete composition
The following elements are part of the construction mixture:
- Large-fraction filler. Broken glass, crushed stone, sand are used as this element.
- Fine-fraction filler. The introduction of such a component reduces the cost of the product. Graphite or quartz becomes the filler.
- Binder. A polymer resin is added to the mixture, for example, polyester, furan, urea-formaldehyde or epoxy. Polymer concrete contains 5% of a binder.
- Auxiliary additives. These include substances that increase elasticity and frost resistance, giving the composition the desired color.
Production technology
Two technologies are utilized in the manufacturing of building materials:
- Periodic. In this case, the container is cleaned after each cycle of material production. Polymer concrete can be produced using a concrete mixer or a simple basin.
- Continuous. The technology is used by large enterprises. The conveyor includes casting machines, dispensers and automatic mixers.
Release agent-treated molds are used in the production of polymer concrete products. The final product is easily extracted due to its composition. The mold can be made of metal, fiberglass, wooden boards, or silicone.
The following steps are involved in the manufacturing process:
- Preparation. The mold is treated with a release agent and covered with a gelcoat of the required color.
- Creation of the composition. Fillers and polymer additives for concrete are thoroughly mixed using a mixer.
- Laying the mixture into molds. At large enterprises, concrete pavers are used at this stage. When manufacturing products in a small workshop, the action is performed manually.
- Vibration compaction. By vibrating the mixture, the desired properties are imparted. The duration of this stage is 2 minutes. At factories, a resonant vibration platform is used. Small enterprises are equipped with vibration tables.
Products made of polymer concrete undergo heat treatment in an industrial setting. This shortens the product’s curing period. In other situations, hardening happens naturally.
Advantages of the material
Because of its many advantages, polyconcrete can be used in situations where traditional concrete is unable to yield the required results.
The following qualities are among the benefits of the composite composition:
- Resistance to high humidity. Water droplets evaporate quickly from the surface without having time to be absorbed.
- Insensitivity to temperature changes. Products do not deform during rapid heating or cooling. The quality of the material does not depend on the number of freezing cycles. In the production of concrete mixtures, a polymer is used instead of traditional cement or silicate.
- Resistance to aggressive substances. The coating is not damaged by the influence of disinfectants and solvents. This eliminates the need to use additional methods of surface treatment.
- Possibility of restoring damaged areas. The composite massif is restored by using special mixtures.
- Increased strength. With a small weight, this characteristic is not inferior to that of classic concrete.
- Smoothness of the surface. No unevenness is formed during the manufacture of products. The material does not slip and does not wear off. This avoids contamination of the coating. If necessary, the surface can be washed in the usual way.
- Possibility of recycling. The material is used in the creation of process waste. This reduces the cost of the product manufactured using waste-free technology.
Features and scope of use
The following items are made with polymer concrete:
- Countertops. Kitchen furniture elements made from this material are characterized by increased strength, hygiene and a long service life. They fit well into any interior. Polymer concrete countertops are no different from products made from natural stone.
- Floors. Floor coverings are resistant to dirt and easy to install. The surface is flexible, resistant to mechanical damage, has an aesthetic appearance. A 2 mm thick layer can be used for 10 years.
- Decorative parts of facades. Polymer concrete is no different from marble or granite. Polymer products are lightweight, so they can be installed without creating a massive base.
- Monuments and fences. Polymer massif is resistant to atmospheric factors, which allows it to be used for decorating ritual objects.
Types of polymer systems
A broad category of construction mixtures with varying compositions and manufacturing processes are collectively referred to as polymer concrete.
Group of plastic concretes
The kind of fillers, polymers, and auxiliary additives added affect the material’s properties. Finishing room applications are not suitable for furfural acetone mixtures. Both humans and animals can safely handle compounds like epoxy and methacrylate.
Plastic concrete is more elastic, frost-resistant, and moisture-resistant than traditional concrete. Rapid wear is a drawback.
Polymer -cement systems
Cement is a component of these materials.
Obtain the blend in three methods:
- Mixing the base with aqueous solutions of polymers – polyvinyl acetate or artificial rubber.
- Introduction of a dispersion of polymers or monomers. The most commonly used furan alcohol and epoxy resins.
- Patching concrete. Polymer components are introduced to the desired depth, such as urea or styrene.
The connecting component’s recommended volume is between 15% and 20%. This enables you to preserve the cement composition’s structure. The products become less robust as the amount of polymer increases. Filler is either finely crushed stone or sand. Flooring that resists wear is made with polymer-cement blends.
Concrete polymer compositions
Concrete polymer is a cured cement mixture that is impregnated with liquid on its surface. The substance consists of catalysts and metal acrylate resins that solidify within the mineral framework’s structure.
One drawback that arises during the product production process is the abundance of pores.
These flaws weaken one’s resistance to harsh substances and reduce strength. Polymer filling the pores contributes to the composition’s improved properties.
Geoconcrete
Natural components are being used in the production of materials used in construction on a larger scale. While the performance characteristics of geopolymer concrete and traditional concrete are similar, they differ slightly. The composition of the stone is similar to that of natural stone.
The material is in demand among individual developers due to its low cost. Geoconcrete is utilized in the construction of ornamental elements as well as multi-story buildings.
| Application of Polymer Concrete | Composition, Characteristics, DIY Production |
| Used for building durable floors, walls, and countertops due to its strength and resistance to chemicals. | Composed of resin, aggregates, and a hardener. It is strong, durable, and resistant to corrosion. To make it yourself, mix resin with aggregates, add the hardener, pour into molds, and let it cure. |
| Ideal for outdoor furniture and architectural elements as it withstands weather conditions. | Polymer concrete includes materials like epoxy or polyester resin combined with sand, gravel, or crushed stone. Mix these components, pour into a desired shape, and allow curing for a solid finish. |
| Frequently used in the construction of drainage systems and pipes because of its non-porous nature. | This concrete variant is created by blending a polymer binder with fillers such as quartz or granite. For DIY, blend the ingredients thoroughly, shape them as needed, and cure them to achieve a sturdy and resilient material. |
For a variety of construction applications, polymer concrete provides an adaptable and long-lasting solution. Because of its special composition, which combines aggregates and resins, the material is extremely resistant to wear, water, and chemicals. Because of this, it is perfect for use in drainage systems, industrial flooring, and even decorative elements.
Anyone wishing to take advantage of the advantages of polymer concrete must comprehend its features. It performs better than conventional concrete in many ways thanks to its remarkable strength and durability. Its adaptability to different sizes and shapes adds to its allure for unique projects.
With the proper supplies and tools, it is completely possible to produce polymer concrete at home. Through meticulous blending of the resin, hardener, and aggregates, a robust and long-lasting product customized to your requirements can be produced. With this do-it-yourself method, you can save money and have the satisfaction of creating a high-quality material for your building projects.
Polymer concrete offers a strong and adaptable solution for a range of applications, whether you’re a professional contractor or a do-it-yourself enthusiast. Its exceptional performance and versatility make it an invaluable addition to any construction toolbox, guaranteeing the long-term viability of projects.
By combining conventional concrete with polymer resins, polymer concrete is a strong, weather- and chemical-resistant material that is both versatile and long-lasting. This cutting-edge material is perfect for a lot of uses, like architectural elements and industrial flooring. We’ll go over the ingredients and salient features of polymer concrete in this post, along with a simple how-to guide, so you can take advantage of it for your upcoming building project.
