Polymer concrete floors: characteristics, device

For a variety of industrial and commercial applications, polymer concrete floors offer a contemporary solution. These floors offer remarkable strength, chemical resistance, and longevity by fusing the longevity of conventional concrete with the improved qualities of polymers. They are perfect for factories, warehouses, and other high-traffic areas because they are made to withstand heavy loads.

Superior bonding ability is one of the main features of polymer concrete. By adding polymers, the aggregate and binder adhere to one another better, creating a dense, cohesive material that is less likely to crack and shrink. Because of this, polymer concrete floors are incredibly resilient, even in areas with significant temperature swings or mechanical stress.

The installation of polymer concrete floors is not too difficult. Preparing the existing surface, combining the aggregate and polymer ingredients, and then evenly applying the mixture are the usual steps in the process. The floor cures quickly after it is laid, reducing downtime and facilitating quick use of the area. This efficiency is especially useful in industrial environments where maintaining operations is essential.

Polymer concrete floors also resist corrosion and chemicals, which is a major benefit. Polymer concrete is resistant to damage from harsh chemicals, unlike traditional concrete, which can be harmed by them. This makes it the best option for environments where chemical spills are a concern, such as laboratories and chemical processing plants.

Polymer concrete floors also provide design flexibility. They can be altered to match specific functional and aesthetic needs with different hues, textures, and finishes. Polymer concrete can be customized to meet specific needs, such as a glossy finish for a sleek appearance or a non-slip surface for safety.

All things considered, polymer concrete floors are a strong, resilient, and adaptable choice for contemporary building. They are a sensible option for many applications due to their special qualities and simplicity of installation, offering dependable long-term performance.

Materials and types of coatings

Polymer concrete is one of the materials in this class whose structural elements are improved by the addition of polymers.

Compound

One of the following techniques can be applied to polymers and materials derived from them:

  • as additives in a concrete mixture;
  • as binder;
  • like polymer impregnations for concrete in order to improve the properties of finished products;
  • in the form of light fillers and aggregates;
  • like polymer compounds for concrete repair.

Even at the setting stage of the formed product, these substances that were added to the mixture in small amounts are actively contributing to the formation of the concrete structure. Stabilizers, plasticizers, hardeners, and other modifying additives can also be added to the solution to speed up these reactions.

The most common application for different thermoactive resins is as polymer binders:

Both large and small fillers are made of standard materials, as per GOST 26633-2015 (quartz sand, dolomite, granite, etc.). High wear resistance and resistance to all mechanical loads are determined by their presence in the composition of solutions.

Typically, the following substances serve as fillers in polymer solutions:

  • quartz flour;
  • ground andesite;
  • graphite;
  • marshalite, etc.

Microfillers, which are essentially finely ground rocks, can be added to mixtures to preserve binders. When products are being produced, binders typically harden in natural environments with temperatures no lower than 15 °C and humidity levels between 60 and 65 %.

Concrete polymers can be classified into two primary categories based on the amount of binders present:

  1. Polymer concrete, in which the amount of polymer binders is 20-50% of the total volume of fillers, is called filled. In this case, the polymers completely fill all the voids between the grains of large and small fillers. The density of such material depends on the fractional composition of the components used.
  2. Polymer concrete, in the structure of which there is 4-6% of binder, is called frame concrete. Here, polymer substances are used only for gluing grains of different fillers (framework of the product), while most of the voids of the frame remain unfilled. Taking this circumstance into account, there is a technical need to use strengthening polymer impregnations.

Hints: Because of the volume of polymers, frame concrete is substantially less expensive than filled concrete. The selection of such a material must be done carefully though, as the final product’s cost—after accounting for coating strengthening and impregnations—can be much more than that of a filled, balanced product.

Types of coatings

Polymer floors vary from one another in terms of the kind of binder and filler used, as well as the ideal working layer thickness and filling quantity.

Furthermore, a lot of specialized businesses create their own unique recipes based on one of the aforementioned polymers. As a result, it can be challenging to characterize a substance precisely and draw boundaries around its effects.

However, the most common structural types utilized in the installation of self-leveling floors are as follows:

The coatings on this list have a very wide range of properties.

The primary characteristics that set them apart are all that can be mentioned:

  1. Floors based on epoxy resins have increased adhesion to any base, hardness, chemical resistance.

  1. Floor structures made on the basis of elastomeric polyurethanes are distinguished by high wear resistance, elasticity, positive characteristics in relation to impact loads, but relatively low chemical resistance.

  1. The advantages of acrylic floors include such qualities as: fast setting at low temperatures, resistance to ultraviolet radiation and a stable state at the moment of a sharp change in temperature values ​​​​(thermal shock).

  1. Polyesh coatings have high chemical resistance, but more than the epoxy floor, shrinkage deformation and relatively low wear resistance.

  1. Furanic resin -based coatings are characterized by high wear industry, water resistance and low cost.

The following floor designs are possible based on the working layer thickness and computed loads:

  1. Polymer impregnations for concrete – serve to create a protective or decorative coating. Ingredients: thermoactive resins, organic or waterproof solvents. Usually two -layer. The thickness of the finished layer, depending on the planned loads, can range from 0.15 to 1.0 mm.

  1. Thin -layer constructions are performed in two layers. Thickness – 0.3–1.0 mm.
  2. Multi -layer floors (Sentwitch), layer thickness> 2 mm. Quartz sand is added to the solution to improve adhesion and increase the roughness of the finished base.
  3. Self-leveling systems for medium and high loads. Smooth surface, 2–6 mm thick. The technology involves finishing (grinding) of surfaces manually or mechanically.
  4. Polymer concrete screeds for high mechanical loads are self-supporting monolithic systems, more than 6 mm thick.

Offering increased strength, chemical resistance, and speedy installation times, polymer concrete floors are a dependable and adaptable choice for commercial and industrial settings. These floors, which are created by mixing polymer resins with aggregates like sand and gravel, offer a seamless, non-porous surface that is resistant to wear, impact, and stains. Polymer concrete floors are a practical and aesthetically beautiful flooring option. They are not only simple to clean and maintain but also highly customizable in terms of color and texture, making them ideal for areas with high traffic or exposure to harsh chemicals.

Characteristics Device
High strength and durability Prepare the surface by cleaning and leveling
Resistance to chemicals Apply a primer layer
Waterproof and non-porous Mix the polymer concrete components
Low maintenance Pour and spread the mixture evenly
Fast curing time Allow it to cure completely

Because of their special combination of toughness, chemical resistance, and ease of maintenance, polymer concrete floors are a great option for a range of environments. These floors offer a robust, long-lasting solution that can resist heavy use and challenging conditions in commercial spaces, industrial facilities, and even residential homes.

Sand or gravel aggregates are combined with a polymer binder during the installation of polymer concrete floors. After that, this mixture is poured onto the prepared surface and spread out. After curing, it creates a smooth, solid floor that is incredibly functional and aesthetically pleasing. Because of the installation’s relative speed, there is less downtime and more time to utilize the freshly finished floor.

Polymer concrete floors are notable for their exceptional resistance to damage from oils, chemicals, and other potentially hazardous materials. Because of this, they work especially well in settings where spills and stains happen frequently. Furthermore, because of their non-porous surface, they are inexpensive to maintain over time due to their ease of cleaning and upkeep.

Polymer concrete floors can be tailored to match the surrounding decor with a variety of colors and finishes. This allows for a unique aesthetic. Polymer concrete floors are a great investment for anyone wishing to improve the look and feel of their space because of their adaptability and practical advantages.

All things considered, polymer concrete floors are an effective, contemporary flooring option that satisfies the needs of the various settings of today. They are going to be a popular option for many years to come because of their strength, chemical resistance, and ease of maintenance.

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Dmitry Sokolov

Chief engineer in a large construction company. I have extensive experience in managing construction projects and implementing modern technologies.

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