Polymer concrete production: technology, material properties

The novel material known as polymer concrete combines the advantages of polymer resins with the benefits of conventional concrete. This special combination produces a product that is strong and adaptable, perfect for a range of construction uses. Polymer concrete offers better performance and properties than conventional concrete because it uses a polymer binder instead of cement as a binder.

Aggregates such as sand, gravel, or crushed stone are combined with a polymer resin during the production process of polymer concrete. The aggregates are held together by the resin’s binding action. After that, this mixture is cured to create a sturdy, solid substance. Although there are many different types of polymer resin that can be used, polyester, epoxy, and vinyl ester resins are common choices. Different resin types impart distinct properties to the finished product, enabling customization according to project requirements.

Polymer concrete is distinguished by its exceptional resistance to chemicals, moisture, and weathering. Because of this, it is especially appropriate for situations where conventional concrete may eventually deteriorate. Furthermore, polymer concrete frequently demonstrates exceptional strength and durability, frequently surpassing conventional concrete in these domains. Because of its resilience to extreme circumstances, it is a top option for demanding applications such as industrial settings and infrastructure projects.

Additionally advantageous are polymer concrete’s flexible design and simplicity of installation. It is versatile and can be molded into a variety of sizes and shapes for a multitude of applications. Additionally, because it cures more quickly than conventional concrete, projects can be completed more quickly, saving downtime and boosting productivity at the job site.

All things considered, polymer concrete is a major development in building materials. For engineers, builders, and architects, its special blend of qualities creates new opportunities. Polymer concrete is still useful in modern construction, whether it is applied as protective coatings, decorative elements, or structural components.

Polymer concrete: composition, characteristics

The primary functional characteristics are determined by the type and quantity of fine fillers used, as well as the chemical makeup of the synthetic resin.

The following resin modifications are used in industrial manufacturing technology:

• furan;
• polyester;
• urea.

Types of synthetic resins for the production of material: brief characteristics

Condensation of furfural with ketones and phenols yields furan resins. This kind greatly outperforms its rivals because of its inexpensive price.

• Furfural acetone monomer usually acts as a binder in this group of components. A liquid with a high boiling point, insoluble in water, but soluble in esters and ketones. The hardening of the FA monomer occurs with the help of sulfonic acids, sulfochlorides, etc.
• Main requirement Use of fillers that interact with acids (limestone, dolomite, etc.), unacceptable.
• Polyester resins Their hardening process occurs due to methyl ethyl ketone peroxide or isopropyl benzene hydroperoxide and reaction accelerators – activators. A cheaper and more common variety is the polyester maleate variety.

• Ureas are products of the synthesis of urea and formaldehyde in an aqueous solution.

• Hardening enzymes are organic and inorganic acids, as well as: zinc and ammonium chlorides, aniline hydrochloride. The latter is used most often.
• Dispersed mineral fillers have a significant impact on the quality of the material. Thanks to their diverse characteristics, it is possible to regulate the properties.
• Thus, the addition of carbon-containing fillers significantly increases their moisture and frost resistance.

Fillers: Andesite and quartz flour interact with polyesters to boost strength.

You can learn about the lightweight polymer concrete technology in this video.

Fillers and excipients

One primary requirement for product production is that technological proportions, or To, be strictly adhered to. There are precisely specified filling levels for all types of synthetic resin that give the finished product its maximum strength. By acting as thinning additives, mineral fillers drastically lower the material’s cost.

The higher filler and filler content permits:

• reduce the consumption of polymer binder, the price of which significantly affects the final cost;
• limit temperature and shrinkage deformations;
• control the strength, density, hardness and other physical and mechanical properties of products.

The chemical compatibility of fillers and aggregates with hardeners and catalysts is a prerequisite for their use. Powders (mineral or polymer) that have been dispersed and have a maximum particle size of 0.15 mm are known as fillers.

Among the most used fillers are:

Their chemical component, particle shape and dispersion, base condition, percentage content, and other factors all directly affect how much of an impact they have on a given set of properties.

Crushed stone is used as a large filler; the fraction size used is chosen according to the product’s size, shape, and operating conditions. Sand and crushed stone serve as the product structure’s framework and have no effect on the operational characteristics’ quality indicators. Crushed stone extracted from sedimentary rocks cannot be used.

The table below lists the most popular material compositions based on furfural acetone monomer:

Features of industrial production technology

The production apparatus, which includes the following items, is displayed as a technological scheme for producing polymer concrete on a flow conveyor of an industrial enterprise (see photo).

• raw material warehouse;
• bins for receiving sand and crushed stone;
• drums for drying materials;
• batchers;
• turbulent concrete mixer;
• vibrating platform;
• heat treatment chamber;
• forms;
• warehouse.

Selection of the composition of polymer concrete

The microfiller volume is determined by first choosing the densest filler composition empirically. This volume should equal the number of voids plus 10% of the total volume. Next, it is determined how much resin and hardener are needed to get the mixture to move in the desired direction. The type of resin and the curing conditions are taken into consideration when calculating the hardener.

Some pointers: – Using too much resin will have unfavorable effects such as increased shrinkage, temperature deformation, and weakened strength.

Preparation of polymer concrete mixture

Thus, polymer concrete: manufacturing process.

There are two steps involved in getting the composition ready for industrial production:

1. Preparation of binders by mixing the calculated parts of resin, plasticizer, microfiller and hardener in a turbulent concrete mixer for 30 s.
2. Mixing the finished binder with small and large components in forced-action mortar mixers.

The solution is created by dosing a pre-made binder into a continuously running concrete mixer while also mixing dry ingredients (sand and crushed stone). The dry composition takes one and a half to two minutes to mix. It is recommended that the dry composition of the binders be mixed for no more than two minutes.

In order to promptly halt the reaction of polymer structure formation in the event of an accident caused by a production technology violation, the mixer should be equipped with specialized temperature sensors and an emergency water supply system.

Forming and heat treatment of polymer concrete products

The completed mass is delivered to a paver equipped with a moveable hopper and a unique distributing mechanism that uniformly smoothes the mixture in accordance with the product’s intended shape.

• Compaction is carried out on a resonant vibration platform with horizontal vibrations.
• Compaction and laying of the solution must be carried out in a closed workshop equipped with ventilation.
• The duration of the vibration compaction process is 2 minutes.
• Heat treatment of finished products is carried out in modes that ensure the complete course of the polymerization stages of the resins that serve as binders.

The final products will continue to shrink and deform if the heat treatment mode is chosen incorrectly or if the process flow diagram is not followed. This will have a substantial impact on the material’s quality.

The process of making polymer concrete involves mixing conventional concrete with polymer resins to produce a strong, adaptable substance ideal for a range of building uses. Concrete’s strength, chemical resistance, and durability are all increased by this cutting-edge technology, which makes it perfect for use in challenging situations where conventional concrete might not hold up. Builders and engineers can take advantage of polymer concrete’s advantages to produce more durable and resilient structures by learning about the material’s characteristics and manufacturing processes.

Application of polymer concrete

Their superior strength, heightened abrasion resistance, and favorable physical and chemical characteristics enable their application in the most demanding domains of civil and industrial construction.

The following structures are the ones that demand this material the most:

• irrigation dams and wear-resistant structures of port facilities;
• production of chemically resistant coatings of industrial buildings, drainage channels and other critical structures with increased operational properties;
• chemically resistant drainage pipes, mine shafts and collectors of underground utilities;
• sumps and various tanks for aggressive liquids;
• contact supports of power transmission lines and other similar structures with increased electrical resistance;
• in civil engineering: for the manufacture of internal and external decorative elements of buildings and structures.

Combining the flexibility and resilience of polymers with the strength and durability of traditional concrete, polymer concrete is a special and adaptable material. This combination produces a product that is perfect for a variety of construction applications because it can withstand harsh environments and heavy loads.

In order to make polymer concrete, an aggregate, like sand or gravel, and a catalyst to start the curing process are mixed together with a polymer resin. After that, this mixture is applied to surfaces or poured into molds, where it solidifies and creates a cohesive, strong material. In order to meet particular performance requirements, the choice of aggregate and polymer can be adjusted, enabling customized solutions for construction projects.

The outstanding resistance of polymer concrete to chemicals, moisture, and temperature changes is one of its main benefits. Because of this, it is especially helpful in industrial settings where conventional concrete could deteriorate or fail. Furthermore, it is possible to design polymer concrete to be lightweight, which lowers the overall load on structures and facilitates handling and installation.

All things considered, polymer concrete is a major development in building materials. Its capacity to blend the best qualities of concrete and polymers results in a host of advantages, including improved performance in demanding conditions and longer lifespans. We should anticipate even more cutting-edge uses of polymer concrete in the building sector as technology develops further.

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