Polymer concrete products: material features and areas of application

The best qualities of conventional concrete are combined with the increased durability and adaptability of polymers to create the novel material known as polymer concrete. Aggregates like crushed stone, gravel, or sand are combined with a polymer binder to create this advanced composite. As a result, a robust, resilient material that is extremely resistant to weathering, abrasion, and chemical corrosion is produced. These characteristics have led to the rapid rise in popularity of polymer concrete in a variety of industrial and construction applications.

The remarkable strength-to-weight ratio of polymer concrete is one of its most notable qualities. It is the best choice for applications where weight and strength are equally important because it has better mechanical qualities than regular concrete. The polymer binder also makes it possible for a quick curing process, which cuts downtime and expedites building projects. In infrastructure projects where time is of the essence, like bridge decks, airport runways, and industrial flooring, this quick-setting feature is especially helpful.

Polymer concrete’s ability to be molded into intricate shapes and forms is just one example of its versatility. Because of its adaptability, it can be used to create a variety of products, such as countertops, drainage systems, and precast panels. Due to its superior adhesion qualities, it is also the perfect material for rehabilitation and repair projects. It offers a dependable way to seal cracks and increase the longevity of already-existing structures.

Polymer concrete is prized for its environmental qualities in addition to its mechanical ones. The carbon footprint of producing cement can be greatly decreased by using polymer binders. Moreover, polymer concrete products’ longevity and durability mean fewer replacements and repairs over time, which lowers material consumption and waste. Because of this, polymer concrete helps to promote sustainable building practices in addition to satisfying the needs of contemporary construction.

Combining conventional concrete with polymer resins to create polymer concrete is a flexible material that produces stronger, more resilient construction that is resistant to weathering and chemicals. This cutting-edge material is becoming more and more common in infrastructure and construction projects, where it is applied to everything from industrial flooring and drainage systems to decorative elements and repairs. Due to its special qualities, which include quick curing and high tensile strength, it is superior to traditional concrete in many ways and can be used for a variety of purposes.

Description of the material

As was already mentioned, the material consists of the standard mixture ingredients of sand and crushed stone, to which a binder in the form of resins with an epoxy, furan, or polyester base is added.

This can be applied in the following fields: construction, furniture manufacturing (tabletops and other unique furnishings), garden design (sculptures, garden furniture), and funeral services (monuments and fences). And the list of areas is not limited to this.

When compared to conventional mortar, it has unique, enhanced mechanical qualities that set it apart. It can mimic natural stones, is lightweight, resistant to harsh environments, and comes in a variety of colors.

Alternatively known as artificial stone. Polymers, which are synthetic resins in the form of viscous liquids, take the place of cement or silicate in the composition.

Typically, filler materials include crushed basalt stone, quartz sand, or crushed sandstone.

Pros and cons

Numerous important performance attributes of polymer concrete make it suitable for use in situations where regular concrete may be destroyed or deformed.

The positive attributes allow for the following observations:

1. It has high water resistance, due to which moisture, evaporating, quickly leaves the surface. Therefore, in winter, the likelihood of cracks and destruction due to moisture penetration is excluded;

1. Resistant to temperature changes, which affects the preservation of integrity regardless of the duration and number of freeze-thaw cycles;

1. In case of mechanical damage to a section of the coating, it can be easily restored using a restoration mixture;
2. Resistant to the effects of chemical reagents, which allows not to treat its surface with additional protective compounds when used in chemically aggressive environments;

1. Polymer concrete combines high strength and low weight, which allows the manufacture of products for various purposes, the price of which is affordable due to the low cost;
2. The ability to reproduce the appearance of natural stones (marble, malachite, granite) allows it to be used in various areas – as a decor, for the manufacture of furniture and countertops, floor coverings;

1. Polymer concrete can be recycled, which also reduces the cost;
2. Its surface is smooth, but not slippery. The combination of these properties allows this material to be used for flooring. In addition, dirt can be easily removed from such a surface.

One of the drawbacks is that the material is ruined by high temperatures, making it impossible to resist the effects of an open flame. Because of the high cost of the binder, the composition is more expensive when compared to a traditional mixture.

What polymer concrete consists of

If you want to make it yourself, you will need to buy the following ingredients:

1. As a binder, you can use one of the following resins:

• unsaturated polyester;
• furfural acetone;
• furan-epoxy;
• urea-formaldehyde;
• methyl methacrylic acid ester;

1. It is recommended to use crushed rock as a coarse filler, the size of the fractions of which is up to 40 mm. To increase the strength of the composition, you can combine fractions of 10-20 mm and 20-40 mm. Grains of quartz sand can have a size of up to 5 mm.

Crucial! Using quartz sand in combination with silt, dust, or clay is prohibited. Pre-cleaning, washing, and sifting are required.

1. As ground – use quartz, andesite flour or graphite powder with particles not exceeding 0.15 mm. This leads to a reduction in financial costs for expensive resins.

Important: You must add construction gypsum when using urea-formaldehyde resin.

Surfactants, dyes, fire retardants, and antiseptics are examples of additional additives that can help improve the quality characteristics.

The amount of heavy filler has an impact on classification.

In light of this, it may be:

1. Super heavy (2.5-4 t/m3);
2. Heavy (1.8-2.5 t/m3);
3. Light (0.5-1.8 t/m3);
4. Super light (less than 0.5 t/m3).

Crucial! For foundations and load-bearing structures, heavy polymer concrete is utilized.

How to make polymer concrete

There are multiple steps in the preparation instructions:

1. Preparation of components;
2. Making the solution;
3. Molding.

These phases ought to be examined independently of one another.

This article’s video will walk you through the process of making polymer concrete correctly.

Preparation of components

Following the separate mixing of resins and filler is essential to expedite the preparation process and produce a robust and uniform material.

You should first get the essential parts ready:

1. Crushed stone or gravel must be washed, removing dirt and foreign inclusions;
2. Quartz sand must be washed and sifted;
3. Fractional filler must be dried so that its moisture content corresponds to 1% – otherwise, the strength properties of the finished solution will be reduced.

Preparation of the solution

The following steps are taken in order to prepare the solution:

1. All components must be loaded into the container sequentially, starting with crushed stone, then sand – and finally fractional filler;
2. The mixture must be stirred for 2 minutes in dry form, then add water and stir again;

1. The binder must be prepared separately, softening it to the required consistency. To do this, you can heat it or do this with a solvent;
2. Additional additives in the form of a plasticizer and stabilizer must be added to the resin, and mixed without adding filler;

1. The resulting composition is added to the filler, and mixed for 2 minutes;
2. Add hardener and stir for about 3 minutes.

Crucial! Because the composition sets quickly, it must be ready right before pouring and in the exact amount needed.

Fill in shape

Make sure the forms’ inside surfaces are clean before filling them with liquid.

The mold looks like this:

1. The inner surface of the form must first be lubricated using paraffin, technical petroleum jelly or machine oil so that the dried product does not stick to the shape, and it can be easily extracted;
2. The entire area of ​​the form should be filled with a solution and leveled. The formation of voids is unacceptable;
3. Vibroostol or hinged vibrator is used to compact the mixture. The solution is compacted until the liquid is formed on its surface;

Important! If the solution is poured into the form portioned, then the seal must be carried out every time.

1. The mold is left for 24 hours, then the finished product is removed.

Important: Before the mixture starts to set, make sure you wash the container well.

Feature	Application
High Durability	Used in bridges and heavy traffic areas
Corrosion Resistance	Ideal for sewer systems and water treatment plants
Lightweight	Preferred for decorative elements and facades
Fast Curing	Beneficial for quick repairs and emergency work

Products made of polymer concrete provide a strong and adaptable answer for a range of building requirements. These products outperform conventional concrete in terms of strength, durability, and chemical resistance because they combine traditional concrete with polymer resins. This makes them especially appropriate for high-performance environments like structural repairs, drainage systems, and industrial floors.

Beyond its durability, polymer concrete has many other advantages. They are perfect for use in harsh environments, such as chemical plants and coastal areas, because they can withstand weathering and corrosion. In addition, the decreased permeability of polymer concrete prolongs the life of structures by preventing corrosion to the embedded steel reinforcement.

The quick curing time of polymer concrete is another important benefit that enables quicker project completion and less downtime. This is particularly advantageous in industrial environments where reducing downtime is essential. Furthermore, the material is flexible in terms of design and application because it can be molded into a variety of shapes and sizes.

Products made of polymer concrete are also green. They generate less waste during production and installation and frequently use recycled materials. This lowers building projects’ overall environmental impact and promotes sustainable construction methods.

In conclusion, polymer concrete products are a wise investment for contemporary building projects requiring durability and adaptability. They are appropriate for a variety of uses, including industrial and infrastructure, thanks to their improved qualities. The use of polymer concrete is anticipated to increase as technology develops, providing the construction sector with even more cutting-edge solutions.

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