Polymer concrete – what is it: composition of concrete polymer, application features, purpose

Innovative and adaptable, polymer concrete is a building material that is becoming more and more popular for a variety of uses. In contrast to conventional concrete, which uses cement alone as a binder, polymer concrete uses polymer resins to improve certain aspects of its composition. Its distinct composition confers multiple benefits, rendering it a compelling choice for particular construction requirements.

Aggregates like sand, gravel, and crushed stone are the main ingredients of polymer concrete; these materials are joined together by polymer resins. Epoxy, vinyl ester, or polyester can be used to make these resins. With outstanding resistance to chemicals, water, and abrasion, the resultant mixture creates a material that is robust and long-lasting.

The quick curing time of polymer concrete is one of its best qualities. This implies that compared to traditional concrete, polymer concrete structures and repairs can be finished considerably more quickly. Furthermore, it is perfect for applications where longevity and durability are essential due to its increased bond strength and decreased porosity.

Chemical containment areas, drainage systems, and industrial flooring are just a few of the uses for polymer concrete. Because of its resilience to extreme weather, it can be used in corrosive environments such as sewer systems, wastewater treatment plants, and other infrastructure projects.

All things considered, polymer concrete has several advantages that make it a useful component of contemporary architecture. It can handle the demands of demanding environments and specialized applications thanks to its improved performance characteristics and versatility. Polymer concrete keeps showing its value in the building sector, whether it is used for new construction or repairs.

Topic	Details
Composition	Polymer concrete is made by mixing a polymer binder with aggregates like sand and gravel. The polymer acts as a glue that holds everything together.
Application Features	This type of concrete is known for its high strength, resistance to chemicals, and quick setting time. It"s ideal for repairs and areas needing durable, long-lasting material.
Purpose	Polymer concrete is used in construction where traditional concrete might not be suitable. It’s perfect for industrial flooring, waterproofing, and structures exposed to harsh environments.

By adding polymers to conventional concrete to improve certain aspects, polymer concrete is a strong, adaptable material. In addition to being stronger and more resilient to chemicals and weathering than ordinary concrete, this inventive blend produces a product with special uses in building and maintenance projects. Polymer concrete is particularly useful for specific applications like flooring, infrastructure projects, and corrosion-resistant coatings because it cures fast and performs well in harsh conditions. This article examines its makeup, advantages, and range of uses to show why it’s starting to gain traction in contemporary building.

What is polymer concrete

Polymer concrete is a type of concrete mixture in which polymer is used in place of traditional cement and silicate to give the hardened monolith a variety of unique properties. Liquid resin that serves as a binder and holds the other ingredients together is called a polymer. Products made of polymer concrete are ideal for construction, repairs, and product manufacturing because they are long-lasting and can easily withstand a variety of negative impacts.

Highly filled compositions known as polymer concretes are made from monomers or synthetic resins mixed with fillers that are resistant to chemicals. Types of polymer binder are used to categorize polymer concretes.

Urea, furan, polyester, phenol-formaldehyde, phenolic, etc.

Thermosetting resins are the foundation for the creation of polymer concretes used to construct load-bearing building structures. However, thermoplastic varieties are more frequently employed in the manufacture of finishing, decorative, and protective cladding materials. The chemical makeup of the synthetic resin, the amount and kind of fillers, and the reinforcement features define the material’s primary technical properties.

The most crucial steps in the material’s production are accurately calculating the binder polymer’s content and selecting the right components (filler volume and fractionality). After carefully combining the ingredients, the mixture is poured into molds and left to harden in designated rooms.

Cast stone is used extensively in the creation of window sills, kitchen countertops, and facade moldings. In addition, the material is used to make paving slabs, fill in floors and stairs, and construct a variety of building structures, monuments, plumbing fixtures, fountains, and other items. Polymer concrete is useful for filling different surfaces, caulking fractures, and fixing a variety of issues.

Certain manufacturers offer ready-made dry mixes of polymer concrete on the market; all that is needed to prepare polymer concrete is mixing it per the directions with a small amount of filler.

Advantages and disadvantages of the material

Because of the characteristics of its manufacturing and composition, polymer concrete has specific qualities. Prior to employing the material in construction or repair projects, it is essential to thoroughly examine all of the subtleties and consider the mixture’s intended use as well as the operating environment.

• High level of water resistance – water quickly evaporates from the surface of the monolith, which prevents cracks and other defects from appearing in the minus.
• Resistance to high/low temperatures, differences.
• The ability to restore sites that were subjected to various mechanical damage.
• Excellent resistance to aggressive chemical components – polymer concrete can be used in different conditions without the need for additional coatings, primers, impregnations.
• None and smooth surface of the material – polymer concrete products are not polluted for a long time, and any dust and pollution are easily and quickly removed.
• A large selection of appearance options – polymer concrete can be of different colors and textures, imitate certain materials (malachite, granite, marble, etc.).D.).
• The ability to process the material and return to production.

The flammability of polymer concrete, which prevents it from being used in areas where there is a risk of fires or excessive heat, is one of its main drawbacks. Another is that it is more expensive than traditional concrete.

Technical characteristics

The primary characteristic of polymer concrete is the use of various polymer substances (synthetic resins) in place of regular cement, which controls the material’s characteristics and range of uses.

Composition and structure

1. Binder – it can be unsaturated polyester, furan-epoxy, furfural acetone, urea-formaldehyde resins, methyl methacrylic acid ester and others.
2. Coarse filler – this can be sand and crushed stone.
3. Ground filler – andesite, quartz flour, graphite powder.

Crushed rock up to 40 millimeters in size is used to make polymer concrete. The whole volume is extracted from fractions of 10–20 millimeters if the particle size is less than 20 millimeters. Two fractions are taken: 10-20 and 20-40 millimeters, when selecting a filler with a fraction of 40 millimeters to boost the material’s strength.

There should be no more than five millimeters between each quartz sand grain. There shouldn’t be any dust or clay in the sand; it should be dry and clean. The use of costly resins is decreased by adding ground filler to the composition; mineral flour with a fraction of up to 0.15 millimeters is added to the binder. Construction gypsum needs to be added to the designated components if the mixture is going to be made with urea-formaldehyde resin.

To further enhance the quality of the finished product, polymer concrete can also be made with the addition of pigments, surfactants, antiseptics, fire retardants, and other additives.

The most common application for saponified wood resin is as a surfactant, which enhances the final product’s thermal insulation properties.

• Super heavy – 2500-4000 kg / m3.
• Heavy – 1800-2500 kg / m3.
• Light – 500-1800 kg/m3.
• Super light – less than 500 kg / m3.

In construction, heavy polymer concretes are used to build loaded supporting structures and foundations. Lighter elements are used to create a variety of objects.

GOST

GOST 7473 sets the parameters for all concrete solutions. GOST 27006 regulates the mixtures’ composition, GOST 27005 indicates their density, and GOST 24211 establishes the volume of plasticizers and other chemical additives.

• Urea-formaldehyde resin – the standards are prescribed in GOST 14231-78.
• Furfural acetone resin (FAM) must comply with TU 6-05-1618-73.
• Methyl methacrylate monomer is regulated by GOST 16505.
• Furan-epoxy resin – according to TU-59-02-039.13-78.

Application areas polymer concrete

Nowadays, polymer concrete finds application in numerous fields, including basic construction projects and building materials as well as specific product manufacturing. Kitchen countertops, bathrooms, sinks, fireplaces, window sills, balusters, railings, washbasins, steps, columns, vases, floors, fences, monuments, facade stucco, fountains, and so forth are all made with this material.

Kitchen countertops

Countertops made of polymer concrete are incredibly fashionable, costly, and available in any hue or texture. In addition, these products are useful, long-lasting, wear-resistant, and reasonably priced (especially when compared to natural stone, which they can mimic).

There is a vast array of options available in the market, making it easy to select one that complements the room’s decor. When used, the countertops are comfortable to the touch, simple to maintain, and don’t need any extra attention.

Although this type of countertop looks almost exactly like natural stone, it differs greatly from it in terms of features and resilience to harsh impacts.

Floors

The process of creating polymer concrete floors is quick and simple; it is poured in the same manner as regular concrete. However, because they are even, smooth, dust-free, and simple to maintain, these types of floors are already fit for use. Given that it is plastic and has a minimum warranty period of 10 years, the coating does not mind handling heavy loads as long as it is 2 millimeters thick. The layer will be stronger and more resilient the thicker it is.

Polymer concrete floors come in a variety of colors and textures and have a very elegant and beautiful appearance. They are frequently manufactured in industrial workshops, warehouses, hangars, garages, and airports in addition to residential buildings.

Facade decor

The benefits of polymer concrete over natural stone are substantial when it comes to building facade structures. The material mimics any texture, including granite or marble, on the outside, but it weighs a lot less, so installing the cladding is easy and quick and doesn’t require building a substantial foundation or additional fortifications.

Frost and precipitation are no match for polymer concrete’s ease of installation, wide range of colors, unique texture, longevity, and affordable price. Columns, cornices, pilasters, bas-reliefs, and other decorative elements of the facade are all made of this material. Completed goods are easily affixed to the facade surface, possess strong, dependable construction, and have distinct shapes.

Monuments

Polymer concrete monuments are just as robust and long-lasting as those composed of granite or marble. Because polymer concrete resists damage and doesn’t crack or break easily from harsh weather conditions like frost or snow, it’s a good material choice. The product has an aesthetically pleasing shine and smooth surface that guarantees maximum pattern clarity.

A novel and adaptable building material, polymer concrete combines regular concrete with polymer resins to produce a product with improved qualities. Aggregates, a polymer binder, and sporadically additional additives to enhance performance make up its composition. Concrete made with this mixture is more durable than regular concrete in terms of resistance to weather, chemicals, and wear.

Polymer concrete has a wide range of uses, from high-strength architectural elements to industrial flooring and drainage systems. Because of its strength and resilience, it’s a great option for places like chemical plants and wastewater treatment facilities where harsh conditions are present. Its capacity to be shaped into intricate forms also gives engineers and designers new creative options.

Knowing why polymer concrete is used is helpful when choosing the appropriate material for a given construction project. It offers alternatives in situations where conventional concrete might not hold up or need a lot of upkeep. In many applications, polymer concrete proves to be an economical and effective option due to its exceptional longevity and minimal maintenance requirements.

In conclusion, polymer concrete is unique due to its increased durability, variety of uses, and unique benefits in harsh settings. Because of its unique composition, which enables it to satisfy contemporary building requirements, it is a crucial component of both inventive and useful building solutions. Adopting polymer concrete can result in structures that are more robust, adaptable, and long-lasting.

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