Polymer concrete
An innovative development in building materials is polymer concrete. Polymer concrete employs resins and polymers to bind its aggregates, in contrast to traditional concrete, which gets its strength from cement and water. This distinguishes it from the traditional mix and gives it some impressive properties that make it a versatile alternative.
The durability of polymer concrete is one of its best qualities. It’s a great option for harsh environments because of its exceptional resistance to chemicals, moisture, and even extremely high temperatures. Because of their durability, polymer concrete structures frequently last longer and require less upkeep over time.
Its short curing time is an additional benefit. Polymer concrete often cures in a matter of hours, but traditional concrete can take weeks to fully set. This can be very advantageous for builders as well as clients because it not only expedites construction projects but also decreases downtime.
Polymer concrete has advantages, but it’s not always the best option for all types of projects. Its cost is generally higher than that of regular concrete, which may be a barrier. However, polymer concrete provides a robust, dependable option for specific applications where speed and durability are essential.
We will delve further into the characteristics of polymer concrete, examine its range of uses, and talk about how it differs from conventional concrete in various contexts in the sections that follow. Gaining knowledge about polymer concrete can provide insightful information about the future of construction, regardless of whether you’re a builder, contractor, or just interested in novel materials.
| Property | Description |
| Definition | Polymer concrete is a type of concrete where polymers are used as a binding agent instead of traditional cement. |
| Advantages | It has higher strength, better durability, and improved resistance to chemicals compared to regular concrete. |
| Applications | Commonly used in environments where concrete is exposed to harsh chemicals, like in chemical plants or wastewater treatment facilities. |
| Types | Includes epoxy-based, polyester-based, and vinyl ester-based polymer concretes. |
| Cost | Typically more expensive than conventional concrete due to the cost of polymers and specialized production processes. |
| Setting Time | Usually has a faster setting time compared to traditional concrete, which can speed up construction projects. |
| Maintenance | Requires less maintenance due to its resistance to wear and tear. |
Advantages of the material
Because of the unique qualities of the recipe, composite concrete has several advantages. It is applied in a number of scenarios where conventional concrete will not yield the required outcome.
The primary benefit of the composite
- Increased resistance to moisture penetration into the composite mass. Water droplets quickly evaporate from the surface of the material, not having time to saturate it with destructive moisture.
- Resistance to significant temperature changes, allowing polymer concrete to maintain integrity, regardless of the duration and number of freezing cycles.
This substance is one of the novel forms of concrete mixtures in which a polymer is utilized in place of cement or silicate (which are employed in the making of regular concrete).
Advantages: several times higher elasticity, impact resistance, light weight, and strength than regular concrete
Weaknesses
In addition to its benefits, polymer concrete has drawbacks.
- susceptibility to open fire and high temperatures, causing destruction of the material;
- higher price, compared to concrete, due to the cost of purchasing special resins.
Components of polymer concrete
Consider studying the composite’s composition if you wish to create polymer concrete at home. The following materials should be used to make polymer concrete:
- Binder, which is urea-formaldehyde, polyester, epoxy and furfural acetone resins.
- Large-fraction crushed stone filler. The size of the crushed stone fraction required to form the composite can be up to 4 centimeters, but crushed stone of 1-2 cm in size should make up the main part of the composition.
- Sifted and cleaned quartz sand. The size of quartz particles should not exceed 5 mm, the presence of clay inclusions and dust are not allowed.
Classification
Polymer concrete is classified into several classes based on the filler concentration, which can account for up to 80% of the total volume:
- especially heavy, a cubic meter of which weighs from 2500 to 4000 kg;
- heavy, with a density of 1800-2500 kg/m3;
- light with a specific gravity of 500-1800 kg/m3;
- lightweight, the weight of a cubic meter does not exceed 500 kilograms.
Scope
Polymer concrete is used in various fields, is the basis for the manufacture of various types of products:
- Tabletops, which have become widespread, used in the kitchen as a fashionable accessory. Products are practical, hygienic, have a long service life, and are in harmony with the room. Visually, a composite product is difficult to distinguish from a natural mineral. Resistance to mechanical impact in a composite is higher than in a natural stone.
There is a lot of usage for cast stone.
- Floor coverings, which are easy to clean and quick to install. The coatings are characterized by plasticity, resistance to impact loads and low costs associated with installation. Long service life allows using the material for 10 years with a layer thickness of up to 2 mm.
- Decorative elements used in facade structures. Polymer concrete is difficult to distinguish from natural granite or marble, which it successfully imitates. Due to the low weight of polymer products, there is no need to build a reinforced base or additionally strengthen the structure. The material is resistant to temperature and humidity, easy to install, durable, has an original texture.
- Monuments and enclosing structures used for ritual purposes. The resistance of the polymer massif to weather conditions while maintaining integrity has ensured the popularity of composite concrete used for ritual purposes. The ideal smoothness and glossy surface of the products allow the products to maintain their appearance while in natural conditions.
Building structures, paving and facing tiles, floors, stairs, drainage channels, sculptures and monuments, and fountains are all made of polymer concrete.
Furthermore, the technology makes it possible to create:
- window sills;
- railings;
- handrails;
- balusters;
- decorative moldings;
- staircases;
- support columns;
- fireplace elements;
- sinks.
Stages of production
The following steps are included in the technology for creating polymer concrete and producing goods:
- Preparation of ingredients.
- Mixing.
- Molding.
Let’s focus on the characteristics of each step.
The most crucial step in the material’s manufacturing process is choosing components that are best suited to the intended use.
Through the combination of conventional concrete and polymer resins, polymer concrete is redefining the construction industry by producing a material that is stronger, more resilient, and setting more quickly. Polymer concrete, in contrast to traditional concrete, is resistant to chemicals and moisture, which makes it perfect for harsh environments like industrial floors and marine structures. This breakthrough not only increases the longevity of concrete applications but also creates new opportunities for imaginative and useful designs, providing a flexible solution that satisfies structural and aesthetic requirements.
How to prepare ingredients?
Once you are comfortable with the composite’s composition, get the ingredients ready for blending:
- clean from foreign inclusions, wash the gravel, which is the filler;
- sift quartz sand;
- dry the fraction, ensuring a moisture concentration of up to 1%.
Preparing the mixture
Assemble the polymer mixture using the subsequent algorithm:
- Place crushed stone, quartz sand and filler in the mixer, observing the proposed sequence.
- Mix the components for 2 minutes, add water, mix again.
- Soften the binder using a solvent.
- Add a plasticizer to the resin, mix.
- Place the binder with the filler, add the hardener.
- Mix thoroughly for 3 minutes.
Since the material hardens quickly, you should start pouring as soon as the composition is ready.
Pouring
Do the task while keeping an eye on the order:
- apply lubricating oil or technical petroleum jelly to the surface of the form, preventing sticking;
- fill the container with the composite, level the surface;
- compact the solution on the vibration platform;
- remove the finished product after 24 hours.
By fusing the adaptability of polymers with the strength of concrete, polymer concrete presents an intriguing substitute for conventional concrete. It is a strong option for many applications due to its resistance to chemicals, severe weather, and heavy loads. The special qualities of polymer concrete can offer both strength and longevity, whether you’re working on a new construction project or thinking about renovating.
The quick curing time of polymer concrete is one of its best features. Polymer concrete hardens more quickly than traditional concrete, which can take weeks to fully set, enabling projects to be completed more quickly. This can be a big help when it comes to construction projects that have a tight deadline or when reducing downtime is essential.
Still, it’s crucial to take the price into account. If money is tight, the cost of polymer concrete may be a consideration for you as opposed to ordinary concrete. Nevertheless, over time, its longer lifespan and lower maintenance needs can pay for the initial cost.
All things considered, polymer concrete is a useful substance with unique benefits that make it perfect for particular uses. It’s worth investigating how polymer concrete might fit into your next project if you need a robust, long-lasting, and adaptable solution. Its special qualities might give you the advantage you require for demands that are both pragmatic and performance-oriented.
