A novel and adaptable building material that has grown in popularity recently is polymer concrete. Polymer concrete holds the aggregate together with polymer resins rather than cement, which is the binder used in traditional concrete. This produces a material that has clear benefits in some uses.
Polymer concrete has decreased permeability, increased durability, and chemical resistance thanks to the usage of polymer resins. Because of these qualities, it is perfect for use in harsh environments where conventional concrete might not hold up. For instance, polymer concrete is frequently utilized in wastewater treatment facilities, industrial settings, and even in the building of countertops and decorative objects.
The short curing time of polymer concrete is one of its main advantages. Polymer concrete can be used in a matter of hours, as opposed to traditional concrete, which can take days or even weeks to fully set. This can cut down on downtime for crucial infrastructure repairs and greatly expedite building projects.
All things considered, polymer concrete presents a cutting-edge substitute for conventional concrete, offering advantages that can save time, lower maintenance, and increase the lifespan of buildings under difficult circumstances. Its increasing application in a variety of industries emphasizes how crucial it is to contemporary building and remodeling projects.
Aspect | Description |
Definition | Polymer concrete is a type of concrete that uses polymers to replace lime-type cements as a binder. |
Benefits | It offers high strength, durability, and resistance to chemicals and water. |
Uses | Commonly used in industrial flooring, repair works, and infrastructure projects. |
Components | Includes aggregates like gravel and sand, and a polymer resin binder. |
Installation | Requires skilled labor for proper mixing and application. |
- What is polymer concrete?
- Concept
- Advantages and disadvantages
- Types of material
- Technical characteristics
- Properties
- GOST
- Composition and structure
- Production and application
- Popular manufacturers
- Recommendations
- Video on the topic
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What is polymer concrete?
Many people research new products before selecting building materials and wonder what polymer concrete is. The new material is distinct from other varieties of concrete mixtures due to the presence of a polymer in place of silicate or cement.
Concept
This ingredient is added during the preparation of composite concrete as a synthetic resin, a viscous liquid that gives the final product even more beneficial qualities. It is compacted, becomes impervious to all types of harm, including natural disasters, and has a far longer lifespan than regular concrete. Such a structure can be fixed by simply filling the crack with a mixture, which will restore it to its original state.
A polymer binder and aggregates, such as sand or gravel, are combined to create polymer concrete, a strong and adaptable material. Comparing this type of concrete to traditional concrete, it has faster curing times, greater strength, and chemical resistance. Because of its resistance to severe conditions and large loads, it is perfect for a variety of applications, including sewer systems and industrial flooring. It can be helpful to know the benefits and composition of polymer concrete when selecting materials for construction projects.
Advantages and disadvantages
When compared to alternative building materials, polymer concrete offers the following benefits:
- high strength and plasticity, which guarantees a long service life;
- light weight and pleasant appearance;
- easily tolerates any weather conditions;
- the upper surface is smooth and dense;
- high level of resistance to damage and easy repair;
- it is not affected by chemical reagents.
However, it also has drawbacks:
- high price of building material per 1 square meter (varies depending on the composition, type of resins);
- rarely can be found in the public domain.
Types of material
The following types of polymer concrete are differentiated based on their composition and intended use, which can include construction, floor or window sill equipment, tile manufacturing, or decorative product manufacturing.
- structural and heat-insulating type. Best suited for the construction of foundations and load-bearing walls, has a density of 0.5-1.5 tons per 1 m3. Excellent heat retention;
- heat-insulating type. Well suited for the construction of internal partitions and increasing thermal insulation, as it has the smallest filler fraction (up to 1 cm) and low density up to half a ton per cubic meter. The porous filler is most often perlite or chips;
- structural type. This type of polymer concrete is often used to imitate expensive stones. It has a high density and an average filler fraction size (up to 2 cm);
- heavy polymer concrete. withstands high load levels, the filler is large (up to 4 cm);
- cast stone. It is quite widely used, the filler is fine sand. It is used for flooring or decorative elements.
Technical characteristics
In many aspects, polymer concrete is superior to regular concrete. It has a 500 cycle limit on freeze-thaw resistance. Its strength is roughly five times greater than that of common construction materials. Its tensile strength is ten times greater, and it is twenty times more resistant to wear.
Properties
The long service life and high strength of polymer concrete are ensured by all of its technical features:
- has a high density – from 300 to 3000 kg/m3;
- resists compression at 50-110 MPa;
- does not bend – 3-11 MPa;
- has a low level of abrasion – up to 0.03 g/cm2;
- withstands the highest temperatures of 50-140 °C;
- thermal conductivity coefficient – up to 0.85 W/ m K;
- elasticity – from 10 thousand to 40 thousand MPa;
- absorbs up to 0.5% of water per day.
GOST
All specifications for concrete mixtures are based on GOST 7473 requirements. GOST 27006 regulates the polymer concrete composition designation, GOST 27005 indicates the density level, and GOST 24211 is established for different chemical substances.
Different requirements apply to the viscous liquids that are used:
- TU 6-05-1618-73 – furfural acetone resin;
- GOST 14231-78 – urea-formaldehyde resin;
- TU-59-02-039.13–78 – furan-epoxy viscous substance;
- GOST 16505 – methyl methacrylate monomer.
Composition and structure
Filler, which can include wood chips, mineral flour, gravel, granite, graphite powder, etc., makes up 90% of the constituent parts. However, the use of chalk, metal dust, and limestone rocks as filler is strictly forbidden.
Polymer binders, which include polyester, phenol-formaldehyde, and other types of resins, make up only 0.05% of the composition.
The smallest portion of the percentage ratio is occupied by dyes, plasticizers, and hardeners.
Production and application
Such building materials are produced through a number of stages:
- determination of the amount and fractionality of the polyconcrete filler;
- calculation of the volume of the binder resin;
- mixing and placing in special forms;
- hardening in a drying chamber.
Composite concrete is frequently used for self-leveling floors and foundations, window sills, decorative wall décor, fountains and sculptures, plumbing, and other home renovation projects.
Popular manufacturers
The following Russian companies are involved in the production of these building materials:
- ZAO PromKlyuch is a company located in Khimki. Polymer concrete is distributed in packages of different sizes. A feature of the products is the absence of water in the composition. The company"s products are used for repair work to restore any concrete structures.
- "Silikal GmbH" is a German company that produces products based on methacrylate resin. Features include high strength and fast setting of products.
- "Maurer Sohne" is another company from Germany. Manufactures Betoflex concrete, which has a low cost and excellent technical characteristics.
Recommendations
You can find a ton more helpful information about home repair on our website:
- during construction, the question arises: foundation UPSh, what is it;
- moisture-resistant concrete: characteristics, proportions;
- we will show you how to make concrete grade 200 with your own hands;
- find out what the initial modulus of elasticity of concrete depends on;
- we will indicate the specific and volumetric weight of concrete B25 in 1 cubic meter;
- what is Knauf screed and how to level the floor with dry screed?
A strong and adaptable substitute for conventional concrete is polymer concrete. This material gains improved strength, decreased permeability, and improved chemical resistance by incorporating polymers into the mixture. Because of these qualities, it’s a great option for a variety of construction applications, such as bridge overlays and industrial flooring.
Polymer concrete is also prized for its better bonding qualities and quick curing time. These benefits lead to longer-lasting structures and more effective building procedures. This cutting-edge material helps satisfy the exacting requirements of contemporary building projects, whether it is utilized in new construction or repair work.
All things considered, polymer concrete’s distinct qualities make it a useful addition to the building sector. The durability of projects made with this material is guaranteed by its capacity to endure severe conditions without compromising structural soundness. We can anticipate even more advancements and uses for polymer concrete in the future as technology develops.