Polymer Concrete by Sangay

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POLYMERCONCRETEPresented by

Sangay Dorjee Bhutia


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WHAT IS POLYMER CONCRETE?

It a kind of concrete in which a thermo set resin binds together natural aggregates, such as silicasand.

Catalysts and accelerators are added up to resin before mixing with inorganic aggregates. Polymer concrete when reinforced with fiberglass

produces exceptional strength and durability.Water is completely absent, as it inhibits thecuring of concrete.


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Known to be water free concrete.Typical resins used are polyester, epoxy andacrylic thermo set resins.Polyesters are the most used, mainly for economicreasons.

High compression strength, and high durability interms of fatigue and corrosion resistance.Permeability is very low, and its curing times are

quite fast.Applicable in the area of precast concreteelements.


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WHY USE POLYMER ONCRETE?

Lightweight - 1/10 to 1/3 the weightof concrete.

High Strength - compressive, flexuraland tensile strengths 3-

5 times higher thantraditional concrete.Reduced Installation Costs - easy to handle, no

special equipmentrequired.

Stable under Freeze/Thaw Conditions.


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Low Water Absorption.

Corrosion Resistant - resistant to alkalines,acids, weathering andother forms ofdeterioration

Cost Effective - outperforms conventionalmaterials for longer serviceand lower life cycle costs.

Nonflammable - will not support combustion.


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PHYSICAL PROPERTIES

Application time:Working time at 70 oF - 30 minutesInitial set at 70 oF - 8 Hours

Density - 2.2 gm/cm 3 Compressive strength, 7 days - 756.4 kg/cm 2

Maximum service temperature - 65 oCModulus of elastic - 1.2 x 104 kg/cm 2

Flexural strength - 262.2 kg/cm 2

Tensile strength - 141.6 kg/cm 2


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CHARACTERISTICS

Resistant to a wide range of solvents, oils andacids over a pH range of zero to 14.0.Maximum service temperature of 150 oF(65 oC).Fast chemical set - less down time.

Low porosity.


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USE OF POLYMER COMPOSITES INCONSTRUCTION

Composite materials have been used inconstruction for thousands of years.Polymer composites are produced bycombining polymer resins such as polyester,vinylester and epoxy, with fillers andreinforcing fibres.

Fillers are often used to provide bulk to thematerial, reduce cost, lower bulk density or to produce aesthetic features.


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Fibres are used to reinforce the polymer andimprove mechanical properties such as

stiffness and strength. Polymer composites arewidely used in the construction industry formany years.

In 1999, the construction sector was theworlds second largest consumer of polymercomposites representing 35% of the globalmarket.

Polymer composites have enjoyed widespreaduse in the construction industry for many yearsin non-critical applications


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In recent times fibre composite materials have been increasingly considered for structural load bearing applications. They have established themselves as a viableand competitive option for rehabilitation andretrofit of existing civil structures.

Concrete reinforced with fibre reinforced polymer (FRP) materials has been underinvestigation since the 1960 s .

A small number of new load bearing civilengineering structures have been made predominantly from FRP materials over the lastthree decades.


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These include compound curved roofs, pedestrian and vehicle bridges and bridgedecks, building systems cooling towerselectricity transmission towers etc.

The benefits offered by fibre compositesinclude high specific strength and specificstiffness, durability, good fatigue

performance and the potential to reduce long-term costs.


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TYPES OF POLYMERS

(1). EpoxiesTypical applications.

* Bonding fresh concrete to old concrete

* Bonding old concrete to old concrete* Bonding other materials to concrete* Protective coating

* Overlays* Sealing water leakage (injection)* Structural restoration of cracks (injection)

* Anchor grouting


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Advantages.* Good adhesion

* High compressive/tensile/flexural strength* Excellent resistance to cycles of freezing and

thawing.

* Good resistance to chemical attack* Good wear resistance* Impermeable* Minimal shrinkage


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(2). PolyestersTypical applications

* Protective coatings* Anchoring

* Adhesive bonder or sealer* Floor coatings* Sealer for epoxy injection

* Binder for polymer mortar* Binder for fiberglass* Thin overlays


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(3). UrethanesTypical applications

* Waterproofing* Water control grouting (moist cured)* Protective coating

* InsulationAdvantages

* Easy to use

* Good chemical resistance* Good wear resistance* Adequate working time


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(4). Polyvinyl acetate (PVA)Typical applications

* Adhesive for patches or overlays* Concrete or mortar additive* Adhesive bond coat* Bonding agent for plaster

Advantages

* Easy to use* Stable under sunlight* Improved aging characteristics


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ENVIRONMENTAL CONSIDERATIONS

Reasonable caution should guide the preparation, use, and cleanup of polymer

materials.Involving potentially hazardous and toxicchemical substances.

Material safety data sheets should be obtainedfrom the manufacturers of such materials.


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Polymer Concrete by Sangay