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About Polymer Concrete and Mortar

About Polymer Concrete and Mortar

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Published by Ashutosh Sharma

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Published by: Ashutosh Sharma on Sep 03, 2009
Copyright:Attribution Non-commercial


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Polymer Concrete and Mortar
Polymer concrete and mortar are binders, compounds, and aggregate mixtures that use epoxy, polyester, vinyl ester or other polymer resin bonds. They cure or set through chemical reactions, thermoset bonds, and multiplecomponent binder systems. Polymer concrete and mortar provides much greater corrosion resistance thanconventional construction materials such as
Portland cement
. Polymer concrete consists of polymer cement mixedwith water, a coarse aggregate such as gravel or crushed stone, and a fine aggregate or sand. Polymer mortar is amixture of a polymer binder or clinker and a fine aggregate. Both polymer concrete and polymer mortar are used to join components and form structures. Products such as grout are used to fill gaps between tiles and bricks. Thin setmaterials such as dry set mortar and dry bond mortar include polymer cement and are used in coating products.There are several chemical systems for polymer concrete and mortar. Acrylic binders provide excellentenvironmental resistance and fast setting times. Epoxy resins or binders exhibit high strength and low shrinkageduring curing. They also provide toughness and resistance to chemical and environmental damage. Furan resins areformed from the polymerization or poly condensation of furfural, furfural alcohol, or other compounds containing afuran ring. They are commonly used in foundry binders, grinding wheels, refractories and other high-temperatureapplications.
Polyurea resins
or binders are used in place of phenolics or other formaldehyde resins in particle or fiberboard binder applications.
provides excellent flexibility, impact resistance and durability. Other chemical systems for polymer concrete and mortar include silicone, polyester, and vinyl ester.Polymer concrete and mortar varies in terms of basic specifications and mechanical, electrical and thermal properties. Basic specifications include set/cure time, set/cure temperature, density, and shrinkage. Density ismeasured as the mass per unit area. Shrinkage is expressed as a maximum percentage. Mechanical properties for  polymer concrete and mortar include compressive strength, bond strength, tensile strength, and modulus of rupture(MOR). Electrical properties include electrical resistivity, dielectric strength and relative permittivity. The dielectricconstant is the relative permittivity of a material compared to a vacuum or free space. Thermal properties for  polymer concrete and mortar include service temperature, thermal conductivity, and the coefficient of thermalexpansion (CTE), the amount of linear expansion or shrinkage that occurs in a material with a change intemperature.There are a variety of features and applications for polymer concrete and mortar. Some products are abrasionresistant, castable, chemical resistant, conductive, fiber-reinforced, sprayable, or waterproof. Other products provide protection against wear, corrosion, or electrostatic discharge (ESD). Polymer concrete and mortar is often used inelectrical power, high voltage (HV), construction, and structural applications. Some products are used as fillers andsealants.
Polyurethane polymer is a combustible solid and will ignite if exposed to an open flame for a sufficient period of time. Decomposition products include
carbon monoxide, oxides of nitrogen, and hydrogen cyanide
. Firefightersshould wear self-contained breathing apparatus in enclosed areas. Polyurethane polymer dust can cause irritation tothe eyes and lungs. Proper hygiene controls and personal protective equipment(PPE), such as gloves, dust masks,respirators, mechanical ventilation, and protective clothing and eye wear should be used.
ApplicationAmount of polyurethane used(millions of pounds)Percentage of total
Building & Construction1,45926.8%Transportation1,29823.8%Furniture & Bedding1,12720.7%Appliances2785.1%Packaging2514.6%Textiles, Fibers & Apparel1813.3%Machinery & Foundry1783.3%Electronics751.4%Footwear390.7%Other uses55810.2%Total5,444100.0%Polyurethane (
, is any  polymer consisting of a chain of  organic units joined by urethane (carbamate) links. Polyurethane polymers are formed through step-growth polymerization  by reacting amonomer containing at least two 
 functional groupswith another monomer containing at least two
groups in the presence of a catalyst. Polyurethane formulations cover an extremely wide range of stiffness, hardness, and densities. These materials include:
Low-density flexiblefoamused in upholstery and bedding
Low-density rigid foam used for  thermal insulation.
Soft solidelastomersused for gel pads and print rollers
Hard solid plastics used as electronic instrument bezels and structural partsPolyurethanes are widely used in high resiliency flexible foam seating, rigid foam insulation panels, microcellular foamseals andgaskets,durable elastomeric wheels and tires, automotive suspension bushings,electrical potting

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