Professional Documents
Culture Documents
Polymer Concrete PDF
Polymer Concrete PDF
ON
o m
. c
e rs
By
in e
T.V.M. Akhilash Guptha
n g B. Nareen Kumar
O E
Email: akil_chari@yahoo.co.in nareen_rathode2007@yahoo.com
D o
a a
F
2
ABSTRACT:
In Concrete Technolgy there are many types of Concretes here we are mainly discussing
coarse and fine aggregates bound together by an appropriate organic resin system. Polymer
concrete is a relatively low-cost composite material system that has been developed to be a
technically viable alternative to porcelain for most high voltage electrical insulation
applications. Polymer composites appear as useful materials for repair and protection of
building structures, as well as for manufacturing pre-cast elements. In the case of pre-cast
m
elements as well as repair materials, the usefulness and durability of polymer composites
o
. c
depend on the selection of the material composition for obtaining the composite with
rs
controllable properties Polymer Concrete consists of a polymer binder which may be a
e
thermoplastic but more frequently is a thermosetting polymer, and a mineral filler such as
e
in
aggregate, gravel and crushed stone. PC has higher strength, greater resistance to chemicals
g
and corrosive agents lower water absorption and higher freeze-thaw stability than
n
O E
conventional Portland cement concrete.
Polymer modified concrete may be divided into two classes; polymer impregnated
D o
concrete and polymer cement concrete. The first is produced by impregnation of pre-cast
a ahardened Portland cement concrete with n monomer that is subsequently converted to solid
F polymer. To produce the second, part of the cement binder of the concrete mix is replaced by
polymer Both have higher strength, lower water permeability, better resistance to chemical,
Polymer concrete is a composite material in which the binder consists entirely of a synthetic
organic polymer. It is variously known as synthetic resin concrete, plastic resin concrete.
Because the use of a polymer instead of Portland cement represents a substantial increase in
cost, polymers should be used only in applications in which the higher cost can be justified
by superior properties, low labor cost or low energy requirements during processing and
handling. It is therefore important that architects and engineers have some knowledge of the
capabilities and limitations of PC materials in order to select the most appropriate and
economic product for a specific application. The first polymer concrete construction in the
o m
worldis
. c
Concrerte-Roman_colosseum_red.
e rs
in e
n g
O E
D o
a a
F Concrerte-Roman_colosseum_red.
the composite is referred to as a polymer mortar. Other fillers include crushed stone, gravel,
limestone, chalk, condensed silica fume, granite, quartz, clay, expanded glass, and metallic
fillers.
To produce PC, a monomer, a hardener and a catalyst are mixed with the filler. Other
ingredients added to the mix include plasticizers and fire retardants. To achieve the full
m
potential of polymer concrete products for certain applications, various fiber reinforcements
o
are used. These include
. c
rs
glass fiber,
e e
in
fabrics and
metal fibers.
n g
O E
The amount polymer binder used is generally small and is usually determined by the size of
the filler. Normal the polymer content will range from 5 to 15 percent of the total weight, but
D o
if the filler is fine, up t 30 percent may be required.
a a
F Polymer concrete composites have generally good resistance to attack by chemicals and other
corrosive agents have very low water sorption properties. Portland cement concrete permits
the use of up to 50 percent less material. This puts polymer concrete on a competitive basis
with cement concrete in certain special applications. The chemical resistance and physical
properties are generally determined by the nature of the polymer binder a greater extent than
by the type and the amount of filler In turn, the properties of the matrix polymer are highly
The typical range of properties of PC products made with each of these four polymers is
Table II.
Table I. Typical Range of Properties of Common PC Products and Portland Cement Concrete
___________________________________________________________________________________
Modulus
Thermal
o m
Coefficient
Water Compressive Tensile Flexural of
. c of
rs
Type of Density, Sorption Strength, Strength, Strength, Elasticity, Poisson Expansion
Binder kg/dm3 % MPa MPa MPa GPa Ratio 10GC-1
Poly(methyl
2.0-2.4 0.05-0.60 70-210 9-11
e e
30-35 35-40 0.22-0.33 10-19
in
rnetha cry late)
g
Polyester 2.0-2.4 030-1.0 50-150 8-25 15-45 20-40 0.16-0.30 10-30
Epoxy 2.0-2.4
E
0.02-1 0
n50-150 8-25 15-50 20-40 0.30 10-35
a
Concrete"
D 1.9-2.5 5-8 13-35 1.5-35 2-8 20-30 015-0.20 10-12
___________________________________________________________________________
durability
o m
Epoxy Strong adhesion to
. c
most Epoxy polymer products are
building materials;
e rs
low relatively costly; they are
e
shrinkage; superior chemical mainly used in special
resistance;
sorption.
g
low
Furan-based polymer
E n
Composite materials with Furan polymer mortars and
a
organic liquids.
F .
Based on workability, polymer content for GFRPC and CFRPC were determined to be 18%
and 20% respectively. Fiber content for both the matrices was varied up to 6%. CIGMAT
standards (CIGMAT PC1-01, CIGMAT PC2-01, CIGMAT PC3-01) were followed for
specimen preparations, compression test and tension test. Destructive tests were performed in
displacement-controlled mode.
Adding 6% glass fibers required 18% polymer in the GFRPC system for good
workability. Glass fibers increased the failure strain, peak strength and modulus in
compression and tension.
Adding 6% PAN based carbon fibers required 20% polymer to develop a workable
CFRPC. The addition of carbon fibers increased the failure strain, but strength and
modulus decreased. In tension, it increased the tensile strain, modulus and strength.
Carbon fibers also increased the failure strain in compression, but reduced the
strength and modulus.
90
80
70
m
60
Stress,MPa
o
50
c
40
.
PC
30 GFRPC
rs
CFRPC
20
10
ee
0
0 0.2 0.4 0.6 0.8 1
g i nStrain,%
Compression Test
16
14
E n
o O 12
10
Stress,MPa
a D 8
6 PC
a
GFRPC
F
4 CFRPC
0
0 0.05 0.1 0.15
Strain,%
Tension Test
Because of its very low tendency to absorb water, acrylic PC has a very high freeze-thaw
resistance.
o m
. c
rs
Because of low cost, the most widely used polymer-binders are based on unsaturated
e
polyester polymer. In most applications, the polyester binder is a general purpose,
e
unsaturated polyester prepolymer formulation. The chemical reaction is called cross-linking,
in
g
the production process associated with it is referred to as curing, and the resulting polymer
E n
o O
Polyester PC has good mechanical strength, relatively good adhesion to other materials, and
a D
freeze-thaw resistance. Polyester PC is used in various pre-cast and cast-in place applications
Fa in constructs works, public and commercial buildings, floor tiles, sewer pipes and stairs.
Epoxy binder like polyester, is a thermosetting polymer. The epoxy polymer can be hardened
with a variety of curing agents, the most frequently used being polyamines. The use of
polyamine hardeners results in PC products with the highest chemicals resistance. Other
curing agents are polyamides and polysulfide polymers. Epoxy PC products cured with
Epoxy PC exhibits high strength, low-setting and post-setting shrinkage, high chemical
resistance, good fatigue and creep resistance. Because they are relatively expensive, epoxy
polymers have not been used very widely as binders in PC products. Therefore, epoxy PC is
used for special applications. Epoxy PC reinforced with glass, carbon or boron fiber is used
o m
. c
Furan polymers are based on furfuryl alcohol, which is derived from agricultural residues
rs
such a corn cobs, rice hulls, oat hulls or sugar cane bagasse. The furan pre-polymer is usually
e
cross-linked with furfuryl alcohol, furfuraldehyde to yield thermosetting polymers, high
e
in
resistant to most aqueous acidic or basic solutions and strong solvents such as ketones,
g
aromatics, and chlorinated compounds. The furan polymers are used as binders in mortars
n
O E
and grouts to achieve chemically resistant brick floors and linings. In addition to exhibiting
superior chemical resistance, these floors have excellent resistance to elevated temperatures
D o
and extreme thermal shock.
a a
F Polymerization :
Polymer- modified cementitious materials date back more than 70 years. In the 194G's they
were developed for use on ships' decks and bridges. Polymers arc made from simple organic
molecules that combine to form more complex structures through a process called
polymerization. The polymers are dispersed in water. These are added to hydraulic cement,
In Polymer- Modified Concrete, a report by the American Concrete Institute. Lists these
Freeze/thaw resistance
Abrasion resistance
o m
Reduced permeability and elastic modulus
. c
rs
How it works :
e
To the normal process of cement hydration, polymer modifications add a process of
e
in
coalescence. As cement hardens, there form small spaces between the aggregate particles.
g
These spaces arc what allow water to penetrate, and do damage in freezing conditions.
n
O E
Polymer particles coalesce to fill these voids. Thai's why the concrete becomes less
permeable and better protected against freeing. Interestingly, polymer concrete does not
D o
produce bleed water. It makes an excellent overlay because it needs very little finishing. It is
a amore accurate to say that it dries, than to call it curing. For that reason that it is used to
F resurface concrete.
There are several chemical systems for polymer concrete and mortar. Acrylic binders provide
excellent environmental resistance and fast setting times. Epoxy resins exhibit high strength
and low shrinkage during curing. They also provide toughness and resistance to chemical and
environmental damage. Furan resins are formed from the polymerization or poly
condensation of furfural, furfural alcohol, or other compounds containing a furan ring. They
are commonly used in foundry binders, grinding wheels, refractories and other high-
11
temperature applications Polymers resins are used in place of phenolics fiberboard binder
Other chemical systems for polymer concrete and mortar include silicone, polyester, and
vinyl ester.
The subject of polymer concrete has generated a lot of interest among researchers during the
past decade. This is due to the many advantages that polymer concrete pavement offers
compared to regular portland cement concrete. The advantages of polymer concrete, when
m
compared to portland cement concrete include, quick curing and setting, reduced moisture
. c o
rs
pavement thickness to support the same load. These advantages will lead to attractive life
e
cycle cost benefits. Material properties and mix designs for PC with epoxy,
e
methylmethacrylate and Polyester as the binder material have been investigated. It has been
in
g
shown in this study that increased material cost of PC can be offset by the reduced thickness
E n
of the pavement. In order to develop life cycle cost information, it is necessary to obtain field
o O
Applicaton of Polymer Impregnated Concrerte:
a D
Keeping in view the numerous beneficial properties of PIC it is found useful in a
c) Marine Works :
Aggressive nature of sea water ,abrasive and leaching action of waves and
inherent porosity ,impair the durability of conventional concrerte in marine works. PIC,
possessing high surface hardness ,very low permiabilty and greatly increased resistance to
chemical attack is a suitable material for marine works.
d) Deslination Plants :
Deslination if sea water is being resorted augment the shortage of surface and
m
ground water in many countries .The material used in the construction of flash distillation
o
vessels in such works has to withstand the corrosive effects of distilled water ,brine and
vapour upto a temp of 143 C. Carbon steel vessels which are currently in use are
comparatively costly .
. c
rs
e) Sewage Disposal Works :
It is common experience that concrete sewer pipes deteriorate due to attack of
e e
effluents and when buried in sulphated infested soils. Further, in the sewage treatment plant,
concrete structures are subjected to severe attack from corrosive gases particularly in sludge
in
digestion tanks.
f) Impregnation of Ferrocement Products :
n g
The Ferrrocement techniques of construction is being extensively used in
manufacture of boats, fishing trawlers , domestic water tanks .Application of Polymer-
impregate concrete due to its high sulphate and high resistance will prove to suitable
References :
O E
material in the ssituations .
1. A. Blaga
a a Research, National Research Council Canada, Canadian Building Digest 241, Ottawa,
F
2. A. Blaga. "Plastics", Division of Building Research, National Research Council Canada,