International Journal of Civil Engineering and Technology (IJCIET)

Volume 9, Issue 5, May 2018, pp. 1042–1050, Article ID: IJCIET_09_05_116

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ISSN Print: 0976-6308 and ISSN Online: 0976-6316

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THE MIX PROPORTION AND STRENGTH OF

POLYESTER RESIN CONCRETE WITH
VARIOUS MICROFILLERS
P. Ravikumar
Associate Professor, Department of Civil Engineering,
Hindustan Institute of Technology and Science, Chennai

Vinodhini Ellappan
Assisstant Professor, Department of Civil Engineering,
Hindustan Institute of Technology and Science, Chennai

Dr. T. Sundararajan
Professor, Department of Civil Engineering,
Pondicherry Engineering College, Pondicherry

ABSTRACT
In this research study, the effect of physical properties of micro filler on a mixture of
coarse aggregate and fine aggregate combination, having void content of 13.96 % is
analyzed. The required proportion of different micro fillers such as fly ash, calcium
carbonate, nekolin, dolomite, red earth and crusher dust are arrived based on law of
mixtures. Therefore, the void content of the entire mixture is filled with polyester resin and
the quantity of resin is within 5%. The resin content is increased up to 10-12% by weight
of mixture to obtain the desired workability. The maximum compressive strength attained
is 82.5 N/mm2 and 82 N/mm2 when dolomite and calcium carbonate is used as micro
filler. The maximum tensile strength is 7.90 N/mm2 and 7.7 N/mm2 when crusher dust and
calcium carbonate is used as micro filler. The maximum ratio of tensile strength to
compressive strength is obtained as 12.31%, 11.98% for red earth and fly ash as micro
filler respectively. In all the cases micro filler to resin ratio is between 0.50 and 0.80. Out
of all micro fillers, fly ash gives high compressive strength of 85 N/mm2.
Keywords: Micro filler, Resin, Polyester, void content, mix proportion.
Cite this Article: P. Ravikumar, Vinodhini Ellappan and Dr. T. Sundararajan, The Mix
Proportion and Strength of Polyester Resin Concrete with Various Microfillers,
International Journal of Civil Engineering and Technology, 9(5), 2018, pp. 1042–1050.
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 The Mix Proportion and Strength of Polyester Resin Concrete with Various Microfillers

1. INTRODUCTION
Polymer concrete is a hybrid building product, formulated by mixing the organic binder with
accelerator and catalyst as recommended by the manufacturer. This system fully eliminates
the conventional method of calcium based binding material in the process of hydration with
the aid of water. The strength attainment is based on the type of monomer, polymer used and
the method of mix proportion adopted with the aid of micro filler in polymer concrete.
Generally calcium carbonate is used as micro filler. The filler imparts a major role in the
polymer matrix system leading to the development of polymer mortar and polymer concrete.
Fillers play an important role in plastic product similarly the different fillers have unique
property associated with their physical property leading to low cost, availability, low oil
absorption, good surface wetting and bonding, good chemical resistance and high strength[1].
The monomer is small and simple organic molecular species with double (π) or triple (σ)
bonds in between the carbon – carbon atoms capable of combining chemically with molecules
of the same or different species to form a material of high molecular weight known as
polymer. The chemical process of linking monomers together is called polymerization. The
polymerization mechanism, types of polymer concrete leads to various application in
construction industry [2]. Aggregate mixture for least void content for use in polymer
concrete with various gradation of fine aggregate, coarse aggregate and micro filler based on
the physical property of respective material and their combination plays an important role [3].
The mix design of polymer concrete is based on appropriate optimal proportions of aggregate
and micro filler at the densest mixture of both in which less void content so as to minimize the
resin content to fill the voids [4].

2. TYPES OF FILLERS AND THEIR PROPERTIES

2.1. Classification of Fillers
Fillers can be classified into different categories and the important one are (i) Mineral fillers
:e.g., calcium carbonate, talc, silica (natural / synthetic), kaolin, feldspar, metallic oxides, etc.
(ii) metallic, conductive, magnetic fillers; e.g., iron powders, stainless steel powder,
aluminum powder, flakes and fibers, nickel powders and flakes, copper powder and flakes,
silver powder and flakes, zinc powder, (iii) carbon black filler (iv) organic fillers e.g., wood
floor, cotton, cellulose fibers, sisal, jute, hemp, starch, asbestos, (v) flame retardants as fillers
e.g., antimony oxide, aluminium trihydrate, halogen, and phosphorous, containing
compounds, miscellaneous compounds and smoke suppressants[1].
In order to improve the efficiency and binding strength of filled polymers various
coupling agents such as organo functional silanes, titanates etc. are used with fillers. Special
effects are obtainable with fillers designed for a specific purpose. Lubricating fillers are
molybdenum disulfide, graphite and teflon, magnetic fillers are black iron oxide, powdered
iron, barium, strontium ferrites, and surface fillers provides significant modification in all the
properties largely due to improved dispersion and blending. Carbon blacks are more often
regarded as pigments but may be used in conjunction with coarser fillers to obtain better
packing. Fused silica is made in various particle sizes from high purity silica for demanding
electrical applications, cotton flock, alpha cellulose and other fibers though generally used as
rein forcement or as fillers for decorative or viscosity control effects.
Solid spherical fillers provide the lowest possible volume ratio, which limits the area of
resin absorption without increasing the viscosities and provides uniform stress distribution.
Glass beads, ceramic, microbeads and various metallic and polymer microspheres are
available commercially.

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 P. Ravikumar, Vinodhini Ellappan and Dr. T. Sundararajan

2.2. Properties of Fillers

i. Primary fillers properties; particle size, particle distribution, surface area, particle
parking (minimum/ maximum packing system), chemical composition, (oxide, salts,
silicates, elements, organics), surface physical chemistry.
ii. Secondary fillers properties; optical, thermal, physical and electrical.
iii. Surface modified filler properties; chemisorption, ionic bonding, covalent bonding,
other chemical bonding, interfacial effects, molecular entanglement, vanderwalls
bonding, cross linking and covalent bonding.

2.3. Effects of Fillers

Fillers have effect in the properties of polymers to which they are added. Some of them are
physical properties, rheological properties, chemical resistant’s, thermal and electrical
properties [1].

3. STUDIES ON THE EFFECT OF MICROFILLERS

3.1. Materials used
Commercially available unsaturated polyester (USP) resin orthophthalic type is obtained from
the manufacturer for the experimental studies on the strength of polyester resin concrete.
Physical and chemical properties of the resin is given in table 2.Hard broken granite stones in
the size range of 20 to 4.75mm is used as coarse aggregate (CA). Locally available river sand
(well graded) in the size range 4.75-0.15mm is used as fine aggregate (FA). In order to study
the effect of various MFs (passing through 75microns) on the strength characteristics of PC,
six types of MFs namely, (1) Fly ash, (2) Calcium Carbonate (LR grade). (3) Nekolin, (4)
Dolomite, (5) Red Earth and (6) Crusher Dust, have been used with USP resin, in this study.
The various properties of the above MFs, (which are relevant for the study) determined by
standard methods, are given in Table 2. Particle size distribution of MFs is obtained by the
sedimentation analysis (hydrometer analysis) and its salient results are in Table 3.

Table 1 Physical and Chemical properties of Unsaturated Polyester Resin (Orthophthallc)

Sl.No Description Value
1 Viscosity @ 25oC (cPs) 500
2 Specific Gravity 25oC 1.10
3 Gel time @ 25oC 25
Catalyst(51% DMP – Dimethyl phthalate solution of
4 1.5 ml/100gms of Resin
methyl ethyl ketone peroxide – MEKPO)
Accelerator ( 6% mineral turpentine solution of
5 1.5 ml/100gms of Resin
Cobalt Octoate – CoOc)
6 Styrene content (%) 38

Table 2 Properties of various MFs used in Polymer Concrete

Sl.No Microfiller Void Content Void Ratio Sp.Gravity
1 Flyash 71.52 2.512 2.70
2 Calcium Carbonate 66.71 2.004 2.71
3 Nekolin 66.28 1.966 2.71
4 Dolomite 61.25 1.550 2.69
5 Red earth 57.07 1.329 2.67
6 Crusher dust 45.84 0.8465 2.63

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 The Mix Proportion and Strength of Polyester Resin Concrete with Various Microfillers

Table 3 Salient results of particle size distribution of various MFs

Range of Particle Size 75% Particles Greater
Sl.No Microfiller
(mm) Than (mm)
1 Flyash 0.0765-0.0105 0.0390
2 Calcium Carbonate 0.0625-0.0013 0.0128
3 Nekolin 0.0672-0.0013 0.0117
4 Dolomite 0.0644-0.0010 0.0071
5 Red earth 0.0624-0.0013 0.0128
6 Crusher dust 0.0174-0.0105 0.0290

Table 4 Properties of Coarse Aggregate (CA) and Fine aggregate (FA) used in Polymer Concrete
Sl.No Aggregate Size (mm) % By Weight Void Content% Void Ratio Sp.Gravity
1 CA 20-10 10-4.75 96.15 3.85 45.92 0.8489 2.73
4.75-2.36 8.4
FA 2.36-1.18 13.77
30.39 0.4366 2.64
2 (I) Sand 1.18-0.60 18.93
37.83 0.6085 2.70
(II) Crusher dust 0.60-0.30 26.17
0.30-0.15 32.73

4. MIX PROPORTION APPROACH

Extensive tests conducted by Kantha Rao and Krishnamoorthy (6,7) with CA and FA
mixtures resulted in the grading and least void content of the mixture for three maximum size
of aggregates (MSA), namely, 20, 10 and 4.75mm. They considered the entire mixture of CA
and FA as a new CA and the MF which is to be added as a new FA is determined so as to
result in the least void for the overall mixture (consisting of CA,FA and MF), using the law of
binary mixtures as given by equations 1 and 2.
( )
N=( )
1

U=( )
2
FA and C= void-ratio of CA.
In this study, a particular aggregate-mixture having minimum void-content (corresponding
to maximum size of aggregate (20mm) and sand type continuously Where, n= solid volume
fraction of CA; u = void-ratio of binary mixture; A= void–ratio of graded), based on the
gradations obtained by Kantha Rao and Krishnamoorthy (6,7), is used. The above method of
mix proportioning is referred to as ‘minimum voids approach’, in subsequent discussion in
this study. The salient properties of the above gradings of aggregates (as given in Table 5) are
determined by standard tests and used in the above equations to proportion the PC mixes.

5. TYPES OF STUDIES CARRIED OUT

Standard test specimens for determining the compressive strength (100mm x 100mm cubes)
and cylinder specimen(100mm dia x 200mm length) for tensile strength are casted using the
materials listed earlier and following the necessary precaution/procedure required for casting
PC. Using the mix proportion obtained by the minimum voids approach, the following studies
have been carried out on the various PCs using the unsaturated polyester resin.
1. Strength of PC using USP (i.e. unsaturated polyester resin) without any
modification in the resin content is adequate or if the viscosity of resin is very low
Table10.
2. Strength of PC using USP, with modification in resin content considering the
effect of viscosity of resin, if the viscosity of the resin is high. For this purpose, the

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 P. Ravikumar, Vinodhini Ellappan and Dr. T. Sundararajan

resin content as obtained by the minimum voids approach is increased (assumed as

2.5 times, in this study) with suitable reduction in aggregates content in the same
ratio as that of CA; FA .Table 11.
3. To maximize the strength obtained by the above two methods (as described in case
1 & 2), the resin content (UPS) is varied from 10-15%.
4. In order to evaluate the adequacy of the resin content (USP) for a minimum level
of workability, the mix proportion obtained by minimum voids approach (as in
case2) is kept unaltered but resin content varied (reduced/increased) by 1-2 % and
strength determined.
5. Effect of various microfillers on the strength of USP resin based PC, for the same
gradation of CA and FA and adjusting the resin content and MF for viscosity and
strength. The mix proportion based on minimum voids approach using various
MFs (without adjusting the resin content for viscosity) is given in Table 11.

Table 5 Weight ratio of each constituent material for different MFs

Mix Proportion (% By Wt)
Material
CA FA MFs R
(A) Microfiller
Flyash 58.18 33.25 4.24 4.33
Calcium Cabonate 57.90 33.00 5.00 4.10
Nekolin 57.96 33.11 5.01 3.92
Dolomite 57.70 32.90 5.70 3.70
Red earth 57.50 32.90 6.20 3.40
Crusher dust 57.00 32.60 7.70 2.70
(B) Crusher dust as FA
57.18 29.84 9.58 3.40
and MF

Table 6 Mix proportion of aggregates (CA&FA) by volume

CA FA Void content% Void raio
62.86 37.14 13.96 0.1622

Table 7 Mix Proportion of Aggregates (CA&FA) and Micro Fillers as Binary Mixtures by Volume
Name of micro filler CA + FA M.F Void content% Void ratio
Fly ash 95.58 4.42 9.98 0.1109

Table 8 Mix Proportion of Aggregate and Micro Fillers by Volume

Name of micro filler CA FA MF Void content
Fly ash 60.08 35.50 4.40 9.98
Calcium corbonates 59.64 35.24 5.12 9.31
Nekolin 59.59 35.21 5.20 9.25
Dolomite 59.11 34.92 5.97 8.48
Red Earth 58.77 34.72 6.51 7.96
Crusher Dust 57.77 34.13 8.10 6.39

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 The Mix Proportion and Strength of Polyester Resin Concrete with Various Microfillers

Figure 1 The relation between the void content of the microfiller and their requirement (% by volume)
Note: In all the cases the total volume of the microfiller and void is around 14% (i.e. void
content of the CA: FA mixture)

Table 9 Mix Proportion of Aggregate and Micro Fillers by Weight

Name of micro Mix Proportions (% by wt)
MF/R Resin
filler CA FA MF
Fly ash 58.44 33.40 4.25 1.08 3.91
Calcium corbonates 58.16 33.23 4.96 1.35 3.65
Nekolin 58.12 33.21 5.03 1.38 3.64
Dolomite 57.85 33.05 5.75 1.71 3.35
Red Earth 57.66 32.94 6.21 1.97 3.15
Crusher Dust 57.11 32.63 7.71 3.02 2.55

Table 10 Mix Proportion of Polymer Concrete taking into Account of Weight of Resin
Name of Mix Proportions (% by wt)
Resin MF/R FA/MF
micro filler CA FA MF
54.00 31.00 4.00 11.00 0.36 7.75
Fly ash
52.78 30.21 5.00 12.00 0.42 6.04
Calcium 53.90 30.85 5.00 10.25 0.49 6.17
Carbonate 52.29 30.21 5.00 12.00 0.42 6.04
54.00 31.00 5.00 10.00 0.50 6.20
Nekolin
52.79 30.21 5.00 12.00 0.42 6.04
53.90 30.85 6.00 9.25 0.65 5.14
Dolomite
52.15 29.85 6.00 10.00 0.60 4.98
54.25 31.05 6.20 8.50 0.73 5.00
Red earth
53.10 30.40 6.50 10.00 0.65 4.68
54.41 31.14 7.70 6.75 1.14 3.94
Crusher dust
52.15 29.85 8.00 10.00 0.80 3.73

6. RESULTS AND DISCUSSION

The results of the specimen casted are presented in table 12. The mix proportion as obtained is
modified in respect of resin content so as to coat the each and every particle. The mix
proportion and the void content is the base for the experiment. The resin is not like as water,
in which the viscosity plays important role as such the weight percentage obtained by the mix
design is not a workable mixture. The surface area plays important role for coating the
particle. Hence the minimum resin content is needed for the Polyester resin concrete with
varying percentage from 10% to 12% using different types of micro fillers. The effect of
micro filler to resin ratio and fine aggregate to micro filler ratio is also analyzed.
Based on the critical analysis of the results in respect of compressive strength

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 P. Ravikumar, Vinodhini Ellappan and Dr. T. Sundararajan

1. The mix proportion obtained by minimum void a[approach is based on water. The
resin is used to mix the voids and so the viscosity of resin is important role. Due to
the surface area and the filler to resin ratio is also have the effects on strength.
2. The void content is the direct effects on the composition of mixture. The fly ash
has the maximum void content of 71.52and the crusher dust have 45.84.
3. The void content of the mixture after taking into account, the micro filler content is
9.98 to 6.39 starting from fly ash to crusher dust as in table 10 if the void content
of micro filler is more the quantity of micro filler consumption in the mixture is
less and the void content of the micro filler is less the quantity of micro filler
content needed is more. In all the cases the total volume of the microfiller and void
is around 14% (i.e. Void content of the CA: FA mixture) as figure 1.
4. Based on the above void content the mix proportion by weight is also arrived and
the resin content is needed starting from 3.92% to 2.5 %.
5. The resin content arrived is not able to coat the constrituent material due to the
viscosity of the resin, so that resin content is increased up to a minimum level of
10%.
6. The compressive strength and tensile strength of polyester resin concrete with
various micro filler is listed in table 12. Out of all the micro filler the maximum
strength of 85 N/mm2 in respect of fly ash as micro filler with 12% resins content.
The strength of 82.50 N/mm2 and 82.00 N/mm2 in respect of dolomite and
calcium carbonate as micro filler at 12% resin content. The minimum strength of
62.50 N/mm2 in respect of red earth as microfiller at 8.5% resin content.
7. The ratio of tensile strength to compressive strength is maximum at 10% resin
content in respect of red earth and crusher test such as 12.31N/mm2 and
11.13N/mm2respectively, even though the compressive strength is less for the
above to micro fillers compare to all other cases.

Table 11 Compressive and Tensile strengths of PCs based on USP resin and with Various Microfiller
Name of Mix Proportions (% by wt) AV. Strength (N/mm2) T/C (%)
SL.NO MF/R
Microfiller CA FA MF R Compressive(C) Tensile (T)
54.00 31.00 4.00 11.00 0.36 80.25 -NP- -
1 Fly ash
52.78 30.21 5.0 12.00 0.42 85.00 10.18 11.98
2 Calcium 53.9 30.85 5.00 10.25 0.49 72.5 5.73 7.9
3 Carbonate 52.79 30.21 5.00 12.00 0.42 82.00 7.7 9.39
4 54.00 31.00 5.00 10.00 0.50 74.00 4.65 6.28
Nekolin
5 52.79 30.21 5.00 12.00 0.42 63.50 6.11 9.62
6 53.90 30.85 6.00 9.25 0.65 80.50 7.13 8.85
Dolomite
7 52.15 29.85 6.00 12.00 0.60 82.50 6.05 7.33
8 54.25 31.05 6.20 8.50 0.73 62.50 4.77 7.63
Red earth
9 53.10 30.40 6.50 10.00 0.65 61.00 7.51 12.31
10 Crusher 54.41 31.14 7.70 6.75 1.14 70.50 6.68 9.47
11 dust 52.15 29.85 8.00 10.00 0.80 71.00 7.90 11.13

Figure 2 Comperessive strength of polyester resin concrete with fly ash as micro filler

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 The Mix Proportion and Strength of Polyester Resin Concrete with Various Microfillers

Figure 3 Comperessive strength of polyester resin concrete with CaCo3 as micro filler

Figure 4 Comperessive strength of polyester resin concrete with Nekolin as micro filler

Figure 5 Comperessive strength of polyester resin concrete with Dolomite as micro filler

Figure 6 Comperessive strength of polyester resin concrete with Red Earth as microfiller

Figure 7 Comperessive strength of polyester resin concrete with Crusher Dust as microfiller

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 P. Ravikumar, Vinodhini Ellappan and Dr. T. Sundararajan

Figure 8 Optimized compressive strength of polyester resin Concrete with various microfiller

7. CONCLUSION
Based on the extensive analysis and different micro fillers in polyester resin concrete and on
the various inferences drawn, following are the salient conclusion
1. The minimum void content mixture is the main part of analysis and the method of
using law of mixture is hold good but the gradation as suggested by Kantharao and
Krishna moorthy is used for the study.
2. The void content of the micro filler is play an important role that is the void
content of a particular micro filler, is more the consumption quantity of micro
filler is less as in fly ash. On the other hand the less void content micro filler the
quantity of consumption is more for the mix as in crusher dust.
3. Fly ash microfiller is most suitable compared to all other microfiller.
4. Viscosity plays important role so that mix proportion is modified by increasing the
resin content
5. In this study the mix proportion is adjusted equally in all constituent present on the
increase in the resin constant.

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[4] Krishnamoorthy, S., Kantha Rao, V.V.L.,’Minimisation of void content and optimization
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[5] Ohama, Y.,Demura,k.,’ Effect of coarse aggregate on compressive strength of polyester
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