Construction and Building Materials 25 (2011) 779784

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Construction and Building Materials

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Strength properties of polymer mortar panels using methyl methacrylate solution of waste expanded polystyrene as binder
Muhammad Aamer Raque Bhutta a,*, Yoshihiko Ohama b, Ken Tsuruta c
a

Department of Structures and Materials, Faculty of Civil Engineering, Universiti Teknologi Malaysia, Malaysia Department of Architecture, College of Engineering, Nihon University, Koriyama, Japan c Research and Development Center, Materras Oume Concrete Industry, Co., Tokyo, Japan
b

a r t i c l e

i n f o

a b s t r a c t
The present study examines the applicability of polymer mortar panels using a methyl methacrylate (MMA) solution of waste expanded polystyrene (EPS) to develop effective recycling processes for the EPS, referring to the strength properties of a polymer-impregnated mortar panel with almost the same performance as commercial products. An MMA solution of EPS is prepared by dissolving EPS in MMA, and unreinforced and steel ber-reinforced polymer mortars are mixed using the EPS-MMA-based solution as a liquid resin or binder. Polymer mortar panels (PMPs) using the EPS-MMA-based polymer mortars without and with steel ber and crimped wire cloth reinforcements and steel ber-reinforced polymer-impregnated mortar panel (PIMP) are prepared on trial, and tested for exural behavior under four-point loading. The EPS-MMA-based PMPs are more ductile than the PIMP, and have a high load-bearing capacity. Consequently, they can replace PIMP in practical applications. 2010 Elsevier Ltd. All rights reserved.

Article history: Received 17 May 2010 Received in revised form 14 July 2010 Accepted 18 July 2010 Available online 24 August 2010 Keywords: Waste expanded polystyrene Methyl methacrylate Polymer mortar panel Reinforcement Strength properties Recycling

1. Introduction Expanded polystyrene is nowadays used as a popular packaging or insulating material in various industrial elds in the world because of its characteristics such as lightweight, low thermal conductivity and high impact resistance. However, most of the expanded polystyrene is disposed as a bulky waste immediately after only one-time use, and the disposal of a large quantity of waste expanded polystyrene has become serious environmental issues in the world. Approximately 61% of waste expanded polystyrene is not recycled as the raw materials in Japan at present. The development of the effective recycling processes is strongly requested for the waste expanded polystyrene. In recent years, the authors have prepared the vinyl monomer solutions of the waste expanded polystyrene by dissolving the waste expanded polystyrene in styrene or methyl methacrylate, and developed new polymer mortar systems by using the vinyl monomer solutions as liquid resins or binders for the systems [13]. Such new polymer mortar systems are considered to be effective recycling processes for the waste expanded polystyrene. In Japan, polymer-impregnated mortar panels have been employed only in the limited applications giving a good cost-performance balance for them for the past 30 years. Only one company currently produces the poly-

mer-impregnated mortar panels as commercial products to order [57]. In the present paper, a methyl methacrylate solution of waste expanded polystyrene is prepared by dissolving waste expanded polystyrene in methyl methacrylate, unreinforced, steel ber-reinforced and crimped wire cloth reinforced polymer mortars using the methyl methacrylate solution as a liquid resin or binder are mixed, and tested for strength properties. Panels using the polymer mortars without and with reinforcements and steel ber-reinforced polymer-impregnated mortar panel are prepared on trial, and tested for exural behavior. The exural behavior of the polymer mortar panels is compared to that of the polymer-impregnated panel. The purpose of this experimental study is to examine the applicability of polymer mortars using a methyl methacrylate solution of waste expanded polystyrene to panels for the development of effective recycling processes for it, referring to the exural behavior of a polymer-impregnated mortar panel with almost the same performance as commercial products.
2. Materials 2.1. Materials for polymer mortars 2.1.1. Chemicals for binder system Expanded polystyrene (EPS), specied in JIS (Japanese Industrial Standards) A 9511 (preformed cellular plastics thermal insulation materials), was used as a model of waste EPS. Table 1 gives the physical properties of the EPS. Methyl methacry-

Corresponding author. Tel.: +60 7 5531736; fax: +60 7 5566157. E-mail address: maraque@utm.my (M.A.R. Bhutta). 0950-0618/$ - see front matter 2010 Elsevier Ltd. All rights reserved. doi:10.1016/j.conbuildmat.2010.07.006

780 Table 1 Physical properties of EPS. Molecular weight ca. 300,000 Density (kg/m3) 17 Thermal conductivity (W/(m K)) 0.040

M.A.R. Bhutta et al. / Construction and Building Materials 25 (2011) 779784 2.3. Reinforcements Commercially available steel bers (size, 0.3 0.4 15 mm; tensile strength, 585 MPa; elastic modulus, 200 GPa; elongation, 50%) and the crimped wire cloth (diameter, 1.5 mm, cross-section area, 1.77 mm2; tensile strength, 412 MPa; elastic modulus, 59 GPa; elongation, 24.5%) as specied in JIS G 3553 (crimped wire cloth) were used as reinforcements.

Flexural strength (N/cm2) 24

Compressive strength (N/cm2) 10

2.4. Materials for polymer-impregnated mortar Table 2 Properties of MMA monomer. Monomer MMA Molecular weight 100.1 Density (g/m3, 20 C) 0.94 Viscosity (mPa s, 20 C) 0.85 Purity (%) 99.9 Ordinary Portland cement as specied in JIS R 5210 (Portland cement) and the same crushed sands and steel bers for polymer mortars as mentioned above were also employed for base mortar. For the preparation of an impregnant, the same MMA monomer for polymer mortars as stated above was used, together with azobisisobutyronitrile (AIBN) as an initiator.

late (MMA) for industrial use was employed not only as a solvent to dissolve EPS but also as an ingredient of the liquid resin for polymer mortars. Table 2 lists the properties of the MMA monomer. Fifty percent dicyclohexyl phthalate powdered dispersion of benzoyl peroxide (BPO) was used as an initiator, and N,N-dimethylp-toluidine (DMT) was done as a promoter. The water content of the EPS was controlled to be less than 0.1% by heat drying at 60 C for 48 h.

3. Testing procedures 3.1. Preparation of EPS-MMA-based solution for liquid resin An EPS-MMA-based solution with an EPS concentration of 30.0% for the liquid resin for polymer mortars was prepared by dissolving expanded polystyrene (EPS) in methyl methacrylate (MMA) monomer at approximately 70 C in a stainless steel vessel at pilot plant for vinyl monomer solution of waste EPS in a factory as shown in Fig. 1.

2.2. Filler and ne aggregates Fly ash Type II as specied in JIS A 6201 (y ash for use in concrete) was employed as a ller. Two types of crushed sands were used as ne aggregates. Table 3 gives the properties of the ne aggregates. The water contents of the ller and ne aggregates were controlled to be less than 0.1% by heat drying at 105 C for 48 h. Table 3 Properties of ne aggregates. Type of ne aggregate Crushed sand (ne) Crushed sand (coarse) Size (mm) 0.15$2.5 2.5$5 Fineness modulus 3.29 4.83

Bulk density (kg/l) 1.48 1.64

Density (kg/m3) 2620 2630

Water absorption (%) 0.94 0.58

MMA monomer

Mixing of EPS-MMA -based mortar

Casting of EPS-MMA
-based mortar

Casting of EPS-MMA -based mortar

Fig. 1. Process for making specimens from polymer mortars using waste EPS-MMA-based binder [4].

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3.2. Preparation of polymer mortar specimens and polymer mortar panel specimens According to JIS A 1181 (test methods for polymer concrete), polymer mortars using an EPS-MMA-based binder with the formulations of EPS-MMA-based solution:BPO:DMT = 100:2.0:1.0 (by mass) were mixed with the mix proportions shown in Table 4. Beam specimens 40 40 160 mm for exural and compressive strength tests and cylindrical specimens U50 100 mm for splitting tensile strength test were molded using the polymer mortars, and subjected to a 24 h20 C60% (RH)-dry plus 15 h70 C-heat curing and a 24 h20 C60% (RH)-dry plus 3 h100 C-heat curing.

Polymer mortar panel specimens 450 900 30 mm without or with embedded crimped wire cloth reinforcement were also molded using the polymer mortars, and subjected to a 24 h 20 C60% (RH)-dry plus 15 h70 C-heat curing. Fig. 1 demonstrates the process for making specimens from polymer mortars using waste EPS-MMA-based binder. Fig. 2 represents the molding process for the polymer mortar panel specimens. 3.3. Preparation of polymer-impregnated mortar panel specimens According to JIS R 5201 (physical testing methods for cement), steel ber-reinforced mortar was mixed with the following mix

Table 4 Mix proportions of polymer mortars. Steel ber content (%) (volume fraction) 0 1.2 Mix proportions (mass percentage) Binder 12.0 12.0 Filler 12.0 12.0 Crushed sand (F) (0.15$2.5 mm) 46.0 42.0 Crushed sand (C) (2.5$5 mm) 30.0 30.0 Steel bers 0 4.0

Polymer mortar 30 mm Crimped wire cloth

Fig. 2. Molding process for polymer mortar panel specimens.

Machine crosshead
Specimen P/2 Load cell P/2

Strain gage LVDT

250 /3

250 /3 750

250 /3 (Unit: mm)

Fig. 3. Setup of exural test for polymer mortar panel specimen.

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Table 5 Strength properties of EPS-MMA-based polymer mortars. Curing condition 15 h70 C-heat curing Fiber content (%) (volume fraction) 0 Compressive strength (MPa) 114.1 111.6 110.9 121.3 123.0 124.7 100.1 107.6 109.1 125.0 127.7 126.5 112.2
a

Tensile strength (MPa) 14.9 13.0 14.1 16.1 14.9 15.2 13.4 12.7 13.8 14.7 15.2 14.2 14.0

Flexural strength (MPa) 29.1 25.4 28.3 29.6 29.2 31.2 25.6 27.8 25.2 29.2 29.9 31.5 27.6

1.2

123.0

15.4

30.1

3 h100 C-heat curing

105.6

13.1

26.2

1.2

126.4

14.8

30.2

Average value.

proportions (kg/m3): water 175, cement 500, crushed sand (ne) 958, crushed sand (coarse) 715, steel bers 95 and superplasticizer 3.5; steel ber content = 1.2% (volume fraction) and watercement ratio = 35.0%. Base mortar specimens 450 900 30 mm for polymer-impregnated mortar panel specimens were molded using the steel ber-reinforced mortar in accordance with the same molding process as seen in Fig. 2, and subjected to a 2 h-ambient temperature-precuring plus 3 h60 C-steam plus 7 d20 C60% (RH)-dry curing. The cured base mortar specimens were dried at 120 C for 15 h in an oven. The dried base mortar specimens were cooled to ambient temperature, evacuated at 400667 Pa for 2 h, and then

soaked in an impregnant with the formulations of MMA:AIBN = 100:1 (by mass) under atmosphere pressure for 2 h. After monomer impregnation, the specimens were placed in hot water at 70 C for 4 h for thermal polymerization to make polymer-impregnated mortar panel specimens. Their polymer loading was 5.0%. 3.4. Strength test for polymer mortar specimens Beams specimens were tested for exural and compressive strengths in accordance with JIS A 1184 (method of test for exural

Fig. 4. Flexural stressextreme tension ber strain curves for EPS-MMA-based PMPF without reinforcement.

Fig. 6. Flexural stressextreme tension ber strain curves for EPS-MMA-based PMPF with crimped wire cloth reinforcement.

Fig. 5. Flexural stressextreme tension ber strain curves for EPS-MMA-based PMPF with steel ber reinforcement.

Fig. 7. Flexural stressextreme tension ber strain curves for PIMPF with steel ber reinforcement.

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strength of polyester resin concrete) and JIS A 1183 (method of test for compressive strength of polyester resin concrete using portions of beams broken in exure), and cylindrical specimens were done for splitting tensile strength according to JIS A 1181. 3.5. Flexural test for polymer mortar and polymer-impregnated mortar panel specimens Polymer mortar and polymer-impregnated mortar panel specimens were tested for exural behavior under four-point loading with a span of 750 mm and a loading rate of 50 N/s by using the Amsler-type universal testing machine. Fig. 3 illustrates the setup of exural test for the panel specimen. At the same time, the central (or midspan) deection of the specimens was measured by a sensitive LVDT (linear variable differential transformer), and their extreme tension ber strain was measured by the three 30-mmlong paperback electrical strain gages installed on the extreme tension ber at the midspan. Their exural toughness was calculated as an area under a exural loaddeection curve up to a deection at the maximum exural load (at failure load). Their exural strength was calculated using the following equation:

where Ef is exural modulus of elasticity (103 GPa), P is exural load (N), d is central (midspan) deection (mm), is span (mm), b is width (mm) of specimen, and h is thickness (mm) of specimen. 4. Test results and discussion 4.1. Effects of steel ber reinforcement and curing conditions on strength properties of EPS-MMA-based polymer mortars Table 5 shows the strength properties of unreinforced and steel ber-reinforced EPS-MMA-based polymer mortars, made by applying two types of heat curings. The effects of heat curing conditions on the compressive, tensile and exural strengths of the unreinforced and steel ber-reinforced EPS-MMA-based polymer mortars are not signicantly evident, however, the strength properties of 15 h70 C-heat-cured polymer mortars are somewhat higher than those of 3 h100 Cheat-cured polymer mortars. This is attributed to the acceleration of the polymerization reaction of MMA monomer in the matrixes by a longer heat curing. The steel ber reinforcement of the EPS-MMA-based polymer mortars improves their compressive, tensile and exural strengths regardless of the heat curing conditions. 4.2. Flexural behavior of EPS-MMA-based polymer mortar panels and polymer-impregnated mortar panel as reference panel Figs. 47 represent the exural stressextreme tension ber strain curves for EPS-MMA-based polymer mortar panels (PMPs) without reinforcement and with steel ber and crimped wire cloth reinforcements and for a polymer-impregnated mortar panel (PIMP) with steel ber reinforcement as a reference panel. The exural stressextreme tension ber strain relationships of the EPS-MMA-based PMPs without reinforcement and with steel ber and crimped wire cloth reinforcements are almost the same, and the effects of the steel ber and crimped wire cloth reinforcements on the relationships are hardly recognized. The maximum exural stress of the EPS-MMA-based PMPs without reinforcement and with steel ber and crimped wire cloth reinforcements is comparable to that of the PIMP with steel ber reinforcement, but the maximum extreme tension ber strain of the PMPs is about twice larger than that of the PIMP. Fig. 8 and Table 6 show the exural behavior of EPS-MMAbased PMPs without reinforcement and with steel ber and crimped wire cloth reinforcements and of a PIMP with steel ber reinforcement as a reference form. The deection of the EPSMMA-based PMPs without reinforcement and with steel ber and crimped wire cloth reinforcements increases almost linearly with increasing exural load until the maximum exural load giving a brittle failure irrespective to the type of reinforcement. The exural loaddeection relation of the PIMPF with steel ber rein-

rf

P bh
2

where rf is exural strength (MPa), P is maximum exural load (N), is span (mm), b is width (mm) of specimen, and h is thickness (mm) of specimen. Their exural modulus of elasticity was calculated by the following equation:

Ef

23P3 54bh d
3

EPS-MMA-based PMP
PIMP with steel fiber reinforcement Steel fiber reinforcement

Crimped wire cloth reinforcement

Without Steel fiber reinforcement

Fig. 8. Flexural loaddeection curves for EPS-MMA-based PMPFs and PIMPF.

Table 6 Flexural behavior of EPS-MMA-based polymer mortar and polymer-impregnated mortar panels (PMPs and PIMP). Type of polymer mortar panel PMP without reinforcement PMP with steel ber reinforcement PMP with crimped wire cloth reinforcement PIMP with steel ber reinforcement
a

Max. extreme tension ber strain (106) 1137 1169 1190 1216 1104 1136 551 577 1153a 1203 1120 564

Max. deection (mm) 4.90 4.94 4.84 4.98 5.15 5.10 2.31 2.79 4.92 4.91 5.13 2.55

Flexural toughness (kN mm) 37.5 36.1 37.6 39.4 38.1 41.1 21.4 19.4 36.8 38.5 39.6 20.4

Flexural strength (MPa) 29.3 30.1 30.8 31.4 28.7 29.9 31.7 29.9 29.1 31.1 29.3 30.8

Flexural modulus of elasticity (GPa) 23.0 21.0 23.8 25.2 19.0 20.0 51.2 49.8 22.0 24.5 19.5 50.5

Average value.

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forcement also is almost linear like the EPS-MMA-based PMPs. The maximum deections, exural toughnesses, exural strengths and exural moduli of elasticity of the EPS-MMA-based PMPFs without reinforcement and with steel ber and crimped wire cloth reinforcements are almost the same, and the effects of steel ber and crimped wire cloth reinforcements on their exural behavior are hardly recognized. The exural strength of the EPS-MMA-based PMPs is almost the same as that of the PIMP. However, the maximum deection and exural toughness of the EPS-MMA-based PMPs are about twice larger than those of the PIMP, and the exural modulus of elasticity of the PMPs is almost a half of that of the PIMP. From the above exural behavior trend, it is obvious that the EPS-MMA-based PMPs are more ductile than the PIMP. This means that the EPS-MMA-based PMPs have a high load-bearing capacity compared to the brittle PIMP. 5. Conclusions The conclusions obtained from the test results are summarized as follows: (1) The effects of curing conditions on strengths of EPS-MMAbased polymer mortars are not signicantly evident. The steel ber reinforcement of the EPS-MMA-based polymer mortars improves their strength properties regardless of the curing conditions. (2) The maximum exural stress of EPS-MMA-based PMPs without reinforcement and with steel ber and crimped wire cloth reinforcements is comparable to that of PIMP with steel ber reinforcement, but the maximum extreme tension ber strain of the PMPs is about twice larger than that of the PIMP. (3) The effects of reinforcements on the exural behavior of EPS-MMA-based PMPs are hardly recognized. Nevertheless, any reinforcements for the EPS-MMA-based PMPs are needed to prevent the brittle failure by sudden impact loading under their installation and use. The exural strength of the EPS-MMA-based PMPs without reinforcement and with steel ber and crimped wire cloth reinforcements is almost the same as that of PIMP with steel ber reinforcement. However, the maximum deection and exural toughness

of the EPS-MMA-based PMPs are about twice larger than those of the PIMP, and the exural modulus of elasticity of the PMPs is almost a half of that of the PIMP. (4) From the above exural behavior trend, it is obvious that EPS-MMA-based PMPs are more ductile than PIMP and have a high load-bearing capacity compared to brittle PIMP. Consequently, it is concluded that the production of the EPSMMA-based PMPs as precast products is possible and they can be used in place of PIMP in the practical applications.

Acknowledgments The authors wish to express their sincere appreciation to Research and Development Center, Takamura Holdings Co. for nancing this research work and conducting experiments in its laboratory. The authors would also like to thank Kasahara Industry Co., Ltd., for providing EPS-MMA-based solution. References
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