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POLYMER CONCRETE

Presented by Sangay Dorjee Bhutia

WHAT IS POLYMER CONCRETE?

It a kind of concrete in which a thermo set resin binds together natural aggregates, such as silica sand. 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 the curing of concrete.

Known to be water free concrete. Typical resins used are polyester, epoxy and acrylic thermo set resins. Polyesters are the most used, mainly for economic reasons. High compression strength, and high durability in terms of fatigue and corrosion resistance. Permeability is very low, and its curing times are quite fast. Applicable in the area of precast concrete elements.

WHY USE POLYMER ONCRETE? Lightweight - 1/10 to 1/3 the weight of concrete. High Strength - compressive, flexural and tensile strengths 35 times higher than traditional concrete. Reduced Installation Costs - easy to handle, no special equipment required. Stable under Freeze/Thaw Conditions.

Low Water Absorption. Corrosion Resistant - resistant to alkalines, acids, weathering and other forms of deterioration Cost Effective - outperforms conventional materials for longer service and lower life cycle costs. Nonflammable - will not support combustion.

PHYSICAL PROPERTIES Application time: Working time at 70oF Initial set at 70oF Density Compressive strength, 7 days Maximum service temperature Modulus of elastic Flexural strength Tensile strength

- 30 minutes - 8 Hours - 2.2 gm/cm3 - 756.4 kg/cm2 - 65oC - 1.2 x 104 kg/cm2 - 262.2 kg/cm2 - 141.6 kg/cm2

CHARACTERISTICS

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

USE OF POLYMER COMPOSITES IN CONSTRUCTION


Composite materials have been used in construction for thousands of years. Polymer composites are produced by combining polymer resins such as polyester, vinylester and epoxy, with fillers and reinforcing fibres. Fillers are often used to provide bulk to the material, reduce cost, lower bulk density or to produce aesthetic features.

Fibres are used to reinforce the polymer and improve mechanical properties such as stiffness and strength. Polymer composites are widely used in the construction industry for many years. In 1999, the construction sector was the worlds second largest consumer of polymer composites representing 35% of the global market. Polymer composites have enjoyed widespread use in the construction industry for many years in non-critical applications

In recent times fibre composite materials have been increasingly considered for structural load bearing applications. They have established themselves as a viable and competitive option for rehabilitation and retrofit of existing civil structures. Concrete reinforced with fibre reinforced polymer (FRP) materials has been under investigation since the 1960s. A small number of new load bearing civil engineering structures have been made predominantly from FRP materials over the last three decades.

These include compound curved roofs, pedestrian and vehicle bridges and bridge decks, building systems cooling towers electricity transmission towers etc. The benefits offered by fibre composites include high specific strength and specific stiffness, durability, good fatigue performance and the potential to reduce longterm costs.

TYPES OF POLYMERS
(1). Epoxies Typical 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

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

(2). Polyesters Typical applications * Protective coatings * Anchoring * Adhesive bonder or sealer * Floor coatings * Sealer for epoxy injection * Binder for polymer mortar * Binder for fiberglass * Thin overlays

Advantages * Good chemical resistance * Easy to use * Good physical properties (some formulations) * Good wear resistance * Resistant to staining * Impact resistance similar to concrete * Impermeable

(3). Urethanes Typical applications * Waterproofing * Water control grouting (moist cured) * Protective coating * Insulation Advantages * Easy to use * Good chemical resistance * Good wear resistance * Adequate working time

(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

ENVIRONMENTAL CONSIDERATIONS

Reasonable caution should guide the preparation, use, and cleanup of polymer materials. Involving potentially hazardous and toxic chemical substances. Material safety data sheets should be obtained from the manufacturers of such materials.

In cases where the effects of a chemical substance on occupational health or environmental quality are unknown, chemical substances should be treated as potentially hazardous toxic materials.

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