Polymer concrete blocks. Polymer concretes. Stamped concrete: basic properties

Drainage pipes- one of the directions of production of the company PBT, Polymer Concrete Technologies, which is located in St. Petersburg and produces materials such as: drainage pipes, drainage, sewer pipes, fittings for drainage pipes, drainage wells (including covers for drainage wells), drainage trays, water pipes(HDPE pipes), corrugated cable channels, shaft pipes and much more, in particular polymer sand products, namely polymer sand tiles, polymer manhole, polymer sand tiles and drainage trays (polymer sand trays).

We are ready to offer you the most favorable terms of cooperation! We are confident in the quality of our products and give the best prices for drainage pipes and drainage systems, as well as for water pipes (HDPE pipes) and polymer sand products (polymer sand tiles, polymer sand tiles, drainage tray).

Drainage pipes - polyethylene, concrete, or any other pipes that collect (or, depending on the purpose, give) water from the ground.

Drainage 63, 110, 160, 200 mm can be bought wholesale and retail.

Drainage pipes with geotextiles perfectly protect the entire drainage system from unwanted soil getting into it, the dronite geotextile material retains the smallest particles of soil and perfectly passes water.

Drainage wells are provided for cleaning the drainage system, for example, drainage wells are washed with water under strong pressure, which flushes out all unwanted soil from the drainage pipes.

Fittings for drainage pipes and various adapters are made of high-strength material to securely connect drainage pipes to each other. Able to withstand both high and low temperatures.

Drainage trays are designed to drain excess water into special tanks, PBT offers you drainage trays at a special price! And the quality of drainage trays will make you become our regular customer! The drainage tray is made of polymer-sand materials, which form the basis for its durability.

HDPE pipes (Polyethylene pipes) are pipes made of polyethylene low pressure. Made for pipelines transporting water (also for drinking and domestic water supply) and any other liquid and gaseous substances. HDPE pipes confidently replace steel and concrete pipes, with a number of advantages, such as - significantly lower cost, excellent performance, quick and easy installation of pipes, allowing the use of trenchless technologies.

Drainage pipes, HDPE pipes, Polyethylene pipes, PE pipes, water pipes (pipes for water), sewer pipes, gas pipes(gas pipes), pressure pipes, mine pipes, as well as everything for drainage and drainage systems (drainage wells, storm water inlets, covers for drainage wells, covers for storm water inlets) you can buy from PBT at the best prices in St. Petersburg.

Polymer sand tiles withstand both cold with a thick layer of snow and sultry heat under scorching sun, thanks to the special proportions of the mixture of sand and polymer. Polymer sand tiles look great and please with their appearance. In addition, we have a special price for all polymer sand products for wholesale buyers.

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Polymer concrete: composition, types, features, application technology and reviews

Polymer concrete is a special building material that is used as a bonding element, as well as to replace lime cements. In some cases, the polymer is used as an addition to Portland cement. It is a versatile, durable composite material obtained by mixing various mineral fillers with synthetic or natural binders. This advanced technical material used in many industries, but most common in the construction industry.

Kinds

Three types of polymer concrete are used in construction. Next, we will take a closer look at their manufacturing technology, scope and compositions in order to have general idea about polymer concretes and their modifications.

Polymer compositions for concrete (polymer-modified concrete)

This type of concrete is made of Portland cement material with a modified polymer such as acrylic, polyvinyl acetate and ethylene vinyl acetate. It has good adhesion, high bending strength and low permeability.

Acrylic polymer modified concrete is characterized by a stable color, which is why it is in great demand among builders and architects. Its chemical modification is similar to the traditional cement variation. The amount of polymer is usually 10 to 20%. Concrete modified in this way has a lower degree of permeability and a higher density than pure cement. However, its structural integrity is significantly dependent on the binder of Portland cement.

Concrete may take longer to degrade if it has a high density and less surface area. A relative improvement in the chemical resistance of a polymer-modified material to Portland cement is possible in an acidic environment.

Resin impregnated concrete

Polymer impregnation for concrete is usually done by incorporating a low density monomer into hydrated Portland cement followed by radiation or thermal catalytic polymerization. The modulus elasticity of this type of concrete is 50-100% higher than that of conventional concrete.

However, the polymer modulus is 10% greater than that of normal concrete. Thanks to these excellent characteristics, among the many options for using a polymer building material, production can be separately noted:

• decks;
• bridges;
• pipes;
• floor tiles;
• building laminate.

Implementation process technology involves drying concrete to remove moisture from its surface, using monomers in a thin layer of sand, and then polymerizing the monomers using heat flow. Consequently, concrete surfaces have lower water permeability, absorption, abrasion resistance and generally high strength. Also, in order to increase wear resistance, resistance to cold and moisture, polymer varnishes are used for concrete, brick, stone, floors, etc.

Polymer concrete

It has nothing to do with our usual Portland cement. It is formed by combining stones with a polymeric binder that does not contain water. Polystyrene, acrylic and epoxy resins are monomers that are widely used in the manufacture of this type of concrete. Sulfur is also considered as a polymer. Sulfur concrete is used for buildings requiring high acid resistance. Thermoplastic polymers, but most commonly thermoset resins, are used as the main polymer component because of their high thermal stability and resistance to a wide range of chemicals.

Polymer concrete is made up of aggregates that include silica, quartz, granite, limestone and other high quality materials. The unit must be good quality free of dust, debris and excessive moisture. Failure to meet these criteria may reduce the bond strength between the polymer binder and the aggregate.

Features of polymer concrete

Modern building material is different from its predecessors. It has the following characteristics:

• High resistance to chemical and biological media.
• Compared to cement-concrete products, it has a lower mass.
• Perfectly absorbs noise and vibrations.
• Good weatherability and UV resistance.
• water absorption.
• Can be cut with drills and grinders.
• Can be recycled as crushed stone or crushed for use as a road base.
• Approximately 4 times stronger than cement concrete.
• Good ones thermal insulation properties and stability.
• Ultra-smooth finish that promotes efficient hydraulic flow.

Usage

Polymer concrete can be used for new construction or renovation of old material. Its adhesive properties make it possible to restore both polymeric and conventional cement-based concretes. Its low permeability and corrosion resistance make it suitable for use in swimming pools, sewer systems, drain channels, electrolytic cells and other structures containing liquids or harsh chemicals. It is suitable for well construction and rehabilitation due to its ability to resist toxic and corrosive sewer gases and bacteria commonly found in plumbing systems.

Unlike traditional concrete structures, it does not require coating or welding of protected PVC seams. You can see the use of polymer concrete on the streets of the city. It is used in the construction of road barriers, sidewalks, drainage ditches, fountains. Also on the street, a polymer coating for concrete is added to asphalt during the construction of open areas, runways and other objects that are under open sky and constantly exposed to external atmospheric influences.

Reviews

Polymer concrete has not been widely adopted due to the high costs and difficulties associated with traditional manufacturing techniques. However, recent progress has led to significant cost reductions, meaning that its use is gradually becoming more common. Despite all its advantages over conventional concrete, there are opinions about the hidden negative environmental factors that often occur due to improper production, the use of low-quality components and the wrong proportions.

Also, the technology for the production of polymer concrete has many nuances and secrets that no one seeks to disclose. And of course, as the reviews say, market price polymer concrete is quite high. This is due to the difficulty of its production and the expensive components that are used to create it.

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Technologies for the manufacture of polymer concrete and the production of products from it

Polymer concrete (otherwise, cast stone) is a material that combines the strength and beauty of natural stone with an affordable price (thanks to cheap mineral additives) and ease of manufacture. The possibility of using almost any aggregate (sand, granite and marble chips, glass and many others) guarantees a variety of polymer concrete products. And the presence of a polymer binder makes them durable, resistant to frost, water and overheating.

Let's consider typical technological processes for the manufacture of polymer concrete, as well as the possibility of creating it yourself.

Polymer concrete manufacturing technology

What will be required?

To get the product you need:

• A filler of a sufficiently large fraction (sand, crushed stone, coarsely crushed glass).
• A finer grinded aggregate that reduces the cost of the material. It is a powder of graphite, quartz or andesite.
• Binder - it will need about 5 percent. In this capacity, one of the polymer resins is used. For example, polyester (unsaturated), urea-formaldehyde, furan, epoxy.
• Hardeners, plasticizers, special modifiers, dyes.
• Mold release lubricant and top coat gel coat.

Production methods

The production process can take place in batch or continuous technology.

• In the first case, the containers used for the manufacture of the material must be washed after each completed cycle. But it is possible to make polymer concrete in the most ordinary bucket or concrete mixer.
• Continuous technology is mainly applied to large industries. At the same time, special injection molding machines, dispensers and automatic mixers work together, organizing a single chain.

The following video talks about the manufacture and spraying of lightweight polymer concrete:

To make a cast stone, you will need a mold well coated with a special release agent (otherwise it will be impossible to remove the finished product). The form can be made of silicone, fiberglass, metal or even chipboard (budget option).

1. A layer of gelcoat is applied to the release paste desired color.
2. A composite mixture is placed inside the mold, consisting of the above ingredients, previously well mixed in a concrete mixer. In large industries, where the volumes are very solid, the mixture is put into the mold using a concrete paver. If the products are small, and the technological process is periodic, then this is done manually.
3. Now it is necessary that the laid mixture is subjected to vibration (vibration compaction). This procedure takes approximately two minutes. At the plant, a resonant vibration platform is used for this, at a small production site - a vibrating table.

Under production conditions at the plant for the production of polymer concrete, if necessary, heat treatment is carried out for faster hardening of the parts. In other cases, they wait for the natural completion of this process.

We will talk about machines, molds and other equipment for the production of polymer concrete products below.

Necessary equipment

Features of choice and costs

Those who dream of aiming at continuous technology and solid volumes by organizing large-scale industrial production will need special conveyor equipment. Which will include machines for dosing, mixing, casting, finishing, as well as a mechanized warehouse.

All this will cost a tidy sum of several million dollars. If we confine ourselves to turnkey branded equipment, then the costs will be much less - from 30 to 50 thousand dollars.

But still, it is not always possible to find money for a purchase, especially in our difficult time. However, you can get by with even lower costs. If you purchase all the necessary machines and other things separately. And something to make yourself. Below is more about this option.

List of equipment and devices

So, here is a list of equipment and devices that you can not do without:

• Vibrating table - ready will cost about 27 thousand rubles. If you want to save money, weld the table yourself using two-millimeter metal corners (60s). We weld a vibrator to the table industrial type- ready.
• A stirrer that will combine all the components into a homogeneous mixture. If you purchase a powerful vacuum device of European quality, you will have to pay about 10 thousand dollars. But you can also use a domestic concrete mixer or a construction mixer. It will be much cheaper - the cost depends on the volume and power. Even cheaper is to make a mixer yourself from an iron barrel and an electric drive with a gearbox.
• You will also need a compressor system with a gun. Without it, it will not be possible to apply the gelcoat evenly. The gun costs from 50 to 100 dollars. You can take automobile compressors - two pieces from ZIL will be enough. They are connected in parallel and attached to metal platforms installed on a strong frame.
• Molds made of fiberglass or silicone are not yet widely available for sale. They can be ordered for specific products (for example, window sills) from a specialized company. Or make molds yourself, starting with a cheaper material - chipboard with lamination.
• AT without fail an exhaust hood will be needed - at the casting stage, production is characterized by harmful fumes. Accordingly, we will also purchase individual protection: gloves, respirators.
• For finishing work, you will need electric tools: grinding and polishing machines. And also a drill, a jigsaw, a grinder, a milling cutter (if necessary).

We will talk about emissions into the atmosphere from the production of polymer concrete below.

This video will also tell about another method of manufacturing polymer concrete:

As mentioned just above, during casting, the release of harmful components is present.

• In particular, it is styrene, which is contained in resins used as a binder. As soon as we open a hermetically sealed container with such a resin, the poisonous gas begins to evaporate.
• In addition, the hardener is also extremely dangerous (as a rule, it is methyl ethyl ketone peroxide). However, it is not volatile and requires only the protection of hands with rubber gloves.

These facts force polymer concrete manufacturers to carefully equip the casting room, making it hermetic, installing a powerful exhaust above the table, not forgetting about their own protection (respirator). And if all these measures are observed, and the air leaving the hood is cleaned, then there will be no emissions into the atmosphere (after all, the room is airtight).

How to make elastic polymer concrete yourself (with your own hands), read below.

DIY creation

And now we will talk about how to make small products from fashionable cast stone on our own, spending a minimum of money. For example, it can be flower pots, countertops, window sills (especially popular, as they are warmer than marble or granite).

Room selection and arrangement

First you need to think about the room - you need 80 square meters of total area. It is advisable to look for a suitable house somewhere on the outskirts. and 12 square meters immediately it will be necessary to fence off for the casting room, and you will have to try to seal all the cracks as much as possible. So that the styrene does not leak.

In the center of this room we make a table on a frame of iron corners, covering it with a chipboard top. We expose its surface according to the level - this is important! Above the table we install a hood - a metal box with an electric motor.

To make it light, we mount the lamps on top daylight. In the next room we put the same table - for finishing and other work. Here we will place the tool and containers for drying chalk and sand (metal low boxes).

Required raw materials

Required raw materials:

• River quartz sand (packed in 20 kilograms). It must dry well.
• Sifted chalk - we also dry it.
• Polyester resin - in buckets of 20 liters is bought.
• Hardener, gelcoat, release paste.

1. You will need a clean plastic bucket for stirring, a 450-watt perforator and a construction mixer (we will attach a perforator to it by welding a perforating drill - we get a mixer).
2. We make a form from laminated wood boards making it collapsible. It is convenient to apply the separating paste with a brush, rubbing with a nylon stocking.
3. We dilute the gelcoat with resin (adding 10 percent of it) and apply with a flute brush. We do this twice. We make sure that the hairs from the brush do not stick.
4. After mixing the resin with the hardener in a clean bucket, add 15 percent chalk, and then sand in portions. The mass should become viscous. To remove air bubbles, tap the bucket on the floor from time to time.
5. Once ready, pour the solution into the mold. Now let's smooth the surface: two people take their hands on the form (certainly equipped with handles) and, lifting it, tap it on the table. The mixture is left (for 40 minutes) and exit the casting room.
6. After hardening to a “rubber” state - this can be determined by a very hot surface and a special sound when tapped - we take the product out of the mold (disassemble it) and turn it over with the pouring side down. Let it harden completely, then sand and polish.

Security measures: when weighing the resin, as well as working with it, with the gelcoat and with the mixture poured into the mold, we work only in a respirator, under a hood. We add the hardener with a syringe, wearing rubber gloves.

The following video will tell you how to make polymer concrete with stains with your own hands:

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polymer concrete

With rare exceptions, the technology for construction, restoration or repair work involves the use concrete solutions. All these materials differ in brand, class and some other parameters, for example, moisture resistance. And all have a common similarity - cement is used as the only binder component in these mixtures. But modern industry has launched the production of other similar building materials, one of which is polymer concrete.

Its fundamental difference is that special ingredients - resins - are added as an astringent to the usual sand-cement mixture. They are gradually introduced during the preparation of the solution. Polymer-based concretes are suitable for surface finishing both inside and outside buildings, pouring floors, stairs.

Composition and fillers

For the preparation of these concretes, fillers and binders are also used. Given the special qualities of the polymers, the ratio between the components can vary from 5:1 to 12:1.

As with traditional analogues, polymer concrete contains fractions different sizes, and unlike cement grades, and finely dispersed. Given that these materials are widely used, including for operation in conditions of direct contact with aggressive compounds, substances with increased resistance to chemical attack (for example, quartzite, basalt, tuff) are used as fillers.

Astringent components:

• The cheapest are furan polymers. But the strength is also low.
• More quality concretes, which include polyesters (unsaturated).
• by the most the best options materials containing epoxy resins are considered. They combine strength, ductility, wear resistance. However, their price is quite high.

Manufacturing

There is no definite answer to the question of how to make polymer concrete. All sources speak of an experimental way to obtain the required composition. It is necessary to ensure that when the applied mixture dries, it forms an elastic elastic coating. Much depends on the place of installation, on what result you want to achieve. There is general recommendation that from total weight polymer additive solution should be approximately 1/5 part.

Much depends on what class of concrete you need to get. Therefore, you will have to vary the percentage of resins, hardeners. It is also necessary to take into account the type of polymer binder that is decided to be used, since each has its own specific properties. Some sources indicate that the use of epoxy resins involves the replacement of cement with slag, ash and liquid glass. In all other respects (mixing), the procedure is the same.

Distinctive features of polymer concrete

• High water resistance. Allows you to significantly simplify the technology of work in areas where structural elements of the structure are exposed to intense exposure to liquids. By purchasing polymer, or natural concrete, you can significantly save on waterproofing and reduce the total time of work.
• Resistance to aggressive environments, low temperatures.
• Indicators mechanical strength significantly exceed the similar characteristics of concretes based on cements: for bending - up to 10, for compression - up to 3 times.
• Small specific gravity which significantly increases the range of applications.
• The property of elasticity allows it to be used in areas subject to dynamic loads. Can be applied on planes with any orientation: horizontal, vertical, inclined.
• Excellent adhesion, regardless of the base material.
• The curing time is less than that of cement.
• The ability to achieve perfect evenness of the coating. Surfaces finished with polymer concrete are easy to maintain.

polymer concrete

In the process of development of building technologies, new materials and concrete mixes appear, for the preparation of which special fillers are used. This allows you to create strong composite materials, which has high operational characteristics, decorative properties. Polymer concrete - one of these compositions, is gaining popularity in the market of building materials.

The material, along with the traditional components - sand and gravel, includes polymer resins based on epoxy, furan, polyester as a binder. Polymer concrete is in demand in the construction industry, is used to create sculptures, manufacture original furniture as well as in the ritual realm.

Polymer concrete (cast stone, polymer cement, concrete polymer, plast concrete, plast concrete) was invented in America as a stronger and more durable alternative to ordinary concrete

Polymer concrete has a number of serious advantages associated with improved properties compared to ordinary concrete. mechanical characteristics, resistance to aggressive environments, lightness, an expanded color palette that allows you to imitate a natural stone. Consumers of the composite are convinced that it is a reliable composition with a wide range of applications. We will consider the material in detail, delve into the technology, evaluate the advantages and disadvantages, and study the recipe.

Material advantages

Composite concrete, due to the peculiarities of the formulation, has a number of positive characteristics. It is applied in different situations where the use of traditional concrete will not provide the desired result.

The main advantage of the composite:

• Increased resistance to moisture penetration into the composite array. Water drops quickly evaporate from the surface of the material, I do not have time to saturate it with destructive moisture.
• Resistance to significant temperature changes, allowing polymer concrete to maintain integrity, regardless of the duration and number of freezing cycles.

  

  This material is one of the new types of concrete mixtures, where instead of silicate or cement (used during the preparation of ordinary concrete), a polymer is used.

• The resistance of the material to aggressive substances, chemical reagents, which allows the use of polymer concrete in various areas without surface protection using special coatings.
• The possibility of restoring mechanically damaged sections of the composite array using a restoration mixture.
• Increased strength characteristics with a relatively small mass of the composite, allowing the production of various products with extended performance properties.
• The absence of roughness on a perfectly smooth, absolutely non-slippery surface of the material. This property allows the artificial stone to remain clean for a long time, and, if necessary, various pollution easily removed from the surface of the material.
• Expanded color range of polymer concrete imitating natural marble, malachite, granite. The created artificial stone is difficult to distinguish from the real one, which makes it possible to provide a wide range of applications for the composite.
• The possibility of recycling, use in the manufacture of technological waste, which significantly reduces the cost of products manufactured in conditions of waste-free technology.



Pros: strength, low weight, impact resistance, elasticity is many times higher than that of conventional concrete

Weak sides

Along with positive moments polymer concrete has disadvantages:

• susceptibility to influence open fire and elevated temperature, causing the destruction of the material;
• increased, when compared with concrete, price, due to the cost of purchasing special resins.

Components of polymer concrete

If you want to prepare polymer concrete at home, study the composition of the composite. To prepare polymer concrete, use the following ingredients:

• A binder, which is used as urea-formaldehyde, polyester, epoxy and furfural acetone resins.
• Large-fraction crushed stone filler. The size of the crushed stone fraction required for the formation of the composite can be up to 4 centimeters, however, crushed stone 1-2 cm in size should make up the bulk of the composition.
• Screened and cleaned quartz sand. The size of quartz particles should not exceed 5 mm, the presence of clay inclusions, dust is not allowed.

  

  For polystyrene concrete (where polystyrene is taken as a filler), there are standards

• Crushed graphite powder with a particle size of not more than 0.15 mm, quartz flour, used as a ground filler, which reduces the need for expensive resins.
• Building gypsum used in the presence of urea-formaldehyde resin in the composite formulation.
• Surfactants, additives with antiseptic properties and ingredients that increase the volume of the array, increase the thermal insulation properties of the finished composite.

Classification

Polymer concrete, depending on the concentration of the filler, the share of which in the total volume is up to 80%, is divided into classes:

• especially heavy, cubic meter, which weighs from 2500 to 4000 kg;
• heavy, with a density of 1800-2500 kg/m3;
• light with a specific gravity of 500-1800 kg/m3;
• lightweight, the mass of a cubic meter does not exceed 500 kilograms.

Scope of use

The development of the chemistry of synthetic binders and polymers predetermined the emergence of a new material in the construction industry, known as polymer concrete. And although the first patents for its manufacture appeared 80 years ago, the novelty received practical application only in the 60s of the last century. As the name implies, the developers managed to obtain a building material based on resins and polymers, capable of completely replacing modern cement and slag in terms of composition and characteristics. cement concretes.

What is polymer concrete

Often building terms able to confuse a non-specialist or a novice builder, a lover of building with his own hands. At the household level, polymer concrete includes all types of building materials, which include cement, water and polymer resin.

In fact, the technology of building polymers divides such materials into several groups:

• Polymer concrete is a mixed composition, which includes mineral ballast or filler, polymer binder, hardener, stabilizer and adhesive, without the use of cement and water;
• Polymer cement concrete - a material obtained by adding a water-soluble polymer composition to the composition of the parent cement mortar or concrete;
• Concrete-polymer materials are hardened concrete or cement stone subjected to additional processing with liquid or vapor polymers, usually the composition of the liquid includes styrene with a catalyst, which polymerizes in the thickness of the concrete mineral matrix.

Note! Polymer concretes obtained on the basis of thermosetting and epoxy resins are also called plast concretes.

The properties of polymer concrete depend on the composition of the used binder, resin, filler and method of preparation. Such materials are successfully used not only in construction, but also in mechanical engineering, in the chemical industry and even in the production of household items and furniture. The technology of using various mineral fillers to reduce the cost of producing castings from synthetic resins began to be used in the 80s of the last century, and at the beginning of the 21st century, almost 80-90% of plastic products are made using polymer concrete technology, which contains resin and finely ground ballast powder.

To obtain construction grades of polymer concrete, compositions based on five main varieties of synthetic resins are used:

• Phenol-formaldehyde and urea-formaldehyde polymers;
• Epoxy matrices, including those modified with furan resins;
• Methacrylate and polyvinyl acetate polymers;
• Furfural acetone matrix, or FAM for short;
• Polyester and polyurea resin.

Note! FAM is one of the few types of binders used for the production of so-called faizol concretes, which have unique properties extinguish and dissipate vibrations by an order of magnitude better than the most viscous grades of cast iron.

The composition of furfural acetone resins includes volatile substances with very bad smell, capable of causing suffocation and headache, which are pronounced carcinogens. Therefore, they are used only for the production of polymer concrete, conservation steel structures pipelines and communication systems. For residential premises, polymer concretes are most often used, which include polyester resins, epoxy and methacrylate oligomers.

In the composition of polymer concrete, the resin content is relatively small, from 10 to 15%. The rest is a mineral filler - marble chips, ground ash, crushed dolomites, calcites, granulated vermiculite, clinker and ordinary Portland cement. Quite rarely, resin with an organic filler based on modified wood fibers mixed with chopped basalt fiber.

Why change ordinary cement mortar to polymer concrete

Modern grades of concrete based on cement and sand work well in huge masses, where the static load is constant and there are no shocks, vibrations or complex bending moments or torsional forces. In all other cases, it is necessary to introduce special additives into the composition, use reinforcement with expensive metal, make multilayer structures, or completely replace cement concrete with metal or polymer concrete. In some variants, it is technologically easier to cast a part building structure from polymer concrete than to use reinforced concrete. For example, during the construction of product pipelines.

If we compare the characteristics of polymer concrete with ordinary concrete, we can name five advantages of using polymers:

• 3-4 times higher bending strength, torsion and alternating dynamic load. The resin in polymer concrete makes the material behave like metal;
• The presence of polymers in the composition ensures low water absorption and high frost resistance of polymer concrete structures;
• Polymer concretes of certain grades, containing fine particles, have low thermal conductivity, if necessary, they can be used without insulation even in the manufacture of floors and ceilings of the basement, basements;
• Good machinability by cutting, drilling, without the risk of chipping or cracking;
• Epoxy resins in the composition of polymer concrete make them inert to chemical active substances, organic solvents, gasoline, oil, chlorinated hydrocarbons, hot and sea ​​water. In shipbuilding, cladding, floors, floorboards, protective panels and deck elements are made from polymer concrete.

Note! The main "value" of the polymer concrete composition is the possibility of obtaining High Quality castings, without shells, striae, cracks, with "programmed" mechanical and strength characteristics. Characteristics are easily adjusted by changing the composition of the material.

For example, in the manufacture of a pipeline, polymer concrete is used with the addition of polyvinyl alcohol or liquid glass. Alcohol in the composition of concrete improves the wettability of cement grains, removes air from the intergranular space and helps the hydration process. After casting the pipeline due to the intense binding of water, the inner surface of the concrete pipe quickly dries up and becomes covered with cracks. To make it strong, hard and wear-resistant, concrete is treated with a liquid solution of polystyrene in styrene. The result is a surface that rivals cast iron in terms of performance and durability.

Today, the cost of polymer concrete is still quite high, so there is no talk of a complete replacement of cement in the composition of the material, but as new resins are developed, the prospect of switching to polymer concrete becomes more and more real.

Features of the use of various grades of polymer concrete

Most people will be surprised to learn how many household items are polymer concrete in their composition. For example, from polyester resin and filler from finely ground natural stone - gabro, basalt, marble, calcite are made artificial stones, sculptures, decorative elements and facing tiles for stone finishing. Tabletops and window sills are cast under the stone from inexpensive polymer concrete, the cost of a similar product made of natural marble or granite will cost 2-3 times more.

Communication elements are made from epoxy polymeric concretes - pipes, tanks, wells, catchment trays and even entire collectors. With the help of polymer cement casting, it is quite easy to repair concrete load-bearing structures, seal the screed and restore the tightness of the container. Polymer concretes, which include epoxy resin, have exceptionally high adhesion, so they are often used to repair holes and joints in concrete panels in high-rise buildings.

From methacrylate filled with ground glass powder and marble dust, it is possible to obtain such a high-quality imitation of natural stone that professional restorers borrowed and used this material for work. Large granules of marble or calcite can be introduced into the composition. On the basis of polymer concrete, all polymer plasters, putties, tile adhesives, grouts are made, that is, almost all materials for decorative finishes houses.

Separately, it is necessary to remember self-leveling floors. In this case, quartz sand crushed into dust is used instead of glass filler. The most expensive grades, which include forced-curing modified methacrylate, after curing, give a perfectly smooth surface that is superior in strength to cement screed.

How to make the simplest polymer concrete at home

In order to prepare polymer concrete with your own hands, you will need two components, resin and filler. For the simplest version of polymer concrete, you can use epoxy glue or resin, hardener and filler. It is best to use cement washed and dried in the composition of the material. river sand or granite dust, which you can get hold of in any workshop for the manufacture of monuments.

The resin is diluted with acetone or an alcohol-acetone mixture. Different brands of epoxy resin require their own brand of solvent, so for the preparation of polymer concrete, it is necessary to choose a thinner. A hardener is added to the resin, stirred and a thinner is added to the composition. After 10 minutes, the filler can be added in small portions to the adhesive mass. After another 3-10 minutes of mixing, the polymer concrete will be ready for use.

Conclusion

Similarly, it is possible to prepare polymer concrete based on PVA, acrylic resin and sand oil paint and cement filler. Finally, you can add a mixture for self-leveling floors to the composition, which will allow you to use the material for casting parts for finishing ceilings and walls, columns, stucco moldings, pilasters. In any case, such a composition will be cheaper, and the quality of the products will be no worse than that of purchased options.

• Eliminates the effect of cracking
• Increases the quality of the mixture
• Gives concrete increased hardness
• Increases the adhesive properties of the mixture

Polymer-concrete is a water-based polymer additive to a cement-sand mixture.

Advantages polymer concrete very diverse, which wide opportunities their use. First of all, it is necessary to note the increased characteristics in terms of resistance to stretching. This figure significantly exceeds that of conventional concrete. The product has better deformability and does not collapse when exposed to significant force. As additional benefits polymer concrete it is worth pointing out the increased durability achieved due to the significant resistance to wear and some other external influences.

Application of dedusting impregnation "Polymerbeton":

About the product

Polymer concrete, when added to a dry mix, makes it durable and water resistant. It can be applied with a thickness of even 1 mm. on concrete, brick, wood, metal, plastic, and it adheres to them very firmly. It becomes strong immediately after drying - within an hour. For example, a dry mix with polymer concrete applied in a thin layer on cardboard bends as you like, does not peel off, does not crumble.

Alabaster, when kneading it on polymer concrete, slows down its hardening up to 2 hours. The material becomes waterproof. It can be used for outdoor work. The hardening time is regulated by diluting the polymer concrete with water.

Builders have long noticed that if any cheap imported dry plaster, self-leveling floor, is prepared on diluted polymer concrete, then water resistance and strength will increase dramatically. The amount of polymer concrete regulate the strength of the material

A lot of buildings, underground garages have been restored using polymer concrete. The church of the 15th century in Sheremetyevo (Moscow region) was completely restored with the help of plaster on polymer concrete. Decorative stucco molding on its facade is gypsum with polymer concrete.

Any old structure is literally glued together with polymer compositions. For example, metal box front door sealed into concrete doorway. For six years of operation - no cracks.

Repair, restoration work acquire a different meaning. Dilute polymer concrete 1/1 with water and soak concrete, wood, plaster. They become durable and water resistant. Add polymer concrete to the chalk paint and it becomes strong, flexible and waterproof. Paint a tree (logs, beams, boards) with polymer concrete and it will no longer crack, dry evenly and will not darken.

What we are talking about has been applied at all times. People have always improved the properties of building materials with polymers - mainly egg white, casein, flour. The result is the highest strength and durability of buildings for tens and hundreds of years.

PURPOSE:

• For interior and exterior use
• ultra-strong, flexible concrete
• glue for insulation, foam. Adheres to wood, concrete, metal, glass, plastic
• hardening impregnation, high-quality, waterproofing
• betokontakt - durable and cheap
• non-cracking, dust-free plaster, smooth and embossed
• impact resistant screed floor
• water and weather resistant alabaster, gypsum

PROPERTIES:

• especially strong, elastic coating
• does not crack
• odorless, environmentally friendly
• consumption 5kg./100kg. mixtures (cement + sand)
• drying time from 2 hours to 2 days, depending on the thickness of the layer
• non-flammable, fireproof

What is this material? How does it differ from the usual concrete mixtures in terms of composition and consumer properties? Is it possible to make polymer concrete with your own hands? Where and how is it used? Let's try to find answers.

What it is

Definition

Let's find out what is polymer concrete? Key difference the material of interest to us from ordinary concrete is that synthetic resins are used as a binder instead of Portland cement. Typically thermoset; less often - thermoplastic.

Reference: A thermosetting polymer is a polymer in which, when heated, irreversible chemical changes occur, leading to a change in its strength or other properties.
Simply put, once heated, the plastic no longer melts when the same temperature is reached.
Thermoplastic polymers, in contrast, undergo a phase transition with each heating.

Do not confuse our hero with another material - polymer concrete. In our case, polymers are used as the sole binder. Polymer concrete is ordinary concrete based on Portland cement, modified with synthetic additives to give it any specific properties (increased elasticity, wear resistance, water resistance, etc.).

Key properties

What does the replacement of cement with polymers give in terms of consumer qualities?

• Increased tensile strength. Cement-based concretes have excellent compressive strength, but bending or tensile loads are perceived by the reinforcing cage.
• Reduced brittleness. The material is much more resistant to shock loads.
• Elasticity. Where the concrete monolith bursts, the polymer concrete only slightly deforms.
• Waterproof. Portland cement shrinks significantly during drying, which provides a porous concrete structure. In contrast, polymers, after the final set of strength, decrease in volume extremely slightly; moreover, shrinkage does not lead to porization, but to a slight decrease in the linear dimensions of the finished product.

To clarify: to improve the thermal insulation qualities and reduce weight, in some cases, the use of porous fillers is practiced in the production of polymer concrete products.
In this capacity, expanded clay and perlite sand are used.
However, the pores of the filler do not come to the surface, and if so, the water resistance does not suffer.

• Frost resistance. Actually, this property directly follows from the previous paragraph: there are no pores - there is no crystallization of water in them, tearing the material when frozen.

• Increased wear resistance. The polymer binder is corny stronger than the cement stone at break; tearing off a filler particle from it is much more difficult.
• Chemical resistance. And it is due to the properties of polymers: most of the resins are inert to the action of aggressive gases and liquids.

Application

Let's explore the main applications of polymer concrete.

Production

Regulations

The material we are discussing is considered to be relatively new and of foreign origin; however, study normative documents, on which it is produced, will lead to an unexpected discovery. Instruction for the production of polymer concrete and products from them under the number CH 525-80 was adopted in 1981 and remains relevant to this day.

Let's study the main theses of the document. For all polymer concrete products normal temperature regime the range from -40 to +80 degrees Celsius is considered.

Let us clarify: if the upper limit is due to the possibility of using thermoplastic resins that soften when heated, then the lower limit is due to the increased fragility of polymers during freezing.
In the absence of shock and mechanical loads in general, the lower limit of operating temperature can be painlessly increased to the current one in the most severe climatic zones.

Binder

The composition of polymer concrete, according to the text of the document, may include the following polymers:

Aggregate

Rock crushed stone is used as the main filler. The use of sedimentary rocks (limestone, shell rock, etc.) is not allowed: its low compressive strength will significantly impair the performance of the product.

The size of the crushed stone fraction is determined, no matter how funny it sounds, by its maximum diameter:

1. If the largest size does not exceed 20 mm, one fraction is used - 10-20 millimeters.
2. In cases where the largest size reaches 40 mm, it is recommended to use two fractions: 10-20 and 20-40 millimeters. Small gravel will contribute to a denser filling and, accordingly, increase the final strength of the material.

Please note: for porous aggregates (already mentioned expanded clay and perlite), it is permissible maximum size 20 mm; two fractions are used: 5-10 and 10-20 millimeters.
Wherein, percentage composition aggregate is divided between coarse and fine fractions in the ratio of 60:40 percent by weight.

In addition to coarse, fine (so-called grain) aggregate is used. Usually this role is played by quartz sand - natural or crushed. The requirements for it are mainly reduced to the absence of impurities - dust, silt and clay, which can worsen the adhesion between the aggregate and the binder.

Filler

In addition to the mineral filler, the product contains ground filler - mineral flour. The standard provides for several options.

It is allowed to use ground crushed stone and quartz sand. For a material that is prepared on the basis of urea-formaldehyde resins, an additional water-binding additive is used - building gypsum (GOST 125-70).

Composition example

As a sample, we will analyze the composition of heavy polymer concrete based on the furan-epoxy binder FAED. The same document SN 525-80 will serve as a source of information for us.

It is curious: BSC performs two functions at once.
It serves as a polymerization catalyst (hardener) and provides dehydration (dehydration) of the raw material.

BSC is an effective and safe hardener with added functionality.

Technology

What does the technology of polymer concrete (more precisely, its production) look like in industrial conditions?

1. Fillers are thoroughly washed from all kinds of contaminants. As we remember, they can adversely affect the final strength of the product.
2. The next step is drying. The moisture content of the aggregate should not exceed 1 percent; it is recommended to keep the mass content of water up to 0.5%.
3. The components divided into fractions are loaded into the mixer.
   The sequence of loading and intermediate operations is strictly regulated:
   1. Gravel is loading.
   2. Sand is added.
   3. Filler added.
   4. The mixture is stirred for 1-2 minutes.
   5. A binder is added.
   6. The mixture is stirred for 3 minutes.
   7. Hardener is added.
   8. Mixing for 3 minutes - and the material is ready for pouring.
4. A separating layer is applied to the inner surface of the mold, which will prevent the polymer concrete from sticking to it. In this role, paraffin, machine oil or technical petroleum jelly are usually used.
5. The mold is poured as evenly as possible and, if possible, without cavities.
6. The last stage is the compaction of the mixture on a vibrating table or using a mounted vibrator. The optimal amplitude is 2-3 millimeters, the frequency is 3000 vibrations per minute (50 Hz). If the mixture is kneaded and laid out in several steps, its compaction is repeated after each calculation.
   Signal to stop the liquid fraction of the material on the surface (usually 2-3 minutes are enough for this).

The form can be removed from the finished product in a day. Curing at room temperature takes from 20 to 60 days. It, however, can be accelerated by heating up to 60-80 degrees; the temperature rises and falls at a rate of 0.5°C per minute to avoid the growth of internal stresses.

As you can see, the production technology does not imply any particular difficulties; in the presence of a binder, hardener, concrete mixer and vibrating table, it is quite possible to make polymer concrete at home.

Nuance: it will be necessary to clean the concrete mixer from the remnants of the mixture extremely quickly.
After adding the hardener, setting takes no more than an hour.

Treatment

What and how are polymer concrete products processed? Can they be sanded and glued?

How to cut and drill this material?

• For bonding, mastics and adhesives based on the same synthetic resins are used. Mastics, in addition to the actual binder, contain stone flour.

In the photo - Belarusian-made polyurethane adhesive with a creative name.

• Normal sandpaper is suitable for sanding. A felt wheel is used for polishing; gloss can be applied using GOI paste (polishing paste developed by the State Optical Institute).

• Drilling material, in principle, can be done with conventional concrete drills; however, diamond drilling in polymer-bonded concrete gives much better results. The edges of the hole remain perfectly smooth, without chips. For holes large diameter(e.g. under a faucet in a polymer concrete worktop for a kitchen) a diamond core bit is used.
• The ideal tool for cutting is again a diamond saw. It is also preferable for structures whose appearance is not so important (reinforced concrete cutting diamond circles allows you to make the edges of the cut perfectly even and not change the circle when passing through the reinforcement); in the case of the same countertop, an inaccurate cut will hopelessly spoil its appearance.

Diamond saw - perfect tool for cutting material.

When processing the material, in general, it is worth avoiding its strong heating. Temperatures above 120 - 150 degrees are contraindicated for a thermoplastic binder.

Conclusion