Polymer concrete is the latest material with improved characteristics. Polymer concrete technology

Drainage pipes are one of the lines 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 hatch, 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 we 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 trays).

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 low pressure polyethylene. 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 technology.

Drainage pipes, HDPE pipes, Polyethylene pipes, PE pipes, water pipes (water pipes), 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 at the PBT company at the best prices in St. Petersburg.

Polymer-sand tiles withstand both cold with a thick layer of snow and sultry heat under the 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 is used in many industries, but is 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 a general idea of ​​​​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 of 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 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 in the open and are 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 noted by the reviews, the market price of 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 used mainly in 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 of the desired color is applied to the release paste.
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 an industrial-type vibrator to the table - done.
• 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.
• Without fail, an exhaust hood will be needed - at the casting stage, production is distinguished 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 will immediately have to be fenced 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 fluorescent lamps on top. 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 the 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 of 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 of different sizes, and, unlike cement grades, they are also 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 ingredients:

• The cheapest are furan polymers. But the strength is also low.
• Higher quality concretes, which include polyesters (unsaturated).
• The best options are materials containing epoxy resins. 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 a general recommendation that polymer additives should be approximately 1/5 of the total mass of the solution.

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.
• Resistant to aggressive environments, low temperatures.
• The mechanical strength indicators significantly exceed the similar characteristics of concretes based on cements: for bending - up to 10, for compression - up to 3 times.
• Low 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.

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, which, in terms of composition and characteristics, can completely replace modern cement and slag-cement concretes.

What is polymer concrete

Often, building terms can 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-concrete, which has unique properties to dampen 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 a very unpleasant odor that can cause suffocation and headache, which are pronounced carcinogens. Therefore, they are used only for the production of polymer concrete, conservation of steel structures of 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. Rarely enough, resin with an organic filler based on modified wood fibers mixed with chopped basalt fiber is used as part of polymer concrete.

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 cases, it is technologically easier to cast a part of the 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 chemically 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 a high quality casting, 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, artificial stones, sculptures, decorative elements and facing tiles for stone finishing are made from polyester resin and filler from finely ground natural stone - gabro, basalt, marble, calcite. 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 finishing of houses.

Separately, it is necessary to remember about self-leveling floors. In this case, quartz sand crushed into dust is used instead of glass filler. The most expensive brands, which include forced-curing modified methacrylate, after hardening, give a perfectly smooth surface that is superior in strength to a 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 river sand or granite dust in the composition of the material, 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.

Most of the inhabitants are sure that polymer concrete and cement-polymer concrete are two names for the same material. In fact, these are completely different building mixtures with high strength characteristics.

Cement is not added to polymer concrete (plastic concrete), and various polymers act as a binder. Portland cements mixed with polymer additives are added to polymer cement concretes.

There are two types:

1. Filled - high-molecular organic compounds fill the voids between the particles of the filler (gravel, crushed stone, quartz sand).

2. Frame - the voids remain unfilled, and the polymer serves only to fasten the particles of the mineral filler together.

In the first case, the amount of the mixture ranges from 20 to 50%. In the second case, it does not exceed 6%.

It is considered a high-strength material in which aqueous dispersions of polymers (vinyl chloride, vinyl acetate, styrene, latexes, polyamide resins, and others) act as additives that improve performance. Their use allows you to change the properties of building materials for the better and improve its technical performance.

Applications, production and sale

Compound

Resins are added to polymer concrete more often than others:

• epoxy;
• polyurethane;
• methyl methacrylate;
• polyvinyl.

Various plasticizers are added to the resins to improve elasticity and increase resistance to stretching, and hardeners to reduce the setting time. The composition of cement-polymer concrete also includes Portland cement.

Gets its characteristics due to the organic binder. This contributes to the fact that free particles of gravel or crushed stone are fastened together, turning into a strong monolith with a complete absence of cracks. As moisture evaporates, a special film forms on the surface, adding strength and increasing adhesive properties (adhesion to other surfaces).

Thanks to this, polymer concrete becomes extremely resistant even to serious loads, as well as to the effects of acids and sudden changes in temperature. The strength becomes even higher if the solution is kept in conditions of low humidity (40-50%).

Characteristics:

• moisture resistance;
• wear resistance;
• high chemical resistance;
• resistance to temperature extremes;
• increased tensile strength;
• no negative impact on living organisms;
• high level of adhesion to surfaces;
• fast curing;
• good breathability.

The only thing that can become a stumbling block and cross out all the advantages of this building material is its high cost. It is unlikely that you will be able to buy polymer concrete cheaply. The price directly depends on the amount of the connecting element used. Filled polymer concrete is always more expensive than frame concrete. Additives can be painted in absolutely any color. This also affects the final cost of the building mixture.

Production

As additives in the production of polymer concrete, water-soluble resins, PVA and latexes are most often used. When the finished mixture dries, a film forms on the surface of its particles, which swells when a large amount of moisture enters. However, this does not affect the strength characteristics.

The only correct ratio of components in the recipe does not yet exist. But most often, manufacturers mix cement with additives not exceeding 20% ​​of the cement part.

The highest quality cement solution is obtained with a water-soluble polyamide or epoxy resin and a hardener (polyethylene-polyamine).

The production of a cement-polymer mixture is as follows:

1. Special water for polymers with a small amount of cement is poured into the concrete mixer;

2. Equal amounts of ash and slag are added.

3. The solution is mixed.

4. Polymeric and other additives are added.

5. Finally knead.

Application

The material can be used for landscape design (paths and terraces), interior and exterior decoration of walls, floors and facades of buildings.

Designers and architects love it because it is easily shaped and can be applied manually and mechanically. A special stamp is applied to the surface of the poured concrete a certain number of times, imitating various natural structures (stone, cobblestone, wood, paving slabs, etc.). The dried surface can subsequently be painted in the desired color with acrylic-based paints.

They can also be used to decorate fireplace portals, fences, plinths, stairs, pools, borders, barbecue areas, building facades.

Polymer coatings for concrete can give the material additional improved properties of wear resistance, durability and strength. Thanks to them, the monolith is able to last more than 20 years.

Manufacturers and cost

In Russia, the following companies are engaged in production and supply: TeoChem LLC, BASF CJSC (a representative office of the German concern BASF), DI-Trade LLC, the Moscow representative office of DUROCEM ITALIA, Zika LLC (a representative of the Swiss company SIKA), LLC "Topbeton"

The price of a polymer concrete self-leveling floor starts at around 400 rubles per 1 m 2, a further increase in the cost depends on the high cost of polymer additives, working conditions and footage.

With rare exceptions, the technology for construction, restoration or repair work involves the use of 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 of different sizes, and, unlike cement grades, they are also 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 ingredients:

• The cheapest are furan polymers. But the strength is also low.
• Higher quality concretes, which include polyesters (unsaturated).
• The best options are materials containing epoxy resins. 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 a general recommendation that polymer additives should be approximately 1/5 of the total mass of the solution.

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.
• Resistant to aggressive environments, low temperatures.
• The mechanical strength indicators significantly exceed the similar characteristics of concretes based on cements: for bending - up to 10, for compression - up to 3 times.
• Low 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 durable composite materials with high performance, 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, it is used to create sculptures, make original furniture, as well as in the ritual sphere.

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 significant advantages associated with improved mechanical characteristics compared to conventional concrete, resistance to aggressive environments, lightness, and an expanded color palette that allows imitating 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. They are used in various 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 contaminants are 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 the positive aspects, polymer concrete has disadvantages:

• susceptibility to the effects of 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