Polymer concrete: composition, types, features, application technology and reviews. Polymer concrete - concrete admixture Concrete mixture mineral binder polyester resin

Modern needs of the construction industry contribute to the emergence of newer and more advanced materials. For example, polymer concrete recent times began to gain great popularity. We will tell you about this unique composition further.

Properties

History reference

As we said, this material is innovative. However, there is evidence that it was used several thousand years ago in the construction of the Egyptian pyramids. Of course, we are talking only about similar technology.

The blocks from which the pyramids were built consisted of the following components: silt from the Nile River, limestone, gravel, trusted salt, ash and crushed lime. As a result, they were able to stand for so long without cracking. At the same time, the so-called “tan” did not form on them (any natural stone becomes covered with it over time).

Advantages

Now it's time to get acquainted with the advantages of this know-how:

• . Even cutting reinforced concrete diamond circles difficult to complete his task.
• Long life span. Significantly higher than that of its ancestor.
• Very low shrinkage during drying.
• High compressive strength. This allows you to withstand enormous loads.
• Resistant to almost all acids.
• The technology of polymer concrete is fundamentally different from all known. The fact is that only environmentally friendly raw materials are used in its production.

Interesting: the permeability of this material is comparable to natural granite. Today, only he can boast of such dignity.

• Polymer concrete products have low greenhouse gas emissions.
• Withstands temperature fluctuations. It retains all its properties even when heated to 1300 degrees.
• Does not wear out over time and does not crumble.

Among all this variety of advantages, there is one drawback - high price. However, the situation is likely to change in the future. The point is that this new technology, which means that for some time its cost will be significantly reduced.

Specifications

The wild growth in popularity is due to the fact that polymer concrete has a very high performance, which leave all its main competitors on the sidelines. Let's get acquainted with them:

Important! The above values ​​are controlled building code 525–80 from 01.01.81

It is also worth bringing to your attention the chemical resistance to various substances:

From the data in this table it can be seen that this material meets all standards of chemical resistance. So polymer protection concrete floors carries high efficiency. Therefore, this technology is often used in industry.

Cooking

Now consider how to independently prepare polymer concrete. In fact, this is a simple procedure that will require you only to strictly observe the proportions.

Ingredients

Consider what we need:

1. Potassium hydroxide. These are hygroscopic crystals, colorless and odorless. They instantly blur in the air, so they must be stored in a vacuum package and taken out before use.

This substance is very aggressive, that is, it strongly affects the mucous membrane and skin. For this reason, the instruction prescribes wearing protective equipment (goggles, gloves, a respirator) when working with it. Otherwise, there is a high risk of damage, especially to the eyes.

1. Liquid glass(Surely many of us, after reading this phrase, will think about the element that fills our windows). In fact, these are colorless crystals without any odor. They consist of silicic acid and alkaline potassium.

You can buy it at the nearest agricultural store. The fact is that gardeners often use liquid glass to fertilize various crops.

1. fly ash. This ingredient can be obtained independently (by burning a certain amount solid fuel) or buy ready-made at a hardware store. Experts say that the addition of ash makes polymer asphalt concrete 75% stronger and more durable.
2. Chilled water at room temperature. It must not contain any impurities. If you add tap water, then it must be allowed to stand for some time.
3. In addition, you can use any additives (for example, slag or dye). This is necessary in order to obtain an attractive texture and improve the characteristics of the mixture.

Tools

Now consider what tools you will need:

• already mentioned remedies.
• Container for mixing ingredients (preferably glass).
• Wooden spatula for mixing.
• Electronic balance. Remember that it is very important to observe all proportions. If we are talking about a small amount of solution, then a simple kitchen scale will do.
• Casting mold.

cooking secrets

It is time to answer the question of how to make polymer concrete with your own hands.

So, to prepare 1 liter of the mixture, we observe the following proportions:

1. Potassium hydroxide - 160 g.
2. Liquid glass - 200 g.
3. Ash - 540
4. Water - 100 ml.
5. Slag (it is needed to give special strength, it is not necessary to add it) - 300 g.
6. Special cement for polymer concrete - 20% of the total volume.
7. Additives as desired (their consumption should be indicated on the package).

Important! When mixed, the mixture will heat up due to the release carbon dioxide so don't be scared.

The ingredients must be mixed in the following order:

1. Pour clean water into the container.
2. Add cement to it.
3. Then pour ash, slag and liquid glass in equal proportions.
4. Then add the rest of the components.
5. Now using construction mixer you need to mix everything thoroughly. Remember that the mass should be perfectly homogeneous. Otherwise, polymer concrete will not be durable.
6. The resulting mixture can be poured into a mold or formwork for solidification.

It will completely harden only after 3 weeks. Only after this period, you can conduct any operations with it, for example, diamond drilling holes in concrete.

It is worth noting that experiments to create ideal proportions are ongoing to this day. In this regard, people often begin to change recipes on their own. Therefore, you can try yourself in this path.

Afterword

Now you know what polymer concrete is. However, if any nuances remain unclear to you, then there is no reason to be upset (.

In the video presented in this article, you will find additional information on this topic, which will allow you to better understand everything.

The price is rub/kg depending on quantity. Including VAT and packaging.

Packing: p / p canisters 5kg, 10kg, 30kg.

Warranty period of storage in the manufacturer's container - 12 months.

Store and transport at temperatures from +5° to +25°C.

label

Packing

Buy a polymer additive for concrete

Based on a polymer additive for concrete Elastobeton-B made heavy-duty polymer concrete.
Strength: on crushed dolomite - M600-M800; on the crushed granite– М800-М1000 and more.

Commissioning for 5-6 days.

Polymer additives in concrete Elastobeton-B is supplied in liquid form.
They are introduced in the manufacture of concrete, at the rate of 20 kg of additive per 100 kg of cement.

Thickness of the polymer cement floor Elastobeton-B:
for moderate loads - 20mm, for heavy loads - 30mm, minimum thickness - 15mm.

Unlike magnesia concrete, polymer concrete has complete resistance to water.

Polymer concrete

Other names: cement-polymer concrete, cement polymer concrete.

As mentioned above, polymer-cement floors based on Elastobeton-B concrete additive are 20-50% cheaper than magnesia floors. But this is a direct calculation - that is, they took polymer cement concrete - they calculated the price of the components; similarly - for magnesia concrete.
But besides this, there are a number of factors that affect final price polymer cement concrete and magnesia concrete. The main of these factors are listed below.

1. Transportation.
Transportation of concrete components greatly affects its final cost.
If transport costs are only 1 rub/kg, then delivery main components magnesia concrete, which make up approximately 23% of total mass, will increase the price of 1 m³ of concrete by 500 rubles! With a delivery price of 5 rubles / kg, this is already 2500 rubles / m³!

If all components of magnesia floors are transported, then at a delivery price of 1 rub/kg, the price will increase by 2200 rub/m³.
With a delivery price of 5 rubles / kg - magnesia floors will become more expensive by 11,000 rubles / m³!

Additive for concrete Elastobeton-B is approximately 3.5% of the mass of concrete, you purchase the rest of the components on the spot. Accordingly, the transportation of a polymer additive for concrete, even over long distances, practically does not affect the price of polymer cement concrete.

The savings are obvious.

2. Storage.
Components of magnesia concrete (in particular burnt magnesia - magnesium oxide) are very sensitive to storage and transportation conditions. Penetration, ingress of moisture into the components significantly reduces the final strength of magnesia concrete. As a result, you will receive magnesia floors with brand strength M200-M300, instead of M400-M600.

There are no such problems with polymer-cement concrete, since you buy all components, including additives, on the spot and you can always control their quality.

3. The cost of fillers.
The cost of concrete with the additive "Elastobeton-B" depends on the modulus of sand size (SFR), bulk density of sand and bulk density of crushed stone. The higher the MKR and the higher the density of sand and crushed stone, the less cement and additives for concrete in relation to sand and crushed stone. Accordingly, the cheaper polymer concrete.

Savings can be up to 2000 rubles. per 1m³ of polymer concrete.

4. Equipment corrosion.
Magnesia concrete will include a bischofite component, which causes enhanced corrosion of both steel and aluminum surfaces equipment. Equipment (concrete mixers, vibrating screeds, helicopters, etc.) must be constantly flushed. But even with careful maintenance, the life of the equipment is reduced by several times, which as a result is reflected in the price of magnesia floors!

The polymer additive for concrete Elastobeton-B does not have a corrosive effect on metal surfaces.

The savings are obvious.

Polymer additive for concrete - properties, advantages

Elakor "Elastobeton-B"- a complex modifying polymer additive for concrete (Portland cement concrete).
For use, cement grade M500D0 is recommended. If you want to use other cements, we recommend that you first check them for compatibility with the Additive (see Additive Application Technology). The fact is that some fillers that are introduced during the manufacture of cement can "conflict" with the additive.

To make colored polymer-cement floors, you can add the pigment yourself directly during concrete mixing or order an Additive of the desired color from us.
Colored polymer cement floors can be made on gray cement, but if a "pure" color is required, then it is necessary to use white cement.

Properties of polymer-cement floors with an additive for concrete "Elastobeton-B".

• Operation indoors and outdoors outdoors.
• Thickness from 15 to 50mm. The recommended thickness is 20-30mm depending on the loads.
• The strength of the coating is: on dolomite filler - M600-M800. on granite filler - M800-M1000 and more.
• Extremely high wear resistance (less than 0.2 g/cm²).
• High impact resistance (10-20 kg m depending on the thickness).
• Bending strength - not less than 12 MPa.
• Complete dustlessness (after polishing).
• The cover is vapor permeable.
• Antistatic coating: specific volumetric electrical resistance- no more than 10 7 Ohm;
  specific surface electrical resistance - no more than 10 9 Ohm∙m (test voltage 100V).
• Chemical resistance to water, fuels and lubricants, salt solutions, detergents, etc.
• The coating is non-combustible (combustibility group - NG).
• Great appearance, the ability to combine several colors, various fillers, etc.
• Ease of cleaning, the ability to use any detergent.

Polymer cement floors - advantages.

• Allows you to refuse to perform leveling screeds with subsequent application of protective polymer impregnations and coatings or dry hardening compounds (toppings). This results in a coating with higher decorative and strength qualities and a much lower cost.
• Combines the advantages of latex-cement concrete and polyvinyl acetate-cement concrete - water resistance and oil resistance.
• Fully complies with SNiP 2.03.13-88 "Floors".
• The strength is similar to topping and higher, but not only in the upper layer of 2-2.5 mm, but throughout the entire thickness.
• Unlike magnesia concretes, magnesia floors are completely resistant to water.
• When abrasion (wear) polymer-cement floor does not change its appearance, does not lose strength and chemical resistance.
• Polished during use.
• Requires no reinforcement.
• Short technological cycle of works (6-8 days).
• The beginning of operation - next day after the termination of works.
• Polymer cement concrete is cheaper than any finish coats similar thickness.

Polymer cement floors are used on objects.

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. into polymer cement concretes Portland cements mixed with polymer additives are added.

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 better side change the properties of building materials 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 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 mix.

Production

As additives in the production of polymer concrete, water-soluble resins, PVA and latexes are most often used. When ready mix dries, a film is formed on the surface of its particles, which swells when hit a large number moisture. 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. Pour into the concrete mixer special water for polymers with a small amount of cement;

2. Are added the same number ash and slag.

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), internal and exterior finish walls, floors and facades of buildings.

Designers and architects love it because it is easy to shape and can be applied by hand and by mechanical means. 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 and others). The dried surface can subsequently be painted with desired color 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 are able to 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 cost depends on the high cost polymer additives, working conditions and footage.

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, practical use the novelty received 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, construction 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 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 cured 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 mineral matrix of concrete.

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 in early XXI 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 volatiles 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, there are 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 floor, 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, polyester resin and finely divided filler natural stone- Gabro, basalt, marble, calcite are produced 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 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 self-leveling floors. In this case, quartz sand crushed into dust is used instead of glass filler. The most expensive grades, which include modified forced-curing 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. Various brands epoxy resin require their own brand of solvent, therefore, for the preparation of polymer concrete, it is necessary to select 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.

(otherwise, cast stone) - a material that combines the strength and beauty of natural stone with affordable price(due 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 variety. And the presence of a polymer binder makes them durable, exposed to water and overheating.

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

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:

Process

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 items are small and technological process is periodic, it 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.

In the conditions of production 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 a large industrial production require 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’t 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 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 on your own, 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 get personal protection: gloves, respirators.
• For finishing works 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:

Air emissions from such production

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 airtight, 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 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.

Manufacturing process

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: