Polymer concrete on acrylic resins. Polymer concrete - additive to concrete

With rare exceptions, the technology for carrying out construction, restoration or repair work provides for 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 binding 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 to the usual sand-cement mixture as a binder. They are gradually introduced during the preparation of the solution. Polymer-based concretes are suitable for finishing surfaces both inside and outside buildings, pouring floors, and stair steps.

Composition and fillers

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

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

Binding components:

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

Manufacturing

There is no clear answer yet to the question of how to make polymer concrete. All sources talk about the experimental way of obtaining required composition. It is necessary to ensure that when the applied mixture dries, it forms an elastic, resilient coating. Much depends on the installation location and on what result needs to be achieved. Eat general recommendation that polymer additives should make up 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 and 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 replacing cement with slag, ash and liquid glass. In all other respects (mixing) the technique 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 a structure are exposed to intense exposure to liquids. By purchasing polymer or natural concrete, you can significantly save on waterproofing and reduce the overall work time.
• Resistance to aggressive environments, low temperatures.
• Indicators mechanical strength significantly exceed similar characteristics of cement-based concrete: for bending - up to 10 times, for compression - up to 3 times.
• Small specific gravity, which significantly increases the range of applications.
• Its elastic property allows it to be used in areas subject to dynamic loads. Can be applied to planes with any orientation: horizontal, vertical, inclined.
• Excellent adhesion, regardless of the base material.
• The curing time is shorter than that of cement.
• Possibility of achieving ideal evenness of the coating. Surfaces finished with polymer concrete are easy to maintain.

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

Polymer concrete is called water-based polymer additive To cement-sand mixture

Advantages polymer concrete very diverse, which provides ample opportunities their use. First of all, it is necessary to note the increased characteristics in terms of tensile strength. This indicator 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 mentioning increased durability, achieved due to significant resistance to wear and some other external influences.

Application of dust-removing impregnation "Polymer concrete":

About the product

Polymer concrete, if added to a dry mixture, makes it durable and waterproof. It can be applied even 1 mm thick. on concrete, brick, wood, metal, plastic and it sticks to them very firmly. It becomes strong immediately after drying - within an hour. For example, a dry mixture with polymer concrete applied in a thin layer on cardboard bends as desired, does not peel off, does not crumble.

Alabaster, when mixed on polymer concrete, slows down its hardening 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 or self-leveling floor is prepared using diluted polymer concrete, then the water resistance and strength will increase sharply. The strength of the material is controlled by the amount of polymer concrete

A lot of buildings and underground garages have been restored using polymer concrete. A 15th century church in Sheremetyevo (Moscow region) was completely restored using plaster on polymer concrete. Decorative stucco on its façade there is plaster with polymer concrete.

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

Repair, restoration work take on a different meaning. Dilute polymer-concrete with water 1/1 and saturate concrete, wood, and plaster. They will become durable and waterproof. Add polymer concrete to chalk paint and it becomes strong, flexible and water resistant. Paint wood (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 whites, casein, and 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
• strengthening impregnation, high-quality, waterproofing
• Betokontakt - durable and cheap
• non-cracking, dust-free plaster, smooth and textured
• impact-resistant self-leveling floor
• water-weatherproof alabaster, gypsum

PROPERTIES:

• especially durable, 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

Price RUR/kg depending on quantity. Including VAT and packaging.

Packing: plastic canisters 5kg, 10kg, 30kg.

Guaranteed shelf life in manufacturer's containers is 12 months.

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

label

Packing

Buy a polymer additive for concrete

Polymer-based concrete additive Elastobeton-B manufactured to be heavy-duty polymer cement concrete.
Strength: on dolomite crushed stone – M600-M800; on granite crushed stone– M800-M1000 and more.

Commissioning within 5-6 days.

Polymer additives in concrete Elastic concrete-B is supplied in liquid form.
They are introduced during the production 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 magnesium concrete, polymer cement concrete is completely resistant to water.

Polymer cement concrete

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

As mentioned above, polymer-cement floors based on the concrete additive Elastobeton-B are 20-50% cheaper than magnesium floors. But this is a direct calculation - that is, they took polymer-cement concrete and calculated the price of the components; similarly for magnesium concrete.
But besides this, there are a number of factors that affect the final price of polymer cement concrete and magnesium 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 magnesium concrete, which constitute approximately 23% of the total mass, will increase the price of 1 m³ of concrete by 500 rubles! With a delivery price of 5 rubles/kg, that’s already 2500 rubles/m³!

If you transport all the components of magnesium floors, then at a delivery price of 1 ruble/kg, the cost will increase by 2200 rubles/m³.
With a delivery price of 5 rubles/kg, magnesium floors will become more expensive by 11,000 rubles/m³!

The concrete additive Elastobeton-B is approximately 3.5% of the concrete mass, the remaining components are purchased locally. Accordingly, transportation of a polymer additive for concrete, even over long distances, has virtually no effect on the price of polymer-cement concrete.

The savings are obvious.

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

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

3. Cost of fillers.
The cost of concrete with the Elastobeton-B additive depends on the sand fineness modulus (SFM), bulk density of sand and bulk density of crushed stone. The higher the MCR and the higher the density of sand and crushed stone, the less cement and concrete additives in relation to sand and crushed stone. Accordingly, the cheaper polymer-cement concrete.

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

4. Equipment corrosion.
Magnesia concrete includes the bischofite component, which causes increased corrosion of both steel and aluminum surfaces of equipment. Equipment (concrete mixers, vibrating screeds, helicopters, etc.) must be constantly washed. But even with careful care, the service life of the equipment is reduced several times, which as a result affects the price of magnesium floors!

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"- complex modifying polymer additive for concrete (Portland cement concrete).
Cement grade M500D0 is recommended for use. If you want to use other cements, we recommend that you first check them for compatibility with the Additive (see Technology for using the Additive). The fact is that some fillers that are introduced during the production of cement can “conflict” with the additive.

To make colored polymer-cement floors, you can add the pigment yourself directly when mixing concrete or order an Additive from us desired color.
Colored polymer cement floors can be made on gray cement, but if a “pure” color is required, then white cement must be used.

Properties of polymer-cement floors with the concrete additive “Elastobeton-B”.

• Operation indoors and outdoors outdoors.
• Thickness from 15 to 50mm. Recommended thickness is 20-30mm depending on the load.
• 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 strength (10-20 kg m depending on thickness).
• Bending strength – no less than 12 MPa.
• Completely dust-free (after polishing).
• The coating is vapor permeable.
• Antistatic coating: specific volume electrical resistance– no more than 10 7 Ohms;
  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-flammable (flammability group - NG).
• Fabulous appearance, the possibility of combining several colors, various fillers, etc.
• Easy to clean, can be used with any detergent.

Polymer cement floors - advantages.

• Allows you to avoid performing leveling screeds with subsequent application of protective polymer impregnations and coatings or dry reinforcing compounds (toppings). This results in a coating with higher decorative and strength qualities and a significantly 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”.
• Strength as the topping and higher, but not only in top layer 2-2.5 mm, and throughout the entire thickness.
• Unlike magnesium concrete, magnesia floors are completely resistant to water.
• When abraded (weared), the polymer-cement floor does not change its appearance, does not lose strength and chemical resistance.
• It is polished during use.
• Does not require reinforcement.
• Short technological cycle of work (6-8 days).
• Start of operation - the next day after completion of work.
• Polymer cement concrete is cheaper than any finishing coating of similar thickness.

Polymer cement floors are used in buildings.

Polymer concrete

In development construction technologies New materials and concrete mixtures are appearing, for the preparation of which special fillers are used. This allows you to create durable composite materials, with high performance characteristics, decorative properties. Polymer concrete is one such composition that is gaining popularity in the construction raw materials market.

The material, along with traditional components - sand and crushed stone, includes polymer resins based on epoxy, furan, and polyester as a binder. Polymer concrete is in demand in the construction industry, used for creating sculptures, manufacturing original furniture, as well as in the ritual sphere.

Polymer concrete (cast stone, polymer cement, concrete polymer, plastic concrete, plastic 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 improvements compared to conventional concrete mechanical characteristics, resistance to aggressive environments, lightness, expanded color palette, allowing you to simulate a natural stone. Consumers of the composite are convinced that it is a reliable composition with a wide range of applications. Let's look at the material in detail, delve into the technology, evaluate the advantages and disadvantages, and study the recipe.

Advantages of the material

Composite concrete, due to the characteristics of its 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 mass. Water droplets 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 its integrity, regardless of the duration and number of freezing cycles.

  

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

• Material resistance to aggressive substances, chemical reagents, allowing the use of polymer concrete in various areas without surface protection using special coatings.
• Possibility of restoring mechanically damaged areas of a composite mass using a restoration mixture.
• Increased strength characteristics with a relatively low weight of the composite, allowing the production of various products with enhanced performance properties.
• Absence of roughness on a perfectly smooth, absolutely non-slip surface of the material. This property allows artificial stone long time stay clean and, if necessary, various pollution are easily removed from the surface of the material.
• Expanded color range of polymer concrete imitating natural marble, malachite, granite. Created fake diamond difficult to distinguish from the real thing, which allows for a wide range of applications for the composite.
• Possibility of recycling and use in the production of technological waste, which significantly reduces the cost of products produced under waste-free technology.



Pros: strength, light weight, impact resistance, elasticity is several times higher than that of ordinary concrete

Weak sides

Along with the positive aspects, polymer concrete has disadvantages:

• susceptibility to open fire and elevated temperatures, causing destruction of the material;
• higher price compared to concrete, which is 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 used as urea-formaldehyde, polyester, epoxy and furfuralacetone resins.
• Coarse crushed stone filler. The size of the crushed stone fraction required for the formation of the composite can be up to 4 centimeters, but crushed stone measuring 1-2 cm should make up the bulk of the composition.
• Sifted and peeled quartz sand. The size of quartz particles should not exceed 5 mm; the presence of clay inclusions and dust is not allowed.

  

  For polystyrene concrete (where polystyrene is used as a filler) there are its own standards

• Crushed graphite powder with a particle size of no more than 0.15 mm, quartz flour, used as a ground filler, reducing the need for expensive resins.
• Construction 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, increasing thermal insulation properties 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;
• lightweight with a specific gravity of 500-1800 kg/m3;
• lightweight, the mass of a cubic meter does not exceed 500 kilograms.

Scope of use

Polymer concrete is a special construction material, which is used as a binding element and also to replace lime cements. In some cases, the polymer is used as an addition to Portland cement. It is a universal, durable composite substance obtained by mixing various mineral fillers with synthetic or natural binding agents. 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 of application 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 from Portland cement material with modified polymers such as acrylic, polyvinyl acetate and ethylene vinyl acetate. Has good adhesion high strength for bending and low permeability.

Acrylic polymer modified concrete is characterized by durable 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 from 10 to 20%. Concrete modified in this way has a lower degree of permeability and higher density than pure cement. However, its structural integrity is significantly dependent on the Portland cement binder.

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

Polymer impregnated concrete

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

However, the modulus of the polymer is 10% greater than that of normal concrete. Thanks to these excellent characteristics, among the many options for using polymer building materials, we can specifically mention the production of:

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

The technology of the implementation process includes drying concrete to remove moisture from its surface, using monomers in thin layer sand and then polymerize the monomers using heat flow. Hence, concrete surfaces have lower water permeability, absorption, abrasion resistance and generally high strength. Also, to increase wear resistance, resistance to cold and moisture, polymer bricks, stones, floors, etc. are used.

Polymer concrete

It has nothing in common with our usual Portland cement. It is formed by combining stones with a polymer 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 that require high resistance to acidic environments. Thermoplastic polymers, but most commonly thermoset resins, are used as the main polymer component due to their high thermal stability and resistance to a wide range of chemicals.

Polymer concrete consists of aggregates that include silica, quartz, granite, limestone and other high-quality materials. The unit must be good quality, free from dust, debris and excess 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 differs from its predecessors. It has the following characteristics:

• High resistance to chemical and biological environments.
• Compared to cement-concrete products, it has less weight.
• Excellent noise and vibration absorption.
• Good weatherability and UV resistance.
• Water absorption.
• Can be cut using drills and grinders.
• Can be recycled as crushed stone or crushed for use as 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 polymer and conventional cement-based concrete. Low permeability and corrosion resistance allow it to be used in swimming pools, sewer systems, drainage 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 city streets. It is used in the construction of road barriers, sidewalks, drainage ditches, fountains. Also on the street, concrete is added to asphalt during the construction of open areas, runways and other objects that are under open air and are constantly exposed to external atmospheric influences.