Polymer concrete: do-it-yourself manufacturing process. Polymer additives in concrete Polymer concrete technologies

Polymer concrete (which is also called cast or artificial stone, polymer cement, concrete polymer and plastic concrete) is alternative view a concrete mixture in which a polymer (synthetic resin) is used instead of a standard binder. Thanks to this component and cheaper mineral fillers, the composition is highly resistant to moisture and frost, but at the same time the price of cast stone is lower. Let's take a closer look: polymer concrete - what is it and is this material really worth using in construction as a replacement for conventional concrete?

To answer this question, we first determine what components plastic concrete includes.

Composition of polymer concrete

The lion's share of the polymer cement composition is occupied by filler and it is added in two types at once:

• Ground – talc, graphite powder, andesite flour, ground basalt, mica and other raw materials.
• Coarse – gravel, crushed stone, quartz sand.

Important! When producing cast stone, you cannot use metal dust, cement lime and chalk.

Resin is used as a “fastening” component:

• furano-epoxy (must meet the requirements of TU 59-02-039.13-78);
• furfural acetone (FAM), meeting the standards of TU 6-05-1618-73;
• urea-formaldehyde (corresponds to GOST 14231-78 standards);

Polyester resin is often used to hold the filler together, as it is cheaper than others. It is also allowed to use methyl methacrylate monomer (methyl ester) that meets the standards of GOST 16505.

In addition, the cast stone contains hardeners, plasticizing additives and coloring components. They must also meet the requirements for chemical additives (GOST 24211).

Depending on the quantity and type of components, polymer concrete of different qualities can be obtained.

Types of polymer concrete

Depending on what kind of filler (or rather its fraction) you added to the casting stone solution, you can get the material to create lightweight decorative elements, and for the construction of more massive structures.

Based on this, the following classes of polymer concrete are distinguished:

1. Super heavy. The density of such concrete is from 2.5 to 4 t/m 3. As a filler for extra heavy building material use components measuring at least 2-4 cm. This type of concrete is used for the construction of structures that are subject to high pressure ( bearing structures, foundation).
2. Heavy (density from 1.8 to 2.5 t/m3). This type of plastic concrete is suitable for the production of decorative cast stones that imitate marble and other expensive stones. The size of the heavy polymer concrete aggregate should not exceed 2 cm.
3. Easy. Since the density of such material is 0.5-1.8 t/m 3, it is usually classified as structural-thermal insulation class concrete. This type of concrete polymer is distinguished by high heat conservation rates. The filler used for its preparation is the same fraction as for heavy polymer concrete, only its quantity changes.
4. Ultralight. The density of this composition is from 0.3 to 0.5 t/m3, so it is used for thermal insulation works and during construction internal partitions. The fillers most often used are various shavings, perlites, cork and polystyrene with a fraction of no more than 1 cm.

Healthy! Most often, polymer concrete is used for the manufacture of: kitchen countertops, sinks, window sills, columns, steps, monuments, fireplaces, fountains, floors, vases and much more.

There is also the lightest artificial stone, with a filler no larger than 0.15 mm. This material has found application in the production of decorative elements.

Properties of polymer concrete

If we compare polymer concrete with ordinary concrete, it is worth noting the fact that in many of its characteristics the composition with the addition of resins outperforms conventional mixtures. Polymer concrete has the following properties:

• density – 300-3000 kg/m3;
• resistance to compression – from 50 to 110 MPa;
• bending resistance – from 3 to 11 MPa;
• abrasion in the range of 0.02-0.03 g/cm 2 ;
• temperature limit – from 60 to 140 0 C;
• elasticity – from 10,000 to 40,000 MPa;
• thermal conductivity coefficient – ​​0.05-0.85 W/m K;
• moisture absorption volume – 0.05-0.5%;

The strength characteristics of polymer concrete are 3-6 times higher than those of conventional concrete. The same applies to tensile strength, which is almost 10 times higher for concrete polymer.

It is also worth considering the chemical passivity of modern concrete composition, which is determined according to GOST 25246-82. From this regulatory document it follows that at 200 0 C Celsius, the chemical resistance of concrete polymer components to nitric acid will be no less than 0.5%, and to hydrochloric acid, ammonia or calcium solution of at least 0.8%.

Based on this, we can conclude that polymer concrete, which contains resins, has all the qualities necessary for the construction of various objects.

Advantages and disadvantages of casting stone

Polymer cement is often used in the construction of structures that cannot be made from ordinary concrete due to its fragility. Thanks to the polymer composition, structures will be less susceptible to deformation or destruction.

In addition, polymer concrete has the following advantages:

• Due to the high water resistance and resistance of the concrete polymer to changes temperature conditions, water droplets on the surface of the finished product evaporate almost immediately, as a result of which cracks and other defects do not form.
• The surface of the polymer cement remains smooth throughout its entire service life, so polymer concrete products do not get dirty.
• The variety of colors allows you to create from this material products stylized to resemble expensive natural rocks (granite, marble, etc.).
• The material is recyclable with the possibility of reusing concrete polymer.
• Designs from this lightweight concrete do not require additional processing.

Speaking of disadvantages modern material, then it is worth highlighting the following disadvantages:

• Flammability of polymer concrete.
• The high cost of some binding components (however, if you use ground flour as a filler, the costs will be significantly reduced).
• It is not always possible to find on sale everything necessary for the production of such a composition.

Speaking about the production of polymer concrete, it is worth considering possible options production of such concrete.

Methods for producing cast stone

The process of producing concrete polymer can be continuous or batch.

Continuous production

In this case we are talking about large production, for which you will need to purchase the appropriate equipment:

• Vibrating table
• Stirrer.
• Compressor system with gun.
• Silicone matrices.
• Hood.
• Grinding and polishing machines.

To purchase everything you need you will have to spend about 250,000 rubles. Even if you take into account that you will make some of the equipment yourself, the most expensive tools will have to be purchased. Therefore, we will not dwell on this production method and will consider a more accessible technology.

Making polymer cement at home

Knowing what polymer concrete is, it becomes obvious why it is most often used for the production of countertops and decorative elements for suburban area This is the material used. Fortunately, you don’t need specialized equipment to produce it at home.

To make polymer cement with your own hands:

1. Rinse and clean the filler. After this, dry it until the moisture content of the crushed stone or gravel is 0.5-1%. If you use wet aggregate, the strength of the finished product will decrease.
2. Sift the sand and remove impurities from it.
3. First pour crushed stone into the concrete mixer, then sand and aggregate and mix the components for 2 minutes.
4. Add water and mix everything again.
5. Soften the binder component (resin) with a solvent or simply by heating the solid mass.
6. Add a plasticizing additive, stabilizers and other components to the resin. Mix them separately from the aggregate for 2 minutes.
7. Add hardener.
8. Mix all ingredients for at least 3 minutes until you get a creamy mixture.
9. Pour the resulting mixture into a paraffin-lubricated matrix or prepared formwork. Try to immediately fill in the volume of composition that will completely fill the mold. Polymer concrete sets very quickly, so you need to act quickly.
10. Level the surface and compact the mixture on a vibrating table.
11. Wait a day and take it out ready product from the matrix.

At this point, the production of polymer concrete can be considered finished.

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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 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 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 gamut polymer concrete, imitating natural marble, malachite, granite. The created artificial stone is difficult to distinguish from the real one, 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.
• Screened and purified 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

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 new product was received only in the 60s of the last century. As the name suggests, the developers managed to obtain a building material based on resins and polymers, capable of completely replacing modern cement and slag-cement concrete in composition and characteristics.

What is polymer concrete

Often construction terms can confuse a non-specialist or a novice builder or someone who likes to build with their own hands. At the household level, polymer concrete includes all types of building materials that contain cement, water and polymer resin.

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

• Polymer concrete is a mixed composition that includes mineral ballast or filler, a polymer binder, hardener, stabilizer and adhesive, without the use of cement and water;
• Polymer cement concrete is 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 liquid contains styrene with a catalyst, which polymerizes in the thickness of the mineral matrix of concrete.

For your information! Polymer concretes obtained on the basis of thermosetting and epoxy resins, also called plastic concrete.

The properties of polymer concrete depend on the composition of the binder, resin, filler used and the method of preparation. Such materials are successfully used not only in construction, but also in mechanical engineering, in 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 beginning of XXI century, almost 80-90% of plastic products are made using polymer concrete technology, which contains resin and fine ballast powder.

To obtain building grades of polymer concrete, compositions based on five main types 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.

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

Furfural acetone resins contain volatile substances with very unpleasant smell which may cause 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 contain polyester resins, epoxy and methacrylate oligomers.

The resin content of polymer concrete is relatively small, from 10 to 15%. The rest is mineral filler - marble chips, ground ash, crushed dolomite, calcite, granulated vermiculite, clinker and ordinary Portland cement. Quite rarely, polymer concrete contains a 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 expensive metal reinforcement, 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 conventional concrete, we can name five advantages of using polymers:

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

For your information! The main “value” of a polymer concrete composition is the possibility of obtaining High Quality castings, without cavities, ridges, cracks, with “programmed” mechanical and strength characteristics. The characteristics can be easily adjusted by changing the composition of the material.

For example, in the manufacture of a pipeline, polymer concrete with the addition of polyvinyl alcohol or liquid glass is used. Alcohol in concrete improves the wettability of cement grains, removes air from the intergranular space and helps the hydration process. After casting the pipeline, due to intensive binding of water, the inner surface concrete pipe quickly dries out and becomes cracked. 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 is not inferior in characteristics and durability to cast iron.

Today, the cost of polymer concrete is still quite high, so there is no talk of completely replacing cement in the composition of the material, but as new resins are developed, the prospect of switching to polymer concrete is becoming more and more realistic.

Features of the use of various brands of polymer concrete

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

Communication elements - pipes, tanks, wells, drainage trays and even entire collectors - are made from epoxy polymer concrete. Using polymer cement casting, you can quite simply repair concrete load-bearing structures, seal the screed and restore the tightness of the container. Polymer concretes, which contain epoxy resin, have exceptionally high adhesion, so they are often used to restore holes and joints concrete panels in high-rises.

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

Separately, it is necessary to remember self-leveling floors. In this case, instead of glass filler, quartz sand crushed into dust is used. The most expensive brands, which contain modified forced-curing methacrylate, after hardening give ideal smooth surface, superior in strength 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 adhesive or resin, hardener and filler. It is best to use cement, washed and dried, as part of the material. river sand or granite dust, which you can get in any monument-making workshop.

The resin is diluted with acetone or an alcohol-acetone mixture. Various brands epoxy resin requires its own brand of solvent, so to prepare 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 you can add to the adhesive mass in small portions filler. After another 3-10 minutes of mixing, the polymer concrete will be ready for use.

Conclusion

In a similar way, you can 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, which will allow you to use the material for casting parts for finishing ceilings and walls, columns, stucco moldings, and pilasters. In any case, such a composition will cost less, and the quality of the products will be no worse than that of purchased options.

The main difference between polymer concrete and ordinary concrete is that during its production high molecular weight compounds are added to the initial solution. organic compounds. If we talk in simple language, then in the composition of such a solution the role of a binder is played by resins: epoxy, polyvinyl, polyester, polyurethane, methyl methacrylate or others. Also, components such as solvents, hardeners, catalysts and others are added to the composition of this material to improve various properties.

This material is used for external or interior decoration various buildings and premises, as well as in road construction, landscape design and in the manufacture of various small architectural forms. Due to the ability to vary the consistency of the material during its production, polymer concrete can be used on both horizontal and vertical planes.

Characteristics of polymer concrete

The main components for the production of geopolymer concrete are slag, ash, liquid glass, binding resins. During the polymerization of such a solution, a monolith is formed, which, both in strength and in most other technical characteristics, is significantly superior to ordinary concrete. Compared to a solution prepared on the basis of Portland cement, it has several advantages:

• increased adhesion to virtually any surface;
• high hardening speed;
• excellent vapor permeability indicators;
• increased resistance to bending and stretching;
• strength and wear resistance;
• resistance to temperature changes and acidic chemical compounds.

Also this building material It is lightweight and completely environmentally friendly. If we talk about disadvantages, then this material has only one. Due to the fact that it was developed not so long ago, and high-quality components are used for its production, it is quite expensive. However, there is every reason to believe that in the very near future it will become the most popular view concrete used in construction.

Features of the preparation of polymer concrete

In addition to the components already mentioned, PVA glue, latexes and water-soluble resins are most often used as additives for geopolymer concrete. If PVA is used, then only the type that uses polyvinyl alcohol as an emulsifier should be selected.

When this mixture dries, a durable film forms on the surface, which swells over time and absorbs water. That is why, during the hardening of the material, it is not allowed to come into contact with air with a high moisture content.

The optimal amount of various additives for such a material is most often determined experimentally. However, the key to ensuring high quality mortar is the correct ratio of cement and polymer components. The volume of polymer components should be no more than 20% of the total mass of cement. And the volume of water-soluble resins is no more than 2% of the mass of cement. The highest quality can be achieved by using polyamide or epoxy resins, as well as polyethylene-polyamine hardeners.

When preparing geopolymer concrete, like regular concrete, you will need a concrete mixer. First, water and cement specially designed for polymer concrete are poured into it (ordinary Portland cement cannot be used, since it does not suit the characteristics). Then slag and ash are added to the solution equal parts, after which it is thoroughly mixed. After this, polymer components and additives are added.

Innovative technologies delight us more and more every day. New developments have also affected the construction industry. In particular, the creation of new building materials, among which polymer concrete is in great demand. It is a mixture whose composition consists of various polymer substances, and not from the cement or silicate that has long been familiar to us. This material has mass positive properties, thanks to which it is superior to conventional building mixtures.

Polymer concrete: characteristics

Thanks to a huge number For its positive properties, the cement-polymer mixture justifiably deserves respect among builders. Using this material, any specialist will appreciate its strength and durability. Polymer concrete is not susceptible to moisture, does not deform, and responds well to temperature changes and bad weather. It hardens quickly and adheres perfectly to any surface. This material has high tensile strength and good air permeability. It is not affected by any chemical reactions.

But the most important of all the properties of polymer concrete is that it is environmentally friendly and does not pollute environment and does not harm human health in any way. The polymer mixture is allowed to be used even in the construction of public catering establishments, various food outlets, as well as other buildings Food Industry.

Advantages and disadvantages

A huge number of positive properties elevate the cement-polymer construction mixture over conventional concrete. Due to the rapid hardening with polymer concrete, the first work can be carried out within a few days, which cannot be said about regular material. The new type of concrete is much more durable and stronger. For complete hardening, it only takes one week, and not a month, as for ordinary cement.

Among the positive properties of the polymer mixture is waste-free production. Previously, all agricultural and construction waste was simply thrown away or buried in the ground, thereby polluting our nature. Now the recycled material is used to make polymer concrete. The use of such technology not only solves the problem of waste disposal, but also protects the environment from pollution.

Unfortunately, this building material also has disadvantages. Among the negative properties, one can highlight the inclusion of artificial materials in the composition. Second negative point lies in the high cost of some additives necessary for the preparation of polymer concrete. Due to this, the price is already rising finished product.

Application

Due to the presence of many positive properties, polymer concrete has a fairly wide range of applications. It is used in landscape design, laying out paths and terraces. A similar mixture is used to decorate walls, both external and external. outside, decorate, stairs, fences, plinths. Such material can easily be handmade. It makes different shapes, figures, decorative elements. Its beauty is that it is easy to paint after drying.

The use of such a building mixture is suitable for pouring floors. Polymer concrete floors will provide excellent protection against moisture. Polymer concrete floors will keep your home warm.

Kinds

Considering specifications and composition, new generation concrete is divided into:

• Polymer-cement. This type concrete has excellent strength. Similar material used in the construction of airfields, finishing slabs and bricks.
• Plastic concrete. It exhibits excellent resistance to acid-base reactions and temperature imbalance.
• Concrete polymer. This mortar differs from others in that the ready-made, frozen block is impregnated with monomers.

These substances, filling holes and defects in the material, provide it with durability and resistance to sub-zero temperatures.

Also depending on the type construction work Experts divide polymer concrete into filled and frame molecular. The first type allows the presence of organic materials such as quartz sand and gravel. These materials perform the function of filling voids in concrete. In the second option, the concrete is left with unfilled voids. And the connection between concrete particles is carried out by polymer substances.