PAPER PRESENTATION ON

By
T.V.M. Akhilash Guptha Email: akil_chari@yahoo.co.in

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B. Nareen Kumar

nareen_rathode2007@yahoo.com

2 ABSTRACT: In Concrete Technolgy there are many types of Concretes here we are mainly discussing about Polymer Concrerte. Polymer concrete is a composite material. A graded mixture coarse and fine aggregates bound together by an appropriate organic resin system. Polymer concrete is a relatively low-cost composite material system that has been developed to be a technically viable alternative to porcelain for most high voltage electrical insulation applications. Polymer composites appear as useful materials for repair and protection of building structures, as well as for manufacturing pre-cast elements. In the case of pre-cast elements as well as repair materials, the usefulness and durability of polymer composites depend on the selection of the material composition for obtaining the composite with

controllable properties Polymer Concrete consists of a polymer binder which may be a thermoplastic but more frequently is a thermosetting polymer, and a mineral filler such as aggregate, gravel and crushed stone. PC has higher strength, greater resistance to chemicals and corrosive agents lower water absorption and higher freeze-thaw stability than conventional Portland cement concrete.

Polymer modified concrete may be divided into two classes; polymer impregnated concrete and polymer cement concrete. The first is produced by impregnation of pre-cast

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hardened Portland cement concrete with n monomer that is subsequently converted to solid polymer. To produce the second, part of the cement binder of the concrete mix is replaced by polymer Both have higher strength, lower water permeability, better resistance to chemical, and greater freeze-thaw stability than conventional concrete.

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3 INTRODUCTION Polymer concrete is a composite material in which the binder consists entirely of a synthetic organic polymer. It is variously known as synthetic resin concrete, plastic resin concrete. Because the use of a polymer instead of Portland cement represents a substantial increase in cost, polymers should be used only in applications in which the higher cost can be justified by superior properties, low labor cost or low energy requirements during processing and handling. It is therefore important that architects and engineers have some knowledge of the capabilities and limitations of PC materials in order to select the most appropriate and economic product for a specific application. The first polymer concrete construction in the worldis Concrerte-Roman_colosseum_red.

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Concrerte-Roman_colosseum_red.

NATURE AND GENERAL PROPERTIES:

4 Polymer concrete consists of a mineral filler and a polymer binder (which may be a thermoplastic, but more frequently, it is a thermosetting polymer. When it is used as a filler, the composite is referred to as a polymer mortar. Other fillers include crushed stone, gravel, limestone, chalk, condensed silica fume, granite, quartz, clay, expanded glass, and metallic fillers.

To produce PC, a monomer, a hardener and a catalyst are mixed with the filler. Other ingredients added to the mix include plasticizers and fire retardants. To achieve the full potential of polymer concrete products for certain applications, various fiber reinforcements are used. These include glass fiber, glass fiber-based mats, fabrics and metal fibers.

The amount polymer binder used is generally small and is usually determined by the size of the filler. Normal the polymer content will range from 5 to 15 percent of the total weight, but if the filler is fine, up t 30 percent may be required.

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Polymer concrete composites have generally good resistance to attack by chemicals and other corrosive agents have very low water sorption properties. Portland cement concrete permits the use of up to 50 percent less material. This puts polymer concrete on a competitive basis with cement concrete in certain special applications. The chemical resistance and physical properties are generally determined by the nature of the polymer binder a greater extent than by the type and the amount of filler In turn, the properties of the matrix polymer are highly dependent on time and the temperature to which it is exposed.

5 The polymers most frequently used are based on four types of monomers systems: methyl methacryl , polyester prepolymer-styrene, epoxide prepoiymer hardener and furfuryl alcohol. The typical range of properties of PC products made with each of these four polymers is presented in Table I. General characteristics and principal applications are described in Table II.

Table I. Typical Range of Properties of Common PC Products and Portland Cement Concrete ___________________________________________________________________________________ Thermal Modulus Coefficient Water Compressive Tensile Flexural of of Type of Density, Sorption Strength, Strength, Strength, Elasticity, Poisson Expansion Binder kg/dm3 % MPa MPa MPa GPa Ratio 10GC-1 2.0-2.4 0.05-0.60 70-210 9-11 30-35 35-40 0.22-0.33 10-19 Poly(methyl rnetha cry late) Polyester Epoxy 2.0-2.4 2.0-2.4 030-1.0

Furan polymer 1.6-1.7 Concrete"

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1.9-2.5

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0.20 5-8

0.02-1 0

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8-25 8-25 7-8 1.5-35 15-45 15-50 2-8

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20-40 20-40 20-30 -

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10-35

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3B-.61'

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Table II General Characteristics And Applications of Polymer Concrete Products ___________________________________________________________________________ Type of Binder Used in PC Poly (methylmethacrylate) General Characteristics Low tendency to Typical Applications

absorb Used in the manufacture of units, faade products plates, for

water; thus high freeze-thaw stair

resistance : low rate of sanitary shrinkage during and after curbstones

6 setting; very good chemical resistance durability Polyester Relatively strong, good Because of lower cost, widely and outdoor

adhesion to other materials, used in panels for public and good chemical and freeze- commercial buildings, floor thaw resistance, but have tiles, pipes, stairs, various prehigh-setting and post-setting cast and cast-in applications in shrinkage. Epoxy Strong adhesion building to construction works.

most Epoxy polymer products are low relatively costly; they are

materials;

shrinkage; superior chemical mainly resistance; sorption. Furan-based polymer low

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Composite

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used in

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special

water applications, including use in mortar for industrial flooring.

materials

with Furan polymer mortars and

high resistance to chemicals, grouts are used for brick strong resistance to polar floors. organic liquids.

MATERIALS AND TESTING PROGRAM Based on workability, polymer content for GFRPC and CFRPC were determined to be 18% and 20% respectively. Fiber content for both the matrices was varied up to 6%. CIGMAT standards (CIGMAT PC1-01, CIGMAT PC2-01, CIGMAT PC3-01) were followed for specimen preparations, compression test and tension test. Destructive tests were performed in displacement-controlled mode.

TEST RESULTS AND CONCLUSIONS Based on the experimental study the following conclusions can be drawn:

7 Adding 6% glass fibers required 18% polymer in the GFRPC system for good workability. Glass fibers increased the failure strain, peak strength and modulus in compression and tension. Adding 6% PAN based carbon fibers required 20% polymer to develop a workable CFRPC. The addition of carbon fibers increased the failure strain, but strength and modulus decreased. In tension, it increased the tensile strain, modulus and strength. Carbon fibers also increased the failure strain in compression, but reduced the strength and modulus.

90 80 70
Stress,MPa

60 50 40 30 20 10 0 0 0.2 0.4 0.6

PC GFRPC CFRPC

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Stress,MPa

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12 10 8 6 4 2 0

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Compression Test

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PC

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GFRPC CFRPC

0.05 Strain,%

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0.15

Tension Test

Acrylic Polymer Concrete: The most common acrylic polymer is poly, obtained by polymerization of methyl methacrylate. PC made with this acrylic polymer as a binder is versatile material,has

8 excellent weathering resistance good waterproofing properties good chemical resistance and relatively low setting shrinkage its coefficient of thermal expansion is equivalent to that of Portland cement concrete. Because of its very low tendency to absorb water, acrylic PC has a very high freeze-thaw resistance.

Polyester Polymer Concrete :

Because of low cost, the most widely used polymer-binders are based on unsaturated

polyester polymer. In most applications, the polyester binder is a general purpose, unsaturated polyester prepolymer formulation. The chemical reaction is called cross-linking, the production process associated with it is referred to as curing, and the resulting polymer binder is a thermosetting polymer.

Polyester PC has good mechanical strength, relatively good adhesion to other materials, and

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freeze-thaw resistance. Polyester PC is used in various pre-cast and cast-in place applications in constructs works, public and commercial buildings, floor tiles, sewer pipes and stairs.

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Epoxy Polymer Concrete :

Epoxy binder like polyester, is a thermosetting polymer. The epoxy polymer can be hardened with a variety of curing agents, the most frequently used being polyamines. The use of polyamine hardeners results in PC products with the highest chemicals resistance. Other curing agents are polyamides and polysulfide polymers. Epoxy PC products cured with polyamides give greater flexibility.

Epoxy PC exhibits high strength, low-setting and post-setting shrinkage, high chemical resistance, good fatigue and creep resistance. Because they are relatively expensive, epoxy polymers have not been used very widely as binders in PC products. Therefore, epoxy PC is used for special applications. Epoxy PC reinforced with glass, carbon or boron fiber is used in the fabrication of translucent panels, boat hulls and automobile bodies.

Furan Polymer Concrete :

Furan polymers are based on furfuryl alcohol, which is derived from agricultural residues such a corn cobs, rice hulls, oat hulls or sugar cane bagasse. The furan pre-polymer is usually cross-linked with furfuryl alcohol, furfuraldehyde to yield thermosetting polymers, high resistant to most aqueous acidic or basic solutions and strong solvents such as ketones, aromatics, and chlorinated compounds. The furan polymers are used as binders in mortars and grouts to achieve chemically resistant brick floors and linings. In addition to exhibiting superior chemical resistance, these floors have excellent resistance to elevated temperatures and extreme thermal shock.

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Polymerization :

Polymer- modified cementitious materials date back more than 70 years. In the 194G's they were developed for use on ships' decks and bridges. Polymers arc made from simple organic molecules that combine to form more complex structures through a process called polymerization. The polymers are dispersed in water. These are added to hydraulic cement, with or without aggregate or admixtures, depending on trip desired result.

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Advantages of adding polymers to concrete :

In Polymer- Modified Concrete, a report by the American Concrete Institute. Lists these advantages to polymer concrete: Increased bond strength Freeze/thaw resistance Abrasion resistance Flexural and tensile strengths Reduced permeability and elastic modulus How it works :

To the normal process of cement hydration, polymer modifications add a process of coalescence. As cement hardens, there form small spaces between the aggregate particles. These spaces arc what allow water to penetrate, and do damage in freezing conditions. Polymer particles coalesce to fill these voids. Thai's why the concrete becomes less permeable and better protected against freeing. Interestingly, polymer concrete does not produce bleed water. It makes an excellent overlay because it needs very little finishing. It is

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more accurate to say that it dries, than to call it curing. For that reason that it is used to resurface concrete. Applications & Advantages : There are several chemical systems for polymer concrete and mortar. Acrylic binders provide excellent environmental resistance and fast setting times. Epoxy resins exhibit high strength and low shrinkage during curing. They also provide toughness and resistance to chemical and environmental damage. Furan resins are formed from the polymerization or poly condensation of furfural, furfural alcohol, or other compounds containing a furan ring. They are commonly used in foundry binders, grinding wheels, refractories and other high-

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11 temperature applications Polymers resins are used in place of phenolics fiberboard binder applications. Polyurethane provides excellent flexibility, impact resistance and durability. Other chemical systems for polymer concrete and mortar include silicone, polyester, and vinyl ester.

The subject of polymer concrete has generated a lot of interest among researchers during the past decade. This is due to the many advantages that polymer concrete pavement offers compared to regular portland cement concrete. The advantages of polymer concrete, when compared to portland cement concrete include, quick curing and setting, reduced moisture sensitivity and permeability and improved mechanical properties resulting in reduced

pavement thickness to support the same load. These advantages will lead to attractive life

cycle cost benefits. Material properties and mix designs for PC with epoxy, methylmethacrylate and Polyester as the binder material have been investigated. It has been shown in this study that increased material cost of PC can be offset by the reduced thickness of the pavement. In order to develop life cycle cost information, it is necessary to obtain field performance data of PC pavement, especially in the composite design mode.

Applicaton of Polymer Impregnated Concrerte:

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a) b) c) d) e)

Keeping in view the numerous beneficial properties of PIC it is found useful in a

large no of applications some of which have been listed &discussed below Prefabricated structural elements Prestressed Concrete Marine works Desalination plants Sewage works Pipe & Disposal Works

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a) Prefabricated structural elements:

For solving the tremendous problems of Urban housing shortage, maintaining , quality econmy and speed ,builders had to fall back on prefabricated techniques of construction. At present due to the low strength of conventional concrete, the prefabricated sections are large and heavy ,resulting in costly handling and erection. These reasons have prevented wide adoption of prefabrication in many countries. At present, the technique of polymer impregnation is ideally suited for precast concrete .It will find unquestionable use in industrialization if building components .Owning to strength , much thinner &lighter sections could be used which enables easy handling and erection.

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b) Prestressed Concrete :
Further development in prestressed concrete inability to produse high strength concrete, compatible with the high tensile steel available for prestressing .Since PIC provides a high compressive strength of the order of 100 to 140 Mpa will be possible to use it for larger spans and for heavier loads.Low creep properties of PIC willl also make it good material for prestressed concrerte

c) Marine Works :
Aggressive nature of sea water ,abrasive and leaching action of waves and inherent porosity ,impair the durability of conventional concrerte in marine works. PIC, possessing high surface hardness ,very low permiabilty and greatly increased resistance to chemical attack is a suitable material for marine works.

d) Deslination Plants :
Deslination if sea water is being resorted augment the shortage of surface and ground water in many countries .The material used in the construction of flash distillation vessels in such works has to withstand the corrosive effects of distilled water ,brine and vapour upto a temp of 143 C. Carbon steel vessels which are currently in use are comparatively costly . e) Sewage Disposal Works : It is common experience that concrete sewer pipes deteriorate due to attack of effluents and when buried in sulphated infested soils. Further, in the sewage treatment plant, concrete structures are subjected to severe attack from corrosive gases particularly in sludge digestion tanks.

f) Impregnation of Ferrocement Products :

The Ferrrocement techniques of construction is being extensively used in manufacture of boats, fishing trawlers , domestic water tanks .Application of Polymerimpregate concrete due to its high sulphate and high resistance will prove to suitable material in the ssituations . References : 1. A. Blaga

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Research, National Research Council Canada, Canadian Building Digest 241, Ottawa,

2. A. Blaga. "Plastics", Division of Building Research, National Research Council Canada, Canadian Building Digest 154. Ottawa, 1973

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and J.J. Beaudoin. "Polymer Modified Concrete", Division of Building

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3. A. Blaga. "Thermoplastics" , Division of Building Research, National Research Council Canada, Canadian Building Digest 158, Ottawa, 1974.