Create a concrete conglomerate with superior performance to traditional ones using polymers

When we talk about reinforced concrete, we tend to imagine a structure of great resistance, where the cement acts as the glue for a mixture calibrated, made of aggregates and water which, with the help of reinforcing irons, allows the construction of elements of great load-bearing and resistance.

The word itself, reinforced concrete, expresses the main element that allows the other components to be wrapped, creating a monolithic structure.

So, cement is the means by which the mixture is allowed to consolidate, creating the structural elements that we see, such as walls , decks, floors, attics and many other things.

What are polymer concretes

Today we know that cement is no longer the only element that allows the mixture to stiffen, and not it is more what allows you to achieve the best structural performances ever.

In fact, when it is born, polymer concrete expresses greater compressive, tensile and flexural strengths than ordinary concrete.

It is also more resistant to corrosion, chemical attack and wear, making it suitable for a variety of applications, including industrial floors, bridges, wall panels, acoustic barriers, prefabs and many other elements.

Polymer concretes, also known as RPC (Reactive Powder Concrete), are composed of a high percentage of reactive powders, aggregates fines, fibers and a minimal amount of water. This makes them much more resistant and long-lasting than traditional concretes.

There are different types, including epoxy, polyester, acrylic and more, depending on the type of resin used.

If we examine, for example, epoxy concrete, we can say that it is a type of polymer concrete in which an epoxy resin is used as binder instead of traditional Portland cement. This binder binds the aggregates together to form a very strong and long-lasting material.

Epoxy resin offers several advantages compared to traditional concrete. First, it is extremely resistant to chemicals, which makes epoxy concrete a great choice for applications in aggressive environments, such as water treatment facilities, chemical warehouses, and industrial facilities where there may be exposure to corrosive chemicals.

Additionally, epoxy resin can provide a stronger and more flexible binder than traditional concrete, as it can resist tensile loads and prevent cracks and breaks. This makes epoxy concrete a popular choice for applications such as industrial flooring, concrete structure repairs and protective coatings.

How to balance aggregates with episodic resin in concrete

The process of balancing the aggregates with the epoxy resin in epoxy concretes is crucial to achieving the desired properties of the concrete.

This can vary based on several factors, such as the specific application, the type of epoxy resin used, and the properties of the aggregates themselves.

A common way to balance epoxy resin with aggregates is through a testing process, in which several samples are made with different proportions of resin and inert, until the mixture that provides the desired properties is found.

However, there are also some general guidelines that can be followed. For example, for a standard epoxy concrete, the amount of resin can be between 10% and 20% by weight of the total mix. Aggregates, which may include sand, gravel and other similar materials, will then make up the bulk of the mix.

It is also important to consider the specific properties of the aggregates and the epoxy resin. For example, some aggregates may have high absorbency, which would mean they may require more resin to ensure all elements are completely covered.

Finally, the balance of resin and aggregates can also be influenced by the mixing technique used, and therefore it may be necessary to recalibrate the proportions to achieve the desired consistency, ensuring that the concrete can be worked correctly.

How to make a correct mix to obtain epoxy concrete

Preparing a correct mix for epoxy concrete requires attention and care.

The choice of epoxy resin and aggregates (such as sand and gravel) is crucial, in fact these must be of high quality and suitable to the specific application.

The proportion of epoxy resin to aggregates may vary depending on the specific application and the desired properties of the concrete, as we have view.

First of all you will need to mix the epoxy resin with the hardener according to the manufacturer's instructions. Next, you will slowly add the aggregates, making sure they are completely covered in the resin.

Continue mixing until you obtain a homogeneous consistency. In this operation it will be important to use appropriate equipment to avoid exposing operators to resin fumes.

Once mixed, the epoxy concrete mix should be placed in the desired area or shape as quickly as possible, given that the epoxy begins to harden as soon as it is mixed with the hardener.

Once the epoxy concrete has been placed, it should be left to cure for the necessary time, which can be variable depending on the specific resin used, but usually requires at least 24 hours.

Fire resistance of polymer concretes

Like all medals, polymer concrete also has a side of great quality, as we have seen, but it also has a side that should not be underestimated, which is expressed in low fire resistance.

In fact, the fire behavior of polymeric concretes is not as well studied as that of traditional concretes. However, polymeric materials generally tend to be more sensitive to heat and flame than inorganic materials such as concrete.

One of the main problems is that, at high temperatures, the chemical bonds between polymer molecules can break, causing the material to decompose. This can lead to the formation of toxic gases and can trigger structural collapse.

It would therefore be important to carry out further research to better understand how to improve the fire resistance of polymeric concretes, with the addition of fireproof additives or the use of design techniques to reduce the impact of heat on the material.

Automatic translation. We apologize for any inaccuracies. Original article in Italian.