Polymer concrete

Polymer concrete is a type of concrete that uses a polymer to replace lime-type cements as a binder. One specific type is epoxy granite, where the polymer used is exclusively epoxy. In some cases the polymer is used in addition to Portland cement to form Polymer Cement Concrete (PCC) or Polymer Modified Concrete (PMC).[1] Polymers in concrete have been overseen by Committee 548 of the American Concrete Institute since 1971.

In recent developments, the term "polymer-based concrete" (PBC) serves as an umbrella term for subtypes, which are distinguished by their binder, composition and performance.[2][3]

Composition

In polymer concrete, thermoplastic polymers are often used to form a film at the interface between the cement matrix and the aggregate, subsequently improving bonding and lowering permeability,[2][3][4][5] however more typically thermosetting resins are used as the principal polymer component due to their high thermal stability and resistance to a wide variety of chemicals. Polymer concrete is also composed of aggregates that include silica, quartz, granite, limestone, or other material. The aggregate should be of good quality, free of dust and other debris, and dry. Failure to fulfill these criteria can reduce the bond strength between the polymer binder and the aggregate.[6]

Uses

Polymer concrete may be used for new construction or repairing of old concrete. The adhesive properties of polymer concrete allow repair of both polymer and conventional cement-based concretes. The corrosion resistance and low permeability of polymer concrete allows it to be used in swimming pools, sewer structure applications, drainage channels, electrolytic cells for base metal recovery, and other structures that contain liquids or corrosive chemicals. It is especially suited to the construction and rehabilitation of manholes due to their ability to withstand toxic and corrosive sewer gases and bacteria commonly found in sewer systems. Unlike traditional concrete structures, polymer concrete requires no coating or welding of PVC-protected seams.[7] It can also be used as a bonded wearing course for asphalt pavement, for higher durability and higher strength upon a concrete substrate, and in skate parks, as it is a very smooth surface.

Polymer concrete has historically not been widely adopted due to the high costs and difficulty associated with traditional manufacturing techniques. However, recent progress has led to significant reductions in cost, meaning that the use of polymer concrete is gradually becoming more widespread.[7][8]

Polymer concrete in the form of epoxy granite is becoming more widely used in the construction of machine tool bases (such as mills and metal lathes) in place of cast iron due to its superior mechanical properties and a high chemical resistance.

Properties

The exact properties depend on the mixture, polymer, aggregate used etc.[9] Generally speaking with mixtures used:

  • The binder is more expensive than cement
  • Similar or greater compressive strength to Portland concrete[1]
  • Faster curing
  • Good adhesion to most surfaces, including to reinforcements
  • Good resistance against corrosion[10]
  • Lighter weight (slightly less dense than traditional concrete, depending on the resin content of the mix)[10]
  • May be vibrated to fill voids in forms
  • Allows use of regular form-release agents (in some applications)[11]
  • Product hard to manipulate with conventional tools such as drills and presses due to its density. Recommend getting pre-modified product from the manufacturer[12]
  • Small boxes are more costly when compared to its precast counterpart however pre cast concretes induction of stacking or steel covers quickly bridge the gap.

Mechanical Properties and Behavior

High compressibility, tensile strength and flexibility, along with greater durability characterize polymer concrete. [1][13]Compared with Portland cement concrete, the most common concrete type utilized in construction, polymer concrete better bonds to steel materials and other concrete materials. In polymer concrete, the polymer binders that are central to the composition exhibit a low elastic modulus making it far more flexible than traditional cement concrete that contain mineral binders exhibiting high elastic modulus. The rapid polymerization of polymer-based concrete enables greater ability to repair structural issues. [2][3][5]

Thermal and Chemical Properties

The thermal expansion coefficient of polymer concrete is approximately twice that of traditional cement concrete. However, the combination of a low elastic modulus and a high thermal expansion coefficient induces interfacial shear stresses. There is a possibility to avoid these stresses so long as the potential risk are considered in the design phase of the polymer. In high temperature environments, the elastic modulus of these polymer matrices are greatly reduced so this must be considered in structural applications. [2][3] In low temperature environments, there is good long-term durability with respect to freeze and thaw cycles.[1]

The low permeability of water in polymer concrete is attributed to the hydrophobicity of the polymers that compose the concrete. As a result, polymer concrete is far more suitable for chemically aggressive environments compared to traditional cement concrete. [5][10][14]

Limitations

The upfront costs involved with developing polymer concrete is much larger than traditional cement concrete. For example, the primary binding agents in polymer concrete are more expensive than the mineral binders in cement concrete.[15]

Specifications

Following are some specification examples of the features of polymer concrete:

Material Density
kg/m3		 Compressive strength
Urea formaldehyde polymer concrete 2260[16] 37 MPa (5,400 psi)[17]
Polyester concrete N/A 95 MPa (13,800 psi)[18]
Epoxy concrete N/A 58 MPa (8,400 psi)[19]
Polymer Modified Concrete N/A 31 MPa (4,500 psi)[20]

Sustainability

Contrary to traditional cement concrete, polymer concrete is posited as a sustainable alternative as it incorporates the use of recycled aggregates, industrial by-products, and waste within its composition. Although the input costs for developing polymer concrete and polymer-based concrete can be greater than traditional cement concrete, the incorporation of these materials extends the life of the concrete through greater resistance to environmental degradation. [5]

References

  1. ^ a b c d "Page 37". in Kim, D-H (1994). "Properties of composites". Composite Structures for Civil and Architectural Engineering. pp. 35–75. doi:10.1201/9781482271430-7. ISBN 978-0-429-25707-0.
  2. ^ a b c d Ostad-Ali-Askari, Kaveh; Singh, Vijay P; Dalezios, Nicholas R; Crusberg, Theodore C (October 26, 2018). "Polymer Concrete". International Journal of Hydrology. 2 (5): 630–635 – via MedCrave.
  3. ^ a b c d Salami, Babatunde A; Bahraq, Ashraf A; Moin ul Haq, Mohd; Ojelade, Opeyemi A; Taiwo, Ridwan; Wahab, Sarmed; Adewumi, Adeshina A; Ibrahim, Mohammed (July 2024). "Polymer-enhanced concrete: A comprehensive review of innovations and pathways for resilient and sustainable materials". Next Materials. 4 (100225) – via Elsevier Science Direct.
  4. ^ Figovsky, Oleg; Beilin, Dmitry (2013). Advanced Polymer Concretes and Compounds. doi:10.1201/b16237. ISBN 978-0-429-16848-2.
  5. ^ a b c d Odeh, Ali; Taha, Omar S; Almakhadmeh, Mahmoud N; Al-Rababah, Ahmad; Al-Fakih, Amin (August 2025). "Comprehensive review of polymer-based concrete: properties, sustainability, and challenges". Environ Sci Pollut Res Int. 32 (36): 21271–21300 – via PubMed.
  6. ^ L J Daniels, PhD Thesis, University of Lancaster, 1992 Polymer Modified Concrete
  7. ^ a b "Polymer Concrete Manholes & Precast Concrete | Armorock". Genevapolymerproducts.com. 2020-03-23. Retrieved 2022-04-15.
  8. ^ "Home". napsco.co.
  9. ^ Ramachandran, V. S. (1996). Concrete Admixtures Handbook: Properties, Science and Technology. William Andrew. ISBN 978-0-8155-1654-5.
  10. ^ a b c "Polymer concrete". ULMA Architectural. Retrieved 2026-02-12.
  11. ^ "Concrete Form Release Agent - Walttools". Retrieved 2025-09-19.
  12. ^ "Polyester concrete, if not concrete, what else?". MaterialDistrict. 2007-07-18. Retrieved 2025-09-19.
  13. ^ Bharani, S; Ramesh Kumar, G; Suryavarman, R (June 12, 2025). "An investigation on properties of polymer modified concrete and its application - A review". AIP Conference Proceedings. 1 (020094) – via AIP Publishing.
  14. ^ Adamu, Musa; Labib, W.A.; Ibrahim, Y.E.; Alanazi, Hani (May 15, 2025). "Mechanical Behavior and Durability Performance of Concrete Reinforced with Hybrid Date Palm and Propylene Polymer Fibers". Polymers. 17 (10): 1350 – via PubMed Central.
  15. ^ Cholewinski, Aleksander; Si, Pengxiang; Uceda, Marianna; Pope, Michael; Zhao, Boxin (February 20, 2021). "Polymer Binders: Characterization and Development toward Aqueous Electrode Fabrication for Sustainability". Polymers. 13 (4): 631 – via PubMed Central.
  16. ^ Suh, Jung Do; Lee, Dai Gil (June 2008). "Design and manufacture of hybrid polymer concrete bed for high-speed CNC milling machine". International Journal of Mechanics and Materials in Design. 4 (2): 113–121. Bibcode:2008IJMMD...4..113S. doi:10.1007/s10999-007-9033-3.
  17. ^ Alzaydi, A. A.; Shihata, S. A.; Alp, T. (June 1990). "The compressive strength of a new ureaformaldehyde-based polymer concrete". Journal of Materials Science. 25 (6): 2851–2856. Bibcode:1990JMatS..25.2851A. doi:10.1007/BF00584892.
  18. ^ Ohama, Y., ed. (2003). Polymers in Concrete. doi:10.1201/9781482271829. ISBN 978-0-429-07765-4.
  19. ^ "Power-Patch Concrete Epoxy Kit (Grey)". Interstate Products Inc. Retrieved 2021-06-04.
  20. ^ "10 Minutes Concrete Mender". Concrete Repair. Retrieved 2024-06-21.

Further reading

  • Mehta, P. Kumar; Paulo J. M. Monteiro (2013). "12.7 Concrete Containing Polymers" (PDF). Concrete: Microstructure, Properties, and Materials. McGraw Hill Professional. p. 505to510. ISBN 978-0-07-179787-0.
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