Polymer Concrete Materials Research Articles

Fracture toughness determination for epoxy-based polymer concrete mixtures: Applicability of different rectangular beam and circular disc specimens

The purpose of this study was to examine the potential impact of the testing procedure, the shape of the test sample, loading method and sample size on the KIc value of polymer concrete (PC) materials. The research involved experimental investigations using five different testing techniques and specimen types, namely the single edge notched beam (SENB), short bend beam (SBB), semi-circular bend (SCB), edge notch disc bend (ENDB), and center cracked Brazilian disc (CCBD). A typical PC mixture made of mineral silicious aggregate, ML506 epoxy resin, chopped E-glass, and foundry sand filler. Despite the difference in the shape and loading type of the tested samples, the KIc data obtained from all groups of specimens are in good agreement with together and with the SENB proposed by RILEM. Depending on the test type, the KIc value varied from 1.43 to 1.74 MPa.m0.5 and the discrepancy between the data was mainly attributed to the type of loading (compression or bending) and the crack type (center crack or edge crack). The T-stress affects the fracture toughness for different testing samples and configurations. The lowest fracture toughness corresponds to the CCBD specimen (the center cracked disc loaded diametrically). The other test samples with edge cracks and loaded by a three-point bend setup showed KIc = 1.7 - 1.74 MPa.m0.5. Moreover, the fracture toughness data for PC mixtures can be achieved by utilizing sub-sized samples like SBB (for smaller amounts of PC material) instead of larger beam samples (i.e., SENB).

The performance of novel polymer mortar containing vinyl ester resin reinforced by fly ash and iron sand under compressive, tensile, dan flexural test

Polymer concrete is a type of advanced concrete widely used globally in the last few decades. It is suitable for a variety of applications such as in pipes, roadway pavements, and bridge decks. Concrete can also be used sustainably to mitigate CO2 emissions due to the partial or total replacement of cement normally used as a binder with polymer. Several studies have explored polymer concrete materials and their applications but only a very few references were made to the mechanical properties and utilization of polymer mortar. One of the polymers most widely used is vinyl ester due to some advantages such as excellent corrosion and chemical resistance. Therefore, this study focused on examining the materials and compositions used in vinyl ester polymer mortar mixtures as well as their compressive, tensile, and flexural strength. The process involved conducting a preliminary test to assess the materials used in order to have an optimal composition. This was followed by the combination of the vinyl ester (VE) and its catalyst hardeners, mepoxe (ME) and cobalt (CO), fly ash (FA), and Lumajang iron sand (LIS) to determine compression strength, density, and cost with due consideration for the workability. Moreover, tensile and three-point bending tests were also applied to the materials. The results showed that the optimal content for the VE:ME:CO:FA:LIS was 42,2:2,9:0,63:18,1:36 with a compressive, tensile, and bending strengths of 92.64 MPa, 12.19 MPa, and 106.18 MPa, respectively. It was concluded that the novel polymer mortar has excellent mechanical properties and can be further implemented into structural elements such as pipes, beam-columns, slabs, walls, and others.

Effects of waste rubber powder and resin content on the free shrinkage of polymer concrete

In this study, the effects of waste rubber powder (WRP) and resin content on the free shrinkage of vinyl resin polymer concrete (PC) were investigated for use in corrosive environments, such as wet flue gas desulfurization (WFGD). The mechanical properties, free shrinkage performance, microstructure, and pore structure of PC were examined with varying levels of WRP (0%, 2.5%, 5.0%, and 7.5% of binder volume) and resin content (23.1%, 24.7%, and 26.2% of total volume). The results indicated that increasing the proportion of resin in the PC material led to an enhancement in the strength of the samples. However, it was observed that high resin contents resulted in a significant increase in shrinkage. Specifically, when the resin content was elevated, the volume of the resin increased by 3% and shrinkage increased by more than 14%. Conversely, the inclusion of WRP had a negative effect on the mechanical strength but significantly reduced the shrinkage rate and exothermic peak during the curing process by over 50%. The primary factors found to be responsible for the reduction in shrinkage of PC is that the inclusion of WRP resulted in the formation of an appropriate air void system and the stress relaxation owing to the retardation of resin curing. Overall, the study revealed that WRP is a promising and sustainable filler for shrinkage reduction in PC, particularly in corrosive environments.

Modal Assurance Criterion as an iron cast and hybrid machine tool's body comparison tool

The paper presents the results of research on increasing the dynamic properties of the machine tool body. For this purpose, a hybrid body was manufactured, which was created by filling the free technological spaces in the cast iron body with a polymer concrete material. The modes of free vibrations, modal frequencies, amplitudes, and damping ratios were revealed using experimental modal analysis. In some cases, the amplitude value decreased by up to 68%, as well as the damping ratio increased by almost 109%. Then, using the MAC (Modal Assurance Criterion) method, the body with polymer concrete fillings was compared with the cast iron body to estimate the degree of similarity of the various modes of free vibrations of both structures. The obtained results in the range of 0.54–0.96 indicate high similarity between the vibration modes, which were revealed in both analyses.

Modeling the properties of lightweight polymer concrete produced from polyvinyl chloride and combined heat and power plant waste

Although concrete based on mineral binders is most commonly used in construction, polymer concrete is on the rise lately. This is due to the fact that polymer concrete allows to expand concrete usage in civil and industrial construction thanks to its properties. However, there is extensive research on including thermoplastic polymer. Construction polymer concrete materials have high compressive strength, as well as atmospheric, cold and chemical resistance, thus resulting in long term lifetime. This paper suggests a technological process of producing concrete based on polyvinyl chloride and lightweight porous aggregate, e. g. fly ash that comes from Vladimir combined heat and power plant (used to run on coal). There are up to 80 thousand tons of this aggregate in stock. It turns out that technological parameters of this process are strongly intertwined with compound. Research indicates that lightweight polymer concrete based on polyvinyl chloride and fly ash can be achieved under certain technological parameters. A new polymer concrete was created as a result of this research having the following properties: density - 800-830 kg/m3, compressive strength - 12-13 MPa, impact strength -16-18 kg/m2, coefficient of thermal conductivity - 0.16-0.18 Wt/m.K, frost resistance - at least a 100 cycles.

Statistical assessment on relationship between fracture parameters of plain and fiber reinforced polymer concrete materials

Polymer concrete is a relatively new concrete in which a matrix made of a polymeric resin material is used to bind the ingredients. In this paper, 288 specimens made of 72 different plain and fiber-reinforced polymer concrete mixtures (PC and FRPC) are prepared and tested to assess the fracture behavior under pure mode I and pure mode II conditions. The main purpose of this research is to determine the relationships between fracture load and work of fracture as two important fracture mechanics parameters using statistical clustering or trends analysis. The weight percentages of the ingredients were varied as 17–25% resin, 75–81% fine and coarse aggregates, and 0–2% glass fibers. A general comparison of results obtained from the PC and FRPC materials show that for a given mix-design, addition of glass fiber increases the work of fracture by about 10%. The assessment shows a good correlation between fracture load and work of fracture. Results also show that the relation between the fracture load and work of fracture obeys the dominantly linear curve. The scatter of results obtained for the FRPC material were higher than the data of PC mixture for both modes I and II. In addition, the fracture resistance characteristics of both PC and FRPC mixtures tested under mode II loading conditions are greater than the corresponding values of mode I case.

Modelling and dynamic simulation of polymer concrete material for machine tool structure of a lathe

Dynamic features such as natural frequencies and mode shapes for the machine tool structure are modelled using the finite element software in this work. A polymer concrete lathe bed structure is studied for the analysis. Polymer Concrete’s are finding a place in the machine tool industry as a structural material because of their high damping properties. Therefore, Basalt Fiber Polymer Concrete (BFPC), which is a mineral composite with epoxy resin as the matrix and Basalt aggregate as a filler material along with other curing and toughening agents, is considered as the material. Forces generated during the operation of the machine will be transferred to the structure through the carriage, guideways, etc. The force flow to the machine structure is modeled in the harmonic analysis. These forces generate vibrations on the machine tool that affects the dimensional accuracy of the machined components' surface finish. Therefore, the structures should reduce the amplitude of vibrations to get the required quality as well as the operational stability. For this purpose, the displacement-frequency and acceleration-frequency curves were plotted to explain the complex behavior of the configuration of the machine tool at various frequencies. Interferences for the structural design of the machine tool are provided from the obtained results such that failure should not occur at the resonance frequency of the machine.

Porosity, Permeability, and Compressive Strength after Freezing and Thawing of Permeable Polymer Concrete

Permeable pavements are one of the most widely employed low impact development techniques. In this study, the physical characteristics of permeable polymer concrete materials were assessed. For varying contents of silica sand, the porosity, permeability, and compressive strength were experimentally evaluated before and after freeze-thaw cycles. The results indicate that specimens with a high content of silica sand possess low porosity, low permeability, and high compressive strength. Additionally, under identical compaction efforts, specimens with greater content of silica sand had higher unit weights. After 300 freeze-thaw cycles, the compressive strength of the specimens reduced to approximately 60% of the initial value. The standards for moisture conditions associated with freezing and thawing of permeable concrete have not been established yet. Hence, it is necessary to develop testing standards that take Korean environments into consideration. Keywords: Permeable Pavement, Polymer Concrete, Permeability, Compressive Strength, Freezing and Thawing

Dynamic compressive and splitting tensile response of unsaturated polyester polymer concrete material at different curing ages

The present study performed quasi-static and dynamic compressive and splitting tensile tests on unsaturated polyester polymer concrete (UPPC) at four different curing ages (6 h, 3 days, 7 days, and 28 days). We examined a total of 136 specimens, specifically 24 cubic specimens and 12 cylindrical specimens for quasi-static tests and 45 cylinders and 55 FBD specimens for dynamic compressive and tensile tests, respectively. The experimental results indicated that UPPC exhibited rapid strength enhancement in the early stages of curing, and the natural curing condition-treated cubic specimens exhibited 6-h compressive and splitting tensile strengths of 40 MPa and 6.5 MPa, respectively, which was almost the 50–60% of the 28-day strengths. The UPPC is also sensitive to the strain rate, such that both the compressive and splitting tensile strengths exhibited significant increases following an increase in the strain rate. Conversely, the strain rate sensitivity decreased with the curing age. We deemed the CEB-FIP equation for normal cement concrete to be inadequate for estimating the strain rate sensitivity of UPPC.

Changes in the Strength of the Polymer Concrete Used in the Electroplating Vats Under Operational Load

Due to the strong and aggressive electrolyte media and thermal load, design of the electroplating vats in the copper industry often relies on the resin concrete. The article presents the results of the strength tests of the polymer concrete based on the "Derakane" resin, used in the construction of electroplating vats. Samples were taken from the real vats - both new and 17-year old. Strength tests included compression and bending tensile strength test. To assess the effect of operational conditions the tests were performed on the same-age vats, some of which were never used while others were subjected to the operational load. During the operation, the vats sustained load of the anode and cathode weights, cyclic electrolyte loading with a temperatures up to 60°C. As a result, it was noted that the operational conditions led to the increased strength of the polymer concrete material.

Mechanical behaviour analysis of polyester polymer mortars reinforced with tire rubber fibres

Tires effective reutilization has become an important research topic in recent years due to the stockpiles increase that creates environmental problems. Recent European regulations forbid the tires burning and landfilling, setting several recycling objectives. Within this context, the reutilization of tire rubber recyclates into cement and polymer concrete materials, as reinforcement or aggregate replacement, has received lately a great attention. The present work aim is to analyse the modifications induced by tire rubber addition in the mechanical properties of polyester based polymer mortars (PM). The effect of different tire rubber fibre amounts (0.1, 0.4 and 0.5wt.%) were analysed in this investigation. Plain polymer mortar was also prepared for comparison. Mechanical behaviour of both reinforced and plain polymer mortars formulations was assessed by flexural and compressive tests. Flexural and compressive strength improvements were particularly significant for PM trial formulation reinforced with the higher amount of tire rubber fibres. The observed trend on mechanical properties seems to indicate that higher increases could be achieved with higher amounts of tire rubber fibres. Thus, further experiments will be required in order to determine the critical amounts of rubber fibre reinforcement that define the turning points on material trend behaviour of PM.

An Outlook on the Application of Glass-Reinforced Plastic and Polymer Concrete Components in Bridge Construction

In general, the experience at inspection of motor road bridges and viaducts indicates the “water-proofing” system as one of the most vulnerable elements in a roadway structure. In many cases they are made with considerable deviations from specifications, violations of the engineering construction technology, etc.To manufacture a strong and durable roadway covering with a high wear resistance and resistance to the attack of corrosive media (water, salt, oil, etc.), the polymer concrete on the polyester, furfural acetone and epoxy, and the carbamide resin was studied. The most profitable material for the roadway pavement appears to be a polyester polymer concrete capable to harden at the subzero temperature and at the cost which is 2-3 times less than that of the epoxy material. Polyester polymer concrete materials possess the sufficient water resistance (Kb=0.7-0.85) and frost resistance (300-500 cycles). The high resistance to the attack of various acids and alkalis permits to obtain wear resistant coatings for bridge roadways.

Are Polymer Concrete Materials and Products Really Sustainable?

Sustainability is important in all engineering decisions. Every technical organization now has the objective to promote sustainability. Polymer concrete (PC), in order to have a rightful place in industry, must be sustainable. Based on several criteria, it can be shown that PC materials and products are sustainable. PC applications to be discussed include repair, concrete overlays, and precast products. When designed and constructed appropriately, PC materials and products are sustainable.

Testing and Specification of Polymer Concrete Materials in Singapore

Pure cement mortar and concrete possess disadvantages such as brittleness, low bonding or adhesion strength, low tensile strength, large drying shrinkage, low chemical resistance. In order to overcome these disadvantages, polymer concrete is used as a construction material in Singapore as the properties of polymer-modified (or polymer cement) mortar and concrete are superior to conventional cement mortar. In Singapore, new products or technologies can be found through distributers, agents, etc. Singapore is able to afford and try high quality products to maintain the quality of a building and structure. The importance of applying polymer to protect, repair, coat and strengthen concrete structures in Singapore have grown in the last two decades. To ensure and maintain the standards of construction and building quality, polymer concrete are used extensively in new developments in Singapore. In this paper, the mechanical properties and its corresponding testing methods for several types of polymer concrete used in Singapore are discussed. These products include mortar used to repair concrete spalling, acrylic polymer cementitious coating, waterproofing membrane, epoxy mortars and grouts, fibre reinforced plastic (FRP) and epoxy resin. In addition, the specifications for the above products used in Singapore’s Housing Development Board (HDB) are discussed in the paper as it’s a requirement for suppliers to test their products in accredited laboratories before it can be used.

Mechanical durability of an optimized polymer concrete under various thermal cyclic loadings – An experimental study

Investigating the tensile strength (σt) and mode I fracture toughness (KIc) of polymer concrete (PC) materials due to their quasi-brittle behavior is of great interest to engineers. In this paper, the mechanical durability of an optimized epoxy PC, focused on the two above properties, are experimentally investigated under three different freeze/thaw cycles. The diametrally compressed un-cracked Brazilian disc (BD) and the single edge notch bending (SENB) test configurations are used to measure the split tensile strength and fracture toughness, respectively. The thermal cycles; 25°C to −30°C (cycle-A), 25°C to 70°C (cycle-B) and −30°C to 70°C (cycle-C) applied for 7days to the test specimens; are chosen according to the climate of Iran in different seasons. Experimental results show the noticeable influence of thermal cycles, especially cycle-B, on both fracture toughness and tensile strength. Heat-to-cool thermal cycle-A and thawing thermal cycle-B indicate the most increase and reduction, respectively on both σt and KIc in comparison to ambient conditions. Also, it was shown that the fracture toughness and tensile strength of tested PC materials are reduced by increasing the mean temperature values of thermal cycles.

Fire Reaction and Mechanical Performance Analyses of Polymer Concrete Materials Modified with Micro and Nano Alumina Particles

Article Fire Reaction and Mechanical Performance Analyses of Polymer Concrete Materials Modified with Micro and Nano Alumina Particles was published on June 1, 2013 in the journal Restoration of Buildings and Monuments (volume 19, issue 2-3).

Review on Application of Polymer Concrete in Singapore

Singapore is a small island country, but has won renown as uncorrupted government and high quality products. Independent testing and inspection played a very important role for this achievement[1]. The Housing and Development Board (HDB) is the sole public authority in Singapore and was set up as a statutory on 1 February 1960. Within 45 years, it built more than 700,000 flats housing approximately 86% of the population. Every year, around 40,000 new flats (about 400 blocks) are built up to meet the demands. In March 1992, HDB launched the 15-year main upgrading programme (MUP) to vying the finishes and facilities of old estates up to the standard of those in the new towns. The upgrading programme is a conscious effort by the government to provide a better living environment, strengthen existing community ties and enhance the value of our flats. The potential size of the upgrading program is approximately 370,000 units spread across 20 years, which works out to be 350 blocks per year. To ensure and maintain the high standards of the housing quality, Polymer concrete materials including polymer modified cement mortar, epoxy or PU floor screed and injection materials, and fibre-reinforced plastic (FRP) materials are extensively used in the new and upgrading projects. In this paper, the various applications of polymer concrete composites in Singapore are described and discussed. The various categories of polymer concrete composites are extensively used in Singapore’s public and private projects. To ensure and maintain the high standards of the building quality, independent testing and inspection plays a very important role. Through implementing a quality control program to ensure high standards in product quality and performance requirements, Housing & Development Board (HDB), Singapore's public housing authority and statutory board under the Ministry of National Development, screens and provides a comprehensive selection of quality products needed for HDB construction projects through HDB's Materials List [2] with a set of product evaluation requirement. The development of the requirements and specifications for various polymer concrete composite products are also described and discussed

Development of a Cost-Effective End-Use Application for Thermoset Composite Wastes as Reinforcement for Polymer Concrete Materials#8217;

Development of a Cost-Effective End-Use Application for Thermoset Composite Wastes as Reinforcement for Polymer Concrete Materials#8217;

Behaviour of Cement and Polymer Mortar Materials to Rapid Freeze-Thaw Cycling

The aim of this investigation work is threefold: 1) To analyse and quantify freeze-thaw resistance of glass fibre reinforced epoxy polymer mortars, comparatively to both normal cement mortars and plain epoxy polymer mortars; 2) To determine glass fibre reinforcement effect on freeze-thaw behaviour; and 3) To evaluate the reliability of ASTM C666M-03 test methodology for the assessment of freeze-thaw resistance of polymer concrete materials. For this purpose several test specimens, normal cement mortars, plain and glass-fibre reinforced epoxy polymer mortars were submitted to freeze-thaw cycling between 36 up to 300 cycles, according to the above norm. Dynamic elasticity modulus, with basis on fundamental resonance frequency measurements, was calculated every 36 cycles, and the correspondent relative dynamic elasticity modulus was determined for each cycling period. In order to assess the reliability of this non-destructive test methodology, three specimens of each formulation were withdrawn at regular periods and tested in bending and compression. Relative mechanical strengths, as function of conditioning period, were compared with corresponding relative dynamic modulus of elasticity.

Structural analysis of FRP reinforced polymer concrete material

The paper deals with a study of precast elements made of polyester polymer concrete (PPC) reinforced with glass fibre rebars (GFRP). The paper describes the properties of the materials, which were tested on a microscopic scale using different experimental techniques such as porosimetry, scanning electron microscopy and petrography. Likewise, characterisation in a macro-scale was carried out to define the mechanical properties of the material (modulus of elasticity, stress–strain curve, ultimate strength and bond). Based on the latter properties, a relatively simple method is presented to estimate the ultimate bearing capacity of beams under bending load. The calculation method has been verified by testing beams and full-scale elements.