1.

0 Introduction

Concrete is a material which is combining cement, water, and aggregates (fine and
coarse).Concrete is the result of chemical reaction between water and cement. Concrete is
easy availability and low cost of its ingredients. The strength of concrete will be effect by the
porosity of concrete. The cause of porosity due to high temperature produced during
hydration which lead to high volume of water leaving the concrete.

In improving the tensile strength, adhesion, acid resistance, wear resistance and reduce
porosity of ordinary concrete or to find other concrete with excellent performance and cost-
effectiveness, polymer concrete is one of the options. Because of it, polymer concrete is an
important consideration to civil engineering compared to the other. Beside it , polymer
concrete is less produced carbon dioxide (CO2) compared to Portland cement which
produced high volume of CO2 that contribute to global warming and greenhouse effect.
However, this type of concrete is brittle material as high compressive strength but low tensile
strength which able to lead to crack development and produced fail concrete. To overcome
such problem, fibre reinforcement is introduced with acting as crack arrestor in polymer
concrete to strengthen tension and also reduce the crack development. This concrete is called
into fibre reinforcement polymer concrete.

Polymer concrete were first used in 1950s as single layer of coal tar epoxy was removed
from the concrete substrate and inoculated with fine aggregate. In 1970s polymer concrete
was developed rapidly. Polymer concrete can be applied to rapid repair of concrete works
because polymer concrete become hardened faster than ordinary concrete, but this concrete
will more expensive than ordinary concrete.

Polymer concrete is a composite material which is combining with the organic polymer
materials. It is very specials material as it has no liquid binding system, must be very
carefully to control it. Polymer concrete made of synthetic resin or impregnated with gaseous
monomer as a cementations materials and with a corresponding curing agent. Further, the
type of resins and hardeners must be properly select.

Even though polymer concrete have brought the new dimension. But these materials are
mainly done in the laboratory, and their ability is limited to a limited part.
POLYMER CONCRETE

The composite using polymer to supply or replace as binder:

1. Polymer concrete (PC) - where polymer act as binder to replace cement to form
concrete
2. Polymer Modified Concrete (PMC) - which polymer act as supplement by mixing
along with the cement paste

EXP: Latex-Modified Cement Concrete

Pre-Polymer Modified Cement Concrete

3. Polymer Impregnated Concrete (PIC) -when the concrete is under the process of
soaking and polymerization

Figure1.1：Polymer concrete
2.0 Type of Material

Polymer concrete is the result of monomer/aggregates mixture through process of

polymerization and it also composed of aggregates that include :

1. silica – component by silicon and oxygen which able to found at earth’s crust . Able
to found in crystallized state or amorphous state and composed 1 atom of Silicon (Si)
and 2 atom of oxygen (O2) to form SiO2.
2. quartz – having the same component with silica (silicon and oxygen) , however in a
continuous framework of silicon–oxygen tetrahedra (SiO4) . It able to found after
feldspar where located at the Earth's continental crust.
3. granite - a light-colored igneous rock and the main component of quartz and feldspar
with small amounts of mica, amphiboles, and other minerals.
4. Limestone - is a sedimentary rock mainly composed of calcium carbonate (CaCO3)
and forms through the accumulation of shell, coral, algal, and fecal debris . It also
able produced through the precipitation of calcium carbonate from lake or ocean
water.
5. aggregates - a broad category of coarse particulate material used in construction,
including sand, gravel, crushed stone, slag, recycled concrete and geosynthetic
aggregates
6. other high quality material

Figure2.1: Silica Figure2.2: Quartz

 Figure2.3: Granite Figure2.4: Limestone

Figure2.5: Sand Figure2.6: Gravel

Figure2.7: Crushed stone Figure2.8: Slag

PREPARATION

1. Using well-graded aggregate to reduce the void and also increase the density of
concrete.
2. The concrete must prepacked and vibrated in a mould as able to remove the trapped
air inside the concrete that able cause porosity and honeycomb might lead to long
term strength reduction.
3. May ‘top-up’ some admixture to modify the concrete to achieve desirable strength .
 4. The performance of polymer concrete is depend on polymer properties , type of
aggregates , curing temperature , type and dosage of admixture and etc.
5. The aggregates must free of clay , dust and organic impurities as it will interfere the
process of hydration and also the bond between the aggregates.
6. The resin dosage in the range of 10 to 20% by weight of polymer concrete and binder
content range from 5 to 15% of the total weight.
7. Polymer binder : thermoplastic or thermosetting polymer

In polymer concrete, thermoplastic polymers are used ,but more typically thermosetting
resins are used .

THERMOPLASTIC POLYMER

A synthesis plastic or resin (polystyrene) and becoming soft above a specified

temperature and rehardening on cooling without change the properties. The polymer bond
held together through intermolecular forces, which weaken frequently with increasing
temperature, under pressure which result in a viscous liquid. Thus, thermoplastics may be
reshaped by heating according the shape of mould poured into.

THERMOSETTING POLYMER

A prepolymer in a soft solid or viscous liquid state having the property of becoming
permanently hard and rigid when heated or cured. Curing is induced by a suitable
radiation under high pressure (200 Celcius) or or by mixing with a catalyst.
Thermosetting polymer is stronger compared to thermoplastic polymer so it is suitable
used in high temperature application , however unable reuse as a source for newly plastic
due to permanent shape.

PREPRATION OF POLYMER MODIFIED CONCRETE

Latex-Modified Cement Concrete

1. The lattices is a white milk like suspension.

2. The lattices able suspended in water with the help of emulsifiers and stabilizing
agents.
3. Both elastomeric and glassy polymers in the lattices is the purpose of modifying
cement concrete.
4. The latex admixtures can be stored in an adequate exposure that helps the mixture to
retain the integrity and also not suffer physically (freezing , thawing , alternative
wetting and drying ).

Pre- Polymer Modified Cement Concrete

1. Lower the water cement ratio and filling of pores within the concrete which will help
to advance the durability of the concrete compared with the conventional concrete and
also the compressive strength of concrete.
PREPARATION OF POLYMER IMPREGNATED CONCRETE
1. A well-designed cement concrete is produced with adequately moist cured and an
optimum strength gained.
2. The moisture is removed by drying process which carried out heating the
structural element to surface temperature in order from 120 to 150 degree Celsius
with an air oven.
3. After the complete removal, the concrete surface is cooled until it reach the safe
levels about 35 degree Celsius. This temperature will avoid flammability occurs.
4. The concrete is now taken to a vacuum sucker, where the entrapped air is removed
within the concrete structure. The time and the degree of application of vacuum
will decide by quantity of the monomer.
5. The concrete after the process is dipped in a solution of monomer. It is soaked for
a long time till the desired depth of penetration of monomer is obtained. Used
external pressure like air or nitrogen gas to speed up the penetration.
6. After that, the surface is covered with plastic sheet to prevent the evaporation of
the monomer.
7. The thermal catalytic method of polymerization is carried out by heating the
catalyzer monomer to reach the required temperature level from 60 degrees to 150
degree Celsius.
8. The concrete structure is then under a cooling process.
3.0 Properties of the material

As we know, concrete is made by mixing of coarse and fine aggregate, cement and water.
Type of concrete comprises polymer concrete which is used polymer to replace the cement
paste and act as a binder. The composites using polymer also can form a Polymer Modified
Concrete and Polymer Impregnated Concrete. Pproperties of polymer concrete is based on
the amount and properties of polymer in the concrete, micro fillers, humidity of aggregate's
content and the type and mix proportion of aggregate used will lead to more accurately.

From what we know, polymer is act as a binder. By using the binder in polymer concrete
materials is quite low instead of using the cement due to its cost consideration. First and
foremost, to prepare the polymer concrete, it needed to mix the polymer resin with aggregate.
General using of polymer resin is polyester resin, epoxy resin and furan resin. However,
mostly the unsaturated polyester resin will used in resin system due to its low cost, can be
found easily and good in mechanical properties. To illustrate about the content of polymer
resin, epoxy resin is more good in mechanical properties and can good term in durability
when subjected to a difficult environment like freezing and thawing cycles, compare to others
but it required a higher cost .Unless the polyester resin has been added micro fillers and
silane coupling agent which can same as the level of epoxy resin.

Besides the function of micro fillers is to reduce the void of aggregate thus increase the
strength of polymer concrete. Additional of micro filler like fly ash, silica fume and calcium
carbonate. These can increase the mechanical properties and ensure its workability. Fly ash
can be found from the coal burning in power plant and very useful in polymer concrete like
reduce absorption of water and improve the workability when mixing of fresh polymer
concrete thus produce a polish surface. Adding 15% of fly ash is more higher than adding
silica fume cause it will increase 30% of compressive strength of polymer concrete compare
to Portland Cement Concrete .Furthermore, the effect of fly ash on polymer concrete made
with epoxy, ester and polyester that can reduce amount of polymer used and increase the
compressive strength. Modulus of elasticity also increased however the tensile strength and
flexural strength is decreased while increasing amount of fly ash as well.

Aggregates materials also used in many type in polymer concrete.For example ,crushed
stone, river sand, foundry sand, granite, and gravels. These materials better in small spherical
size because it will reduce its porosity ,low penetration to water and solution of
aggregate .Eventually, it will increase the chemical resistance of polymer concrete indeed.
Humidity of aggregate affect the strength of polymer concrete so that water content shall not
exceed 0.1% to 0.5%.Amount of binder needed will minimized and can ensure that all the
aggregate particles binding properly while mixing proportionally of fine and coarse aggregate
which decrease the content of void in it and maximum the bulk of density.

Adhesion of aggregate to most surface is takes place when occur through a thin layer of
resin around the aggregate.But adhesion at interface is lack of chemical bonding due to the
secondary forces between two phases. By using silane coupling agent,provided chemical
bonding to improve the interface adhesion between the resin and aggregate and also lead to
increase the compressive strength of polymer concrete ultimately.

Curing process is play an important role which is determined the final properties of polymer
concrete. Faster curing in strength improvement after one day of room temperature compare
to normal Portland cement concrete. Polymer concrete may be either used for new
construction or repairing of old concrete because of curing rapidly. Lower density of the
polymer concrete but it still need to depend on the resin content used for mixing. The earlier
of the development of strength in polymer concrete, the most useful in range of precast
application.

Materials Properties:

Bending strength: 20MPa

Compressive strength: 90MPa

Modulus of elasticity: 22000MPa

Specific gravity: 2200kg/m3

Water absorption: 0.05%by weight

Surface roughness: 25um

Figure5.1: Compressive Strength Figure5.2: Surface Roughness

Figure5.3: Water Penetration Figure5.4: Flexural Strength

Summary of mechanical properties of Polymer Concrete:

Author Resin Aggregate Variables Properties Brief Findings

and micro Evaluated
filler used

-Epoxy resin has a

superior properties
than the polyester
Crushed Resin type, Compressive resin.
quartzite, silane strength, -Compressive strength
Mani et al. Epoxy, siliceous treatment, flexural
polyester goes up by 30% for
sand, and and micro strength, and the polyester resin and
calcium filler tensile 36% for the epoxy
carbonate addition strength resin by mixing of a
silane coupling agent.

-The compressive and

flexural strengths of
the polyester resin are
greatly improved on
adding of the micro
filler.
 -14% of resin content
maximum the
Resin Compressive compressive and
content, strength, flexural strength
Vipulananda Epoxy, Ottawa sand, silane flexural
n et al. polyester blasting sand treatment, strength, and -The presence of glass
compaction, tensile fibers increases the
and glass strength flexural strength,
fiber content compressive strength.

-Silane treatment
increases the flexural
strength by 25%.

Vipulananda Epoxy, Ottawa sand, Temperature, Compressive -Compressive strength

n and Paul polyester blasting sand strain rate, strength, increases with curing
aggregate tensile temperature.
type, and strength
curing -Maximum strength
conditions was obtained for one-
day room temperature
curing followed by
one-day curing at
80C.
-Use of gap graded
aggregate resulted in
highest compressive
strength.

Polymer Modified Concrete (PMC):

Polymer Modified Concrete is formed when polymer is mixed along with the Portland
Cement. It also known as Polymer Cement Concrete. Based on the type of modified used,
polymer modified concrete can be classified into Latex-Modified Cement Concrete and
Prepolymers- Modified Cement Concrete. In latex-modified cement concrete, both
elastomeric and glassy polymers have been used in lattices for modifying. The natural rubber
latex, neoprene and rubber latex are some of the commonly used elastomeric latex. The glass
polymers have a greater modulus of elasticity, strength and they undergo a brittle type of
failure. Whereas in prepolymer- modified cement concrete has a good in adhesion property,
the modulus of rupture is more than twice from the conventional concrete and the formation
of the micro cracks is less occurs. Properties of PMC are its can able to bond strongly with
old concrete,and to resist the penetration of water. Additional of the polymers make the
concrete mix workability, hence it reduce the amount of water needed when mixing to form
concrete and also increases the setting time of the concrete which is achieve the early strength.
Besides that the polymer modified concrete consist of at least 3 % more amount of entrained
air than the plain concrete. This additional amount of entrained air will reduce the modulus of
elasticity of the concrete (PMC). It also improved adhesion because PMC act as an adhesive
to enable overlay to stick to a variety surfaces. The traditional cement paste consist of
calcium silicate hydrates and calcium hydroxide connected by the weak Van Der Waals
Forces thus result in a poor tensile strength and flexural strength and micro cracks occur
easily under stress.On the other hand, polymer film lining in the capillary pores which
prevent the micro cracks and impeding the fluid flow in PMC.These characteristics has made
PMC for rehabilitation pavements, bridge decks. Furthermore, the properties of the PMC are
controlled by the polymer-cement ratio rather than the water-cement ratio. The polymer-
cement ratio is the weight ratio of the total amount solid in a polymer to the amount of
cement. Moreover, the polymer film formed in structure of PMC create the sealing effect
which is increase in waterproofness or water tightness, resistance to chloride ion penetration
and other deleterious materials that can gain a higher resistance against such undesirable
effect. It is a dense and non-shrinking material and have a high corrosion resistance to low
permeability and high resistance to abrasion. Finally, the porosity of the concrete generally
tend to decrease with an increase polymer content. This promotes the permeability and
freeze-thaw durability.
Polymer Impregnated Concrete (PIC):
-PIC is produced when the cement concrete is treated by soaking and polymerization.
-Types of monomer used are methyl methacrylate, styrene and other thermoplastic monomers.
-Porosity is greatly reduced thereby increasing its durability when it is exposed to chemical
polluted environments.
-Polymers produce a more compact structures and can seal the cracks.
-The porosities of the Ordinary Portland Cement and PIC were 17.3% and 9.8% respectively.
-Decrease in porosity could sealing the voids during the cement hydration and micro cracks
by the polymer therefore increasing the durability and strength of the PIC.
-The flexural strength of polymer impregnated concrete is usually about 15N/mm2 and this is
slightly higher than the highest strength plain concrete.
-The polymer impregnated concrete possess less creep and shrinkage problem due to a lesser
number of void.
-The polymer impregnated concrete is highly resistant to acid attack, sulfate attack, and
chloride attack when compared to PMC.
-The elastic modulus in a range from 30 to 60 N/mm2. It is similar to the value that is
obtained from high strength concrete which is about 45N/mm2.
4.0 Advantages and Disadvantages of the material

Advantages of polymer concrete:

1. Polymer concrete
The polymer concrete has high chemical and biological resistance and low permeability than
the other common concrete. Due to it low permeability and resistance corrosive the polymer
concrete is used widely in building structure that contain liquid and corrosive chemical such
as swimming pools, drainage channels, and sewer structure applications. The polymer
concrete also widely uses in the sewer structure because it requires no maintenance and easily
to clean it. The polymer concrete also commonly uses in the modern kitchen and baths due to
the zero-water absorption of the polymer concrete. Apart form that the polymer concrete also
has high strength. This is because the polymer concrete can withstand high compression and
abrasion so the polymer concrete is widely use in building the carpark and roadways. Besides,
the polymer concrete also can withstand high impact and high durability to the wide range of
temperature such as freezing and thawing. The polymer concretes more common use in the
construction industries because its provide a long life to the building and the polymer
concrete properties make it become an ideal choice for constructing a building. In addition,
polymer concrete also excellent in absorbing noises and vibrations. The polymer concrete
also can be cut easily with masonry drills and grinders. Hence, the polymer concrete can fix
to the size of the building by cutting it.
2. Polymer modified concrete

The polymer modified concrete almost have the same advantages like polymer concrete.
Polymer modified concrete has a high performance because it is resistance to abrasion, high
compression strength and higher durability than other common concrete. Because of this
characteristic the polymer modified concrete is commonly used to build bridge and road. The
polymer modified concrete also has high durability to the temperature because it is resistance
to thawing and freezing compare to the polymer concrete. Besides that, polymer modifies
concrete has a lower price than the polymer concrete and always use in the restoration work
because it can finish in the limited time. The polymer modified concrete has lower water
absorption because it has a lower water/cement ratio and this also cause the drying shrinkage
of polymer modified concrete become lower.
 3. Polymer impregnated concrete

The polymer impregnated concrete has higher workability because it is selling in precast
form. This is because the process to produce the polymer impregnated concrete is difficult
and complicated. The polymer impregnated concrete also has high performance and high
durability. The polymer impregnated concrete also resistance to chemical substance and
resistance to thawing and freezing. This is because the acid resistance of polymer
impregnated concrete has been observed to improve when exposed to HCl. （Sri Ram
Srinivas Dudala，2014）The polymer impregnated concrete also has high tensile strength
and compressive strength, it depends on the amount of polymer that is added in the concrete.
Sri Ram Srinivas Dudala stated that “the polymer loading on the compressive strength in
polymer impregnated concrete using methyl methacrylate as monomer and with a polymer
loading of 6.4% strength of the order of 144Mpa have been obtained using radiation
technique of polymerization”. This show that the higher the amount of polymer loading, the
higher the compression and tensile strength.

Disadvantages of polymer concrete

1. Polymer concrete

Although polymer concrete has many benefits, it is very expansive. This is because the small
boxes polymer concrete is costlier than the precast polymer concrete. Besides that, the
monomer in polymer concrete may be volatile and this situation will cause the polymer
concrete brittle. For instance, when polymer concrete compared with fibre reinforced
polymer concrete, the fibre reinforced polymer concrete will not tend to develop cracks
because polymer concrete is strong in compression but weak in tension while the fibre
reinforced polymer concrete is opposite. Apart from that, the strength and density of polymer
concrete is hard to control, so most of the polymer concrete is sell in precast form. Lastly, the
polymer concrete is difficult to manage well. This is due to the precast polymer concrete in
the early strength is important because it will permit the building to withstand high stresses,
so using the precast polymer concrete the contactor must do research about the transporting,
the temperature at the day, handling and etcetera.
 2. Polymer modified concrete

The polymer modified concrete has low chemical resistance than the polymer concrete. This
is because the polymer modified concrete consists of Portland cement and the Portland
cement is not a suitable material that cans resistance to corrosive materials. Besides that,
polymer modified concrete has lower modulus of elasticity than unmodified concrete because
the polymer modifies concrete consists of polymer latex. The lower the amount of polymer
latex is used, the higher the modulus of elasticity of polymer modified concrete.

3. Polymer impregnated concrete

Although the polymer impregnated concrete is selling in precast form, the process of
manufacturing polymer impregnated concrete is very complicate and very dangerous. The
process is using the ultraviolet radiation and some chemical agents. Besides that, the polymer
impregnated concrete is also very expensive. This is due to the monomer that used in the
process and the process is more complicated than the unmodified concrete.
5.0 The Usage of the Material In Building Or Construction

Usage of polymer concrete can supplant the lime-type cements as a binder. With addition
Portland cement, it can form several types of polymer concrete such as, polymer cement
concrete (PCC), polymer mix concrete, polymer impregnated concrete, polymer modified
concrete, etc. (Wikipedia on 7 march 2017)

Figure5.1: Polymer impregnated concrete Figure5.2: Polymer modified concrete

- Most of us know that polymer concrete only use for repairing old concrete in order to save
labour cost and renew it to a stronger building structure.

-Polymer concrete consists of low permeability and corrosive resistance which allows it be
able to use in drainage channel to reduce the rate of corrosion.

Polymer Impregnated concrete

Figure5.3: Polymer-Impregnated Concrete (PIC)

-Polymer Impregnated Concrete (PIC) is surface impregnation of bridge decks.

-to increase durability to chemical because the bridge decks constructed in high salt water and
moisture exposure.
-damaged structure able to rectify by polymer impregnated concrete to help in preservation of
stone monuments.

-Conclusion for Polymer Impregnated concrete

- Improving structural properties

- Increase the resistance of water absorption

- reduces in corrosion of steel reinforcement.

Therefore , PIC is highly recommended in construction industry .

Polymer also use in other aspects too. For example , tunnel lining with smooth profile ,
storage tanks for aggregate frames , pipes , in road and bridge construction and etc.

Figure5.4.Polymer Concrete For Figure5.5: Polymer Concrete For

Reparation Of Airport Runway Reparation Of Airport Runway

Polymer concrete also applied in airport runway reparation. The reason why they use it in
airport runway is because emergency repair in runway will be costly. Therefore, polymer
concrete is applied to assures the repair will be cured to full hardness within short times and
lasts forever .

Figure 5.6: Polymer Concrete Pipe

Polymer concrete is needed for piping applications that have high strength and resistant to
corrosive chemicals .
Other than that , polymer concrete able to used as cover with epoxy . It’s because of epoxy
polymer concrete has high bonding strength with concrete and other surface
surfaces .There’re few applications of epoxy polymer concrete can be apply which are floor
topping , Frenches sumps and etc.

Figure 5.7: Epoxy Polymer Concrete

Figure 5.8: Polymer Concrete Drainage Channel and HDDE Drainage Channel

Besides that, polymer modified concrete can be used in repair and rehabilitation of old
damaged concrete and used for floor construction in frozen due to the PMC can resist to a
high freeze and thaw cycles. This especially gains a good application for food factories for
restore food purpose. Other than that, polymer modified concrete can be prepared for
construct steel bridge and ship decks surfaces. It also can construct for produce cementing
ceramic tiles to concrete and for the concrete structure that is more subjected to large doses of
de-icing salts.
 Figure 5.10: Floor Construction in frozen

Figure5.11: Cement ceramic tiles Figure5.12: De-Icing salt

Case Study

MI Polymer Concrete Pipe SD Bhd is a company who producethe polymer concrete pipes
in Malaysia. MI Polymer Concrete Pipes Sdn Bhd - was formed in 2009 to continue the
previous research and development into manufacturing Polymer Concrete Pipes carried out
by MI Pipes Sdn Bhd.

MI Polymer Concrete Pipe SD Bhd. produces a unique proven product that incorporates the
latest technology. This Polymer Concrete Pipe is not only stronger than anything else
available in the market it is totally non corrosive and easier to install. By using the latest
technology the company can produce a superior pipe which can compete in price with the
existing conventional RC and VC Pipes.

The Polymer Concrete Pipe they produce has been developed by Peter J Boatman who has
over 45 years’ experience in the manufacture of composite products. He was the JV partner in
MI Pipes SD Bhd and supplied all the technology for them to produce Polymer Concrete and
GRP Pipes.

The standard range of products includes the following:

Jacking Pipes, Sewer Pipes, Pipe Fittings, Manholes, Pipe Rehabilitation, PCCP
Rehabilitation, Pipe Slip Liners

Figure 6.1: Jacking Pipes Figure 6.2: Pipe Rehabilitation

Conclusion

As a conclusion, it is well known that polymer concrete is a special building material that
far better properties and durability than ordinary Portland cement concrete. Polymer concrete
may be used because of rapid curing; excellent bond to cement concrete and steel
reinforcement, high strength, and durability and it was extensively used as repair material.

The presence of the polymer in the PIC not only encapsulates the cement mortar but also
seals the voids formed during the hydration of the cement, which prevents cement-acid. The
micro fillers are also often added to the polymer concrete mixture to reduce the void content
in the aggregate mixture, thereby increasing the strength of the polymer concrete.

Even though polymer concrete is more expensive than ordinary Portland cement concrete,
but According to its maintenance requirements are low, durability and other parameters to
judge, will be very feasible.

This material has excellent potential for use in various fields and it will bring a large
variation to the construction industry.
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