What is polymer concrete? Polymer additives in concrete Polymer concrete made with acrylic resins

Polymer concrete (also called cast or artificial stone, polymer cement, concrete polymer and plastic concrete) is an alternative type of concrete mixture in which a polymer (synthetic resin) is used instead of the standard binder. Thanks to this component and cheaper mineral fillers, the composition is highly resistant to moisture and frost, but at the same time the price of cast stone is lower. Let's take a closer look: polymer concrete - what is it and is this material really worth using in construction as a replacement for conventional concrete?

To answer this question, we first determine what components plastic concrete includes.

Composition of polymer concrete

The lion's share of the polymer cement composition is occupied by filler and it is added in two types at once:

Ground – talc, graphite powder, andesite flour, ground basalt, mica and other raw materials.
Coarse – gravel, crushed stone, quartz sand.

Important! When producing cast stone, metal dust, cement lime and chalk should not be used.

Resin is used as a “fastening” component:

furano-epoxy (must meet the requirements of TU 59-02-039.13-78);
furfural acetone (FAM), meeting the standards of TU 6-05-1618-73;
urea-formaldehyde (corresponds to GOST 14231-78 standards);

Polyester resin is often used to hold the filler together, as it is cheaper than others. It is also allowed to use methyl methacrylate monomer (methyl ester) that meets the standards of GOST 16505.

In addition, the cast stone contains hardeners, plasticizing additives and coloring components. They must also meet the requirements for chemical additives (GOST 24211).

Depending on the quantity and type of components, polymer concrete of different qualities can be obtained.

Types of polymer concrete

Depending on what kind of filler (or rather its fraction) you added to the cast stone solution, you can obtain material both for creating light decorative elements and for constructing more massive structures.

Based on this, the following classes of polymer concrete are distinguished:

Super heavy. The density of such concrete is from 2.5 to 4 t/m 3. Components of at least 2-4 cm in size are used as fillers for super-heavy building materials. This type of concrete is used for the construction of structures that are subject to great pressure (load-bearing structures, foundations).
Heavy (density from 1.8 to 2.5 t/m3). This type of plastic concrete is suitable for the production of decorative cast stones that imitate marble and other expensive stones. The size of the heavy polymer concrete aggregate should not exceed 2 cm.
Easy. Since the density of such material is 0.5-1.8 t/m 3, it is usually classified as structural-thermal insulation class concrete. This type of concrete polymer is distinguished by high heat conservation rates. The filler used for its preparation is the same fraction as for heavy polymer concrete, only its quantity changes.
Ultralight. The density of this composition is from 0.3 to 0.5 t/m 3, so it is used for thermal insulation work and in the construction of internal partitions. The fillers most often used are various shavings, perlites, cork and polystyrene with a fraction of no more than 1 cm.

Healthy! Most often, polymer concrete is used for the manufacture of: kitchen countertops, sinks, window sills, columns, steps, monuments, fireplaces, fountains, floors, vases and much more.

There is also the lightest artificial stone, with a filler no larger than 0.15 mm. This material has found application in the production of decorative elements.

Properties of polymer concrete

If we compare polymer concrete with ordinary concrete, it is worth noting the fact that in many of its characteristics the composition with the addition of resins outperforms conventional mixtures. Polymer concrete has the following properties:

density – 300-3000 kg/m3;
resistance to compression – from 50 to 110 MPa;
bending resistance – from 3 to 11 MPa;
abrasion in the range of 0.02-0.03 g/cm 2 ;
temperature limit – from 60 to 140 0 C;
elasticity – from 10,000 to 40,000 MPa;
thermal conductivity coefficient – 0.05-0.85 W/m K;
moisture absorption volume – 0.05-0.5%;

The strength characteristics of polymer concrete are 3-6 times higher than those of conventional concrete. The same applies to tensile strength, which is almost 10 times higher for concrete polymer.

It is also worth taking into account the chemical passivity of modern concrete composition, which is determined according to GOST 25246-82. From this regulatory document it follows that at 200 0 C Celsius, the chemical resistance of concrete polymer components to nitric acid will be no less than 0.5%, and to hydrochloric acid, ammonia or calcium solution no less than 0.8%.

Based on this, we can conclude that polymer concrete, which contains resins, has all the qualities necessary for the construction of various objects.

Advantages and disadvantages of casting stone

Polymer cement is often used in the construction of structures that cannot be made from ordinary concrete due to its fragility. Thanks to the polymer composition, structures will be less susceptible to deformation or destruction.

In addition, polymer concrete has the following advantages:

Due to the high water resistance and resistance of the concrete polymer to temperature changes, drops of water on the surface of the finished product evaporate almost immediately, as a result of which cracks and other defects do not form.
The surface of the polymer cement remains smooth throughout its entire service life, so polymer concrete products do not get dirty.
The variety of colors allows you to create from this material products stylized to resemble expensive natural rocks (granite, marble, etc.).
The material is recyclable with the possibility of reusing concrete polymer.
Structures made from this lightweight concrete do not require additional processing.

If we talk about the disadvantages of modern material, it is worth highlighting the following disadvantages:

Flammability of polymer concrete.
The high cost of some binding components (however, if you use ground flour as a filler, the costs will be significantly reduced).
It is not always possible to find on sale everything necessary for the production of such a composition.

Speaking about the production of polymer concrete, it is worth considering possible options for producing such concrete.

Methods for producing cast stone

The process of producing concrete polymer can be continuous or batch.

Continuous production

In this case, we are talking about large-scale production, for which you will need to purchase the appropriate equipment:

Vibrating table
Stirrer.
Compressor system with gun.
Silicone matrices.
Hood.
Grinding and polishing machines.

To purchase everything you need you will have to spend about 250,000 rubles. Even if you take into account that you will make some of the equipment yourself, the most expensive tools will have to be purchased. Therefore, we will not dwell on this production method and will consider a more accessible technology.

Making polymer cement at home

Knowing what polymer concrete is, it becomes obvious why this material is most often used for the production of countertops and decorative elements for suburban areas. Fortunately, you don’t need specialized equipment to produce it at home.

To make polymer cement with your own hands:

Rinse and clean the filler. After this, dry it until the moisture content of the crushed stone or gravel is 0.5-1%. If you use wet aggregate, the strength of the finished product will decrease.
Sift the sand and remove impurities from it.
First pour crushed stone into the concrete mixer, then sand and aggregate and mix the components for 2 minutes.
Add water and mix everything again.
Soften the binder component (resin) with a solvent or simply by heating the solid mass.
Add a plasticizing additive, stabilizers and other components to the resin. Mix them separately from the aggregate for 2 minutes.
Add hardener.
Mix all ingredients for at least 3 minutes until you get a creamy mixture.
Pour the resulting mixture into a paraffin-lubricated matrix or prepared formwork. Try to immediately fill in the volume of composition that will completely fill the mold. Polymer concrete sets very quickly, so you need to act quickly.
Level the surface and compact the mixture on a vibrating table.
Wait a day and remove the finished product from the matrix.

At this point, the production of polymer concrete can be considered finished.

The article provides a step-by-step master class on making a countertop of a conventional size with your own hands. Using this guide, you can create an “eternal” countertop made of artificial stone, spending 2 times less money compared to the market cost.

The undoubted advantage of polymer concrete (or artificial granite) is the ability to make a simple product at home. This does not require special equipment - only hand tools from your home workshop. We will tell you how to create a simple lightweight tabletop with an area of approximately 1.2 square meters. m and 30 mm thick in an economical design.

To work you will need:

Equipment - several clean buckets, a spatula, measuring containers.
Tools - mixer, compressor with spray gun (optional), vibrating table (optional), grinder, mallet.
Ready-made matrix - for a simple tabletop, a box of a given depth (30 mm) can be assembled on the first prototype.
Moisture-resistant plywood (not laminated!), cut in the shape of the future tabletop, 30 mm smaller in size. The thickness of the sheet is equal to the thickness of the tabletop minus 15 mm, i.e. 30 - 15 = 15 mm. The sheet should have holes Ø 20 mm with a pitch of 100-150 mm. Structure the surface of the plywood, make a deep notch.
Materials for the coating layer (for 3 liters of the finished mixture):
- transparent spray gelcoat (or “under the brush”) - 2 l;
- white composite granules - 0.2 l; gray - 0.4 l; black - 0.4 l;
- hardener Luperox K-1 - 0.04 l.
Materials for the polymer concrete itself (for 15 liters of the finished mixture):
- polyester casting resin - 5 l;
- aluminum hydroxide - 2 l;
- pourover - 9 l;
- Luperox K-1 hardener - 0.03 ml.
Materials for the filling layer (for 5 liters of the finished mixture):
- casting resin - 4 l;
- aluminum hydroxide - 1.5 l;
- pigment paste - 0.02 l;
- hardener Luperox K-1 - 0.03 l.

Operating procedure

Stage one. Applying the finishing layer. It is applied first, because it is closely adjacent to the matrix. This layer is done with gelcoat. If you don’t have a spray gun, you can apply the mixture with a brush into the matrix and tap it with a mallet. Please note that for this you will need a gelcoat marked “for brushing”, or with a corresponding mention in the instructions.

Spray Granit method. Mix all components (gelcoat, granules and hardener) thoroughly according to the instructions and load them into the spray gun tank. You can use any container instead of a tank. The nozzle of the gun must have a diameter of at least 2 mm. Then spray on the matrix until a layer of 5 mm is formed. Externally, the layer will look like gray granite. The type can be varied by changing the proportions of the granules.

Stage two. After the gelcoat has dried, you can lay the polymer concrete itself, or rather, install plywood on it. Having mixed all the components together (add the hardener last!), pour 5-6 mm along the top of the gelcoat and install the plywood. The mixture should be pressed through the holes, and the top of the sheet should be recessed 5-10 mm from the edges of the matrix. Level the sheet with a mallet and remove excess solution.

In the case of producing an all-concrete product (without plywood), reinforcing fiberglass mesh should be laid every 10-15 mm of the layer.

Stage three. After the polymer concrete has dried, a filling layer should be laid. To do this, mix all the components and pour the plywood into the matrix. All “liquid” work should be carefully tapped with a mallet to remove air. The product can be disassembled after 1 hour.

Stage four. Finish the edges with a grinder and, if necessary, paint the tabletop.

In this case, plywood is used as a lightening and reinforcing layer; moreover, it reduces the cost of the structure. You can also create a sink, but this will require additional equipment - collapsible forms and a vibrating table.

Countertop calculation

In the previous article we conducted a comparative analysis of the cost of components. The table below calculates the approximate cost of the materials that were needed to make the countertop.

The result was a volume of material of 25 liters or 0.025 cubic meters. m. They can be used in different ways. For example, cast a solid concrete tabletop or slab 30 mm thick. Then its area will be equal to:

S monolith = 0.025 / 0.03 = 0.83 sq. m

At the same time, the cost of 1 sq. m of such a product will be equal to: 78.42 / 0.83 = 95 cu. e.

If we use plywood as a solid filler, we get twice the area and a significantly lower specific gravity of 1 square meter. m. Plywood occupies almost 50% of the volume (we assume 45%), which means that the area of the lightweight economy countertop will be equal to:

S lightened = 0.83 + 45% = 1.2 sq. m

Cost of 1 sq. m will be equal to: 78.42 / 1.2 = 65.35 y. e.

For comparison, 1 sq. m of finished countertop to order costs an average of 120-140 USD. e.

Care of polymer concrete products

The exceptional properties of coating rigidity and structural strength allow polymer concrete products to be handled in the most careless manner. A well-made element is quite difficult to damage even on purpose. There are no kitchen utensils that can destroy the polymer coating. It can withstand any household chemicals, abrasives, and scrapers. After final drying, the resin loses its ability to adhere to substances used in everyday life and in a home workshop. We can say that all efforts to preserve the appearance are invested in these products at the creation stage.

When choosing a finished product that is on sale (for example, a sink), you can be guided solely by your taste and wishes. Sinks, countertops and other plumbing fixtures can withstand repeated installation and reinstallation, and allow you to drill holes in any place without chipping or special tools (a simple crown is enough).

At home, you can produce not only countertops, but also more complex products - bathtubs, sinks, decor. All you need is skill and desire for results. Polymer concrete is the material of the future, thanks to which everyday things become more reliable, lighter and more accessible.

Drainage pipes are one of the areas of production of the PBT company, Polymer Concrete Technologies, which is located in St. Petersburg and produces such materials as: drainage pipes, drainage, sewer pipes, fittings for drainage pipes, drainage wells (including covers for drainage wells), drainage trays, water pipes (HDPE pipes), corrugated cable ducts, mine pipes and much more, in particular polymer sand products, namely polymer sand tiles, polymer hatches, polymer sand tiles and drainage trays (polymer sand trays).

We are ready to offer you the most favorable terms of cooperation! We are confident in the quality of our products and offer the best prices for drainage pipes and drainage systems, as well as for water pipes (HDPE pipes) and polymer sand products (polymer sand tiles, polymer sand tiles, drainage tray).

Drainage pipes - polyethylene, concrete, or any other pipes that collect (or, depending on the purpose, release) water from the ground.

Drainage 63, 110, 160, 200 mm can be purchased wholesale and retail.

Drainage pipes with geotextiles perfectly protect the entire drainage system from unwanted soil getting into it; the dronite geotextile material retains the smallest particles of soil and allows water to pass through perfectly.

Drainage wells are provided for cleaning the drainage system, for example, drainage wells are washed with water under high pressure, which washes out all the unwanted soil from the drainage pipes.

Fittings for drainage pipes and various adapters are made of high-strength material to reliably connect drainage pipes to each other. Able to withstand both high and low temperatures.

Drainage trays are designed to drain excess water into special tanks; the PBT company offers you drainage trays at a special price! And the quality of the drainage trays will make you become our regular customer! The drainage tray is made of polymer-sand materials, which form the basis for its durability.

HDPE pipes (Polyethylene pipes) are pipes made from low-density polyethylene. Manufactured for pipelines transporting water (also for drinking and household water supply) and any other liquid and gaseous substances. HDPE pipes are confidently replacing steel and concrete pipes, having a number of advantages, such as significantly low cost, excellent performance characteristics, quick and easy installation of pipes, allowing the use of trenchless technologies.

Drainage pipes, HDPE pipes, Polyethylene pipes, PE pipes, water pipes (pipes for water), sewer pipes, gas pipes (pipes for gas), pressure pipes, mine pipes, as well as everything for drainage and drainage systems (drainage wells, storm water inlets, covers for drainage wells, covers for storm water inlets) you can buy from the PBT company at the best prices in St. Petersburg.

Polymer sand tiles can withstand both cold weather with a thick layer of snow and sultry heat under the scorching sun, thanks to the special proportions of the mixture of sand and polymer. Polymer sand tiles look great and please with their appearance. In addition, for wholesale buyers we have a special price for all polymer sand products.

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Polymer concrete: composition, types, features, application technology and reviews

Polymer concrete is a special building material that is used as a binding element and also to replace lime cement. In some cases, the polymer is used as an addition to Portland cement. It is a universal, durable composite substance obtained by mixing various mineral fillers with synthetic or natural binding agents. This advanced technical material is used in many industries, but is most common in the construction industry.

Kinds

Three types of polymer concrete are used in construction. Next, we will take a closer look at their manufacturing technology, scope of application and compositions in order to have a general understanding of polymer concretes and their modifications.

Polymer compositions for concrete (polymer-modified concrete)

This type of concrete is made from Portland cement material with modified polymers such as acrylic, polyvinyl acetate and ethylene vinyl acetate. It has good adhesion, high bending strength and low permeability.

Acrylic polymer modified concrete is characterized by durable color, which is why it is in great demand among builders and architects. Its chemical modification is similar to the traditional cement variation. The amount of polymer is usually from 10 to 20%. Concrete modified in this way has a lower degree of permeability and higher density than pure cement. However, its structural integrity is significantly dependent on the Portland cement binder.

Concrete may take longer to degrade if it has high density and less surface area. A relative improvement in the chemical resistance of the polymer-modified material to Portland cement is possible in an acidic environment.

Polymer impregnated concrete

Polymer impregnation for concrete is usually made by incorporating a low-density monomer into hydrated Portland cement, followed by radiation or thermal catalytic polymerization. The modular elasticity of this type of concrete is 50-100% higher than that of conventional concrete.

However, the modulus of the polymer is 10% greater than that of normal concrete. Thanks to these excellent characteristics, among the many options for using polymer building materials, we can specifically mention the production of:

decks;
bridges;
pipes;
floor tiles;
construction laminate.

The technology behind the incorporation process involves drying the concrete to remove moisture from its surface, using the monomers in a thin layer of sand, and then polymerizing the monomers using heat flow. Consequently, concrete surfaces have lower water permeability, absorption, abrasion resistance and generally high strength. Also, to increase wear resistance, resistance to cold and moisture, polymer varnishes are used for concrete, brick, stone, floors, etc.

Polymer concrete

It has nothing in common with our usual Portland cement. It is formed by combining stones with a polymer binder that does not contain water. Polystyrene, acrylic and epoxy resins are the monomers that are widely used in making this type of concrete. Sulfur is also considered as a polymer. Sulfur concrete is used for buildings that require high resistance to acidic environments. Thermoplastic polymers, but most commonly thermoset resins, are used as the main polymer component due to their high thermal stability and resistance to a wide range of chemicals.

Polymer concrete consists of aggregates that include silica, quartz, granite, limestone and other high-quality materials. The unit must be of good quality, free from dust, debris and excess moisture. Failure to meet these criteria may reduce the bond strength between the polymer binder and the aggregate.

Features of polymer concrete

Modern building material differs from its predecessors. It has the following characteristics:

High resistance to chemical and biological environments.
Compared to cement-concrete products, it has less weight.
Excellent noise and vibration absorption.
Good weatherability and UV resistance.
Water absorption.
Can be cut using drills and grinders.
Can be recycled as crushed stone or crushed for use as road base.
Approximately 4 times stronger than cement concrete.
Good thermal insulation properties and stability.
Ultra-smooth finish that promotes efficient hydraulic flow.

Usage

Polymer concrete can be used for new construction or renovation of old material. Its adhesive properties make it possible to restore both polymer and conventional cement-based concrete. Low permeability and corrosion resistance allow it to be used in swimming pools, sewer systems, drainage channels, electrolytic cells and other structures containing liquids or harsh chemicals. It is suitable for well construction and rehabilitation due to its ability to resist toxic and corrosive sewer gases and bacteria commonly found in plumbing systems.

Unlike traditional concrete structures, it does not require coating or welding of protected PVC joints. You can see the use of polymer concrete on city streets. It is used in the construction of road barriers, sidewalks, drainage ditches, and fountains. Also on the street, a polymer coating for concrete is added to asphalt during the construction of open areas, runways and other objects that are located in the open air and are constantly exposed to external atmospheric influences.

Reviews

Polymer concrete has not been widely adopted due to the high costs and difficulties associated with traditional production technologies. However, recent progress has led to significant cost reductions, meaning its use is gradually becoming more common. Despite all its advantages over conventional concrete, there are opinions about hidden negative environmental factors, which often occur due to improper production, the use of low-quality components and improper proportions.

Also, the technology for producing polymer concrete has many nuances and secrets that no one wants to reveal. And of course, as reviews note, the market price of polymer concrete is quite high. This is due to the difficulties of its production and the expensive components that are used to create it.

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Technologies for the production of polymer concrete and the production of products from it

Polymer concrete (otherwise known as cast stone) is a material that combines the strength and beauty of natural stone with an affordable price (thanks to cheap mineral additives) and ease of manufacture. The possibility of using almost any filler (sand, granite and marble chips, glass and many others) guarantees a variety of polymer concrete products. And the presence of a polymer binder makes them durable, resistant to frost, water and overheating.

Let's look at typical technological processes for producing polymer concrete, as well as the possibility of creating it yourself.

Polymer concrete manufacturing technology

What will you need?

To obtain the product you need:

The filler is of a fairly coarse fraction (sand, crushed stone, coarsely crushed glass).
Finely ground aggregate, reducing the cost of the material. This is a powder made from graphite, quartz or andesite.
Binder - about 5 percent will be needed. For this purpose, one of the polymer resins is used. For example, polyester (unsaturated), urea-formaldehyde, furan, epoxy.
Hardeners, plasticizers, special modifying additives, dyes.
Release agent and gelcoat for outer coating.

Production methods

The production process can occur using batch or continuous technology.

In the first case, the containers used to make the material must be washed after each completed cycle. But it is possible to make polymer concrete in a very ordinary bucket or concrete mixer.
Continuous technology is used mainly in large industries. At the same time, they work harmoniously, organizing a single chain, special injection molding machines, dispensers and automatic mixers.

The following video talks about the production and spraying of lightweight polymer concrete:

To make casting stone, you will need a mold well coated with a special release agent (otherwise it will be impossible to remove the finished product). The mold can be made of silicone, fiberglass, metal or even chipboard (budget option).

A layer of gelcoat of the desired color is applied to the release paste.
A composite mixture consisting of the above ingredients, previously well mixed in a concrete mixer, is placed inside the mold. In large industries, where the volumes are very large, the mixture is placed in a mold using a concrete paver. If the products are small and the technological process is periodic, then this is done manually.
Now it is necessary that the laid mixture be subjected to vibration (vibration compaction). The time of this procedure is approximately two minutes. In a factory, a resonant vibration platform is used for this; in small production, a vibration table is used.

In production conditions at a polymer concrete manufacturing plant, if necessary, heat treatment is carried out for faster hardening of parts. In other cases, they wait for the natural completion of this process.

We will tell you about machines, molds and other equipment for the production of polymer concrete products below.

Necessary equipment

Features of choice and costs

Those who dream of using continuous technology and significant volumes by organizing large-scale industrial production will need special conveyor equipment. Which will include machines for dosing, mixing, casting, finishing, as well as a mechanized warehouse.

All this will cost a tidy sum of several million dollars. If you limit yourself to only branded turnkey equipment, then the costs will be significantly less - from 30 to 50 thousand dollars.

But it is still not always possible to find money for a purchase, especially in our difficult times. However, you can get by with even less money. If you purchase all the necessary cars and other things separately. And make some things yourself. Read more about this option below.

List of equipment and devices

So, here is a list of equipment and devices that you cannot do without:

A ready-made vibrating table will cost about 27 thousand rubles. If you want to save money, weld the table yourself using two-millimeter metal corners (60-gauge). We weld an industrial-type vibrator to the table - you’re done.
A mixer that will combine all components into a homogeneous mixture. If you purchase a powerful vacuum device of European quality, you will have to pay about 10 thousand dollars. But you can also use a domestic concrete mixer or construction mixer. It will be much cheaper - the cost depends on the volume and power. It’s even cheaper to make the mixer yourself from an iron barrel and an electric drive with a gearbox.
You will also need a compressor system with a gun. Without it, you won’t be able to apply the gelcoat evenly. The pistol costs between $50 and $100. You can take car compressors - two from ZIL will be enough. They are connected in parallel and attached to metal platforms mounted on a strong frame.
Molds made of fiberglass or silicone are not yet widely available. They can be ordered for specific products (for example, window sills) from a specialized company. Or make molds yourself, starting with a cheaper material - chipboard with lamination.
An exhaust hood will be required - at the casting stage, production is characterized by harmful fumes. Accordingly, we will purchase personal protection: gloves, respirators.
For finishing work you will need electric tools: grinding and polishing machines. And also a drill, jigsaw, grinder, router (if necessary).

We will talk about emissions into the atmosphere from the production of polymer concrete further.

This video will tell you about another method of producing polymer concrete:

As mentioned just above, during casting there is a release of harmful components.

In particular, it is styrene, which is found in resins used as a binder. As soon as we open a hermetically sealed container with such resin, the evaporation of poisonous gas begins.
In addition, the hardener (usually methyl ethyl ketone peroxide) is also extremely dangerous. However, it is not volatile and requires only protecting your hands with rubber gloves.

These facts force polymer concrete manufacturers to carefully equip the casting room, making it airtight, installing a powerful hood above the table, and not forgetting about their own protection (respirator). And if all these measures are followed, and the air escaping into the hood is cleaned, then there will be no emissions into the atmosphere (after all, the room is sealed).

Read below to learn how to make elastic polymer concrete yourself (with your own hands).

DIY creation

And now we’ll talk about how to make small products from fashionable cast stone yourself, spending a minimum of money. For example, these could be flower pots, countertops, window sills (especially popular, as they are warmer than marble or granite).

Choosing a room and its arrangement

First you need to think about the premises - you will need 80 square meters of total area. It is advisable to look for a suitable house somewhere on the outskirts. And 12 square meters will immediately need to be fenced off for the casting room, and you will have to try to seal all the cracks as much as possible. To prevent styrene from leaking.

In the center of this room we make a table on a frame made of iron corners, covering it with a chipboard tabletop. We set its surface level - this is important! We install a hood above the table - a metal box with an electric motor.

To make it light, we attach fluorescent lamps on top. We put the same table in the next room - for finishing and other work. Here we will place tools and containers for drying chalk and sand (low metal boxes).

Necessary raw materials

Required raw materials:

River quartz sand (packaged in 20 kilograms). It needs to be dried well.
Sifted chalk - we also dry it.
Polyester resin - bought in 20 liter buckets.
Hardener, gelcoat, release paste.

You will need a clean plastic bucket for stirring, a 450-watt hammer drill and a construction mixer (we will attach a hammer drill to it, weld a drill for perforating - we get a mixer).
We make the form from laminated wood boards, making it collapsible. It is convenient to apply the release paste with a brush, rubbing it with a nylon stocking.
We dilute the gelcoat with resin (adding 10 percent of it) and apply it with a flute brush. We do this twice. Make sure that the hairs from the brush do not stick.
Having mixed the resin with the hardener in a clean bucket, add 15 percent chalk, and then add sand in portions. The mass should become viscous. To remove air bubbles, tap the bucket on the floor from time to time.
Once ready, pour the solution into the mold. Now let’s smooth the surface: two people take the form (certainly equipped with handles) with their hands and, lifting it, tap it on the table. Leave the mixture (for about 40 minutes) and leave the casting room.
After hardening to a “rubber” state - this can be determined by a very hot surface and a special sound when tapping - we remove the product from the mold (disassembling it) and turn it over with the pouring side down. Allow to harden completely, then sand and polish.

Safety measures: when weighing the resin, as well as working with it, with the gelcoat and with the mixture poured into the mold, we work only in a respirator, under a hood. Add the hardener with a syringe while wearing rubber gloves.

The following video will tell you how to make polymer concrete with streaks with your own hands:

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Polymer concrete

With rare exceptions, the technology for carrying out construction, restoration or repair work involves the use of concrete solutions. All these materials differ in brand, class and some other parameters, for example, moisture resistance. And all have a common similarity - cement is used as the only binding component in these mixtures. But modern industry has launched the production of other similar building materials, one of which is polymer concrete.

Its fundamental difference is that special ingredients - resins - are added to the usual sand-cement mixture as a binder. They are gradually introduced during the preparation of the solution. Polymer-based concretes are suitable for finishing surfaces both inside and outside buildings, pouring floors, and stair steps.

Composition and fillers

Fillers and binders are also used to prepare these concretes. Given the special qualities of polymers, the ratio between the components can vary from 5:1 to 12:1.

Like traditional analogues, polymer concrete contains fractions of different sizes, and, unlike cement grades, they are finely dispersed. Considering that these materials are widely used, including for use in conditions of direct contact with aggressive compounds, substances with increased resistance to chemical influences (for example, quartzite, basalt, tuff) are used as fillers.

Binding components:

The cheapest are furan polymers. But the strength is correspondingly low.
Better quality concretes containing polyesters (unsaturated).
The best options are materials containing epoxy resins. They combine strength, ductility, and wear resistance. However, their price is quite high.

Manufacturing

There is no clear answer yet to the question of how to make polymer concrete. All sources talk about an experimental way to obtain the required composition. It is necessary to ensure that when the applied mixture dries, it forms an elastic, resilient coating. Much depends on the installation location and on what result needs to be achieved. There is a general recommendation that polymer additives should make up approximately 1/5 of the total mass of the solution.

Much depends on what class of concrete you need to get. Therefore, you will have to vary the percentage of resins and hardeners. It is also necessary to take into account the type of polymer binder that is decided to be used, since each has its own specific properties. Some sources indicate that the use of epoxy resins involves replacing cement with slag, ash and liquid glass. In all other respects (mixing) the technique is the same.

Distinctive features of polymer concrete

High water resistance. Allows you to significantly simplify the technology of work in areas where structural elements of a structure are exposed to intense exposure to liquids. By purchasing polymer or natural concrete, you can significantly save on waterproofing and reduce the overall work time.
Resistance to aggressive environments, low temperatures.
The mechanical strength indicators significantly exceed the similar characteristics of cement-based concrete: for bending - up to 10 times, for compression - up to 3 times.
Low specific gravity, which significantly increases the range of applications.
Its elasticity property allows it to be used in areas subject to dynamic loads. Can be applied to planes with any orientation: horizontal, vertical, inclined.
Excellent adhesion, regardless of the base material.
The curing time is shorter than that of cement.
Possibility of achieving ideal evenness of the coating. Surfaces finished with polymer concrete are easy to maintain.

The main difference between polymer concrete and other concrete mixtures is the use of organic compounds in production. Polymer concrete is a mixture of various binders and polyester resins, which are combined with various substances (catalysts, hardeners and solvents). Polymer concrete is much superior to other types of concrete in its physical and mechanical characteristics. It has increased ductility, increased strength, it is not afraid of water and frost, and is resistant to abrasion. If you wish and have some knowledge of production technology, making polymer concrete with your own hands is not difficult.

Polymer concrete is superior in mechanical and physical characteristics to all other types of concrete.

Where is this material used?

Due to all its positive characteristics, the applicability of this material in construction is much higher than that of others. This material is used:

as an insulating coating for concrete;
when laying high-strength bricks;
as a weather-resistant painting material;
for decorative finishing of premises facades;
for putty and plaster;
as an adhesive solution for facing tiles;
covering for heated floors.

Due to its characteristics, such as high plasticity and low porosity, stable strength, which is achieved in a short period of time, polymer concrete can be produced by vibration molding. In particular, it can be used to work with products of small forms of architecture, decorative items for furniture and load-bearing structures.

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Transparent concrete: some features

Improvements occur every day, including in the construction industry. Concrete is known more for its strength than its light transmittance. This was the case until a new product appeared on the market - transparent concrete. This material is a mixture of concrete and glass threads, which allow ordinary cement mortar to take on the increased hardness of concrete mortar, plus also quite significant transparency.

Thanks to the presence of glass fibers in concrete, silhouettes can be seen through it.

The technical name for transparent concrete is litracon. It is made in the form of blocks, not much larger than a brick, and because of its transparency it seems completely weightless. This material can rightfully take its place among decorative and construction materials. According to the manufacturers, such blocks, in addition to being used in the construction of partitions, can even be used for paving sidewalks, since glass fibers make up only 4% of the total part of the concrete solution, and the material retains many of the advantages of the concrete mixture.

Thanks to the presence of glass fibers in the composition, through the new material it is possible to see the silhouette of a person or, for example, a tree. Blocks made from this material allow you to fill your living space with light, making it light and airy. It seems as if the walls practically do not exist. It is preferable to use such blocks in rooms that were originally built “dead”, this applies to corridors and storage rooms. If you use LED lighting when constructing a partition made of transparent concrete, you can achieve amazing effects.

The sizes of the blocks produced can be different, which does not at all prevent the transmission of light through them. These blocks transmit solar and electrical rays up to 20 meters. And production technology may change depending on customer requirements. Glass fibers can be distributed either along the entire perimeter of the block or concentrated in a certain part of it, and in some cases it is possible to form certain contours.

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Printed concrete: basic properties

Printed concrete is widely used for paving sidewalks, pavements, swimming pools, on facades and in interiors.

In recent years, decorative forms of concrete have become increasingly popular. This technology is widely used for paving sidewalks, swimming pools, pavements, in the interior and on facades. Surface finishing with colored concrete is increasingly being used, which is also an innovation in the construction industry. This type of concrete is produced by imprinting a texture on the surface of the concrete, thereby imitating any surface - from stone to tile.

For the production of printed concrete, M-300 grade concrete is used using fiberglass as a reinforcing material. After concrete is poured into molds, its surface is imprinted with molds and, as a final stage, it is treated with varnish, which prevents moisture from penetrating into the pores of the concrete, creating the effect of repelling moisture.

Another name for printed concrete is press concrete, which fully reflects its essence: a matrix with a pattern is imprinted on the surface of the coating, thanks to which it is possible to create a complete imitation of a stone coating with minimal labor costs. Printed concrete combines the main consumer characteristics - wear resistance and decorative appearance. In addition to a large selection of textures for concrete production, it is possible to paint it in various colors.

Stamped concrete is superior to asphalt pavement and concrete tiles in many of its technical characteristics. It has increased resistance to aggressive environmental components, and also has an increased temperature limit from + 50 to -50 ° C. This coating is easy to clean and non-slip, which makes it indispensable when laying the coating in swimming pools. Such concrete does not lose its original color under the influence of ultraviolet rays. Stunning decorative effects can be achieved when using printed concrete.

A coating made from this material can withstand about 300 freezing and thawing cycles, which makes it the absolute leader among other materials. In addition, such concrete is not subject to destruction under the influence of acids and alkalis, which makes it an excellent material for organizing flooring in garages or auto repair shops.

Kinds

Polymer compositions for concrete (polymer-modified concrete)

Polymer impregnated concrete

decks;
bridges;
pipes;
floor tiles;
construction laminate.

Polymer concrete

Features of polymer concrete

Modern building material differs from its predecessors. It has the following characteristics:

High resistance to chemical and biological environments.
Compared to cement-concrete products, it has less weight.
Excellent noise and vibration absorption.
Good weatherability and UV resistance.
Water absorption.
Can be cut using drills and grinders.
Can be recycled as crushed stone or crushed for use as road base.
Approximately 4 times stronger than cement concrete.
Good thermal insulation properties and stability.
Ultra-smooth finish that promotes efficient hydraulic flow.

Usage

Unlike traditional concrete structures, it does not require coating or welding of protected PVC joints. You can see the use of polymer concrete on city streets. It is used in the construction of road barriers, sidewalks, drainage ditches, and fountains. Also on the street, concrete is added to asphalt during the construction of open areas, runways and other objects that are located in the open air and are constantly exposed to external atmospheric influences.