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Fundamentals of Corrosion
4.8.3.3 Polymer Concrete
Polymer concrete is a chemically resistant synthetic concrete consisting of
low-viscosity binders and inert aggregates, which when combined and thoroughly mixed produces a synthetic material that can be precast or poured
in place. It can also be used as a concrete surfacing. When applied in thicknesses greater than 1/2 in. (13 mm), it is considered a polymer concrete.
When applied in lesser thickness, the material is referred to as a surfacing
or coating.
Polymer concretes are not the same as polymer-modified Portland cement
concrete. Polymer concretes are composed totally of synthetic resin compounds with fillers. They do not contain any Portland cement. Polymerized
Portland cement concrete can use some of the same generic resins as used in
polymer concrete, but with different results.
The primary resins used to formulate polymer concretes include:
1. Furan
2. Epoxy, including novalac
3. Polyester
4. Vinyl ester, including vinyl ester novalac
5. Acrylics
6. Sulfur
Before pouring polymer concrete mixes, a liquid-tight membrane should
be placed over the substrate. Such a membrane will act as a liquid barrier
and separate the polymer concrete from the surface below it, allowing it to
move as a unit. The substrate must be smooth, and penetrations through the
polymer concrete should be centered between joints.
Depending on the service, polymer concrete is cast in thicknesses from
1/2 in. (13 mm) to several inches, either with or without reinforcing. Castable
polymer concretes are mixed and cast in a manner similar to that of Portland
cement concrete, being poured into forms to harden. Troweled applications
are generally thin coatings of less than 3/4 in. (20 mm) and are troweled in
place with or without reinforcement.
Like all cementatious materials, polymer concretes are inflexible and tend
to brittleness. Refer to Table 4.18 for the resistance of polymer concretes to
atmospheric corrosion.
4.8.3.4 Mortars and Grouts
Chemically resistant mortars and grouts are based on organic and inorganic chemistry. They consist of a liquid resin or an inorganic binder; fillers such as silica, carbon, or combinations of the same; and a hardener or
Fundamentals of Corrosion
4.8.3.3 Polymer Concrete
Polymer concrete is a chemically resistant synthetic concrete consisting of
low-viscosity binders and inert aggregates, which when combined and thoroughly mixed produces a synthetic material that can be precast or poured
in place. It can also be used as a concrete surfacing. When applied in thicknesses greater than 1/2 in. (13 mm), it is considered a polymer concrete.
When applied in lesser thickness, the material is referred to as a surfacing
or coating.
Polymer concretes are not the same as polymer-modified Portland cement
concrete. Polymer concretes are composed totally of synthetic resin compounds with fillers. They do not contain any Portland cement. Polymerized
Portland cement concrete can use some of the same generic resins as used in
polymer concrete, but with different results.
The primary resins used to formulate polymer concretes include:
1. Furan
2. Epoxy, including novalac
3. Polyester
4. Vinyl ester, including vinyl ester novalac
5. Acrylics
6. Sulfur
Before pouring polymer concrete mixes, a liquid-tight membrane should
be placed over the substrate. Such a membrane will act as a liquid barrier
and separate the polymer concrete from the surface below it, allowing it to
move as a unit. The substrate must be smooth, and penetrations through the
polymer concrete should be centered between joints.
Depending on the service, polymer concrete is cast in thicknesses from
1/2 in. (13 mm) to several inches, either with or without reinforcing. Castable
polymer concretes are mixed and cast in a manner similar to that of Portland
cement concrete, being poured into forms to harden. Troweled applications
are generally thin coatings of less than 3/4 in. (20 mm) and are troweled in
place with or without reinforcement.
Like all cementatious materials, polymer concretes are inflexible and tend
to brittleness. Refer to Table 4.18 for the resistance of polymer concretes to
atmospheric corrosion.
4.8.3.4 Mortars and Grouts
Chemically resistant mortars and grouts are based on organic and inorganic chemistry. They consist of a liquid resin or an inorganic binder; fillers such as silica, carbon, or combinations of the same; and a hardener or