This Syposium Publication is a compilation of 17 papers presented at the 2001 ACI Spring Convention held in Philadelphia. The flow of informative data begins with the historic beginnings through numerous creative endeavors up to today's current multitudinous uses for polymer concrete. Topics include polymer concrete overlays for the repair and protection of concrete and long-term durability of sulfur concrete in harsh chemical environments. Note: The individual papers are also available as .pdf downloads.. Please click on the following link to view the papers available, or call 248.848.3800 to order. SP214

Polymer concrete materials stand today as a very promising group of new building materials. This paper presents a brief overview of the use of polymers in concrete in various industrial applications over the past fifty years. Classification, production, and main advantages and disadvantages of polymer concrete materials are presented. Their physical, mechanical, and chemical properties are reviewed and compared to those of the conventional portland cement concrete. Hazards involved in handling, transporting, storing and mixing the chemicals used to produce polymer concrete materials are discussed, and safety consideration are presented.

Strengthening and rehabilitation of reinforced concrete structures using externally bonded Fibre Reinforced Polymers (FRP) strips has become a well-established technique with a large research database. Epoxy-modified mortar (EMM) has been used in the industry for more than three decades for various strengthening and rehabilitation purposes. Epoxy modified mortar without a hardener has recently been investigated. The new EMM without a hardener includes polymerlcement ratios as low as 20 percent compared to the 40-60 percent that is usually required to provide suitable mechanical properties of conventional EMM. The new EMM utilizes the cement hydrates to polymerize the epoxy resin in the cement matrix in the absence of a hardener through ring-opening polymerization. The use of ring-opening polymerization provides EMM (without a hardener) with an interesting ability to grow through any developed crack and to repair itself, thus showing enhanced fracture toughness with age. The new self-repair epoxy mortar (SREM) has shown better mechanical performance than the conventional EMM with the same polymer/cement ratio. The objective of this work is to discuss the potential use of SREM to bond FRP laminates to existing concrete substrates in rehabilitation and strengthening applications. A multi-phase research programme examining the different strength, fracture and durability criteria of the SREM-FRP composite is proposed here. Fracture mechanics principles in conjunction with microstmctural investigations will explain and maximize the material ability to self-repair.

Deteriorating sewer facilities require rapid in-situ rehabilitation and using coating as a corrosion protection is one method currently being adopted. Hence, applicability and performance of coatings under dry and wet conditions must be investigated. Performance of a polymer concrete coating was evaluated using a combination of full scale and laboratory tests. The polyester based polymer concrete coating had a density of 1.75 g/cm3 (109 lb/ft3) and a hardness in the range of 38 to 45 (Barcol hardness). Full-scale test on coating applicability and performance on concrete substrate was performed under a hydrostatic pressure of over 103 kPa (15 psi) of water, simulating the groundwater condition. Coated concrete cylinders and clay bricks with holidays (pinholes) were used to study the chemical resistance under acidic environments to represent the worst sewer and accelerated test conditions (ASTM G 20). Bonding strength between the coating and the concrete and clay brick substrates were determined using the modified ASTM D 4541 and ASTM C 321 tests. Performance of the polymer concrete coating material was studied for over 3 years and the results are analyzed to determine the performance of the polymer concrete coating.

A wide variety of advanced constmction materials have been developed to meet certain needs and solve specific problems. These materials have all come under the umbrella title of "Polymer Concrete"(PC). Using different types of resins and fillers, composites can be formulated having totally different physical properties. This paper will review several different PC formulations that were developed at Brookbaven National Laboratory (BNL) and installed at operating facilities by construction contractors. The three materials selected for this review are: A) Insulating Polymer Concrete (IPC) for dike insulation at Liquified Natural Gas (LNG) facilities; B) Electrically Conductive Polymer Concrete Overlays used in conjunction with a cathodic protection system on a deteriorated bridge deck and C) Precast PC vaults for natural gas regulator stations.