New Zealand has a predominantly agricultural-based economy and, thus a heavy investment in processing buildings such as export abattoirs and dairy factories. Component failures in these types of plants may have a serious effect on production and profitability. During the past 10 years, the Building Research Association of New Zealand has carried out an extensive research program investigating properties in the laboratory and in use on flooring materials for abattoirs. During the course of these investigations, it became clear that the formulation of widely used commercial polymer concrete toppings could be improved. In particular, these investigations sought a reduction of the resin content below the common figure of approximately 20 percent by weight and alternative aggregate sources to the limited supply of light-colored quartz and quartzite sands. However, it was important to preserve the application of new alternative mixes by trowelling, the traditional method. By starting from the aggregate grading curves of Weymouth and BS 882 and by using gap-grading, it was possible to lower the resin content to percent or less and still retain trowellability while using aggregates from traditional sources. Alternative sources of aggregates, such as sandstone (greywacke) and basalt, that could be used to produce the light-colored floors considered imperative for hygiene by the industry were found. The experimental polymer concrete floor toppings were tested for the necessary mechanical properties (compressive strength, abrasion, and impact resistance) for abattoir use.

Lightweight polymer concrete composites have been developed with excellent insulating properties. The composites consist of lightweight aggregates such as expanded perlites, multicellular glass nodules, or hollow alumina silicate microspheres bound together with unsaturated polyester or epoxy resins. These composites, known as insulating polymer concrete (IPC), have thermal conductivities from 0.09 to 0.19 Btu/hr-ft-F. Compressive strengths, depending on the aggregates used, range from 1000 to 6000 psi. These materials can be precast or cast-in-place on concrete substrates. Recently, it has been demonstrated that these materials can also by sprayed onto concrete and other substrates. An overlay application of IPC is currently underway as dike insulation at an LNG storage tank facility. The composites have numerous potentials in the construction industry, such as insulating building blocks or prefabricated insulating wall panels.

Providing the latest advances in research, design and technology, this ACI symposium publication offers state-of-the-art information and greater insight into the latest use of polymer modified concrete and polymer concrete composites.A collection of 11 symposium papers, Polymer Modified Concrete deals exclusively with the various effects of polymers in concrete and provides an extensive source of reference. Bringing together expertise from around the world, case studies include: lightweight polymer concrete composites, polyester polymer concrete under flexural loading, flexure and bond in fiberglass-reinforced polymer concrete beams, and strength losses of polymer-modified concrete under wet conditions. Filled with illustrations, photos, and graphs, Polymer Modified Concrete provides in-depth answers to all of your questions. 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. SP99

A furfuryl alcohol-based polymer concrete (FA-PC) has been developed for use as an all-weather repair material for concrete and asphalt surfaces. For this application, the following criteria were established: high-strength at an age of one hour, placement of the materials possible during heavy precipitation over temperatures ranging from -32 to 52 C, and the chemical constituents low in cost with long-term stability when contained in a maximum of three packages during storage. A formulation consisting of furfuryl alcohol monomer (FA), à,à,à-trichlorotulene, pyridine, silane, zinc chloride, silica filler, and coarse aggregate meets these requirements. Optimized formulations were established for use with premixed and percolation placement methods. The premixed formulation meets essentially all of the property and storage criteria and is compatible with moisture contents up to 4 percent by weight of the total mass, which stimulates placement in a 2.54 cm/hr rainfall. The working time for the FA-PC slurry can be controlled at ñ15 min over the operating temperature range -20 to 52 C by simply varying the à,à,à-trichlorotoluene catalyst concentration while holding all the other constituents constant. Below -20 C, slight increases in FA and ZnCl2 concentrations are needed to yield optimum properties. Prototype equipment for the mixing and placement of FA-PC was constructed and used in a series of tests up to a size of 6 x 6 x 0.15 m. The equipment consisted of a concrete transit mix supply of mixed aggregate, a hopper-fed volumetric feed screw that supplied aggregate at a known rate to a mixing screw, and a monomer pump and spray nozzle. The unit mixed and delivered FA-PC at ÷ 182 kg/min. The practicability of using equipment currently employed for the continuous placement of conventional portland cement concrete was proven. Field tests were performed under rainfall and dry conditions at temperatures ranging from -15 to 35 C. In all of these tests, the mixing and placement equipment performed well and the FA-PC slurries exhibited self-leveling characteristics. Test results from proxy samples prepared during the placement of the patches and cores taken after simulated aircraft trafficking indicated that the property requirements at an age of one hour were attained.

One brand of polymer concrete beams reinforced with fiberglass rods were tested and evaluated in simple flexure. Testing was carried out by the applying of two equal loads symmetrically placed about the center line of the beam on simply supported spans of 51, 63, and 72 in. The distance of the load points from the center line of the beams was varied to change the available development length for the reinforcing rod. The primary experimental data consisted of strains measured by means of electrical resistance strain gages placed on the surface of the polymer concrete and along the reinforcing rod. These strains were used to establish cracking strains and bond strengths for the beams tested. The results indicate a range of values for cracking strains and bond strengths, the lowest cracking strain being 370 psi and the lowest bond strength, 434 psi.