Use of Alternative Aggregates and Aggregate Gradings in Trowel-Applied Polymer Concrete Floors

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Title: Use of Alternative Aggregates and Aggregate Gradings in Trowel-Applied Polymer Concrete Floors

Author(s): A. F. Bennett, W. R. Sharman, and I. D. MacGreggor

Publication: Special Publication

Volume: 99

Issue:

Appears on pages(s): 1-16

Keywords: abrasion resistance; absorption; acid resistance; aggregates; basalt; compressive strength; corrosion resistance; costs; epoxy resins; floor toppings; gap-graded aggregate; impact resistance; workability; industrial buildings; polyester resins

Date: 5/1/1987

Abstract:
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.