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What is polymer concrete? Technology for the production of polymer concrete products. Features of the use of various brands of polymer concrete

Price RUR/kg depending on quantity. Including VAT and packaging.

Packing: plastic canisters 5kg, 10kg, 30kg.

Guaranteed shelf life in manufacturer's containers is 12 months.

Store and transport at temperatures from +5° to +25°C.

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Buy a polymer additive for concrete

Polymer-based concrete additive Elastobeton-B manufactured to be heavy-duty polymer cement concrete.
Strength: on dolomite crushed stone – M600-M800; on granite crushed stone– M800-M1000 and more.

Commissioning within 5-6 days.

Polymer additives in concrete Elastic concrete-B is supplied in liquid form.
They are introduced during the production of concrete at the rate of 20 kg of additive per 100 kg of cement.

Thickness of the polymer-cement floor Elastobeton-B:
for moderate loads - 20mm, for heavy loads - 30mm, minimum thickness- 15mm.

Unlike magnesium concrete, polymer cement concrete is completely resistant to water.

Polymer cement concrete

Other names: cement- polymer concrete, cement polymer concrete.

As mentioned above, polymer-cement floors based on the concrete additive Elastobeton-B are 20-50% cheaper than magnesium floors. But this is a direct calculation - that is, they took polymer-cement concrete and calculated the price of the components; similarly for magnesium concrete.
But besides this, there are a number of factors that affect the final price of polymer cement concrete and magnesium concrete. The main of these factors are listed below.

1. Transportation.
Transportation of concrete components greatly affects its final cost.
If transport costs are only 1 rub/kg, then delivery main components magnesium concrete, which constitute approximately 23% of the total mass, will increase the price of 1 m³ of concrete by 500 rubles! With a delivery price of 5 rubles/kg, that’s already 2500 rubles/m³!

If you transport all the components of magnesium floors, then at a delivery price of 1 ruble/kg, the cost will increase by 2200 rubles/m³.
With a delivery price of 5 rubles/kg, magnesium floors will become more expensive by 11,000 rubles/m³!

The concrete additive Elastobeton-B is approximately 3.5% of the concrete mass, the remaining components are purchased locally. Accordingly, transportation of a polymer additive for concrete, even over long distances, has virtually no effect on the price of polymer-cement concrete.

The savings are obvious.

2. Storage.
The components of magnesia concrete (in particular burnt magnesia - magnesium oxide) are very sensitive to storage and transportation conditions. Penetration of moisture into components significantly reduces the final strength of magnesium concrete. As a result, you will receive magnesium floors with brand strength M200-M300, instead of M400-M600.

There are no such problems with polymer-cement concrete, since you buy all the components, including additives, locally and can always control their quality.

3. Cost of fillers.
The cost of concrete with the Elastobeton-B additive depends on the sand fineness modulus (SFM), bulk density of sand and bulk density of crushed stone. The higher the MCR and the higher the density of sand and crushed stone, the less cement and concrete additives in relation to sand and crushed stone. Accordingly, the cheaper polymer-cement concrete.

Savings can be up to 2000 rubles. per 1m³ of polymer cement concrete.

4. Equipment corrosion.
Magnesia concrete includes the bischofite component, which causes increased corrosion of both steel and aluminum surfaces equipment. Equipment (concrete mixers, vibratory screeds, helicopters, etc.) must be constantly washed. But even with careful care, the service life of the equipment is reduced several times, which as a result affects the price of magnesium floors!

Polymer additive for concrete Elastobeton-B does not have a corrosive effect on metal surfaces.

The savings are obvious.

Polymer additive for concrete - properties, advantages

Elakor "Elastobeton-B"- complex modifying polymer additive for concrete (Portland cement concrete).
Cement grade M500D0 is recommended for use. If you want to use other cements, we recommend that you first check them for compatibility with the Additive (see Technology for using the Additive). The fact is that some fillers that are introduced during the production of cement can “conflict” with the additive.

To make colored polymer-cement floors, you can add the pigment yourself directly when mixing concrete or order an additive of the desired color from us.
Colored polymer cement floors can be made on gray cement, but if a “pure” color is required, then white cement must be used.

Properties of polymer-cement floors with the concrete additive “Elastobeton-B”.

• Indoor and outdoor use.
• Thickness from 15 to 50mm. Recommended thickness is 20-30mm depending on the load.
• The strength of the coating is: on dolomite filler – M600-M800. on granite filler – M800-M1000 and more.
• Extremely high wear resistance (less than 0.2 g/cm²).
• High impact strength (10-20 kg m depending on thickness).
• Bending strength – no less than 12 MPa.
• Completely dust-free (after polishing).
• The coating is vapor permeable.
• Antistatic coating: specific volume electrical resistance– no more than 10 7 Ohms;
  specific surface electrical resistance – no more than 10 9 Ohm∙m (test voltage 100V).
• Chemical resistance to water, fuels and lubricants, salt solutions, detergents, etc.
• The coating is non-flammable (flammability group - NG).
• Fabulous appearance, the possibility of combining several colors, various fillers, etc.
• Easy to clean, can be used with any detergent.

Polymer cement floors - advantages.

• Allows you to avoid performing leveling screeds with subsequent application of protective polymer impregnations and coatings or dry reinforcing compounds (toppings). This results in a coating with higher decorative and strength qualities and a significantly lower cost.
• Combines the advantages of latex cement concrete and polyvinyl acetate cement concrete - water resistance and oil resistance.
• Fully complies with SNiP 2.03.13-88 “Floors”.
• The strength is the same as the topping and higher, but not only in the top layer of 2-2.5 mm, but throughout the entire thickness.
• Unlike magnesium concrete, magnesia floors are completely resistant to water.
• When abraded (weared), the polymer-cement floor does not change its appearance, does not lose strength and chemical resistance.
• It is polished during use.
• Does not require reinforcement.
• Short technological cycle of work (6-8 days).
• Start of operation - the next day after completion of work.
• Polymer cement concrete is cheaper than any finishing coating of similar thickness.

Polymer cement floors are used in buildings.

What kind of material is this? How is it different from the usual concrete mixtures in terms of composition and consumer properties? Is it possible to make polymer concrete with your own hands? Where and how is it used? Let's try to find the answers.

What it is

Definition

Let's find out what polymer concrete is? The key difference between the material we are interested in and ordinary concrete is that synthetic resins are used as a binder instead of Portland cement. Typically thermoset; less often - thermoplastic.

Reference: thermosetting is a polymer in which, when heated, irreversible chemical changes occur, leading to a change in its strength or other properties.
Simply put, after heating once, the plastic no longer melts when it reaches the same temperature.
Thermoplastic polymers, on the other hand, undergo a phase transition every time they are heated.

Our hero should not be confused with another material - polymer-cement concrete. In our case, polymers are used as the only binder. Polymer-cement concrete is ordinary concrete based on Portland cement, modified with synthetic additives to give it any specific properties (increased elasticity, wear resistance, water resistance, etc.).

Key properties

What does replacing cement with polymers give in terms of consumer qualities?

• Increased tensile strength. Cement-based concretes have excellent compressive strength, but bending or tensile loads are absorbed by the reinforcement frame.
• Reduced fragility. The material is much more resistant to shock loads.
• Elasticity. Where the concrete monolith bursts, the polymer concrete is only slightly deformed.
• Waterproof. Portland cement shrinks significantly when dried, which ensures the porous structure of concrete. In contrast, polymers after the final gain of strength decrease in volume extremely slightly; Moreover, shrinkage does not lead to porosity, but to a slight decrease in the linear dimensions of the finished product.

Let us clarify: in order to improve thermal insulation qualities and reduce weight, in some cases the use of porous aggregates is practiced in the production of polymer concrete products.
Expanded clay and perlite sand are used for this purpose.
However, the pores of the filler do not come to the surface, and if so, the water resistance does not suffer.

• Frost resistance. Actually, this property directly follows from the previous point: if there are no pores, there is no crystallization of water in them, tearing the material apart when frozen.

• Increased wear resistance. The polymer binder is simply stronger than cement stone in tensile strength; It is much more difficult to tear off a particle of filler from it.
• Chemical resistance. And it is due to the properties of polymers: most of resins are inert to the action of aggressive gases and liquids.

Application

Let's study the main applications of polymer concrete.

Application area	Description
Floor coverings	A thin polymer concrete coating with fine-grained aggregate allows you to modify the properties of the base, giving it increased wear resistance and water resistance. In addition, polymer concrete floors, as we remember, are resistant to aggressive environments. The material is used indoors and outdoors (in particular, as an airfield covering).
Furniture	For the needs of furniture production, beautiful and durable tabletops and work surfaces are made from our material; Polymer concrete slabs are often used as window sills.
Plumbing	Kitchen sinks and washbasins made from polymer concrete compare favorably with their metal counterparts in the absence of noise when a stream of water falls on them. They are superior to faience and porcelain primarily due to their appearance, which imitates natural stone.
Drainage systems	Polymer concrete trays and, most importantly, are much more durable. The reason is the already mentioned waterproofness of the material: water will not destroy the polymer concrete tray by freezing in its pores.
Putties	Mineral-filled resin, after adding a hardener, turns into a quickly setting and extremely durable mastic - efficient material for sealing cracks and other defects in concrete surfaces.
Funeral services	Polymer concrete tombstones look at least as good as granite ones; Moreover, their price is noticeably lower than that of natural stone.

Production

Regulations

The material we are discussing is considered to be relatively new and of foreign origin; however, studying the regulatory documents according to which it is carried out will lead to an unexpected discovery. Instructions for the production of polymer concrete and products made from them, number SN 525-80, were adopted in 1981 and remain relevant to this day.

Let's study the main points of the document. For all polymer concrete products it is normal temperature conditions The range is considered to be from -40 to +80 degrees Celsius.

Let us clarify: if the upper limit is due to the possibility of using thermoplastic resins that soften when heated, then the lower limit is due to the increased fragility of polymers when frozen.
In the absence of shock and mechanical loads in general, the lower limit of operating temperature can be painlessly increased to the actual value in the most severe climatic zones.

Binder

The composition of polymer concrete, according to the text of the document, may include the following polymers:

Aggregate

Crushed rock is used as the main filler. The use of sedimentary rocks (limestone, shell rock, etc.) is not allowed: its low compressive strength will significantly worsen performance product.

The size of the crushed stone fraction is determined, no matter how funny it sounds, by its maximum diameter:

1. If largest size does not exceed 20 mm, one fraction is used - 10-20 millimeters.
2. In cases where the largest size reaches 40 mm, it is recommended to use two fractions: 10-20 and 20-40 millimeters. Fine crushed stone will contribute to a denser filling and, accordingly, will increase the final strength of the material.

Please note: for porous aggregates (expanded clay and perlite already mentioned) maximum size 20 mm; two fractions are used: 5-10 and 10-20 millimeters.
At the same time, the percentage composition of the filler is divided between large and small fractions in the ratio of 60:40 percent by weight.

In addition to coarse, fine (so-called grain) aggregate is used. Typically, this role is played by quartz sand - natural or crushed. The requirements for it mainly boil down to the absence of impurities - dust, silt and clay, which can worsen the adhesion between the filler and the binder.

Filler

In addition to mineral filler, the product contains ground filler - mineral flour. The standard provides several options.

It is allowed to use ground crushed stone and quartz sand. For the material, which is prepared on the basis of urea-formaldehyde resins, a water-binding additive is additionally used - building gypsum (GOST 125-70).

Composition example

As a sample, we will analyze the composition of heavy polymer concrete based on the furan-epoxy binder FAED. Our source of information will be the same document CH 525 -80.

It’s interesting: the BSK performs two functions at once.
It serves as a polymerization catalyst (hardener) and provides dehydration (dehydration) of raw materials.

BSK is an effective and safe hardener with additional functionality.

Technology

What does polymer concrete technology (more precisely, its production) look like in an industrial environment?

1. The aggregates are thoroughly washed to remove all kinds of contaminants. As we remember, they can negatively affect the final strength of the product.
2. The next stage is drying. The moisture content of the aggregate should not exceed 1 percent; It is recommended to keep the mass water content to 0.5%.
3. The components separated into fractions are loaded into the mixer.
   The sequence of loading and intermediate operations is strictly regulated:
   1. Crushed stone is being loaded.
   2. Sand is added.
   3. Filler is added.
   4. The mixture is stirred for 1-2 minutes.
   5. Binder is added.
   6. The mixture is stirred for 3 minutes.
   7. Hardener is added.
   8. Mix for 3 minutes and the material is ready for pouring.
4. On inner surface A separating layer is applied to the form, which will prevent the polymer concrete from sticking to it. Paraffin, machine oil or technical petroleum jelly are usually used in this role.
5. The mold is filled as evenly as possible and, if possible, without cavities.
6. The last stage is compaction of the mixture on a vibrating table or using a mounted vibrator. The optimal amplitude is 2-3 millimeters, frequency is 3000 vibrations per minute (50 Hz). If the mixture is kneaded and laid out in several stages, its compaction is repeated after each laying out.
   Signal to stop on the surface of the liquid fraction of the material (usually 2-3 minutes are enough for this).

The mold can be removed from the finished product within a day. Strength gain at room temperature takes from 20 to 60 days. It, however, can be accelerated by heating to 60-80 degrees; the temperature rises and falls at a rate of 0.5 C per minute to avoid an increase in internal stress.

As you can see, the production technology does not involve any special difficulties; If you have a binder, a hardener, a concrete mixer and a vibrating table, it is quite possible to make polymer concrete at home.

A caveat: you will have to clean the concrete mixer from the remaining mixture extremely quickly.
After adding the hardener, setting takes no more than an hour.

Treatment

What and how are polymer concrete products processed? Can they be sanded and glued?

How to cut and drill this material?

• For gluing, mastics and adhesives based on the same synthetic resins are used. Mastics, in addition to the binder itself, contain stone flour.

The photo shows polyurethane glue made in Belarus with a creative name.

• Regular sandpaper is suitable for sanding. A felt wheel is used for polishing; gloss can be achieved using GOI paste (polishing paste developed by the State Optical Institute).

• In principle, the material can be drilled using ordinary Pobedit drills for concrete; however, diamond drilling of holes in concrete with a polymer binder gives much better results. The edges of the hole remain perfectly smooth, without chipping. For large diameter holes (for example, for a mixer in polymer concrete work surface for the kitchen) a diamond crown is used.
• The ideal cutting tool is again a diamond saw. It is also preferable for structures whose appearance is not so important (cutting reinforced concrete diamond wheels allows you to make the edges of the cut perfectly smooth and not change the circle when passing the reinforcement); in the case of the same tabletop, a sloppy cut will hopelessly ruin its appearance.

A diamond saw is an ideal tool for cutting material.

When processing material in general case You should avoid heating it too much. Temperatures above 120 - 150 degrees are contraindicated for thermoplastic binders.

Conclusion

Drainage pipes are one of the areas of production of the company PBT, Polymer Concrete Technologies, which is located in St. Petersburg and produces materials such 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, shaft 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 profitable terms 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 strong pressure, which flushes 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 of polyethylene low pressure. 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 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.

www.p-b-t.ru

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

Polymer concrete is a special construction material, which is used as a binding element and also to replace lime cements. 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 used in many industries, but 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 more high 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 seams. 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 under 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 technologies production. 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 at an affordable price(thanks to cheap mineral additives) and ease of manufacture. 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, use one of polymer resins. 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 ready product it will be impossible to remove). The mold can be made of silicone, fiberglass, metal or even chipboard ( a budget option).

1. A layer of gelcoat of the desired color is applied to the release paste.
2. 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.
3. Now it is necessary that the laid mixture be subjected to vibration (vibration compaction). The time of this procedure is approximately two minutes. At the factory, a resonant vibration platform is used for this, on small production– vibrating table.

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

For those who dream of taking a swing at continuous technology and substantial volumes, having organized a large industrial production, special conveyor equipment will be required. 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 a vibrator to the table industrial type- ready.
• A mixer that will combine all components into a homogeneous mixture. If you purchase a powerful vacuum device European quality, then you will have to shell out 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 iron barrel and electric drive with 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 and 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, evaporation begins poisonous gas.
• 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.

1. 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).
2. 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.
3. 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.
4. 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.
5. 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.
6. 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 provides for the use 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 different sizes, and unlike cement grades, and 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 the experimental way of obtaining 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.
• Indicators mechanical strength significantly exceed similar characteristics of cement-based concrete: for bending - up to 10 times, for compression - up to 3 times.
• Small specific gravity, which significantly increases the range of applications.
• Its elastic 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.

• Eliminates cracking effect
• Increases mixture quality
• Gives concrete increased hardness
• Increases the adhesive properties of the mixture

Polymer concrete is a water-based polymer additive to cement-sand mixture

Advantages polymer concrete are very diverse, which provides wide possibilities for their use. First of all, it is necessary to note the increased characteristics in terms of tensile strength. This indicator significantly exceeds that of conventional concrete. The product has better deformability and does not collapse when exposed to significant force. As additional benefits polymer concrete It is worth pointing out the increased durability achieved due to significant resistance to wear and some other external influences.

Application of dust-removing impregnation "Polymer concrete":

	Application area	Amount of dry cement-sand mixture, kg	Amount of “Polymer concrete” additive, kg	Note
	Installation of thresholds, jambs, repair of steps, waterproofing, self-leveling floors with a top layer from 1 to 5 mm, sealing irregularities up to 5 mm		8-10
	Sealing unevenness in concrete (ceilings, floors, walls) up to 50 mm			Dilute the additive with water in a ratio of 1/1 to 1/4
	Coatings with a thickness of 20 to 100 mm (without cracks and delamination of concrete during laying)			Dilute the additive with water in a ratio of 1/5 to 1/20
	Dust removal of concrete floors			Dilute the additive with water in a ratio of 1/1

About the product

Polymer concrete, if added to a dry mixture, makes it durable and waterproof. It can be applied even 1 mm thick. on concrete, brick, wood, metal, plastic and it sticks to them very firmly. It becomes strong immediately after drying - within an hour. For example, a dry mixture with polymer concrete applied in a thin layer on cardboard bends as desired, does not peel off, does not crumble.

Alabaster, when mixed on polymer concrete, slows down its hardening to 2 hours. The material becomes waterproof. It can be used for outdoor work. The hardening time is regulated by diluting the polymer concrete with water.

Builders have long noticed that if any cheap imported dry plaster or self-leveling floor is prepared using diluted polymer concrete, then the water resistance and strength will increase sharply. The strength of the material is controlled by the amount of polymer concrete

There are a lot of buildings underground garages restored using polymer concrete. A 15th century church in Sheremetyevo (Moscow region) was completely restored using plaster on polymer concrete. Decorative stucco on its façade there is plaster with polymer concrete.

Any old structure is literally glued together with polymer compounds. For example, a metal box front door hermetically glued into concrete doorway. For six years of operation - no cracks.

Repair and restoration work takes on a different meaning. Dilute polymer-concrete with water 1/1 and saturate concrete, wood, and plaster. They will become durable and waterproof. Add polymer concrete to chalk paint and it becomes strong, flexible and water resistant. Paint wood (logs, beams, boards) with polymer concrete and it will no longer crack, dry evenly and will not darken.

What we are talking about has been applied at all times. People have always improved the properties of building materials with polymers - mainly egg whites, casein, and flour. The result is the highest strength and durability of buildings for tens and hundreds of years.

PURPOSE:

• For interior and exterior use
• ultra-strong, flexible concrete
• glue for insulation, foam plastic. Adheres to wood, concrete, metal, glass, plastic
• strengthening impregnation, high-quality, waterproofing
• Betokontakt - durable and cheap
• non-cracking, dust-free plaster, smooth and textured
• impact-resistant self-leveling floor
• water-weatherproof alabaster, gypsum

PROPERTIES:

• especially durable, elastic coating
• does not crack
• odorless, environmentally friendly
• consumption 5kg/100kg. mixtures (cement+sand)
• drying time from 2 hours to 2 days, depending on the thickness of the layer
• non-flammable, fireproof

The use of concrete made from cement is limited. Polymer binder that determines such properties of products from polymer concrete such as chemical resistance and vibration resistance, allow the use polymer concrete and designs from polymer concrete where traditional concrete would fail

Polymer concrete is manufactured as follows: with a binder ( polyester resin) sand, limestone, talc, crushed waste from the production of composite materials, for example, fiberglass, etc. are mixed. Coarse fillers in polymer concrete are crushed stone up to 50 mm in size and sand with a grain size up to 5 mm. In order to reduce consumption binder and the cost of products, as well as to regulate their properties, finely dispersed filler withparticle size less than 0.15 mm (barite, quartz, andesite flour, etc.). The composition of polymer concrete may also includeblowing agents, Surfactants, flame retardants, dyes, etc.
With a high degree of filling (70 - 80%), inexpensive products with high physical and mechanical characteristics are obtained. A filler, such as sand, gives products durability and resistance to abrasion loads, but greatly increases their weight. When producing such products, it is necessary to choose a resin with reduced viscosity. Production parameters must be such that the filler is evenly distributed throughout the volume of the product and does not settle due to the difference in density of the filler and resin. Degassing of the mixture is also necessary to prevent the formation of cavities inside the product, which can lead to a decrease in strength. The disadvantage of polymer concrete products is their unaesthetic appearance, which makes it impossible to use these products as decorative elements when decorating premises, etc.

Application of polymer concrete:

Cladding panels;

Foundations for industrial equipment;

Noise-absorbing structures;

Mooring edges and breakwaters;

Water containers;

Drainage structures;

Road curbs and fences;

Railway sleepers;

Stairs;

Restoration and protection of existing concrete structures;

Containers and reservoirs for chemically active substances;

Drainage sewers of chemical enterprises.