Contents Preface... xi 1 History of Cementitious and Polymer Technology and their Unison... 1 1.1 Introduction... 1 1.2 The Introduction of Polymer into Cementitious Materials... 2 1.2.1 The Basic Advantages of Mixing Polymers with Cementitious Materials... 3 1.3 The History of Cement... 4 1.3.1 Basic Principles of the Cement Manufacture... 5 1.3.2 A Summary of the Hydration of Portland Cement... 8 1.4 History of Polymers... 11 1.4.1 The Introduction of Polymers into Cementitious Materials... 12 1.4.2 Brief Summary of the Physical Properties of Polymer Modified Cementitious Materials... 15 1.5 Concluding Statement... 16 References... 17 2 Common Polymers used in the Formation of Concrete and Cementitious Products... 23 2.1 Introduction... 23 2.2 Summary of the Manufacture and Chemical Composition of a Number of Polymers Commonly used to Modify Concrete and Cementitious Materials... 24 2.2.1 Cellulose... 24 2.2.2 Natural Rubber (NR)... 25 2.2.3 Polyvinyl Acetates (PVA)... 27 2.2.4 Copolymers of Vinyl Acetate/Ethylene... 28 2.2.5 Acrylic Polymers... 30 2.2.6 Styrene-Butadiene Rubber... 32 iii
Polymers in Cementitious Materials 2.2.7 Chloroprene... 34 2.2.8 Polyvinylidene Chloride... 35 2.2.9 Nitrile Butadiene Rubber (NBR)... 36 2.2.10 Epoxy Resins... 37 2.2.11 Polyurethanes... 47 References... 51 3 Polymer Concrete... 59 3.1 Introduction... 59 3.2 Chemical Composition of Polymer Concrete... 60 3.2.1 Advantages of Thermosetting Resins... 60 3.2.2 Thermosetting Resins Typically Used in the Manufacture of Polymer Concrete... 61 3.3 Brief Introduction to Mixing and Application of Polymer Concrete... 65 3.3.1 Summary... 65 3.3.2 Mixing... 65 3.3.3 Aggregates... 65 3.3.4 Workability and Shrinkage Characteristics... 66 3.3.5 Voids... 67 3.3.6 Priming of the Substrate... 67 3.3.7 Mixing... 68 3.4 Application Techniques... 68 3.5 Decision Model... 69 3.6 Repairing Polymer Composites... 69 3.7 Physical Properties of Polymer Concrete... 70 3.7.1 Typical Strength Characteristics Observed for Polymer Concrete... 70 3.7.2 Bond Adhesion of Polymer Concrete to a Substrate and the Effect of Expansion and Contraction... 71 iv
3.7.3 Permeability of the Polymer-Aggregate Matrix and Performance when Subjected to Varying Atmospheric and Environmental Conditions... 72 3.8 Common Uses of Polymer Concrete... 72 3.8.1 General Road and Bridge Repair... 73 3.8.2 Overlays and Coatings... 73 3.8.3 Resin Grouts and Mortars... 74 3.8.4 Sealants... 75 3.8.5 Castable Systems... 76 3.9 Polymer Impregnated Concrete... 77 3.9.1 Concrete Preparation and Impregnation Process... 78 3.9.2 Physical Properties... 79 3.9.3 Common Uses of Polymer Impregnated Concrete... 80 3.9.4 Disadvantages Associated with Polymer Impregnated Concrete... 81 References... 81 4 Polymer Portland Cement Concrete... 85 4.1 Introduction... 85 4.2 Brief Summary of the Advantages of Incorporating Polymer into Cementitious Materials... 86 4.3 Physical Requirements of Latexes in Order to be Suitable as Cement Additives... 86 4.4 Polymer Emulsion... 87 4.4.1 Manufacture of Latex Emulsion... 88 4.5 Redispersible Polymer Powders... 91 4.5.1 Introduction... 91 4.5.2 Conception and Development... 92 4.5.3 Spray Drying Procedure... 92 4.5.4 Particle Size of Redispersible Polymer Powders... 94 4.5.5 Advantages of Adding a Redispersible Polymer Powder... 94 v
Polymers in Cementitious Materials 4.5.6 Rehydrating Redispersible Polymer Powders... 95 4.5.7 A Summary of the Various Redispersible Polymer Powders Commercially Available... 96 4.5.8 Typical Chemical Composition of Modern Day Redispersible Polymer Powders... 96 4.6 The Formation of the Polymer Modified Cementitious Matrix... 97 4.7 Introduction to the Benefits of Modifying Cementitious Materials with Polymer Dispersions... 99 4.7.1 Acrylics... 100 4.7.2 Styrene Acrylics... 100 4.7.3 Vinyl Acetate Ethylene Co-Polymers... 101 4.7.4 Styrene Butadiene Rubber Co-Polymer... 102 4.7.5 Epoxies... 102 4.8 A Summary of the Effect of Polymer Modifying Cementitious Materials... 103 4.8.1 Water Demand... 103 4.8.2 Bleed Water... 104 4.8.3 Workability... 104 4.8.4 Stability... 104 4.8.5 Voids... 105 4.8.6 Drying Characteristics... 105 4.8.7 Strength Characteristics... 106 4.8.8 Influence of Application Method upon the Strength Characteristics of Polymer Modified Cementitious Materials. 108 4.8.9 Abrasion and Impact Resistance... 108 4.8.10 Durability and Modulus of Elasticity... 109 4.8.11 Permeability of Polymer Modified Cementitious Materials... 109 4.8.12 Carbonation... 110 4.8.13 Chemical and Acid Resistance... 111 4.9 Common Polymer Modified Construction Materials... 111 4.9.1 Bridge Decking... 111 vi
4.9.2 Mortars and Renders... 112 4.9.3 Flooring... 113 4.9.4 Primers... 113 4.9.5 Ancillary Construction Products... 114 References... 115 5 The Use of Synthetic Fibres to Reinforce Cementitious and Resin-Based Materials... 121 5.1 Introduction... 121 5.2 Natural Fibres... 121 5.3 Synthetic Fibres... 122 5.3.1 Fibre-Reinforced Composites Incorporating Carbon Fibres and Glass Fibres... 122 5.3.2 Polymer-Based Fibres... 123 5.4 Long-Term Effect of Incorporating Synthetic Fibres into Cementitious Matrices upon their Physical Performance... 123 5.5 Introduction of Fibres into Cementitious Materials... 124 5.5.1 The Effect of Introducing Fibres into a Cementitious Medium upon the Physical Properties... 124 5.5.2 Slump Characteristics... 125 5.5.3 Structural Shrinkage and Effect of Structural Deterioration on the Cementitious Matrix... 126 5.5.4 Microcracking and Deformation within the Cementitious Matrix... 126 5.5.5 Other Factors Influenced by the Inclusion of Fibres... 127 5.5.6 The Introduction of a Latex into Fibre Reinforced Concrete... 127 5.5.7 The Influence on Corrosion of Incorporating Fibres into a Cementitious Matrix... 128 5.6 Comparison of Steel and Polymer-Based Fibres upon the Physical Properties of Cementitious Materials... 128 5.7 Typical Applications of Fibre Reinforced Materials... 129 vii
Polymers in Cementitious Materials 5.7.1 Construction... 129 5.7.2 Introduction of Fibres into Cementitious Overlays... 129 5.7.3 Comparison of Different Types of Reinforcement upon the Long-Term Performance of Cementitious Overlays... 129 5.7.4 Introduction of Synthetic Fibres into Cementitious Repair Mortar... 130 5.7.5 Fibre-Reinforced Resin Composites... 131 References... 134 6 Adhesives and Coatings... 137 6.1 Introduction... 137 6.2 Types of Adhesives Available... 138 6.2.1 Solvent-Based Adhesives... 138 6.2.2 Solvent-Free and Water-Based Adhesives... 138 6.2.3 Hot Melt Adhesives... 139 6.3 Brief Summary of Composition, Properties and General Uses of Adhesives... 140 6.3.1 Epoxy Resins... 140 6.3.2 Polyurethane... 141 6.3.3 Acrylic... 141 6.3.4 Urea-Formaldehyde/Phenolic Resins... 142 6.3.5 Other Polymers used in the Manufacture of Adhesives... 142 6.3.6 The Effect of Incorporating Rubber into Adhesives... 142 6.4 The Use of Adhesives within the Construction Industry... 143 6.5 Automotive and Aerospace Applications... 144 6.6 Resin Coatings... 145 6.6.1 Introduction... 145 6.6.2 Solvent-Based Coatings... 146 6.6.3 Conversion from Solvent-Based to Water-Based Compounds... 147 viii
6.6.4 Solvent-Free and Water-Based Coatings... 147 6.6.5 Common Applications... 152 References... 154 7 Summary of the Applications and Benefits of Utilising Polymers in Construction... 159 References... 166 8 Glossary... 169 Abbreviations... 171 Index... 173 ix