Application polymer modified concrete :

Ferrocement product

Ferroscement is a thin shell of concrete reinforced with steel to distribute evenly throughout the
concrete so that the material is homogeneous when it is charged. It also containing cement
mortar which typically consists of sand, cement and water hydraulic. Ferroscement reinforced
with thin mesh lining, according to the average thickness of only 30 mm. The pattern of
distribution of reinforcement on ferroscement structure somewhat different because every space
is packed with mortar easier to penetrate each layer. Ferrocement found more viscous and has a
waterproof power higher. Polymer ferroscement better in terms of durability because the
polymers we use is a mixture of natural rubber in ferroscement.

Boat

Water Tank
Polymer concrete in making lintels

The uses of concrete lintels is to provide a good support over door and windows opening.
Polymer used in selected the project sites can be classified as new structure, existing structure
and bridge. The typical application of polymer is used to repair concrete defects on columns,
beam and slab. From the figure, the applications of polymer are more on beam for new structure.
For the existing structure and bridge, the applications of polymer are more on slab.
Polymer Concrete Overlays

The uses of polymer concrete overlays is to improve concrete surfaces such as roads, sidewalks,
pool decks and others. Its use is on uneven concrete surfaces which seeks to correct drainage
problems, hiding repair cracks and discoloration of the concrete. Overlays give a new look on the
old concrete.

Before After

Polymer Concrete Drainage System with Grating

This polymer concrete drainage system with garting is resistance to chemical polymer resin ,
which polymer concrete is made of. Besides, it also have shock resistance due its optimum
prefabrication design which lead to increase its capacity to withstand and absorb crash force and
affording great resistance to impact. In addition, it also ideal for fluid run off. The polymeric
nature of this material allows smooth surface with very low friction on fabricated element
compare to traditional concrete.
Prefabricated structural element

For solving the tremendous problem of urban housing storages, maintaining quality, economy
and speed, buildings had to fall back on prefabricated technique of construction. At present due
to low strength of conventional concrete, the prefabricated sections are large and heavy, resulting
in costly handling and erection. These reasons have prevented wide adoption of prefabricated in
many countries.

At present, the technique of polymer impregnated is ideally suited for precast concrete.

It will find unquestionable use in industrialization of building components. Owing to higher

strength, much thinner and lighter sections could be used which enables easy handling and
erection. They can be even used in high raised buildings without much difficulty. Polymer
concrete precast components continue to be widely used for junction boxes, communication
boxes, machine bases, railroad crossings, and wall panels.

Figure : Rail crossings

 Figure : Prefabricated Structure

Prestressed concrete

Further development in prestressed concrete is hindered by the inability to produce high strength
concrete, compatibility with high tensile steel available for prestressing. Since PIC provides a
high compressive strength of the order of 100 to 140 MPa, it will be possible to use it for large
spans and for heavier loads. Low creep properties of PIC will also make it a good material for
prestressed concrete.

Marine Works

Aggressive nature of sea water, abrasive and leaching action of waves and inherent porosity,
impair the durability of conventional concrete in marine works. PIC possessing high surface
hardness, very low permeability and greatly increased resistance to chemical attack, is a suitable
material for marine works.
Desalination Plants

Desalination of sea water is being resorted to augment the shortage of surface and ground water
in many countries. The material used in the construction of distillation vessels in such works has
to withstand the corrosive effects of distilled water, brine and vapour at temperature upto 143 0C.
Preliminary economic evaluation has indicated a saving in construction cost over that of
conventional concrete by thus use of PIC.

Figure : Vessels
Sewage Disposal Works

It is common experience that concrete sewer pipes deteriorate due to the attack of effluents and
when buried is sulphate infested soils. Further, in the sewage treatment plant, concrete structures
are subjected to severe attack from corrosive gases particularly in sludge digestion tanks.
Polymer impregnated concrete due to its high sulphate and acid resistance will prove to be a
suitable material in these situations.

Figure : Egg Shaped Pipes

Figure : Circular Pipes

Water proofing of structures

Seepage and leakage of water through roofs and bathrooms slabs, is a nagging problem and has
been fully over come by use of conventional water proofing methods. The use of polymer
impregnated mortar will solve this problem.

Industrial Applications

Concrete has been used for floor for tanneries. Chemical factories, dairy farms, base for a
transformer and other machines. The newly developed PIC will provide a permanent solution for
durable flooring in such situations.

Machine Base Transformer Base