BNL-23497

CONCRETE POLYMER MATERIALS,

-I
PRODUCTION METHODS AND APPLICATIONS

by

Lawrence E. Kukacka
Department of Energy and Environment
Brookhaven Na tional Laboratory
Upton, New York 11973

Prepared for presentation at Worl d of Concrete Symposium,

"Polymers in Concrete", January 13, 1978,
Phoenix, Arizona

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Abstract:

Concrete polymer materials are being used world-wide in

applications where high strength and durability are required. Methods
for producing two materials, polymer impregnated concrete and polymer
concrete, are discussed and their structural and durability properties
summarized. Existing and potential applications for these materials
such as for chemical storage tanks, pilings, pipe, curbstones, and
bridge decks are reviewed.
 CONCRETE POLYMER MATERIALS,
PRODUCTION METHODS AND APPLICATIONS

by

Lawrence E. Kukacka
Department of Energy and Environment
Brookhaven-National Laboratory
Upton, New York 11973

October 1977

1. Introduction

Concrete polymer materials are a series of composite materials

which have strength and durability characteristics far superior to
those of portland cement concrete. As a result, two of these materials,
polymer impregnated concrete and polymer concrete, are beginning to
be utilized throughout the world in applications where portland cement
cannot be used or where severe maintenance problems occur.

Polymer impregnated concrete (PIC) consists of a precast portland

cement concrete impregnated 1!Vith a monomer system that is subsequently
polymerized in situ. The polymer tends to fill the porous void volume
of the concrete, which results in significant improvements in strength
and durability properties. For a concrete mix that produces specimens
with a compressive strength of 5,000 psi, compressive strengths greater
than 20,000 psi have been measured after impregnation. Similarly large
improvements in other structrual and durability properties have also
been obtained.

Polymer concrete (PC) consists of an aggregate mixed with a

monomer or resin that is subsequently polymerized in place. The
techniques used for mixing and placement are similar to those used
for portland cement concrete. After curing, a high strength (greater
than 10,000 psi), durable material is produced.

A third type of.material, a further development of PIC, is also

being applied. This is a precast concrete that has been partially
impregnated to a finite depth with a monomer that is subsequently
polymerized.

Methods for producing each of the above materials are given·

below. Their properties and current and potential applications are
also discussed.
 -2-

2. Characteristics of Concrete Polymer Materials

Polymer Impregnated Concrete

The concrete polymer composite that has yielded the greatest

improvements in structural and durability properties is PIC. High
quality PIC can be made from concretes with a. variety of compositio~s
and compressive strengths as high as 32,400 psi have been obtained.
For best results, the use of standard-weight concrete containing
a good quality aggregate is recommended. The following processing
cycle has been used successfully to impreg~ate sections of a size·up
to 16x4x0.5 ft: 1) oven dry to constant weight at 1500C, 2) place
in a vacuum chamber, evacuate to approximately 30-in. Hg and
maintain for 30 min., 3) introduce monomer under vacuum and subsequently
pressurize to 10 psig., pressure soak for .60 min., 4) remove monomer,
5) remove and place section in water or, for larger sections,
back-fill impregnator with water, and 6) polymerize monomer· containing
chemical initiator in situ by heating with water at a temperature of
approximately 75°C for~r.

If the above method is used to impregnate specimens fabricated

from a concrete mix that produces specimens with a compressive strength
of 5,000 psi, compressive strengths greater than 20,000 psi are
generally obtained. Design values for PIC that cover the range of
monomer systems used and many types of concrete have been published
by Cowan.2 These values are as follows: compression 15,000 psi, direct
tension 1,000 psi, modulus of rupture 1,300 psi, shear 750 psi,modulus of
rupture 6x106 psi, and Poisson's ratio 0.2.

Flammability tests patterned after ASTM D 635-68, Flammability

of Self-Supporting Plastics, have been performed on PIC and on the
polymers themselves.l The results indicated that while the polymers
support combustion according to this test, the composites are either
self-extinguishing or do not burn at all.

Equally significant improvements in durability have been obtained.

Resistance to abrasion and cavitation are enhanced. The water absorp-
tion is reduced by greater than 99 percent and the resistance to
attack by hot brine, distilled water, acids, and freezing and thawing
is enormously improved.

PIC is relatively impermeable to chlorides and its potential for

preventing reinforcing steel corrosion and surface scaling has been
3
demonstrated in tests performed by the Federal Highway Administration.
After 267 daily salt applications; the maximum chloride concentration
found at a depth of l-in. was negligible.
 -3-

Partially Impregnated Concrete

Partially impregnated concrete is a variation of PIC which is

designed for durability rather than high strength. This permits a
saving in the amount of monomer as compared with fully impregnated
concrete. Laboratory tests have indicated that a penetration depth
of l-in. is adequate to prevent chloride penetration into the concrete.
Good resistance to abrasion and scaling is also obtained.

Several techniques for the partial impregnation of concrete have

been utilized in laboratory and field tests. Two processes, treatment
of all surfaces and of one surface, have been described.4-5 The
former can be accomplished by simply soaking dried concrete in low
viscosity monomers such as styrene or methyl methacrylate. The depth
of penetration varies linearly with the logarithm of the soak time.6

Field-applied methods for penetrating horizontal and vertical

concrete surfaces to depths up to 2-in. have been tested.7-8 The
most effective method for treating a horizontal surface is to place
a thin layer (approximately l/4-in.) of dried sand over the surface
prior to the application of monomer. The aggregate acts as a wick
for the monomer, therefore longer soak periods are possible without
excessive evaporation. Soak times of approximately 6 hr. are required
to give a penetration of l-in. This method has recently been used to
impregnate full-size bridges in four states? and to repair a highly
deteriorated spillway at a dam in Idaho.8

The walls of a water-outlet tunnel at the Idaho dam that were

damaged by cavitation/erosion forces were also repaired by partial
impregnation. In this work the monomer was contained in a pres-
surized soak chamber that was attached to the tunnel wall during the
impregnation step. Soaking for 4 to 6 hr. was required to produce
a l-in. depth of penetration. Polymerization of the monomer was
initiated by heating with hot water to a temperature between 65°C
and l00°C. To date, after more than l yr. in service., little damage
to the impregnated surface is apparent.

Polymer Concrete

PC consists of an aggregate mixed with a. monomer which is

subsequently polymerized in place. The techniques used for mixing
and placement are similar to those used for portland cement concrete,
and after curing a high-strength durable material is produced. The
important process variables are monomer type, aggregate size distribu-
tion, and polymerization method. These and other topics such as
placement and finishing techniques, additives, and safety requirements
are given in Refs. 9 and 10.
 -4-

When compared to the extensive testing program that was performed

to determine the properties of PIC, the PC evaluation effort in the
USA has been small. To date, only a few of the mechanical and
durability properties have been published.2, 9, 11 There are, however,
many applications of PC in foreign countries which tCJ.ke advantage
of the high strength and durability of the material. These applica-
tions are discussed in Section 3 of this paper.
1
Several important properties of PC have been measured. In one
series of tests the specimens contained oven-dried aggregate which
was machine mixed with 97.5 weight percent methyl methacrylate -2.5
weight percent trimethylolpropane trimethacrylate (TMPTMA), placed in
molds, and polymerized at room temperature by use of promoters and
initiators. The samples contained 7 to 8 percent monomer by total
weight of the wet mix. Depending upon the maximum size of the
aggregate and the amount of TMPTMA in the monomer system, the specimens
develop average compressive strengths varying from 18,000 to 20,000 :.
p~i. Full strength is attained immediately after the polymerization
reaction is completed. Depending upon the concentrations of promoter
and catalyst and the ambient temperature, this time can'vary from
a few minutes to 4 hr. Other structural property values include a
tensile splitting strength of 1,400 psi, modulus of elasticity of
5.3xlo6 psi, and a Poisson's ratio of 0.23. The PC exhibited less
creep than normal weight concrete.
11
Recent work at Brookhaven National Laboratory has evaluated
the ~se of methyl methacrylate and polyester PC as a patching material
for concrete bridge decks and pavement. In this work the relationship
between variables such as initiator and promoter concentrations, ambient
temperature, aggreg~te temperature,_work time, and cure time was
studied. The effects of these variables on the strength and freeze-thaw
durability of the PC were also determined. The results from the ·
study indicated that both monomer systems can be cured rapidly and
predictably over the temperature 2° to 35°C and that in all cases the
properties exceeded those of portland cement concrete.

PC formulations are being developed for use as materials of

construction in geothermal processes.12 In this work samples are being
tested in synthetic geothermal brines and at several well sites in
brine and steam ·at temperatures up to 2500C. After exposures of up
to 600'days, little deterioration has been noted. Samples exposed to
pH 1 hydrochloric acid at 90°C for 350 days have also shown good
durability.

3. Applications

World-wide interest in concrete polymer materials exists. At the

present time there are several applications in the USA and many are
reported in foreign countries.l3
 -5-

In the USA impregnated ferrocement is being marketed for use

in chemical storage and processing applications. The use of PIC and
PC for highway, dam, and electrical insulatorl4 applications represent
areas where cotmnercialization is slowly occurring. Three processes -
partial impregnation of new bridge decks, PC patching, and impregna-
tion of prestressed bridge deck members--are currently being
implemented by the Federal Highway Administration. Five full-size
bridge decks have been partially impregnated as a means of preventing
chloride penetration. Similar projects are scheduled. In addition,
the techniques for the use of monomer impregnation for the repair
of highly deteriorated bridge decks have been developed. Projects
to repair a deck and a dam using these techniques are currently in
progress.

Several other potential applications for PIC have been identified

and tests performed. Pipe, tunnel liners, curbstones, and beams
have been impregnated. All of these applications appear cost effective.

In foreign countries, the applications of PC and PIC are numerous

and varied. Three plants in Japan are reported to be producing
PIC. Products offered include beams, panels, water and sewer pipe,
ceiling panels, and high strength piling. PIC pump beds have been
used in a sulfuric acid factory. Previously, cast iron or coated
stainless steel members used for this application had life expectancies
of less than one yr. The PIC pump beds were reported to be in good
condition.after two yr. of service.lS Similar panels are being used as
bottom cover plates on a viaduct that crosses a highly corrosive waste
gas area.lS

PC is also widely used in Japan. Products manufactured include

pipe, tunnel liner segments, telephone cable ducts, piles, decorative
tile, terrazzo, gutter covers, manholes, acid waste storage tanks,
septic tanks, and a variety of panels.

The Soviet Union has made use of both PC and a product called
polymer-silica concrete (PSC), which is composed of either sodium or
potassium silicate, water glass, furfuryl alcohol, and sodium silica-
fluoride, combined with aggregate.l6

Both PSC and PC utilize the same production technology. Both

materials have been used where high acid resistance and impermeability
to gases and water are required. For exampl~, they have been used as
underlayers for acid-resistant floors in the chemical industry.
Economics of the -application and the type of aggressive medium determine
which of these materials should be used. PSC is resistant only to
acid, while PC is resistant to both acid and alkali. PCs generally
have twice the strength of PSCs, and have found application in load
bearing uses. PSCs have been used more for such applications as
foundations for pumps, floors, etc. Other specific applications for
PC include use in conduit pipes in underground mine construction,
 -6-

waterproof lining of mine shafts, mine props and cross pieces,

sewer pipes~ dam facings·, protective coatings for spillways, drainage
pipes, poles: for supporting electri.cal transmiss·ion lines, and
pres·tressed railroad ties·. 16 · .

PC materials have been used in ~.Jest Germany since 1968 and a

Ministerial license to permit its· use for s-tructural members has
been issued.l7 Production plants exist. for producing machinery base
plates, curbstones, facades·, tomostones, sanitary basins, lining
stones- for ball mills, staircase units, and ·electrically heated
stairs·.

4. Summa:ry

Two types· of concrete polymer composites· are beginning to find

applications throughout the world as· a result of their high strengths
and durability. The materials· are polymer impregnated concrete which
consists of a precast portland cement concrete impregnated with a
monomer system that is subsequently polymerized in situ, and polymer
.concrete which consists of an aggregate mixed with a monomer. or resin
that is subsequently polymerized in place.

PIC and PC have strength and durability properties that are

considerably better than those of- portland cement concrete. The
strengths· are inc.reased by a factor of 4 and the water absorption is
reduced by greater than 99 percent. Improvements in hardness,
resistance to abrasion, cavitation, acids, and freezing and thawing
are also obtained.

Concrete polymer materials are being used throughout the world.

In the USA PIC is being used for chemical storage and processing
vessels. Commercialization for highway applications also appears
probable. Several bridge decks have been partially impregnated to a
depth of approximately l-in. as a means of preventing chloride
intrusion, and plans to treat other decks have been formulated. PIC
curbstones have been installed on a bridge deck as an alternative to
granite and PC patching materials are being utilized in areas where
heavy traffic conditions severely limit the time during which repair
work can be performed.

In foreign countries the applications of PIC and PC are more

numerous and varied. Piling, pipe, curbstones, acid storage tanks,
gutters, pump beds, facades, and sanitary basins are only a few of the
things being fabricated. The use of "cost-benefit" analysis will
undoubtably identify other areas where the materials can be used·
economically.
" -7-

References

1. DePuy, G.·w. and Kukacka, L. E. Editors, Concrete-Polymer

Materials, Fifth Topical Report, BNL 50390 and USBR REC-ERC-73-12,
Dec. 1973.

2. Cowan, W. C., Structural properties of polymer-impregnated concrete

with application toward bridge decks, Introduction to Concrete
Polymer Materials, Supplement No. l• FHWA-RD-75-527 ;-pp. 1-16,
Nov. 1975.

3. Clear, K. C. and Hay, R. E., Time-To~corrosion of Reinforcing

Steel~ Concrete Slabs, Vol. !• Effect of Mix Design and Con-
struction Parameters, FHWA-RD-73-32, April 1973.

4. Dikeou, J. T. et al., Concrete Polymer Materials, Third Topical

Report, USBR REC-ERC-71-10 and BNL 50275 (T-602), Jan. 1971. :.

5. Kukacka, L. E. and DePuy, G. W., Editors, Concrete-Polymer Materials,

Fourth Topical Report, USBR REC-ERC-72-10 and BNL 50328, Jan. 1972.

6. Sopler, B., Fiorato, A. E., and Linschow, R., A study of partially

impregnated polymerized concrete specimens, Amer. Concr. Inst. Publ.
SP-40, pp. 149-72, Detroit, 1973.

7. Smoak, W. G., Partial Impregnation £f New Concrete Bridge Deck

Surfaces, Interim Users' Manual of Procedures and Specifications,
FHWA-RD-75-72, June 1975.

8. Schrader, E. K. and Kaden, R. A., Polymer impregnated concrete

repairs at Dworshak Dam, Proceedings of International Symposium on
Polymers in Concrete, Mexico City, Oct. 1976, American Concrete
Institute

9. Kukacka, L. E. et al., Introduction to Concrete Polymer Materials,

BNL 19525 and FHWA-RD-75-507, Dec. 1974.

10. Kukacka, L. E. and Fontana, J., Polymer Concrete Patching Materials

Users' Manual, IP77-ll Vol .. 1, and BNL 22361, April 1977.

11. Kukacka, L. E. and Fontana, J., Polymer Concrete Patching Materials

Final Report, IP77-ll Vol. 2, and BNL 22360, April 1977.

12. Kukacka, L. E., et al., Alternate Materials of Construction for

Geothermal Applications; Progress Report No. 11, BNL 50594,
Sept. 1976.

13. Ironman, R., Resin concrete enjoys rapid growth, Concrete Products,
V, 79, No. 10, Oct. 1976, pp. 36-8.
 -8-

14. Electric Power Research Institute Journal, January/F.ebruary 1977,

pp. 38-9.

15. Tazawa, E. and Kobayaski, S., Properties and.applications of

polymer impregnated cementitious materials, Amer. Caner. Inst.
Publ. SP-40., pp. 57-.92, Detroit, 1973.

16. Davydov, S. S. and Ivanov, A.M., Steel Polymer Concrete Structural

Construction, Stroizdat Publishers, Moscow, 1972. Technical
Translation T'V3-52003 available from National Technical Informa-
tion Service, Springfield, Virginia 22161.

17. Koblischek, P., Synthetic resin-bound concrete; Proceedings

of First International" Congress on Polymer.Concretes, May 5-7, 1975,
The Concrete Society, London, pp~ 409-19, 1976.