How to make a polymer concrete countertop with your own hands. Polymer concrete - technical characteristics of the material, advantages

Modern needs of the construction industry contribute to the emergence of newer and more advanced materials. So, polymer concrete has recently begun to gain great popularity. We will tell you about this unique composition further.

Properties

Historical reference

As we said, this material is innovative. However, there is evidence that it was used several thousand years ago in the construction of the Egyptian pyramids. Of course, we are talking only about similar technology.

The blocks from which the pyramids were built consisted of the following components: silt from the Nile River, limestone, gravel, trusted salt, ash and crushed lime. As a result, they were able to stand for so long without cracking. At the same time, the so-called “tan” did not form on them (any natural stone becomes covered with it over time).

Advantages

Now it's time to get acquainted with the advantages of this know-how:

. Even cutting reinforced concrete with diamond wheels will hardly cope with its task.
Long life span. Significantly higher than that of its ancestor.
Very low shrinkage during drying.
High compressive strength. This allows you to withstand enormous loads.
Resistant to almost all acids.
The technology of polymer concrete is fundamentally different from all known. The fact is that only environmentally friendly raw materials are used in its production.

Interesting: the permeability of this material is comparable to natural granite. Today, only he can boast of such dignity.

Polymer concrete products have low greenhouse gas emissions.
Withstands temperature fluctuations. It retains all its properties even when heated to 1300 degrees.
Does not wear out over time and does not crumble.

Among all this variety of advantages, there is one drawback - the high price. However, the situation is likely to change in the future. The fact is that this is a new technology, which means that for some time its cost will be significantly reduced.

Specifications

The wild growth in popularity is due to the fact that polymer concrete has very high characteristics that leave all its main competitors out of business. Let's get acquainted with them:

Characteristic name	Meaning
Frost resistance (number of cycles)	300
Water absorption coefficient per day (%)	Not more than 0.1
Abrasion (g/cm2)	0,02
Strength (kgf/cm2) in compression in tension	900–100075–85
Porosity (%)	1–1,5
Linear shrinkage (%)	0,3–1
Measure of creep (sq. cm / kg)	0,4–0,5
Aging resistance (points)	3–4

Important! The values presented above are controlled by building code 525–80 of 01/01/81.

It is also worth bringing to your attention the chemical resistance to various substances:

From the data in this table it can be seen that this material meets all standards of chemical resistance. This means that the polymer protection of concrete floors is highly effective. Therefore, this technology is often used in industry.

Cooking

Now consider how to independently prepare polymer concrete. In fact, this is a simple procedure that will require you only to strictly observe the proportions.

Ingredients

Consider what we need:

Potassium hydroxide. These are hygroscopic crystals, colorless and odorless. They instantly blur in the air, so they must be stored in a vacuum package and taken out before use.

This substance is very aggressive, that is, it strongly affects the mucous membrane and skin. For this reason, the instruction prescribes to wear protective equipment (glasses, gloves, respirator) when working with it. Otherwise, there is a high risk of damage, especially to the eyes.

Liquid glass(Surely many of us, after reading this phrase, will think about the element that fills our windows). In fact, these are colorless crystals without any odor. They consist of silicic acid and alkaline potassium.

You can buy it at the nearest agricultural store. The fact is that gardeners often use liquid glass to fertilize various crops.

fly ash. This ingredient can be obtained independently (by burning some solid fuel) or bought ready-made at a hardware store. Experts say that the addition of ash makes polymer asphalt concrete 75% stronger and more durable.
Chilled water at room temperature. It must not contain any impurities. If you add tap water, then you need to let it stand for a while.
In addition, you can use any additives (for example, slag or dye). This is necessary in order to obtain an attractive texture and improve the characteristics of the mixture.

Tools

Now consider what tools you will need:

already mentioned remedies.
Container for mixing ingredients (preferably glass).
Wooden spatula for mixing.
Electronic balance. Remember that it is very important to observe all proportions. If we are talking about a small amount of solution, then a simple kitchen scale will do.
Casting mold.

cooking secrets

It is time to answer the question of how to make polymer concrete with your own hands.

So, to prepare 1 liter of the mixture, we observe the following proportions:

Potassium hydroxide - 160 g.
Liquid glass - 200 g.
Ash - 540
Water - 100 ml.
Slag (it is needed to give special strength, it is not necessary to add it) - 300 g.
Special cement for polymer concrete - 20% of the total volume.
Additives as desired (their consumption should be indicated on the package).

Important! As you mix, the mixture will heat up due to the release of carbon dioxide, so don't be alarmed.

The ingredients must be mixed in the following order:

Pour clean water into the container.
Add cement to it.
Then we pour ash, slag and liquid glass in equal proportions.
Then add the rest of the components.
Now, using a construction mixer, you need to mix everything thoroughly. Remember that the mass should be perfectly homogeneous. Otherwise, polymer concrete will not be durable.
The resulting mixture can be poured into a mold or formwork for solidification.

It will completely harden only after 3 weeks. Only after this period it is possible to carry out any operations with it, for example, diamond drilling of holes in concrete.

It is worth noting that experiments to create ideal proportions are ongoing to this day. In this regard, people often begin to change recipes on their own. Therefore, you can try yourself in this path.

Afterword

Now you know what polymer concrete is. However, if any nuances remain unclear to you, then there is no reason to be upset (.

In the video presented in this article, you will find additional information on this topic, which will allow you to better understand everything.

(otherwise, cast stone) is a material that combines the strength and beauty of natural stone with an affordable price (thanks to cheap mineral additives) and ease of manufacture. The possibility of using almost any aggregate (sand, granite and marble chips, glass and many others) guarantees variety. And the presence of a polymer binder makes them durable, exposed to water and overheating.

Let's consider typical technological processes for the manufacture of polymer concrete, as well as the possibility of creating it yourself.

What will be required?

To get the product you need:

A filler of a sufficiently large fraction (sand, crushed stone, coarsely crushed glass).
A finer grinded aggregate that reduces the cost of the material. It is a powder of graphite, quartz or andesite.
Binder - it will need about 5 percent. In this capacity, one of the polymer resins is used. For example, polyester (unsaturated), urea-formaldehyde, furan, epoxy.
Hardeners, plasticizers, special modifiers, dyes.
Mold release lubricant and top coat gel coat.

Production methods

The production process can take place in batch or continuous technology.

In the first case, the containers used for the manufacture of the material must be washed after each completed cycle. But it is possible to make polymer concrete in the most ordinary bucket or concrete mixer.
Continuous technology is used mainly in large industries. At the same time, special injection molding machines, dispensers and automatic mixers work together, organizing a single chain.

The following video talks about the manufacture and spraying of lightweight polymer concrete:

Process

To make a cast stone, you will need a mold well coated with a special release agent (otherwise it will be impossible to remove the finished product). The form can be made of silicone, fiberglass, metal or even chipboard (budget option).

A layer of gelcoat of the desired color is applied to the release paste.
A composite mixture is placed inside the mold, consisting of the above ingredients, previously well mixed in a concrete mixer. In large industries, where the volumes are very solid, the mixture is put into the mold using a concrete paver. If the products are small, and the technological process is periodic, then this is done manually.
Now it is necessary that the laid mixture is subjected to vibration (vibration compaction). This procedure takes approximately two minutes. At the plant, a resonant vibration platform is used for this, at a small production site - a vibrating table.

Under production conditions at the plant for the production of polymer concrete, if necessary, heat treatment is carried out for faster hardening of the parts. In other cases, they wait for the natural completion of this process.

We will talk about machines, molds and other equipment for the production of polymer concrete products below.

Necessary equipment

Features of choice and costs

Those who dream of aiming at continuous technology and solid volumes by organizing large-scale industrial production will need special conveyor equipment. 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 we confine ourselves to turnkey branded equipment, then the costs will be much less - from 30 to 50 thousand dollars.

But still, it is not always possible to find money for a purchase, especially in our difficult time. However, you can get by with even lower costs. If you purchase all the necessary machines and other things separately. And something to make yourself. Below is more about this option.

List of equipment and devices

So, here is a list of equipment and devices that you can not do without:

Vibrating table - ready will cost about 27 thousand rubles. If you want to save money, weld the table yourself using two-millimeter metal corners (60s). We weld an industrial-type vibrator to the table - done.
A stirrer that will combine all the components into a homogeneous mixture. If you purchase a powerful vacuum device of European quality, you will have to pay about 10 thousand dollars. But you can also use a domestic concrete mixer or a construction mixer. It will be much cheaper - the cost depends on the volume and power. Even cheaper is to make a mixer yourself from an iron barrel and an electric drive with a gearbox.
You will also need a compressor system with a gun. Without it, it will not be possible to apply the gelcoat evenly. The gun costs from 50 to 100 dollars. You can take automobile compressors - two pieces from ZIL will be enough. They are connected in parallel and attached to metal platforms installed on a strong frame.
Molds made of fiberglass or silicone are not yet widely available for sale. 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.
Without fail, an exhaust hood will be needed - at the casting stage, production is distinguished by harmful fumes. Accordingly, we will also purchase individual protection: gloves, respirators.
For finishing work, you will need electric tools: grinding and polishing machines. And also a drill, a jigsaw, a grinder, a milling cutter (if necessary).

We will talk about emissions into the atmosphere from the production of polymer concrete below.

This video will also tell about another method of manufacturing polymer concrete:

Air emissions from such production

As mentioned just above, during casting, the release of harmful components is present.

In particular, it is styrene, which is contained in resins used as a binder. As soon as we open a hermetically sealed container with such a resin, the poisonous gas begins to evaporate.
In addition, the hardener is also extremely dangerous (as a rule, it is methyl ethyl ketone peroxide). However, it is not volatile and requires only the protection of hands with rubber gloves.

These facts force polymer concrete manufacturers to carefully equip the casting room, making it hermetic, installing a powerful exhaust above the table, not forgetting about their own protection (respirator). And if all these measures are observed, and the air leaving the hood is cleaned, then there will be no emissions into the atmosphere (after all, the room is airtight).

How to make elastic polymer concrete yourself (with your own hands), read below.

DIY creation

And now we will talk about how to make small products from fashionable cast stone on our own, spending a minimum of money. For example, it can be flower pots, countertops, window sills (especially popular, as they are warmer than marble or granite).

Room selection and arrangement

First you need to think about the room - you 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 have to be fenced off for the casting room, and you will have to try to seal all the cracks as much as possible. So that the styrene does not leak.

In the center of this room we make a table on a frame of iron corners, covering it with a chipboard top. We expose its surface according to the level - this is important! Above the table we install a hood - a metal box with an electric motor.

To make it light, we mount fluorescent lamps on top. In the next room we put the same table - for finishing and other work. Here we will place the tool and containers for drying chalk and sand (metal low boxes).

Required raw materials

Required raw materials:

River quartz sand (packed in 20 kilograms). It must dry well.
Sifted chalk - we also dry it.
Polyester resin - in buckets of 20 liters is bought.
Hardener, gelcoat, release paste.

Manufacturing process

You will need a clean plastic bucket for stirring, a 450-watt perforator and a construction mixer (we will attach a perforator to it by welding a perforating drill - we get a mixer).
We make the form from laminated wood boards, making it collapsible. It is convenient to apply the separating paste with a brush, rubbing with a nylon stocking.
We dilute the gelcoat with resin (adding 10 percent of it) and apply with a flute brush. We do this twice. We make sure that the hairs from the brush do not stick.
After mixing the resin with the hardener in a clean bucket, add 15 percent chalk, and then sand in portions. The mass should become viscous. To remove air bubbles, tap the bucket on the floor from time to time.
Once ready, pour the solution into the mold. Now let's smooth the surface: two people take their hands on the form (certainly equipped with handles) and, lifting it, tap it on the table. The mixture is left (for 40 minutes) and exit the casting room.
After hardening to a “rubber” state - this can be determined by a very hot surface and a special sound when tapped - we take the product out of the mold (disassemble it) and turn it over with the pouring side down. Let it harden completely, then sand and polish.

Security 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. We add the hardener with a syringe, wearing rubber gloves.

The following video will tell you how to make polymer concrete with stains with your own hands:

Innovative technologies delight us more and more every day. New developments also affected the construction industry. In particular, the creation of new building materials, among which polymer concrete is in great demand. It is a mixture, the composition of which consists of various polymeric substances, and not of the cement or silicate that has long been familiar to us. This material has a lot of positive properties, due to which it is superior to conventional building mixtures.

Polymer concrete: characteristics

Due to the huge number of its positive properties, the cement-polymer mixture justifiably deserves respect among builders. Using this material, any specialist will appreciate its strength and durability. Polymer concrete does not give in to moisture, does not deform, perfectly reacts to temperature changes and bad weather. Dries quickly and adheres well to any surface. This material has a high resistance to stretching, good air permeability. It is not affected by any chemical reactions.

But the most important of all the properties of polymer concrete is that it is environmentally friendly, does not pollute the environment and does not harm human health in any way. The polymer mixture is allowed to be used even in the construction of public catering facilities, various grocery outlets, as well as other food industry buildings.

Advantages and disadvantages

A huge number of positive properties extols the cement-polymer mortar over conventional concrete. Due to the rapid solidification with polymer concrete, after a few days, the first work can be done, which cannot be said about ordinary material. Concrete of the new sample is much more enduring, stronger. For complete hardening, one week is enough for him, and not a month, as for ordinary cement.

Among the positive properties of the polymer mixture is waste-free production. Previously, all agricultural and construction waste was simply thrown away or buried in the ground, thereby polluting our nature. Now recycled material is used for the manufacture of polymer concrete. The use of such technology not only solves the problem of waste disposal, but also protects the environment from pollution.

This building material, unfortunately, has its drawbacks. Among the negative properties, one can single out the inclusion in the composition of artificial materials. The second negative point is the expensive cost of some additives necessary for the preparation of polymer concrete. Due to this, the price of the finished product rises.

Application

Due to the presence of many positive properties, polymer concrete has a fairly wide range of applications. It is used in landscape design, laying out paths and terraces. Walls are finished with a similar mixture, both from the outside and from the outside, they decorate stairs, fences, plinths. Such material easily lends itself to manual work. Various shapes, figures, decorative elements are obtained from it. Its beauty is that it is easily painted after drying.

The use of such a building mixture is suitable for pouring floors. Polymer concrete floors will serve as an excellent protection against moisture. Polymer concrete floors will keep your home warm.

Kinds

Given the technical characteristics and composition, new generation concrete is divided into:

Polymer cement. This type of concrete has excellent strength. A similar material is used in the construction of airfields, finishing slabs and bricks.
Plastic concrete. It exhibits the property of excellent resistance to acid-base reactions and temperature imbalance.
Concrete polymer. This building mixture differs from others in that the ready-made, frozen block is impregnated with monomers.

These substances, filling the holes and defects of the material, provide it with durability and resistance to sub-zero temperatures.

Also, depending on the type of construction work, experts divide polymer concrete into filled and frame molecular. The first type allows the presence of such organic materials as quartz sand, gravel. These materials perform the function of filling voids in concrete. In the second option, the concrete remains with unfilled voids. And the connection between the particles of concrete is carried out by polymeric substances.

Drainage pipes is one of the production lines of 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 channels, shaft pipes and much more, in particular polymer sand products, namely polymer sand tiles, polymer hatch, polymer sand tiles and drainage trays (polymer sand trays).

We are ready to offer you the most favorable terms of cooperation! We are confident in the quality of our products and give 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, give) water from the ground.

Drainage 63, 110, 160, 200 mm can be bought 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 perfectly passes water.

Drainage wells are provided for cleaning the drainage system, for example, drainage wells are washed with water under strong pressure, which flushes out all unwanted soil from the drainage pipes.

Fittings for drainage pipes and various adapters are made of high-strength material to securely 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, PBT offers you drainage trays at a special price! And the quality of 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 low pressure polyethylene. Made for pipelines transporting water (also for drinking and domestic water supply) and any other liquid and gaseous substances. HDPE pipes confidently replace steel and concrete pipes, with a number of advantages, such as - significantly lower cost, excellent performance, quick and easy installation of pipes, allowing the use of trenchless technology.

Drainage pipes, HDPE pipes, Polyethylene pipes, PE pipes, water pipes (water pipes), sewer pipes, gas pipes (gas pipes), 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 at the PBT company at the best prices in St. Petersburg.

Polymer-sand tiles withstand both cold 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, we have a special price for all polymer sand products for wholesale buyers.

www.p-b-t.ru

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

Polymer concrete is a special building material that is used as a bonding element, as well as to replace lime cements. In some cases, the polymer is used as an addition to Portland cement. It is a versatile, durable composite material obtained by mixing various mineral fillers with synthetic or natural binders. This advanced technical material is used in many industries, but is 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 and compositions in order to have a general idea of polymer concretes and their modifications.

Polymer compositions for concrete (polymer-modified concrete)

This type of concrete is made of Portland cement material with a modified polymer 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 a persistent 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 10 to 20%. Concrete modified in this way has a lower degree of permeability and a higher density than pure cement. However, its structural integrity is significantly dependent on the binder of Portland cement.

Concrete may take longer to degrade if it has a high density and less surface area. A relative improvement in the chemical resistance of a polymer-modified material to Portland cement is possible in an acidic environment.

Resin impregnated concrete

Polymer impregnation for concrete is usually done by incorporating a low density monomer into hydrated Portland cement followed by radiation or thermal catalytic polymerization. The modulus elasticity of this type of concrete is 50-100% higher than that of conventional concrete.

However, the polymer modulus is 10% greater than that of normal concrete. Thanks to these excellent characteristics, among the many options for using a polymer building material, production can be separately noted:

decks;
bridges;
pipes;
floor tiles;
building laminate.

Implementation process technology involves drying concrete to remove moisture from its surface, using 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, in order to increase wear resistance, resistance to cold and moisture, polymer varnishes are used for concrete, brick, stone, floors, etc.

Polymer concrete

It has nothing to do with our usual Portland cement. It is formed by combining stones with a polymeric binder that does not contain water. Polystyrene, acrylic and epoxy resins are monomers that are widely used in the manufacture of this type of concrete. Sulfur is also considered as a polymer. Sulfur concrete is used for buildings requiring high acid resistance. Thermoplastic polymers, but most commonly thermoset resins, are used as the main polymer component because of their high thermal stability and resistance to a wide range of chemicals.

Polymer concrete is made up of aggregates that include silica, quartz, granite, limestone and other high quality materials. The unit must be of good quality, free of dust, debris and excessive 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 is different from its predecessors. It has the following characteristics:

High resistance to chemical and biological media.
Compared to cement-concrete products, it has a lower mass.
Perfectly absorbs noise and vibrations.
Good weatherability and UV resistance.
water absorption.
Can be cut with drills and grinders.
Can be recycled as crushed stone or crushed for use as a 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 polymeric and conventional cement-based concretes. Its low permeability and corrosion resistance make it suitable for use in swimming pools, sewer systems, drain 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 the streets of the city. It is used in the construction of road barriers, sidewalks, drainage ditches, 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 in the open 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 manufacturing techniques. However, recent progress has led to significant cost reductions, meaning that its use is gradually becoming more common. Despite all its advantages over conventional concrete, there are opinions about the hidden negative environmental factors that often occur due to improper production, the use of low-quality components and the wrong proportions.

Also, the technology for the production of polymer concrete has many nuances and secrets that no one seeks to disclose. And of course, as noted by the reviews, the market price of polymer concrete is quite high. This is due to the difficulty of its production and the expensive components that are used to create it.

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Technologies for the manufacture of polymer concrete and the production of products from it

Polymer concrete (otherwise, cast stone) is a material that combines the strength and beauty of natural stone with an affordable price (thanks to cheap mineral additives) and ease of manufacture. The possibility of using almost any aggregate (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 consider typical technological processes for the manufacture of polymer concrete, as well as the possibility of creating it yourself.

Polymer concrete manufacturing technology

What will be required?

To get the product you need:

A filler of a sufficiently large fraction (sand, crushed stone, coarsely crushed glass).
A finer grinded aggregate that reduces the cost of the material. It is a powder of graphite, quartz or andesite.
Binder - it will need about 5 percent. In this capacity, one of the polymer resins is used. For example, polyester (unsaturated), urea-formaldehyde, furan, epoxy.
Hardeners, plasticizers, special modifiers, dyes.
Mold release lubricant and top coat gel coat.

Production methods

The production process can take place in batch or continuous technology.

In the first case, the containers used for the manufacture of the material must be washed after each completed cycle. But it is possible to make polymer concrete in the most ordinary bucket or concrete mixer.
Continuous technology is used mainly in large industries. At the same time, special injection molding machines, dispensers and automatic mixers work together, organizing a single chain.

The following video talks about the manufacture and spraying of lightweight polymer concrete:

To make a cast stone, you will need a mold well coated with a special release agent (otherwise it will be impossible to remove the finished product). The form can be made of silicone, fiberglass, metal or even chipboard (budget option).

A layer of gelcoat of the desired color is applied to the release paste.
A composite mixture is placed inside the mold, consisting of the above ingredients, previously well mixed in a concrete mixer. In large industries, where the volumes are very solid, the mixture is put into the mold using a concrete paver. If the products are small, and the technological process is periodic, then this is done manually.
Now it is necessary that the laid mixture is subjected to vibration (vibration compaction). This procedure takes approximately two minutes. At the plant, a resonant vibration platform is used for this, at a small production site - a vibrating table.

We will talk about machines, molds and other equipment for the production of polymer concrete products below.

Necessary equipment

Features of choice and costs

All this will cost a tidy sum of several million dollars. If we confine ourselves to turnkey branded equipment, then the costs will be much less - from 30 to 50 thousand dollars.

List of equipment and devices

So, here is a list of equipment and devices that you can not do without:

Vibrating table - ready will cost about 27 thousand rubles. If you want to save money, weld the table yourself using two-millimeter metal corners (60s). We weld an industrial-type vibrator to the table - done.
A stirrer that will combine all the components into a homogeneous mixture. If you purchase a powerful vacuum device of European quality, you will have to pay about 10 thousand dollars. But you can also use a domestic concrete mixer or a construction mixer. It will be much cheaper - the cost depends on the volume and power. Even cheaper is to make a mixer yourself from an iron barrel and an electric drive with a gearbox.
You will also need a compressor system with a gun. Without it, it will not be possible to apply the gelcoat evenly. The gun costs from 50 to 100 dollars. You can take automobile compressors - two pieces from ZIL will be enough. They are connected in parallel and attached to metal platforms installed on a strong frame.
Molds made of fiberglass or silicone are not yet widely available for sale. 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.
Without fail, an exhaust hood will be needed - at the casting stage, production is distinguished by harmful fumes. Accordingly, we will also purchase individual protection: gloves, respirators.
For finishing work, you will need electric tools: grinding and polishing machines. And also a drill, a jigsaw, a grinder, a milling cutter (if necessary).

We will talk about emissions into the atmosphere from the production of polymer concrete below.

This video will also tell about another method of manufacturing polymer concrete:

As mentioned just above, during casting, the release of harmful components is present.

In particular, it is styrene, which is contained in resins used as a binder. As soon as we open a hermetically sealed container with such a resin, the poisonous gas begins to evaporate.
In addition, the hardener is also extremely dangerous (as a rule, it is methyl ethyl ketone peroxide). However, it is not volatile and requires only the protection of hands with rubber gloves.

How to make elastic polymer concrete yourself (with your own hands), read below.

DIY creation

Room selection and arrangement

In the center of this room we make a table on a frame of iron corners, covering it with a chipboard top. We expose its surface according to the level - this is important! Above the table we install a hood - a metal box with an electric motor.

Required raw materials

Required raw materials:

River quartz sand (packed in 20 kilograms). It must dry well.
Sifted chalk - we also dry it.
Polyester resin - in buckets of 20 liters is bought.
Hardener, gelcoat, release paste.

You will need a clean plastic bucket for stirring, a 450-watt perforator and a construction mixer (we will attach a perforator to it by welding a perforating drill - we get a mixer).
We make the form from laminated wood boards, making it collapsible. It is convenient to apply the separating paste with a brush, rubbing with a nylon stocking.
We dilute the gelcoat with resin (adding 10 percent of it) and apply with a flute brush. We do this twice. We make sure that the hairs from the brush do not stick.
After mixing the resin with the hardener in a clean bucket, add 15 percent chalk, and then sand in portions. The mass should become viscous. To remove air bubbles, tap the bucket on the floor from time to time.
Once ready, pour the solution into the mold. Now let's smooth the surface: two people take their hands on the form (certainly equipped with handles) and, lifting it, tap it on the table. The mixture is left (for 40 minutes) and exit the casting room.
After hardening to a “rubber” state - this can be determined by a very hot surface and a special sound when tapped - we take the product out of the mold (disassemble it) and turn it over with the pouring side down. Let it harden completely, then sand and polish.

The following video will tell you how to make polymer concrete with stains with your own hands:

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polymer concrete

With rare exceptions, the technology for construction, restoration or repair work involves the use of 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 binder 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 as an astringent to the usual sand-cement mixture. They are gradually introduced during the preparation of the solution. Polymer-based concretes are suitable for surface finishing both inside and outside buildings, pouring floors, stairs.

Composition and fillers

For the preparation of these concretes, fillers and binders are also used. Given the special qualities of the polymers, the ratio between the components can vary from 5:1 to 12:1.

As with traditional analogues, polymer concrete contains fractions of different sizes, and, unlike cement grades, they are also finely dispersed. Given that these materials are widely used, including for operation in conditions of direct contact with aggressive compounds, substances with increased resistance to chemical attack (for example, quartzite, basalt, tuff) are used as fillers.

Astringent components:

The cheapest are furan polymers. But the strength is also low.
Higher quality concretes, which include polyesters (unsaturated).
The best options are materials containing epoxy resins. They combine strength, ductility, wear resistance. However, their price is quite high.

Manufacturing

There is no definite answer to the question of how to make polymer concrete. All sources speak of an experimental way to obtain the required composition. It is necessary to ensure that when the applied mixture dries, it forms an elastic elastic coating. Much depends on the place of installation, on what result you want to achieve. There is a general recommendation that polymer additives should be 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, 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 the replacement of cement with slag, ash and liquid glass. In all other respects (mixing), the procedure 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 the structure are exposed to intense exposure to liquids. By purchasing polymer, or natural concrete, you can significantly save on waterproofing and reduce the total time of work.
Resistant to aggressive environments, low temperatures.
The mechanical strength indicators significantly exceed the similar characteristics of concretes based on cements: for bending - up to 10, for compression - up to 3 times.
Low specific gravity, which significantly increases the range of applications.
The property of elasticity allows it to be used in areas subject to dynamic loads. It can be applied on planes with any orientation: horizontal, vertical, inclined.
Excellent adhesion, regardless of the base material.
The curing time is less than that of cement.
The ability to achieve perfect evenness of the coating. Surfaces finished with polymer concrete are easy to maintain.

Concrete mixtures are used today at any construction site. There are a large number of their varieties.

If polymer concrete is applied with a layer of 2 cm, then a couple of hours after drying, drawings can be applied to the surface.

Relatively recently, a mixture appeared, which is called polymer concrete.

Its variety is geopolymer concrete. What is polymer concrete?

The characteristic difference of this concrete mixture from other compositions is the addition of high-molecular-weight organic compounds to it during the manufacturing process. The binder in such a mixture are various polyester resins: polyurethane, methyl methacrylate, epoxy, polyvinyl and some others. A hardener, various catalysts, solvents and other components are added to them.

Advantages of polymer concrete

Geopolymer concrete has a number of advantages:

has a high degree of adhesion to surfaces of any texture and material;
hardens quickly;
has great permeability;
has a high degree of resistance to stretching and bending;
differs in the increased durability and wear resistance;
resistance to temperature extremes and to the effects of acids;
has ecological cleanliness and low specific gravity.

The disadvantage of this material is the high cost.

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Preparation of polymer concrete

To date, geopolymer concrete is undergoing a development stage, so there is no exact recipe for it. But cooking is a very doable task. This will require some experimentation.

PVA, various latexes and water-soluble resins are used as various additives during mixing. When polymer concrete dries, a hard film forms on its surface. It is able to absorb water and swell, therefore, high humidity should be avoided during the manufacture and use of the working mixture. Moisture content of bulk components should not exceed 1%. To achieve this, the fillers are dried in drum dryers. Drying temperatures - 80-110°C. Before mixing the solution, they are cooled to ambient temperature.

Synthetic resins, hardeners are heated before mixing until their melting point is reached - 35-40°C. The optimal amount of various additives for polymer concrete mixture is established experimentally. The main thing in this process is to remember that the proportion of polymers should be about 20% of the mass of cement.

When mixing the solution, water-soluble resins are introduced in small doses not exceeding 2% by weight of cement. The mixture is constantly stirred. It is better to do this with a concrete mixer. Practice shows that the highest quality polymer concrete is obtained by adding polyamide and epoxy resins, and polyethylene-polyamine hardener.

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Methods of using polymer concrete

Such material can be used for spraying and stamping on horizontal and vertical surfaces. This is done in the following sequence:

The working solution is mixed.
If necessary, synthetic dye is added.
Mix everything until the consistency of liquid sour cream.
The mixture is sprayed onto the surface with a plaster gun from a distance of 0.5-1 m.
The metal surface must be degreased before spraying.
Polymer concrete during spraying is applied in two layers - base and finish.

After spraying it on plywood and other plastic materials, they can be bent and the coating will not crack. Polymer concrete is also applied to the insulation. It is suitable for processing facades. This material does not leak. Even with ordinary masking tape, you can easily create the simplest drawing. It is necessary to randomly stick strips of adhesive tape on the surface and cover it with a thin layer of the solution. After the concrete coating has not completely dried, the adhesive tape comes off, the pattern remains.

Polymer concrete, if applied in a layer about 2 cm thick, can be stamped after a couple of hours to obtain a pattern. This is done with polyurethane stamps of different textures. With their help, you can give the surface the appearance of brickwork, as well as leave a wide variety of ornaments. Most often, stamped polymer concrete is painted. This can be done with special stains or acrylic-based concrete paints.

The material is used for the construction of paths and terraces, for finishing walls inside and outside the building, for pouring floors. Portals of fireplaces, stairs, fences, pools, curbs of paths are trimmed with polymer concrete. Sculptures for parks and gardens can be cast from it. Almost all enclosures and rocks in the Moscow Zoo are made of polymer concrete.