SfB Dn

Build. Sci. Vol. 2. pp. 147-163. PergamonPress 1967. Printedin Great Britain.

Polymer-Mineral Mixtures as
New Building Materials
TADEUSZ HOP, D.Sc.*
ZENON MIODYlqSKI, M.Sc.

The technology of mineral-polymer mixtures, their most important properties

proved by testing, and their application in the building industry are discussed.
The first part of the paper deals with the mortars and concretes to which the
proper polymer has been introduced for the optimum change of their specified
properties. After surveying the polymers usedfor the modification of mortars and
concretes, the working of these chemical additions is shown, their influence
on features of mortars and concretes, mode of preparation of proper mixtures,
results of some tests, and the application of a variety of polymer mortars
and polymer concretes are discussed.
The second part deals with those mineral-polymer mixtures in which the sole
binding medium is the appropriate synthetic resin. The authors' test results
are given and the uses of these mixtures for variety of building structures
discussed.

1. INTRODUCTION There is a large number of combinations which

THE CHEMICAL industry is capable at present to
supply a great variety of synthetic materials whose
binding properties can not only improve the quality
of conventional binders but also be used by them-
selves as binders.
A suitable polymer used with a mineral binder
may prove to be a valuable factor in binding of
crushed rocks, sinters, timber wastes, metals etc.,
in making mortars and concretes. The most
appropriate for this purpose are those materials
which can produce solutions and aqueous emul-
sions. To enhance the action of building binders
may also be used, powders and pastes of such
materials which are liable to chemical or thermal
hardening in the presence of water, and chemical
compounds formed during the setting of the binder.
Any synthetic resin can be considered as a self-
contained binder capable of producing the desired
building material (by this are meant chiefly artificial
stones for such uses as for example floors, coverings,
load bearings structure and also mastics, glues etc.),
provided it can be mixed with appropriate filler,
and hardened preferably without application of in-
creased pressures and temperatures, under conditions
prevailing on the building site or precasting shops.
The polymer-mineral mixtures used up to now
in the building industry may be subdivided in two
main groups:
(a) mortars and/or concretes with polymer
admixtures, i.e. mortars and concretes im-
proved by addition of suitable polymers,
(b) resin mortars and concretes in which the only
binding material is the appropriate resin.
*Head of Chair of Communal Building of Silesian
Technical High School.
are formed by binders, aggregates and polymers
producing valuable building materials for a variety
of applications. Thus, the scope of scientific
problems covering the processing, properties and
applications of polymer mineral mixtures is very
extensive.
This paper will be substantially confined to
results of our own investigations covering mainly
resin mortars, supplemented only by the most
interesting data on the present application of
polymer-mineral mixtures.
2. MORTARS AND/OR CONCRETES
WITH POLYMER ADMIXTURES
2.1 The aim of polymer application in mortars and
concretes
The polymers are added to mortars and concretes
to improve certain properties or to confer to them
new properties required for special applications.
Naturally, the best admixture is such one which
will impart the desired properties to mortars and
concretes without impairing those which are of
special interest to the user.
The following properties of mortars and con-
cretes can be considered as unsatisfactory: flexural
and tensile strength, impermeability to water,
resistance to frost, scratch and shock resistance,
abrasibility, adherence and resistance to chemical
attack of various kinds. By choosing suitable
polymer admixtures these properties may be
accordingly changed, sometimes even radically. A
selective introduction of organic additions during
the technological process can for instance totally
eliminate the brittleness of mortars and impart
to them a new feature, i.e. elasticity.

147
148 Tadeux= ttop a m / Z e n o n Miod~l~ski

2.2 Polymers suitable for improt,ing mortars
and concretes
High molecule organic compounds which can be
applied in the preparation of mortars and concretes
may be arbitrarily subdivided into four groups:
(a) Monomers liable to polymerization and
hardening in a basic medium after the forma-
tion of the structure of hardenable mineral
paste, e.g. furil alcohol.
(b) Polymers introduced into aggregate-binder
-water mixture, hardenable during bonding
and maturing of the paste, e.g. latexes,
resins soluble in water.
(c) Polymers conserving their elasticity in mortar
or concrete and changing only their viscosity
with time, as opposed to compounds belong-
ing to groups 'A' and ' n ' changing their con-
dition from visco-plastic to elasto-brittle,
e.g. polyvinyl acetate.
(d) Polymers liable to thermal reactions in the
condition of high fineness introduced directly
into mortar or concrete mixtures. During the
vapour curing polymers melt and in the
subsequent cooling stage fill thoroughly the
pores in the formed artificial stone. As an
interesting example can be cited the pulverized
polyethylene-polyisobutylene compound.
A detailed list of synthetic admixtures
mortars and concretes is given in Table I.
2.3 Proeess'htg oJmortars and concretes ~titlt
polvnter admLvtures
The polymer admixtures do not affect essentially
the processing of mortars and concretes.
The choice of constituents with respect to
quality depends on the application of the tinal
product (floors, plasters, waterproof or corrosion
resistant coatings, structural concretes, joints,
strengthening etc.).
The properties of the product as required lbr
particular applications are a deciding lilctor in
selection of the kind of binder (Portland cement,
aluminous cement, metallurgical cement, lime,
gypsum etc.), of polymer admixtures (specified in
Table 1), and of aggregate (with respect to its
origin and grading).
The strength required from a product - a mortar
or concrete--will be dependent not solely on the
binder, the polymer admixture and the aggregate
but also on such technological factors as:
(a) percentage ratios of constituents,
(b) mode of mixing and moulding as well as
conditions of curing of polymer-mineral
mixture, and
(c) conditions of hardening of mineral binder
depending on the applied stabilizers of
polymer emulsions and binding accelerators.
for The quantitative determination of constituents
is here more complicated than in the case of con-

Table 1. The best known admixtures for ntortars anti concretes

Form of
Application Admixture addition
r furil alcohol solution
I latexes dispersion
I polyvinyl acetate dispersion
Cement mortars, polyvinyl chloride dispersion
concretes i polyethylene with polyisobutylene powder
urea-melamine resins solution
phenolic resins solution
acrylic resins and other solution

[, polyvinyl acetate
polyvinyl chloride
dispersion
dispersion
Lime mortars ~ water-soluble resins solution
[ latexes dispersion

F the same as for lime mortars

Gypsum mortars ~ with the exception of latexes

The range of polymers applied to mortars and
concretes is growing very rapidly. Especially great
hopes are attached to the development of water-
soluble resins, as well as to the polymers specified in
group 'D'.
In addition to polymers given in Table 1 also
magnesia mortars with polymer admixtures are
known.
ventional mortars and concretes. The most
essential factor is the correct determination of the
amount of polymer, given usually as p/c ratio
(p = polymer, c = cement).
The available results of investigations permit an
approximate determination of optimum quantities
of some polymer additions with respect to the
strength of the hardened mix.
 Polymer-Mineral Mixtures as New Building Materials
For example it is considered that the best value of
polyvinyl acetate to cement ratio is 0.2, and for
some latexes p/c = 0.16, and for certain water-
soluble resins p/c = 0.02.
Cement and aggregate are given similarly as for
mortars, e.g. 1: 3.
Polymer admixture permits to lower the w/c
ratio (w = water) without affecting the workability
and consistency of the mix.
To counteract the coagulation of water-dispersed
polymers with the cement various stabilizers are
used, pre-eminently in the form of casein, carboxy-
methylcellulose, methylcellulose, soda and
potash.
The type of stabilizer and its proportion should
be carefully determined, since the exceeding of
allowable amounts has usually an adverse effect
on the strength of mortar or concrete.
Some stabilizers act simultaneously as ac-
celerators of hardening. Such accelerators are
e.g. soda and potash which are added to the latex-
cement mixture stabilized by ammonium caseinate.
Hardening of polyvinyl acetate--cement mixture is
accelerated by calcium chloride.
The binder-polymer-aggregate mixes can be
prepared by three methods:
(a) Aqueous polymer emulsion is mixed
thoroughly with binder, while a necessary
amount of water is added either to the
emulsion or to the binder before the latter is
mixed with emulsion. Then aggregate is
added and all the constituents are subjected
to mixing. This method is specially applicable
to preparing of mixes with coarse-grained or
fibrous filling materials.
(b) Cement is mixed with aggregate and eventu-
ally with pigments and other special addi-
tions. Such a dry mixture is supplied in
bags to the building site where a necessary
amount of aqueous emulsion of polymer is
added to it. The dry constituents should be
preferably added gradually, not all at once.
This method is useful in preparation of
mixes for coloured coverings.
(c) All the constituents are mixed simultaneously.
This general method can be applied to well
stabilized emulsions of polymers.
Mechanical mixing of constituents of mortars
and concretes with polymer admixtures should be
effected only in forced paddle-type concrete
mixers. Very good results (uniform distribution
of polymer, better conditions for hydration of
cement and resulting increase in strength) were
obtained in applying grinding with vibration (vibro-
cavitation process).
Workability, plasticity (consistency) and viscosity
of the mix depend on the amount of the polymer
addition (e.g. a 1 : 3 cement mortar with w/c = 0"43,
to which polyvinyl acetate and appropriate
stabilizer (soap) were added, showed at p/c = 0 a
sufficient workability and no plasticity, at p/c = 0-2
149
its workability was very good and the consistency
was fluid, and at p/e = 0-5 the mortar changed
into a dense and visquous mixture of a very poor
workability).
During hardening of mortars and concretes with
polymer admixtures many correlated physico-
chemical phenomena occur. They have not yet
been sufficiently investigated but it is known that
the progress of hardening depends on the kind of
the polymer used as well as the nature of the
environment (humidity and temperature) in which
hardening takes place.
In the conventional concrete elements stored in
dry air conditions (at the relative humidity varying
from 35 to 50 per cent) the water evaporates before
the cement is fully hardened, leaving voids which
weaken the structure of the concrete. An addition
of the polyvinyl acetate permits a more complete
hydration of the cement, as the water sorption,
taking place on the surface of the hydrophillic
polymer particles, hinders and retards the evapora-
tion of water. In dry-air conditions the polyvinyl
acetate would rapidly dry and attain a high
strength, resulting in a rapid growth of strength
of concrete with polymer admixture.
In water (i.e. at 100 per cent relative humidity)
the polyvinyl acetate cannot dry and reach a high
strength. In such an environment the concrete
with polymer admixture cannot attain a higher
strength than the conventional concrete under
similar conditions. A wet environment does not
affect the concrete with addition of carefully
selected water-soluble resins. Such concretes reach
a higher strength than the conventional concretes.
A combination of conditions is specially favourable
for concretes with addition of these resins. On
preliminary storing this concrete under water or in
environments of 90 per cent relative humidity
and subsequent curing in dry air of 50-70 per cent
relative humidity, initially a faster and more
complete hydration of cement and then an ac-
celerated hardening of polymer were observed.
In this way cement and polymer contribute to high
strength of concrete.
2.4 Effect of polymer admixtures upon the properties
of mortars and concretes in the light of some
investigations
To the most important mechanical properties of
cement mortars with the admixture of polymers,
which determine their quality and suitability
belong: compressive, fluxural and tensile strengths,
hardness and abrasibility. The most thorough and
exhaustive investigations have been carried out on
mortars and concretes with admixtures of various
types of latexes and polyvinyl acetates.
In the Soviet Union, where mortars with polymer
admixtures have been investigated for about 30
years, very interesting results have been obtained.
According to Tcherkinsky and his collaborators,
the admixture in dry-air environments, of poly-
vinyl acetate in form of a 50 per cent aqueous
150 Tadeusz Hop and Zenon M i o d y g s k i

Table 2. Effect of polyvinyl acetate admirture on strength (~/mortars aged 28 days

i

Cement-sand Cement- Kind of Percentage of polyvinyl acetate and

Reference ratio water polyvinyl Strength strength (kg/cm2)
(c/s} ratio acetate 0 0.12 0' 15 0.21 0.27*
(w/c) 0 0. I0 0.15 (}.20 0.30
l :2 0.334 emulsion compressive 480 527 545 480
of PVA flexural 62 163 192 214 --
Tcherkinsky 1: 3 0.370 emulsion compressive 310 453 453 491 455
(Soviet Union) of PVA flexural 51 I 11 124 159 184
1:6 0.577 emulsion compressive 123 200 323 320
of PVA flexural 27 84 124 145
Institute 1 : 3 0.400 Rhodopas compressive 165 193 -
of Building 600 RHG flexural 42 ...... 85 ---
Technology, Budapest 1:3 0"400 Movilith compressive 165 140 140 140 143
DM1H flexural 42 45 48 50 82
1 : 3 0-500 emulsion compressive 212 188 186 172 173
D-25 flexural 68 70 77 82 64
The authors
(Silesian Technical tensile 18 24 26 27 28
High School) 1 : 3 0.500 emulsion compressive 212 201 196 188 180
D 50 flexural 68 75 104 111 109
tensile 18 23 28 46 42

* In investigation carried out by Tcherkinsky

emulsion, has resulted not only in an increase of
flexural strength of mortars (which was confirmed
by other investigations), but also by an increase of
compressive strength (Table 2). The effect of
polyvinyl acetate admixture is considerably greater
in mortars with a low content of cement, than, if
the amount of cement in the mortar is large
(e.g. 1:2). Tcherkinsky carried out compression
tests on cylindrical specimens of identical diameter
and height of 25 mm and flexural tests on 40 mm
×40 mm × 165 mm test beams. These specimens
matured in environments of 30-35 per cent relative
humidity and at the temperature of 16-17°C.
Most thorough and complex investigations of
mortars and concretes with polymer admixture
have been carried out in the Institute of Building
Technology in Budapest. It was found, that the
most beneficial results were obtained with the
admixture of emulsions of polyvinyl acetate Bg
101 S, Rhodocin and Rhodopas 6000 RHG. These
investigations covered also the use of vinyl copoly-
mer (Vinitex). In the environments of 45-50 per
cent relative humidity the admixture of the poly-
vinyl acetate as well as of the vinyl copolymer
resulted in a beneficial effect on the flexural
strength of mortars (carried out on 40 m m × 40 mm
× 160 mm test beams). The optimum proportion
of polymer in cement was found to be 10-20
per cent by weight. Compressive strength of"
polymer mortars as examined on 70 m m × 70 mm
× 70 mm test cubes 28-days-old was lower than
that of conventional mortars (Table 2). A year
later this state reversed in behalf of mortars
improved by polymers, and their admixture pro-
voked an increase in compressive strength by about
10 per cent.
Results obtained by investigations carried out in
the Chair of Communal Building of the Silesian
Technical High School were very close to those
of Hungarian investigators. As shown in Table
2 the better admixture was polyvinyl acetate
of D-50 type. Following strength tests were
made on mortars so prepared: compressive,
flexural and tensile tested specimens comprised
cylinders, of an equal height and diameter of
40 mm, test beams and s p e c i m e n s - - ' 8 ' t y p e - -
of a reference cross-section 2 0 m m × 2 0 m m .
Specimens were stored in a laboratory room in
relative air humidity of 50-70 per cent.
Noteworthy results were obtained by Satalkin
and Popova using resins soluble in water (S-89,
D E G - I and TEG-17) as admixtures to fine-grain
concretes. For mixes with cement to sand ratio
1:3 the optimum admixture was found to be 2
per cent of S-89 and TEG-17 resins. For investiga-
tions Portland cement 500 and sand of mean grain
size 2.25 mm was used. Results of compressive
and tensile strength tests are shown in figure 1.
It has been made evident what a very beneficial
effect present water-soluble resins as admixtures to
mortars and concretes--they definitely improve all
kinds of strength properties.
Satalkin and Popova affirm also, that concretes
with these admixtures are characterized by an
increased elasticity without excessive deformation
in a compressed state and lower creep than con-
ventional concretes without polymers (figure 2).
As to concretes with latex and polyvinyl acetate
additions Satalkin and Popova confirmed the
findings of other investigators.
Very interesting is the suggestion of Leikin, who
proposes to determine the optimum composition of
mortars and concretes with polymer admixtures
and also to conclude on their quality and applic-
ability by way of relative hardness tests with the
testing machine of pendulum type (S.U. Standard-
GOST 5233-50) and wear tests by abrasive method.
According to Leikin such tests are less expensive,
 Polymer-Mineral Mixtures as New Building Materials 151

Polymer-cement mixtures are characterized by

good bonding properties to concrete, steel, wood
6C
~m 600 - - ~ l -T --~,3 and glass.
=" Exemplary compositions for floor mixtures are
4OO - 4C
T~ 4 given in Table 3 (after Tcherkinsky).
5
.~ 20C zc
(u
2.5.2 Repair of concrete, reinforced concrete and
prestressed concrete structures. Due to a high
~ o 7 14 2~ 28 7 14 21 28 strength and good adhesion to the base, the polymer
uo
Days Days concrete is an irreplaceable material for repair of
Fig. 1. Age - strength relationship for polymer concrete
concrete highways, airfield runways, platforms,
specimens stored in water. floors, stair-flights etc.
1. Concrete without polymer The damaged concrete surface must be
2. Concrete + 2 % resin S-89 thoroughly cleaned (e.g. sand-blasted) and ade-
3. Concrete + 2 % resin TEG-17 quately wetted. Then it is covered with a 2 or
4. Concrete + 16 % latex SKS-65GP 3 cm layer composed of cement, sand, of a grain
5. Concrete + 20 % polyvinyl acetate emulsion stabili-
zed with 20 % formalin.
size up to 7 mm and water diluted emulsion of
polyvinyl acetate. It is advisable to vibrate or roll
the polymer concrete after placing. If the repair
easier to perform, and give more representative of the damaged area is made with a normal
results than the usual strength tests for such cement-sand concrete, between the old and the
applications as mixtures for flooring, covering etc. fresh concrete should be introduced a tacky layer,
e.g. of water soluble resin sufficiently diluted.
2.5 Principal applications of mortars and concretes 24
I
improved by polymer admixtures I
20--
2.5.1 Floors. Floors made of mortars and
concretes with polymer admixtures can be: one C) 16 I
x
layer (3-10mm thick), two-course topped (the ; 2
12
base layer 4-10 mm thick, the top layer 2-5 mm A f ~ j I
I !
thick) and multilayer floors. The top layer may be c" 8 t
/ j 1 1 3
simple coloured, or multicoloured. According to I
the character of duty the surface of the floor may
be ground and polished. 0
30
Strength of floors and their resistance to various
other factors can be changed to a large extent.
Admixture of polyvinyl acetate imparts to ~ 6O
floors high hardness and strength, whereas the
~ BO ~
admixture of rubber latexes gives them flexibility .c
and elasticity. N IOO • • • Increase of humidi~y -
As a mineral binder for floors is used, Portland
cement, which is not expensive, and also clay 20 40 60
I I i 140
80 I00
I 120 160 180
cement, which mixes better with latexes and Age, days
provides better strength. Fig. 2. Creep o f polymer concretes with variable humidity.
As fillers in floor mixtures are used: sand,
1. Concrete without polymer
crushed granite, marble, limestone, sawdust, cork 2. Concrete + 2 ~ resin 3'-89 at decreased humidity
and suitably comminuted rubber. 3. Concrete without polymer
Sand is the least expensive filler, but does not 4. Concrete + 2 % resin DEP-1 at increased humidity.
ensure a good resistance to abrasibility. In this
respect granite is a very good constituent. Sawdust To repair the airfield runways concretes with
is used to make the so-called, warm floors, whereas polyvinyl acetate addition are used.
cork and rubber are used to form sound absorbing, Repair of cracked reinforced concrete structures
dustless floors preventing slipping which are easy can be made by pressing into the cracks cement
to clean and resistant to abrasion. Floors of this paste of fluid consistency with addition of polyvinyl
kind have been already applied for experimental acetate.
purposes in hospitals and schools. There are known examples of filling, or rather
For heavy duty floors and pavements, exposed to sealing, joints of large size prefabricated elements
intensive pedestrian or wheel traffic, metal powders of a living house with a mixture, composed (by
or metal oxides are added. weight), of Portland cement (20 parts), sand (60
Floors made with polymer admixtures ensure a parts), emulsion (50 per cent) of polyvinyl acetate
higher resistance to acids, sulphates, animal fats (8 parts) and water (10-15 parts). Polymer con-
and sugars. cretes can also be used to seal pipe joints,
152 Tadeusz Hop and Zenon Miody~ski

Table 3. Uompositionsof pol)'mer-mineral mi.wures [br floors

Proportion of constituents by
weight
Common floor One-colour
Use Constituents 5 mm thick floor 4 mm thick
Hard, single-layer Portland cement 400 1.0 1.0
floors (in commercial emulsion (50 ~) of polyvinyl
premises, administrative acetate or latex SKS-65 0.4 0.6
buildings, cinemas, river sand 4.0
staircases) ground sand, marble or granite 3-0
mineral pigment 0.1-0-3 0-1 0-3
water--according to workability requirements
Bottom layer Top layer
Hard, two-layer floors, Portland cement 400 1.0 1.0
7-10 mm thick emulsion of polyvinyl acetate 0-4 0.4
sand 6.0
ground sand -- 1.0
aggregate of granite or marble -- 2.0
mineral pigment --- 0.1-0.3
calcium chloride 0.01 0.01
ammonium bi-chromate 0.015 0.015
water according to workability requirements

Floors aboard ship cement 1.0

latex 0.54
cork 0.23
water according to workability requirements

2.5.3 Plasters and coverings. Good bonding to
concrete, wood and steel, weather resistance, short
drying time and also simplicity in execution--
these are the properties which make the polymer
mortars the most effective covering materials.
For decorative coverings are used white cement
and such fillers as finely powdered limestone, sand
and silica. To the mixture are added mineral
pigments or organic paints. In coverings are used
admixtures of polyvinyl acetate, latex SKS-65,
polyvinyl chloride and others.
For ornamental purposes multicoloured stones
can be inserted into the covering (e.g. marble);
the finishing treatment may require smoothing and
grinding. Polymer mortars can be used for
incrustated coverings.
2.5.4 Insulation. For thermal and sound insula-
tion an appropriate mixture is (by weight): clay
cement (70 parts), latex (40 per cent solution) (100
parts), casein glue (5 parts), cork (3 m m grains)
(35 parts).
Good fireproof properties can be obtained by
introduction of mica and asbestos into the mix.
By an addition of 1 per cent (by weight) foaming
agent, cellular polymer concrete on Portland
cement of 400-600kg/m 3 bulk density can be
obtained. As a filler can here be used ground
sand, asbestos and vermiculite. The addition of
polyvinyl acetate produces a great increase of"
tensile strength.
A light insulating material (with a bulk density
of 400-450kg/m 3) can be obtained by using
ceramsite as a filler. With 70 kg/m 3 of cement and
14 kg/m 3 of polyvinyl acetate a polymer concrete
had the strength 20-25 kg/cm2.
In mixes for damp-proof insulation, the latex
is replaced by metaphosphates or polymeta-
phosphates. In this instance appropriate amounts
of bitumens, oils or paraffin are added. The
bitumen can be partially replaced by spent sulphite
alkali.
To insure water impermeability a water in-
soluble resin in amounts of 4--10 per cent is added
to the concrete mix. Such a resin acts as a filler.
Then a hardening agent is introduced into the
surface layer of concrete, thus causing the resin to
expand and to completely fill-in all the voids in
the concrete.
2.5.5 Anti-corrosive coatings. To protect steel
and concrete against acids and other corrosive
chemical substances, mixtures with high polymer
content are applied, e.g. as an anti-corrosive
coating for vessels and piping a mixture of the
following composition was tried:
cement (20 parts)
(100 parts)
natural latex (emulsion 70 p.c.)
filler (0.5-2.0 parts)
vulcanizing additions (1 part)
In addition to rubbers also thermoplastic and
other resins~ polymerizing oils and bitumens are
used in anti-corrosive coatings.
 Folymer-Mineral Mixtures as New Building Materials
Anti-corrosive coatings are made up of several
layers, each about 3 mm thick. Between layers
steel wire nets are inserted. The top layer is
applied as a thin film of polyester, epoxy or
resorcin-formaldehyde resin.
Ceramic tiles may be glued upon polymer
mortar surfaces.
2.5.6 Glues and mastics. The latex-cement
mixtures (e.g. composed of 1 part of latex as a
60-70 per cent emulsion and 2 parts of cement) are
suitable for gluing ceramic tiles (e.g. bathrooms),
joining concrete elements, gluing concrete and
steel or glass and joining other materials (e.g.
foamed material with concrete or asbestos concrete).
If required (e.g. for obtaining a mastic), sand,
asbestos and other fillers are added to the latex-
cement mixture. The latex-cement glue does not
burn, does not undergo ageing and is not toxic.
3. P O L Y M E R - M I N E R A L 1VIIXTURES
WITHOUT CEMENT (RESIN MORTARS)
3.1 General features of resin mortars
In building, mortars are defined as mixtures
composed of binder, water and aggregate or other
fillers. By analogy, by a resin mortar will be
understood a mixture of resin, hardener and solvent
with aggregate or similar filler.
The resin mortar is characterized by the ability
to pass from liquid or plastic to solid state, like
mortars with mineral binders.
The cement mortars differ from the concretes by
consistency and aggregate grading (in mortars the
grain size does not usually exceed 2.5 mm (excep-
tionally 5mm) and in concretes all the aggregate
fractions are employed and the grain size may
exceed 100 mm). Similar differences may exist in
polymer-mineral mixtures. Thus, by resin mortar
will be meant such a mixture in which the grain
size of aggregate will not exceed 5 mm and by
resin concrete will be understood a mixture
containing aggregate with grain size larger than
5 mm.
The hardening of the resin mortars and con-
cretes can be effected essentially by similar methods
as used for hardening of pure or mixed resins with
fillers employed in the synthetic resin industry.
Because of particular conditions encountered in
the building industry (dependency of weather,
changes of place of manufacture, distant energy
sources, a great variety of technological processes
etc.) the priority should be given to the chemical
hardening effected by the use of appropriate
catalizers, this requiring, of course, the application
of resins being suitable for such a hardening
method. Also, the process of heat-and-pressure
hardening could be applied, but it requires a more
complicated equipment, the installation of which
would be economically justified rather in specialized
plants manufacturing building materials and pre-
fabricated elements.
153
3.2 Constituents of polymer-mineral mixtures
3.2.1 Resins, hardeners, catalizers and solvents.
In these mortars mainly the thermohardening
resins such as phenol-formaldehyde, furan,
resorcinol-formaldehyde, melamine-formaldehyde,
polyester, epoxy and other resins are employed
as binders.
Of thermoplastic resins only such ones can be
used for mortars which form suspension or
solution and are liable to hardening during the
evaporation of the solvent. As an example of
this application may be given the polyvinyl acetate
which plays the role of a binder in floor putties
called ' spatula pastes '
Also, an elastomer--e.g, neoprene--can be used
as a binder for mortar.
For each type of resin the manufacturer usually
specifies the method of hardening, i.e. the type of
catalyser to be used, its amount in proportion to
resin, the time and the temperature of hardening.
For furan resins the acid hardners (e.g. sulphonic
acids) are used, the hardening of polyester resins is
catalized among others by the benzoyl peroxide
and the cobalt naphtenian, and for the epoxy
resins there is a great variety of hardeners, amines,
polyamines and polyamides included.
To the most known solvents suitable for varying
the viscosity of resins and the consistency of the
resin mortars belong alcohols, acetone, toluene.
For some resins water may be used as a solvent.
3.2.2 Fillers. For the resin mortars the following
filling materials in natural or crushed form are
employed: sand, sand dust, ground sand, silica
flour, andesite, diabase, basalt, granite in form of
dust or grit, light aggregate e.g. carbonaceous
sintered shale or keramsite, the brick fines or
grit, fly ash, asbestos, glass fibres and also such
organic substances as wood flour, sawdusts,
granulated cork, ground graphite as well as coal
and coke in the form of dust and grit.
For the resin concretes can be used the same
aggregate as for the common and light concretes,
and also coal, coke, asbestos and glass or synthetic
fibres. The filling material should be chemically
neutral towards resin, hardener and solvent since
otherwise the process of hardening may be
hindered or rendered impossible.
3.3 Processing of resin mortars
The selection of constituents for mortars and
concretes is closely related to their required pro-
perties (density, strength, hardness, resistance to
abrasion, corrosion resistance etc.). It has been
experimentally established that the strength of the
resin mortars and concretes depend as that of
common concretes on the degree of density of the
mix after hardening. The less voids in the obtained
product, the higher is its strength. Further tech-
nological factors deciding on the strength of the
resin mortars and concretes are: resin to filler
ratio (r/f) and hardener to resin ration (h/r). To
154 Tadeusz Hop and Zenon Miodytiski
illustrate the effects of these ratios some experi-
mental results obtained in the Soviet Union has
been given in Table 4. These data refer to mortars
and concretes prepared with the furfural-acetone
resin and benzenesulphonic acid as hardener. In
these experiments sand was used as a filler.
It can be seen that the hardener to resin ratio
(h/r) has a much more important effect on strength
than the resin to filler ratio (r,f).
Table 4. Effect of FA monomer and benzene-sulphonie acid quantities onflexural strength o/resin mortar
Resin to
filler ratio
(r/f), % 9 11 13
Flexural
strength,
kg/cm2 123 135 150
To obtain a dense product with a low resin
addition, the filler used should have the optimum
grading, i.e. the volume of voids should be as small
as possible. In Table 5 the grading of aggregates is
given as an example.
Table 5. Grading of aggregates
Fractions Weight percentage
(mm) ...............
mastics mortars concretes
<0'15 30 25
0"15-1'2 70 25
O' 1 5 - 5 -- 50
5-20 -- --
The mixing of the resin mortars can be effected
in paddle type mixers as used for cement mortars
and the resin concretes can be mixed in forced
(paddle-type) concrete mixers. With a wider
application of the resin mortars and concretes it
will become necessary to design special mixers
better adapted to the viscosity of the mix as well
as the time of hardening. Parts of these mixers
having contact with the resin mix should be
covered with such materials to which the hardening
mix would not stick. Sticking of resin to the steel
moulds will be avoided if the moulds are greased
with a thin layer of cup grease.
As soon as mixing and placing operations are
finished, the mixer and all the tools which were in
contact with the resin mortar should be thoroughly
cleaned.
Depending on consistency, the mix can be
poured into moulds, placed on a suitably prepared
backing, compacted with bars, vibrated, rammed
or pressed. The resin mortar for pipes can be
compacted by centrifugation. Thin coatings of the
resin mortar can be applied by special spray
apparatus.
3.4 Investigation of resin mortars
Multi-directional studies on resin mortars and
concretes have been started by the Chair of
Communal Buildings in the Technical High
School in Gliwice in 1963. The purpose of these
studies was to tackle the technology of resin
mortars and concretes, to determine their physico-
chemical properties and mechanical-theological
characteristics and to outline the principles of their
aged 14 days
Hardener to
resin ratio
15 (h/r), % 10 15 20 25 30 35 40
150 67 82 93 96 157 165 175
application in building. The research workers
wanted to develop cheap and useful materials,
based on resins produced in this country and easily
available fillers.
We shall present below our results obtained in the
initial period of investigation. These investigations
were undertaken with the aim to determine the
suitability of particular resins for preparing
mortars with various fillers, to outline essential
principles of technology (preparing, proportioning
of constituents, mixing, compacting, hardening,
--
curing), to determine the strength of the obtained
materials under pressing, bending and tensile
15
loads, as well as the rate of increase of strength
30 with time.
The resins employed in our investigations are
55
specified in Table 6. The phenol resin powder was
obtained as a pilot-production material and hence
one cannot specify its full characteristic. The same
applies to resorcinal resin obtained under laboratory
conditions.
In the samples of the resin mortars, 9 different
fillers were employed (for their names and grading
see Table 7). The same table contains proportions
of particular aggregate fractions with the grain
size varying from 0 to 1 mm and from 0 to 4 mm.
The fly ash with the bulk density of 762 kg/m 3
had the following analysis (%): 48.8 SiO2, 28.9
AIEO3, 9.3 Fe203, 6.1 CaO, 2.6 MgO and 2.1 SO3.
The sintered coal shale with the bulk density of
890kg/m 3 revealed the same properties as the
aggregates of this type used in light concretes.
The aggregate from the sintered fly ash had the
bulk density of 880 kg/m 3 and the strength of
73 kg/cm 2 (as determined by the method used in the
Soviet Union). The specific weight of the respective
sintered coal shale and sintered fly ash was 2.58
g/cm 3. The ceramsite originated from the experi-
mental production made in the pilot plant in
Mszczon6w near Warsow. The bulk density
of this aggregate was 430 kg/m 3 and its specific
weight varied from 2.5 to 2-6 g/cm a. Out of the
 Polymer-Mineral Mixtures as New BuiMing Materials 155

~7 ~J

0.,-~
I I
~o'~ ~ 'n = ~
Z~ ~ O~
O
NO

oS5

t'N

"O

uJ
>-, O
O 8
O _=
Z~
~J NO

"O

"0
6
r~
.=_
u
O
O
O
.'7' O o
~mN~
.o

~J

"0
o

3
.<
_u

=o k ~ ""
~ "" T
0
% % %
D
0

8
._= "6 = "0

=o " b ~'
R

o
•o =.2
156 Tadeusz Hop and Zenon Miodytiski

Table 7. Filler,~
i
Percentages of various fractions
in fillers
Filler Grading 0-1 mm 0 4 mm
Fraction (%) Fraction ( %}
size size

Sand dust 0-0'2 0 0' 1 6 0-0.2 25

Quartz dust 0-0-2 0' I -O'2 7 0.2-0-5 20
Fly ash 0-0.2 0-2 0-5 40 0.5-1.0 20
River sand 0'5 1.0 47 1.0 1.5 l0
Granite 0-1-0 1"5-2-0 5
Basalt 1"5-2"0 2"0-3"0 I0
Expanded day 3'0-4"0 3"0-4-0 I0
(ceramsite) 0 -4.0
Expanded shale
Sintered fly ash

above constituents nearly 70 mixtures have been
prepared. Detailed data of 30 mixtures are given
in Table 8. The percentage proportions of parti-
cular constituents have been calculated as follows:
The total weight of the mix is
wm= ~+w~+wh+w,
The terms on the right side of this equation denote
the weight of filler, resin, hardening agent and
dissolvent, respectively. To express the proportions
of particular constituents as percentages the above
equation has to be divided by 14/,, and multiplied
by 100.
Hence
~1~+ 147+ wh+ W~, = 100,
where
w~ wr wh
H'f = W m . 1 0 0 ; Wr = -14/;i. 100 It'/, = Win' 100;
w,.
' " = W,,," 100
Mixes were prepared manually in an enamelled
vessel. On mixing the resin with the hardening
agent which was added in batches, the aggregate
was introduced also in batches and the whole was
mixed for 5 min. Preheating of resin to about 40 °
facilitates and shortens the mixing operation.
First the pulverized phenol resin and the filler
were mixed, then the hardening agent was intro-
duced and the mixing operation continued until a
homogeneous mixture was obtained. Mixing was
mainly effected with wooden stirrers. Initially, it
was intended to prepare from each type of mix nine
test cylinders of 40 m m dia. and 40 m m height for
testing compressive strength, nine 20 m m x 20 m m
x 160 m m prisms for testing flexural strength and
nine test beams (see figure 4) with 20 m m x 20 mm
reference cross section for testing strength in axial
tension. For economy of resins the tests of tensile
strength had to be reduced to 3. Thus, the volume
of the batch prepared at one time was about
1500 cm 3.
The test cylinders were made in paper moulds.
Prior to compressive tests the paper was torn off
the specimens. Test bars for respective flexural and
tensile tests were prepared in phenol laminate
moulds.
Compacting of mixes in moulds was effected
manually.
The test pieces were stored in the laboratory
room, in which the temperature was about 18 °
and the relative humidity of air did not exceed
50 per cent.
The results of mechanical tests are summarized
in Tables 9 and 10 and shown in figures 3-9.
Table 10 contains--in addition to strength test
d a t a - - t h e composition of the mixtures prepared
with pulverized phenolic resin.
The calculation of flexural strength was made
under assumption that the concentrated load was
distributed on a cut of the beam 2 cm long and the
zone of tension was plasticized. The formula
used was
3.09. M
f = - blh 2
where f = flexural strength
M=~-
Fl (bending moment)
F = concentrated load applied amid the span
of test beam
l = span of test beam
b = breadth of test beam
h = height of test beam.
Testing of mortars prepared with polyester resin
was confined to the minimum necessary for com-
parison purposes. Such mortars were investigated
earlier in other Polish research centres.
Experimental mixtures with resorcin and pul-
verized phenol resin were prepared only on a
sufficient scale to permit making the decision on
whether further experiments would be justified.
Conclusions from these investigations will be
drawn first of all on the basis of figures 8 and 9.
1. All resins used in these experiments have been
found to be suitable for preparing mortars.
provided that a proper filler and an adequate
method of preparation will be employed.
 Polymer-Mineral Mixtures as New Building Materials 157

.~ .R ~ .~ ~ ~ .R ~ e .~ .~ .~
0
~ ~ ~ ~ ~ ~ ~ ~ ~ Z ~ ~ ~ ~ ~ ~ Z ~ Z = ~

I I I I I I I I I I I I I I I I I I I I::o:l i I I I~

I I I I I J I I I I I I L I I I I L I q ~ ~ L I I I I~

¢.

r"

e-

.~_

e4.. e~, .¢~ 0 0 0 0 0 0 0 e,I ¢4 eq 0 0 0 o 0 0 ¢q ¢q e4 0 0 ¢,~ e-4 0 e,l 0 e-4

r,3o o o o o o o o o o o o o o o o o o o o o o o

h-.

.~d
158 Tadeusz Hop and Zenon Miody~ski

Table 9. Strength of the res& mortars

iii i

Compressive Flexural Tensile

Mix Symbol strength (in strength strength
No. of kg/cm 2) after (in kg/cm 2) (in kg/cm 2)
mixture days after days after days

14 28 90 14 28 90 14 28 90

1 A-s-0 74 76 128 5 10 60 0
2 A-q 0 239 310 312 16 38 48 18
3 A-a-0 13 65 136 0 21 28 0
4 A-s-I 103 162 165 13 21 21 6
5 A-s-4 256 268 306 34 38 40 38
6 A-g-1 0 16 76 0 70 96 19"
7 A-g~. 97 97 164 28 30 34 21 --
8 A es-4 51 81 163 15 34 34 11
9 A-ec-I 0 81 132 8 12 15 8 -
10 A-ec 4 210 221 252 3[ 31 31 12
11 K-s-0 249 251 264 31 42 43 10 --
12 K-q-0 168 174 175 9 23 8 6 .....
13 K-a-0 0 0 0 0 0 0 0
14 K-s 1 58 43 20 3 4 2 2
15 K-s-4 24 20 9 4 6 4 2
16 K-g-I 166 179 120 20 17 19 4 -
17 K-g-4 136 135 120 17 15 10 6
18 K-es 1 135 148 107 18 28 21 6 - •
19 K-b-I 37 74 74 17 35 37 10
20 R--q-0 85 90 91 13 15 16 2 94
21 E--s-0 802 1010 1010 370 374 374 . . . . 122
22 E-q 0 693 929 1125 305 334 334 .... 119
23 E-s-4 558 565 618 246 293 299 - - 92
24 E-ec~- 277 277 277 112 114 144 - 48
25 L-s-0 1270 1280 1435 333 378 387 .... 238
26 L-q 0 1025 1 1 0 1 1110 360 419 428 - - 162
27 L-s 4 665 747 776 286 309 325 . . . . . . .
28 P-s-0 756 836 -- 105 108 -- 82 89 -
29 P-s-4 493 493 .... 86 88 -- 50 50 -~
30 Php-q-0/10 . . . . . . . 159

* A f t e r 90 days

2. Assuming that the strength of mortar is a
criterion of evaluation, the resins can be arranged
in the following order:
epoxy, polyester, pulverized phenol, AG-type
phenol, carbamide and resorcinol.
3. Even the application of phenol and carbamide
resins with a relatively low strength permits to
obtain mortars with the compressive strength
ranging from 250 to 300 kg/cm 2.
4. The best fillers revealed to be:
silica flour, sand dust (ground sand) and river
sand.
5. A very effective filler, when used with AG-
type phenol resin, revealed to be ceramsite.
6. Results of preliminary experiments permit to
think that the pulverized phenol resin is a very
effective and easy to prepare binding agent for
mortars.
Prior to discussing in more detail the observations
and findings, let us consider the costs of resins.
Resins evaluated by the criterion of cost can be
arranged in the following order: carbamide, AG-
type phenol, pulverized phenol, polyester and
epoxy resins. The epoxy resin is about 10 times

Table 10. Flexural strength of pulverized phenolic resin mortars

Proportions by weight Flexural

strength
resin hardening agent water after
Mix 28 days
No. Mix symbol aggregate resin mix (kg/cm 2)

1 f 10 50 6"8 28
2 15 50 6"3 65
3 20 25 10'2 98
4 20 30 9.8 121
5 25 20 10.8 91
Php-q-O 25 25 9"6 102
6
7 25 30 8-3 116
8 30 20 11-8 124
9 30 25 10.3 146
10 30 30 8-8 159
 Polymer-Mineral Mixtures as New Building Materials 159

Mineral fillers:
250
[] Sand dust
[] Quartz dust
~zoc
[] Fly ash
[] River sand
~, 15o
,= [] Granite

[] Expanded shale
.~, IO0
• Expanded clay

5o Grading of fillers:
foz 0-0-2 rnrn
f= O- I'0 mm
f4 O-4.0mm

"E
" ~ 50. [ ~ ~ L Phenolic -formaldehyde
resin type '~,G"

~ 0
50 - , fo~fozfozfl f4 fl f4 f4 fl f4, fo2fo2fozfl f4fl f4 f4fl f4,
9"0
,,.,.=~, Z5 days

t~N~fJ f,f, f4f, f~ %,

R
Fig. 3. Strength of phenolic- formaldehyde resin mortars.

25o Mineral fillers:

r~ Sand dust
%
200- C] Quartz dust

Fly ash
>
150 [] River sand

[] Granite
I00 [] Expanded shale

[] Basalt
Eo 5C
Grading of fillers:
to2 O-0.2mm
f~ 0 - I.Ornm
f4 O-4'Ornrn
o ~ Corbomide - formaldehyde
resin type "KMC-60"

•a ~ 25

!.[
~-- 0

I"
25 I--
~.~001~_~

" ~
;
~
. -~,or,
, ~02f02~02 f' f4 fl f4 f' fl,

ar~J o
L i rJ
2~
Days
, [02fO2[02ft f4 f' f4 f' f',
90

fozfo2fo2flf4 fl f4f4 fl,

Fig. 4. Strength of carbamide -fomaldehyde resin mortars.

more expensive than the carbamide resin, 5 times resins (e.g. the application of epoxy resin in com-
more expensive than the AG-type phenol resin bination with ceramsite is not economical, since
and about 3 times more expensive than the pul- the much cheaper phenol resin permits to obtain
verized phenol resin. As in many applications only a slightly lower strength).
(floors, coverings, anti-corrosive coatings) the Very advantageous may reveal the combination
strengths of mortars with cheaper resins are of cheap resins (e.g. carbamide resin) with an in-
sufficiently high; such resins should be given more expensive filler such as sand dust. Deposits of
consideration in further investigations. Epoxy dust sands and fine-grained sands are rich in this
resins should be used only in such applications country.
where it is not possible to replace them by other The mortars with carbamide resin showed a
160 Tadeusz Hop and Zenon Miody~ski

1400--
(o) (b)

1200

I000

~ 8o0i
FI
~ 6O(?

400

I
2OO

E_
0
.IE

200I (o) (b) [-~

o -

Age, doys Minerol fillers ond groding

[ ] Send dust O-O-2mm(fo2 )
Quortz dust O-O-2mm(fo~
River sond 0-4ram(f4)
Et~pended cloy O-4mm
Fig. 5. Strength o f epoxy resin mortars
(a) epoxy resin type " Epidian 5 "
(b) epoxy resin type " Lekuthern K 5 7 "

900
Io0
800
90
700 ~ ; Mineral fillers:
I 80

/
60C I- i [] Sand dust
) 7o
O~ 5 0 0 ~ - ~ River s o n d
c~ 60
400 - - Mineral filler:
Grading of fillers: 5O
300~- f;2 0-0"2 mm quartz dust 0-0"2 mm
~ 4o
i

f4 0-4- mm i
o~ 200 -
L) N 3o
=_j I00 -

o, 0
2o ~...L.,------'-'"-
Polyester resin
type "polimol 109"
.... "1" .......
[4 28
J
90
=~ OL- Days

Resin mortars
Compressive strength
14 28 .... Flexurol strength
D'oys ....... Tensile strength
FiE. 6. Strength of polyester resin mortars. Fig. 7. Strength o f resoreinol- Jbrmaldehyde reshl mortars.
 Polymer-MineralMixturesasNewBuildingMaterials 161

(~ Phenolic resin type "AG"

1200 ! 6) Corbomide resin type "KMC-60"
Epoxy resin type "epidion 5"
I000
4~ Epoxy resin type "lekutherm K-57"
Resorcinol resin
Pulverised phenolic resin type 149/14/65

Polyester resin type"polimol 109"

' i

E
8

....
dust
14 28
k);--..,.,..4
14 28
0-1 mml~..~n;,,,
b-o.z r a p " "*"* 0-4 mm,1~'0"'' 0-4 mm
901~_1428
0-1 mm "~-'x'p~ed shore ~ Age, doys
Filler o~1
grading
Fig. 8. Compressive strength of resin mortars.

(D Phenolic resin type "AG"

~) Corbomide resin type "KMC--.60"
400
~) Epoxy resin type "epldion 5"
(~) Epoxy resin type "lekutherm K57"
T
~) Resorcinol resin
/
(~ Pulverised phenolic resin type 149/1"
(~) Polyester resin type "polimol 109"
=-
g
] !l

: °t
('~ O_~l mm 0 - 4 mm
Oi)~
0 m

"- 0)/
14 28 9C 1428 9~ 14 ~1 9014 28 9C 14 28 cJC 14 28 9C Age, cloys
..... O-O-2mrr Quortz dust
SOnd dust Granite
O-O-2mm ~iver sand 0-10_4mmmm 0 - I mm Exponded s h a l e
0 - 4 mm
Expanded
0 - I mm cloy
O-Iron Filler ohd
O~.rnrr grading

Fig. 9. Flexural strength of resin mortars.

tendency to a slight decrease of strength with
time, Only the mixture of carbamide resin and
sand did not exhibit any traces of destruction
(ageing). The remaining mortars showed an
increase in strength up to 90 days. The highest
increase of strength was revealed by mortars with
phenol and epoxy resin additions.
The mixture of AG-type phenol with respective
granite or basalt aggregates exhibited bloating.
The value increase after one hour from making-up
was from 5 to 13 per cent. Such bloating mixtures
can be used as mastics for sealing joints (e.g. in
buildings erected from prefabricated elements).
To determine more closely the deformations
under short- and long-term loads as well as physico-
chemical properties the following mixtures were
selected: carbamide resin and sand dust, AG-type
phenol resin and sand of different grading, quartz
flour and ceramsite, phenol resin and various
pulverized fillers, polyester resin and sand of
different grading, epoxy resin and sand of different
grading. A strengthening of resin mortars and
concretes by steel wire net, glass fibre and synthetic
fibre is considered. Investigations on epoxy resin
mixtures, with the aim of obtaining structural
materials, will be pursued.
162 Tadeusz Hop and Zenon Miody~iski
3.5 Spec(p'c properties oJ' resin mortars and
COllcretes
Resin mortars and concretes, in comparison with
conventional materials, are, in the first place,
notable for a considerably increased resistance to
the effects of aggressive agents. Epoxy, polyester,
and some phenol resins, used as binding agents,
affect favourably some of the physical properties,
which can greatly surpass those of hitherto known
conventional mortars and concretes. Thus, it is
possible to obtain resin mortars and concretes with
a much superior compressive strength, a consider-
ably better flexural strength, more resistance to
impact and frost and also more impermeability
to fluids. Resin mortars and concretes have much
better adhesion to other materials than normal
mortars and concretes.
Some of the disadvantages of resin mortars and
concretes are: inferior fire resistance, a higher creep
(with the exception of epoxy resins), a lower
modulus of elasticity (which complicates the
structural applications), ageing, and also a higher
cost in comparison with the normal cement mortars
and concretes.
To the drawbacks of resin mortars and concretes
should be also listed the necessity of strict observa-
tion of the safety and hygiene rules.
By perfecting the processing technique and
applications of strengthening materials it should be
possible to reduce the creep, to increase the
modulus of elasticity and to improve the fire
resistance of resin mortars and concretes. Pro-
duction costs can be controlled within broad
limits by an appropriate choice of resins.
3.6 Applications of resin mortars and concretes
3.6.1 Corrosion-resistant coverings and coatings.
Epoxy resins as corrosion-resistant materials
can have the widest applications (provided that
their cost can be reduced). Epoxy resins are
resistant to most acids (with the exception of the
highly oxidizing), alcohols, petrols and lubricants.
Epoxy resin mortars are moreover remarkable for
their excellent strength properties, impact re-
sistance, water-tightness, and they are also water-
proof. Not being toxic they are suitable for use in
linings in tanks for drinking water. For coverings
and corrosion resistant coatings are also employed
mortars based on: phenol resins (resistant to
acids and fat solutions), furyl and furfuril-acetone
resins (resistant to strong oxidizers such as nitric,
chromic and acetic acids), as well as polyester
resins.
3.6.1(I) Floors. Resin mortars are irreplaceable
as material for floors in chemical and pharmaceu-
tical plants, in premises of the food industry,
laboratories, galvanizing shops and the like. In
Poland formulations have been worked out for
floor coverings made with polyester resins and
applied on an industrial scale. In these floor
mixtures the filler is composed of sand and quartz
flour, and in some mixes also of limestone flour.
3.6.1(2) Plasters (vertical coverings). Vertical
coverings are generally made with fluid mixes
applied with brushes or special spraying apparatus.
To prevent the mixture flowing down, a thixotropic
agent is added, e.g. colloidal silica. The mix
formulated in Poland consists of (by weight):
epoxy resin (Epidian 5), (1 part); bi-dibutyl
phthalate, (0-15); acetone (0.25); hardening agent
' Tecza ' (0.15); and 0-0.2 mm sand (1 to l-5 parts).
This mixture is suitable for all coverings and
coatings which are required to be watertight,
waterproof, chemical and biologically resistant and
possess high strength properties. Such coatings
have high hygienic advantages.
The foundation for floors and plasters should
have a rough and clean surface. Floor covering is
deposited in layers of the thickness which depends
upon the grading of the filler and the future duty
requirements.
3.6.2 Repair of concretes, reinforced concrete and
prestressed structures. Resin mortars and concretes,
due to their excellent adhesive and strength
qualities, permit to solve radically the very difficult
problems of repair and strengthening of all kinds of
concrete structures.
Resin concretes can be used to patch up and
smooth all losses and irregularities in structures,
and also be applied as strengthening layers re-
inforced or not.
Resin mortars are used to repair large cracks and
cavities. They are suitable for filling up joints and
for fixing reinforced iron bars and steel sections.
Resin mortars have already been applied as
corrosion protective coatings in prestressed concrete
structures.
3.6.3 Glues. Investigations on the application of
epoxy resin glues for joining structural elements
are conducted by the Polish Research Centre for
Development of Road Building Techniques. Formu-
lations for mixtures of epoxy resins, sand and
quartz flour have been developed, properties of
these mixtures investigated and principal types of
connections (concrete beam to concrete slab, pre-
stressed concrete to concrete slab, steel girder to
concrete slab) designed and tried under load. An
experimental bridge has been constructed by
using glued elements. The Chair of Communal
Building in the Silesian Technical High School is
engaged in extensive investigations on the glued
structures composed of different materials. As a
filler for epoxy resins, mainly Portland cement is
used.
3.6.4 Bearing structures. During erection or
repair work carried out in chemical plants in
industrial, sanitary and communal building indus-
tries, the application of structural (bearing)
elements of resin concretes (slabs, beams, columns,
pipes etc.) may be necessary and advantageous.
Preliminary studies on these applications were
made in the Soviet Union and other countries.
 Polymer-Mineral Mixtures as New Building Materials 163

In this instance, first of all the epoxy resin concretes
can be employed owing to their low creep and a
relatively high modulus of elasticity. Such con-
cretes can be armoured with steel or strengthened
by glass fibres. The application of other resins
(e.g. pulverized phenol resin) in structural concrete
elements is not precluded. Also possible is the
application of compound prefabricated or glued
constructions. Thus, a wide field for very interest-
ing studies and theoretical analysis is opened. A
problem of special concern will be that of protect-
ing structures of resin concretes against fire.

REFERENCES

1. G. FRANZand R. BOSSLER,Investigation of the most important properties of resin con-

cretes. Betonstein Ztg. 2, (1962) (in German).
2. T. HoP and Z. MtODYNSKt,The polymer-mineral mixtures as new building materials.
Proc. XI Scient. Conf. Krynica (Poland). Vol. III. (1965) (in Polish).
3. S. Kus, J. BOGACZand J. DZIADOSZ,Application of polyester-resins in prestressed con-
structions. InL Budown. 5, 0965) (in Polish).
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Russian).
5. A.N. MOSHCHANSKY,Faizol--An insulating and protecting material, Moscow (1961) (in
Russian).
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Tudom. k6zl. 39 (1964) (in Hungarian).
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elements in bridge building, Drogownictwo 5, (1964) (in Polish).
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with polymer admixtures, Beton Zbelezobeton 9, (1964) (in Russian).
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girders made up of segments, In2. Budown. 4, (1966) (in Polish).
10. Yu. S. TCHERKINSKY,Polymer-cement concrete, Moscow (1960) (in Russian).
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resin concretes. Beton Zhelezobeton, 9, (1965). (in Russian).

La technologie des m61anges min6ral-polym6re, leur plus importantes propri6t6s

prouv6es par des tests et leur application dans l'industrie de la construction sont
discut6s. La premi6re partie du rapport d6crit les mortiers et b&ons au×quels le
polymer appropri6 ~t 6t6 introduit pour le changement optimum de leurs propri6t6
sp6cifiques.
Apr6s l'inspection des polym6res employ6s pour la modifications des mortiers et des
b6tons, le fonctionnement de ces additions chimiques est d6montr6, leur influence sur
les caracteristiques des mortiers et des bdtons, mode de pr6paration de m61anges
particuliers, r6sultats de quelques tests, et l'application d'une vari6t6 de mortiers
polym6res et b6tons polym6res sont discut6s.
La deuxi6me partie se concentre sur ces m61anges min6ral-polym~re, pour lesquels
le seul moyen de liaison est la r6sine synth6tique appropri6e. Les rdsultats des tests de
l'auteur sont donn6s et l'emploi de ces m61ange pour diverses structures de construc-
tions est discut6.

Es wird die Technologie mineralisch-polymerer Mischungen, ihrer wichtigsten, durch

Versuche erforschten Eigenschaften, sowie ihre Anwendung auf das Baugewerbe
er/Srtert. Der erste Teil der Abhandlung besch~iftigt sich mit M/Srtel- und Zemen-
tarten, denen das geeignete Polymer beigemischt wurde um ihre spezifischen Eigen-
heiten bestm/Sglichst herauszuarbeiten.
Nach einem ~berblick fiber die Polymeren, die ffir die Aufbesserung der M/Srtel-
und Zementarten verwendet werden, wird die Arbeitsweise dieser chemischen Zus~itze
gezeigt, sowie ihr Einfluss auf gewisse Charakteristiken der MiSrtel- und Zementarten,
die Zubereitungsart fiir geeignete Mischungen, die Resultate von einigen Versuchen
und die Anwendung einer Reihe yon Polymer-M/3rtel und Polymer-Zemente.
Der zweite Teil behandelt mineralisch-polymere Mischungen, bei denen das geeignete
Kunstharz als einziges Bindemittel fungiert. Es werden die Ergebnisse der vom
Verfasser durchgeffihrten Versuche gezeigt, sowie die Verwendung dieser Mischungen
ffir eine Reihe yon Geb&iudestrukturen er6rtert.