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Hi-tech mortars from portland cement and inerts combination by means of polymers

Aims to develop a class of new mortars based on mortar
'portland + inert' and combined to different kinds of resins
polymerising 'in situ' with improvement of some mechanical
characteristics of concretes.

The importance of inserting new products in the building field, with the aid of materials with peculiar characteristics, obtained for impregnation or muddle and polymerisation 'in situ' in Portland mortars of monomers and polymers, is one of the most important ways of answering to the growing demands of materials with high chemical- mechanic characteristics, to be used in different fields, from the chemical to the biological, to the electro-technical, etc. Today, only few mortars with high resistance and chemical inertia are available: - RPC mortars ('Reactive Powder Concrete'), made of micronised sands and pozzolana/hydraulic binders, also together with steel fibres and super-lubricants and other additives, they have high costs and are of difficult production; - PC mortars. They are not however 'true' mortars cements, since they are almost completely made of resins; even if they have excellent characteristics of chemical resistance and elasticity, unfortunately they have low resistance to high temperatures. The Project aims to develop a class of products based on mortar Portland and inert combined, by different techniques of muddling or impregnation, to resins (monomers and/or polymers, like thermoplastic, reticulating and elastomers, together to initiators and catalysts) in order to obtain cement products with general characteristics of the Portland mortars but with innovative and competitive peculiarities given by the presence of resins polymerised with the concrete and the inert material. The product therefore is neither a PC nor a mortar RPC, being constituted from Portland and base inert with polymerising 'in situ'. In particular, two typologies of mix concrete - inert - resin will be studied: * Composite PIC - (Polymer Impregnated Concrete). Consolidated concrete impregnated of polymer/monomer * Composite PPCC - Portland Polymer Concrete Cement (polymer/monomer mixed with Portland and inert, during the muddling). The Project then aims to set-up a PIC composite by means of suitable techniques of monomer impregnation in consolidated mortars and then to perform the polymerisation. Great attention will be given to the porosity of the material that will allow a greater liquid monomer penetration (and eventual co-monomer) having low vapour tension. For these types of composites, mainly thermal radical initiation (and peroxytic or azo-compound initiators) or Electro-waves for fine structures and particular structural shape will be applied. At the same time the Project aims to produce composites PPCC where the resins are inserted in the mixture; to study particular ratios of cement/inert/resin/water, since the water will have to act both as a hydrating agent for the fraction of Portland concrete and as a dispersant for the suspension of the resin. The Project also includes the experimentation of other solvents to be added to the mix. Depending on the polymer or the used monomer, a premix technique will be used (i.e. latex from thermoplastic polymer) or post-mix in order to have the best results and the less gelatinous mixtures. The search will be developed with laboratory tests and trials on the obtained products according to international standards. Keywords: polymers, concrete, composite.
Acronym: 
POLYCONCRETE
Project ID: 
2 779
Start date: 
01-01-2003
Project Duration: 
27months
Project costs: 
1 800 000.00€
Technological Area: 
Building materials
Market Area: 

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