1 Introduction
Concrete-polymer composites (CPC) are generally classified into the following three types by the principal of their process technology [1, 2]: (1) polymer-modified concrete (PMC), (2) polymer concrete (PC), and (3) polymer-impregnated concrete (PIC). PMC is a composite material made by partially replacing and strengthening the cement hydrate binders of conventional concrete with polymeric modifiers or admixtures. PC is a composite material made by entirely replacing the cement hydrate binders of conventional concrete with polymeric binders or liquid resins. PIC is a composite material that impregnates hardened cement concrete with monomeric impregnants. Herein, the definition of “concrete” encompasses “mortar” that does not incorporate coarse aggregates.
Historically [1‐6], PMC was registered as a British patent by Cresson in 1923, and a fundamental study was conducted by Geist et al. in 1953. Later, practical research and development on polymer-modified concrete began in the 1960s worldwide, including in the US, Russia, Germany, Japan, and the UK. PC has a shorter history than PMC, but research and development were conducted in Russia, the United States, Germany, and Japan in the late 1950s to the early 1960s. PIC has the shortest history among CPCs. The processing technology for PIC was developed based on the concept of wood-polymer in the late 1960s. Therefore, CPC has a history of 60–70 years; however, if based on Cresson's patent registration, it could also be considered 100 years. This study aims to overview the current state of CPC applications and suggest future directions to move.
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2 Polymer Materials for CPC and Their Benefits
2.1 Polymer-Modified Concrete
Polymer materials [1, 7, 8].
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Latex polymers
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Synthetic rubber latex: SBR, etc.
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Resin latex: EVA, epoxy, etc.
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Emulsified polymers
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Water-soluble polymers: Polyvinyl alcohol
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Re-dispersible polymers: Ethylene vinyl acetate
Benefits [6].
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Rapid curing
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High strength (compressive, tensile, and flexural strength)
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Good abrasion resistance
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Good adhesion
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Long-term durability
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Low permeability and water tightness
2.2 Polymer Concrete
Polymer materials [6, 9].
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Unsaturated Polyester resin
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Epoxy resins
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Methyl methacrylate
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Urea formaldehyde
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Poly Urethane Resins
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Furan Resins
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Phenol formaldehyde, etc.
Benefits [6].
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Rapid curing
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High strength (compressive, tensile, and flexural strength)
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Good abrasion resistance
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Good adhesion
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Long-term durability
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Low permeability and water tightness
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2.3 Polymer Impregnated Concrete
Polymer materials [10].
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Styrene
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Methyl methacrylate (MMA)
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Butyl acrylate
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Acriloniyrite
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Epoxies and their copolymer combinations
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Polyester
Benefits [9].
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Partial impregnation: durability and chemical resistance
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Full impregnation: structural properties (strength, elastic module, etc.)
3 Cases Studies
3.1 Polymer-Modified Concrete
PMC applications in previously published literature and technical data include industrial floorings, bridge and pavement overlays, integral waterproofings, decorative coatings, repair materials, anticorrosive linings, deck coverings, and grouting works [1, 3, 9]. Currently, PMC is mainly used for patching and repairing, grouting and installing tile, waterproofing and flooring, road and bridge overlay, etc. PMC was used in the form of concrete only for pavement and bridge overlay applications, while the rest were used in the form of mortar. As a polymer material, SBR or epoxy-based latex is often used. Notably, PMC is used to restore existing structures rather than for new construction. Also, among the three CPCs, it is the easiest to use. However, PCM differs depending on the type of polymer material used for modification. It is generally advantageous to improve physical properties such as adhesion or waterproofness, but it makes hard to improve the mechanical properties such as compressive strength and modulus of elasticity.
Grouting and installing tile.
Waterproofing and flooring.
3.2 Polymer Concrete
Applications of PC presented in previously published literature and technical data include floorings (including decorative finishings), pavements, anticorrosive linings, pipes for sewage and irrigation systems, artificial marbles, repair to corrosion-damaged concrete, prestressed concrete, nuclear power plants, electrical or industrial construction, marine works, prefabricated structural components (acid tanks, manholes, drains, etc.), highway barriers, waterproofing of structures, sewage works and desalination plants, kerbstones, precast slabs for bridge decks, marine works, and high voltage insulator [1, 6, 9]. PC is currently mainly used for pipes, manholes, trenches and channels, curb drains and rainwater sumps, artificial marble claddings and bathroom sinks, troughs and heating plates, trash and waste containers, overlay and repairing, etc. As a polymer material, unsaturated polyester resin is widely used. Polymer concrete is mainly used to manufacture precast products rather than cast-in-place applications. Although some use PC for overlaying or repairing existing concrete pavement, PC has a significant difference in material properties, such as modulus of elasticity and coefficient of thermal expansion from conventional cement concrete, which must be considered.
Pipes.
Manholes.
Trenchs and channels.
Curb drains and rainwater sumps.
Artificial marble claddings and bathroom sinks.
Troughs and heating plate.
Trash and waste containers.
3.3 Polymer-Impregnated Concrete
PIC applications presented in previously published literature and technical data include bridge decks, irrigation structures, structural members, marine functions, nuclear power plants, sewage disposal works, Ferro cement products, waterproofing, flooring (dairy farm product buildings), tanneries and chemical factories, etc. [10, 29]. However, follow-up studies were hardly conducted since some used PIC in highways and dams in the 1970s and 1980s [30‐33]. Only a few case studies in permanent forms [34] and concrete spacers [35] were reported recently. The reason for the less popularity of PIC is that the processing technology of PIC is complicated, and high thermal energy is required for its applications, which is costly. Also, it is hard to measure the polymer impregnation depth (especially in the field), which makes contractors hard to control the quality.
Permanent form.
4 Proposal for Development and Generalization of CPC
4.1 Challenges
Slow propagation compared to its long history.
As mentioned earlier, CPC was researched and developed in the 1950s and 1960s and has a history of 60–70 years. Despite such a long history, the propagation of these technologies has been very slow. The possible reason stems from the conservative nature of the construction industry, but it might also be true that CPC technology has not been appealing to the relevant industries. No significant progress has been made in terms of the quantity or quality of publications on the R&D of CPC. These are undoubtedly important challenges that we CPC researchers should face.
Cost ineffectiveness.
It should be understood that one of the primary limitations CPC is cost. PC is still much more expensive than conventional cement concrete. The cost of polymers can range from 10 to 100 times that of portland cement, even considering the specific gravity unit volume cost of the polymer [5]. As such, CPC is still disadvantageous compared to other construction materials in terms of price [4]. However, since the comparison between the cost of polymers and portland cement by unit is unjust, cost-effectiveness should be compared, and research and development should be conducted in a direction that can improve it.
A bias against the merits of CPC.
CPC is different from conventional concrete in manufacturing methods and performance. Compared to conventional concrete, CPC definitely has excellent performance, such as high strength and good durability. Thus, CPC can be effective for repairs, structural applications, and architectural components. However, it should always be considered that polymer concrete also has various disadvantages.
Understanding polymer properties and manufacturing challenges.
The three types of CPC significantly differ in properties because they use different processing technologies. In addition, because the type, addition amount (injection amount), mixing ratio (mixing ratio of the main material, hardener, etc.), and curing method (curing temperature) lead to significantly different material properties, it is important to choose a suitable type, addition amount, mixture proportions, and curing regime. This complexity makes the field applications of CPC difficult. Eventually, CPC applications required high skills and precise work.
4.2 Suggestions
Advancing practical value of research outcomes.
Most studies on CPC are premised on field applications. Applied research is essential for the rapid dissemination and generalization of research results. Impractical research results sometimes confuse users and end up not getting attention. Even fundamental research should focus on advancing practical contributions and values to avoid these undesirable outcomes. In other words, practical research should be conducted while clarifying the purpose of the research. In particular, field application research should be able to provide practical information to subsequent researchers or users through follow-up research.
Advancing cost-effectiveness.
CPC has not been widely adopted mainly due to its high cost. However, recent progress has greatly reduced the cost, and its use has gradually spread. However, CPC cannot be cheaper than conventional concrete, no matter how much the cost is reduced. Therefore, comparing the unit price is contradictory. However, it is necessary to seek to reduce the cost of polymer materials through the development (modification) of low-cost polymers and the optimization (minimization) of polymer usage. Also, it is necessary to find a way to increase cost-effectiveness by minimizing production cost and maximizing performance. A study on the cost-effectiveness analysis method of CPC is also one of the necessary tasks.
Raising awareness of CPC.
Although CPC is expensive and difficult to manufacture, limiting its widespread application, it has advantages over conventional concrete. Despite these advantages and a long history of development, it is still not recognized by field engineers. Therefore, it is very important to disseminate technologies that raise awareness and appeal to users through conferences, workshops, fairs, etc. In addition, to advance the technology of CPC, it is necessary to expand the research base by increasing the pool of researchers. In addition, it is necessary to create an environment where researchers in different fields can actively collaborate.
5 Conclusions
This study reviewed the current state of CPC applications, which has a 60–70 years of research and development history, and sought the development direction to move forward. The results are summarized as follows:
1)
PMC is used for patching and repairing, grouting and installing tiles, waterproof flooring, and road and bridge overlays. As a polymer material, SBR or epoxy-based latex is widely used. PMC is commonly adopted for reconstruction rather than new construction.
2)
PC is currently adopted for pipes, manholes, gutters, flumes, curb drains, rain gutters, artificial marble cladding and bathroom sinks, troughs and soleplates, trash and waste containers, overlays and repairs. As a polymer material, an unsaturated polyester resin is widely used. PC is primarily used to manufacture precast products rather than cast-in-place.
3)
Only a few PIC case studies have been reported since the 1970s and 1980s. The reason for the less popularity of PIC appears to stem from the complicated processing technology and high thermal energy requirement.
4)
However, CPC is taking its place as an essential material in the construction industry. The current challenges of CPC applications include slow propagation compared to a long history, expensive materials, bias towards the advantages of CPC, and difficulties in manufacturing and quality control. More applied, practical, cost-effective research, awareness raising, and research base expansion were proposed as countermeasures.
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