With an overlay, you can give worn, lackluster concrete a decorative makeover or restore it to likenew condition in as little as a day and at a fraction of the cost. Each option has advantages and disadvantages that should be analyzed before a choice is made. Polymermodified mortars concrete construction magazine. This guide provides an overview of thin less than 1 in. Polymer modified product description akona polymermodified concrete resurfacer is a special acrylic polymer modified cement used to resurface spalled andor damaged interior and exterior concrete surfaces such as steps, sidewalks, patios, and garage floors. Polymer concrete is a type of concrete that uses polymer to replace limetype cements as a binder. A comparison of flexural strengths of polymer sbr and pva. This concrete resurfacer is a special acrylic polymermodified cement used to resurface spalled andor damaged interior and exterior concrete surfaces such as steps, patios, garage floors and sidewalks. Understanding polymers in concrete concrete construction. Polymers improve adhesion to the old surface, flexural strength, tensile. The efficiency of fibres in the roller compacted, polymer modified concrete, that is, their contribution in resisting the opening and propagation of a crack and the ensuing development of the fibre bridging law should be of significant value to all those dealing with other than conventionally reinforced concrete. A concrete overlay can be very thin, 116th of an inch or up to 12 an inch or more depending on your situation.
Decorative concrete overlays are a great solution for interior or exterior concrete flooring. Sep 15, 2001 in liquid form they come in two parts, liquid and powder, to be mixed together. Repair newly overlain areas discovered to be unbonded by tapping or chaining and areas of the overlay damaged by the contractors operation. Latexmodified concrete an overview sciencedirect topics. Latexmodified concrete is a portland cement concrete in which an admixture of latex emulsion is used to replace a portion of the mixing water. Epoxy and urethanemodified concrete decorative concrete toppings are modified with latex polymers, but there are large industrial and commercial markets for polymermodified cementitious toppings based on epoxy and urethane resins.
Doody and rick morgan the results of a survey of polymer concrete bridge deck installations test patch and overlay in new york and the results of a canvassing of the experiences of other states with these overlays are summarized. The binder actually consists of two components blended togethera component with the epoxy resin and a component with the curing or hardening material. Speccrete stampable overlay is available in either white or gray. The cost effectiveness of surface impregnation of concrete subject to erosion abrasion is questionable since the minimal depths being impregnated may erode too rapidly. Pdf the installation and condition of the first two veryearlystrength latexmodified concrete lmcve overlays constructed for the virginia. In dry form they are prepackaged materials blended for specific applications. Concrete overlays butterfield t stampable t stampable overlay is a polymer modified cementitious topping formulated for resurfacing structurally sound, nonmoving concrete floors and exterior hardscapes. A concrete overlay makeover how i resurface ugly concrete. As the demand grew, delong concrete added employees who travel around kentucky, tennessee, and other states for requested jobs. Latex modified concrete lmc overlays perform well, provide a long service life. Pdf effect of polymer modified fibers on strength of. Evaluation of highly polymer modified asphalt mixtures. Back then there wasnt much for user friendly products that would.
A polymermodified topping was used in the 111,000squarefoot plaza. Ardex guide specification ardex cd concrete dressing polymer. Distribution statement polyester polymer concrete, ppc, rut filling, studded. These include rapid curing at ambient temperatures from. Concrete overlays are an alternative to breaking out and replacing an existing concrete slab, which can be expensive, messy, disruptive, and timeconsuming. Bridge deck concrete overlays the texas department of. Polymers in concrete have been overseen by committee 548 of the american concrete institute since 1971. Pdf on sep 18, 2005, ibtisam kamal and others published modified concrete. Inventory is sold and received continuously throughout the day. Polymer modified mortar types, properties, and applications. Surfaces should be rougher than light broom finish to ensure proper bond adhesion. The aggregates are then added to form the concrete overlay. The polymer modified concrete can be used in the repair and the rehabilitation of old damaged concrete.
Abstract concrete being the most important and widely used material is called upon to possess very high strength and sufficient workability properties. From a simple resurfacing to something quite decorative, the possibilities are amazing. Determination and prediction of bonding strength of. Polymer modified mortars are widely used for repair purposes because of their minimized shrinkage and ability to bond with the densest surfaces. Nov 07, 2008 a polymer modified topping was used in the 111,000squarefoot plaza. Evaluation of the installation and initial condition of. You should know what polymers you are using and their strengths and weaknesses. Polymer concrete is a composite material in which the aggregate is bound together in a matrix with a polymer binder. It was carried out a study on the properties of polymer modified concrete pcm in fresh and hardened state.
Epoxy and urethane modified concrete decorative concrete toppings are modified with latex polymers, but there are large industrial and commercial markets for polymer modified cementitious toppings based on epoxy and urethane resins. High early strength latexmodified concrete overlay. The purpose of adding a hybrid polymer resin to the cement and aggregate is to greatly increase the performance characteristics and versatility of conventional cements, mortars. With millions of square feet of bridge deck polyester concrete overlays placed, ppc 1121 has a successful history dating back to the first overlays placed in 1983. Thinfinish is a hybrid proprietary formula that can make the claim to being the only polymer modified overlay that both chemically and mechanically adheres to concrete substrate. The overlay wa prepared with type ill cemeul atlll with more ement and. The technology is similar to normal pcc since the polymer modifier is added similar to other admixtures to the. Doody and rick morgan the results of a survey of polymerconcrete bridge deck installations test patch and overlay in new york and the results of a canvassing of the experiences of other states with these overlays are summarized. It is a preblended cement and sand mixture that also has the addition of a polymer as a bonding and application agent. The test sections will be monitored for a minimum of five years to determine the performance of the ppc with particular emphasis on its ability to resist studded tire wear. West virginias research and field usage indicates that the application of a relatively thin 1 to 2in. Polymer concrete and premixed over lays can be cast in. When to use a polymer overlay the concrete network. Latex modified concretelatex modified concrete microsilica thin polymer synthetic asphaltic.
Polymer modified concrete pmc consists of portland cement concrete with a polymer modifier. There are many reasons to add polymers to concrete overlay mixes. Pdf veryearlystrength latexmodified concrete overlay. Latexmodified concrete is a portland cement concrete in which an admixture of. Before asphalt mixtures with hp binder were used on a jointed concrete overlay project, a trial project to evaluate the. Polymer concrete composites possess a unique combination of properties dependent on the formulation. Determination and prediction of bonding strength of polymer. Portland cementbased, polymermodified concrete resurfacing material 1. Fhwa ltbp summarycurrent information on the use of. These gain a superior tensile and flexural strength compared to the conventional concrete. Pdf properties of polymer modified concrete in fresh and. Decorative concrete overlays everything about concrete. Provide an epoxy resin base and hardener that is a modified type iii, twocomponent. Emphasis is placed on their use in the transportation sector.
Study on polymer modified steel fiber reinforced concrete. Overlay can be applied over cracks, chips, discoloration and other blemishes, providing a smooth, level, attractive surface thats incredibly durable. Polyester polymer concrete can achieve rapid 2 hour cure after placement, even in cold, humid conditions below 40f. Polymer modifiers act as an adhesive to enable the modified mortar overlay to stick to a variety of surfaces such as concrete, masonry, brick, wood, rigid polystyrene and polyurethane foam, glass, and metals. Polymer modified cement overlays polymer cement overlays consist of a proprietary blend of portland cements, various aggregates and proprietary hybrid polymer resins. It applies to both new construction and rehabilitation of existing structures. Fhwa ltbp summarycurrent information on the use of overlays. A concrete overlay can give your ugly concrete patio, floor, or pool deck a makeover. This work consists of constructing a polymer modified concrete pmc bridge deck overlay for the purpose of protecting structural concrete from the deterioration caused by absorption of deicing salts and water. In some cases the polymer is used in addition to portland cement to form polymer cement concrete pcc or polymer modified concrete pmc. The epoxy polymer forms the binder for this type of concrete overlay. For best results, apply to clean surface with a concrete surface profile texture between csp 4 and. The composites do not contain a hydrated cement phase, although portland cement can be used as an aggregate or filler. The technology is similar to normal pcc since the polymer modifier is added similar to other.
Rosphalt is a polymer modified asphalt formulated to be suitable for use as a wearing surface and protection system on bridge decks without the use of a waterproof membrane between the overlay and the concrete deck and without the need for vibratory compaction. Although concrete is tough, a polymer overlay can make it even tougher. Adding pattern, texture, and color to exterior concrete slabs, including patios, pool decks, driveways, and sidewalks. Durability of epoxy polymer concrete overlays for bridge decks. To reduce environmental landfill problems with the accumulation of tire rubbers, scrap tire rubbers were added to epoxy polymer concrete in this investigation. No other overlay on the market has been able to match the performance, durability or ease of use of thinfinish and yet maintain an economical solution. The surface shall be damp at the time the overlay is placed. Polymer modified concretes in bridge deck overlay systems.
Typically, no primers are required for this type of overlay. Laboratory studies showed potential for the usage of the resulting concrete for bridge decks. Rosphalt is a polymermodified asphalt formulated to be suitable for use as a wearing surface and protection system on bridge decks without the use of a waterproof membrane between the overlay and the concrete deck and without the need for vibratory compaction. Using special techniques and tools, skilled installers can precisely replicate the look and feel of natural stone, brick, tile, or slate. The properties of polymer concrete make it suitable for the repair of concrete structures and for the placement of impermeable, skidresistant overlays. The polymer acts as a water reducer, ultimately leading to a stronger mortar with fewer voids, or weak spots. A general purpose polymermodified concrete repair mortar for concrete floors, walls, precast, tiltup and masonry surfaces. Chapter 6application of polymer concrete overlays, p. The overlay protects the deck by providing a nonpermeable sacrificial layer that prevents water and chlorides from penetrating to the deck reinforcing steel typical overlay materials include.
Ppc 1121 polyester polymer concrete kwik bond polymers. Mechanical and durability performance evaluation of crumb rubbermodified epoxy polymer concrete overlays. The science of thin, polymermodified toppings concrete decor. In order to achieve a durable repair overlay, high bonding strength to substrate concrete and having the least amount of cracks in overlay are the main issues. The science of thin, polymermodified toppings concrete. To read pdf files, you need the adobe acrobat reader 6. Wsdot uses a modified concrete as its primary type of bridge deck overlay, but in some cases a bridges physical characteristics, such as lightweight design or narrow roadway width, will not allow using a modified concrete overlay.
This work shall consist of furnishing all materials and labor required to remove and dispose of deteriorated concrete, and replace it with a polymer modified portland cement mortar at those locations shown on the plans or designated by the engineer. Pdf effect of polymer modified fibers on strength of concrete. Polymer concrete topic american concrete institute. Polymer modified thinset mortar is designed to adhere tile to concrete and cement board substrates without needing to soak the tiles beforehand. Polymer modified pm structural repair is a multiuse product that can be used to fix damage to concrete and masonry surfaces. It is a preblended cement and sand mixture that also has. Effect of polymer modified fibers on strength of concrete.
Polyester polymer concrete ppc was used in a trial application on. Whether in liquid or dry form, each polymer has strengths and weaknesses and recommended uses. The purpose of adding a hybrid polymer resin to the cement and aggregate is to greatly increase the performance characteristics and versatility of conventional cements, mortars and concrete materials. Pdf modified concrete using polymers and locally available. Hpc concrete overlays should be treated similar to typical bridge deck curing. High early strength latex modified concrete overlay michael m. Speccrete stampable overlay is a preblended polymer modified, nonshrink cementitious thin applied overlay for resurfacing concrete flatwork.
The ductility property of the polymer modified concrete is more compared with the conventional concrete. This paper emphasizes on polymer modified steel fiber reinforced concrete, a recent advancement in the field of reinforced concrete. Mechanical and durability performance evaluation of crumb. Being a concrete contractor since the early 80s, ive seen a lot of concrete that needs a new surface. The epoxybased polymer concrete has been widely used for concrete repairing and overlays due to good mechanical properties and durability. Traffic vibrations can also prohibit good overlay bonding, if possible, detour traffic during the curing phase. Latex modified concrete for bridge deck overlays cemen tech. Polymer modified concrete types, properties and applications. Styrenebutadiene, concrete overlays, latexmodified. Fowler, in failure, distress and repair of concrete structures, 2009.
Latexmodified concrete overlay multilayer polymer overlay. Polymer concrete overlay evaluation, final report iowa. Prices, promotions, styles and availability may vary by store and online. Thinfinish premixed polymer modified concrete overlay. Quikrete structural concrete is dot approved in a variety of locations throughout the country. It includes certification requirements of the latex products, storage, handling, surface preparation, mixing, application. In the 1960s, dow chemical developed an overlay material using lmc.
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