Polymer Concrete and Mortar

Polymer concrete and mortar are binders, compounds, and aggregate mixtures that use epoxy, polyester, vinyl ester
or other polymer resin bonds. They cure or set through chemical reactions, thermoset bonds, and multiple
component binder systems. Polymer concrete and mortar provides much greater corrosion resistance than
conventional construction materials such as Portland cement. Polymer concrete consists of polymer cement mixed
with water, a coarse aggregate such as gravel or crushed stone, and a fine aggregate or sand. Polymer mortar is a
mixture of a polymer binder or clinker and a fine aggregate. Both polymer concrete and polymer mortar are used to
join components and form structures. Products such as grout are used to fill gaps between tiles and bricks. Thin set
materials such as dry set mortar and dry bond mortar include polymer cement and are used in coating products.

There are several chemical systems for polymer concrete and mortar. Acrylic binders provide excellent
environmental resistance and fast setting times. Epoxy resins or binders exhibit high strength and low shrinkage
during curing. They also provide toughness and resistance to chemical and environmental damage. Furan resins are
formed from the polymerization or poly condensation of furfural, furfural alcohol, or other compounds containing a
furan ring. They are commonly used in foundry binders, grinding wheels, refractories and other high-temperature
applications. Polyurea resins or binders are used in place of phenolics or other formaldehyde resins in particle or
fiberboard binder applications. Polyurethane provides excellent flexibility, impact resistance and durability. Other
chemical systems for polymer concrete and mortar include silicone, polyester, and vinyl ester.

Polymer concrete and mortar varies in terms of basic specifications and mechanical, electrical and thermal
properties. Basic specifications include set/cure time, set/cure temperature, density, and shrinkage. Density is
measured as the mass per unit area. Shrinkage is expressed as a maximum percentage. Mechanical properties for
polymer concrete and mortar include compressive strength, bond strength, tensile strength, and modulus of rupture
(MOR). Electrical properties include electrical resistivity, dielectric strength and relative permittivity. The dielectric
constant is the relative permittivity of a material compared to a vacuum or free space. Thermal properties for
polymer concrete and mortar include service temperature, thermal conductivity, and the coefficient of thermal
expansion (CTE), the amount of linear expansion or shrinkage that occurs in a material with a change in
temperature.

There are a variety of features and applications for polymer concrete and mortar. Some products are abrasion
resistant, castable, chemical resistant, conductive, fiber-reinforced, sprayable, or waterproof. Other products provide
protection against wear, corrosion, or electrostatic discharge (ESD). Polymer concrete and mortar is often used in
electrical power, high voltage (HV), construction, and structural applications. Some products are used as fillers and
sealants.
Polyurethane:

Polyurethane polymer is a combustible solid and will ignite if exposed to an open flame for a sufficient period of
time. Decomposition products include carbon monoxide, oxides of nitrogen, and hydrogen cyanide. Firefighters
should wear self-contained breathing apparatus in enclosed areas. Polyurethane polymer dust can cause irritation to
the eyes and lungs. Proper hygiene controls and personal protective equipment (PPE), such as gloves, dust masks,
respirators, mechanical ventilation, and protective clothing and eye wear should be used.

Amount of polyurethane used

Application Percentage of total
(millions of pounds)

Building & Construction 1,459 26.8%

Transportation 1,298 23.8%
Furniture & Bedding 1,127 20.7%
Appliances 278 5.1%
Packaging 251 4.6%
Textiles, Fibers & Apparel 181 3.3%
Machinery & Foundry 178 3.3%
Electronics 75 1.4%
Footwear 39 0.7%
Other uses 558 10.2%
Total 5,444 100.0%

Polyurethane (PU), is any polymer consisting of a chain of organic units joined by urethane (carbamate) links.
Polyurethane polymers are formed through step-growth polymerization by reacting a monomer containing at least
two isocyanate functional groups with another monomer containing at least two hydroxyl (alcohol) groups in the
presence of a catalyst. Polyurethane formulations cover an extremely wide range of stiffness, hardness, and
densities. These materials include:

 Low-density flexible foam used in upholstery and bedding

 Low-density rigid foam used for thermal insulation.
 Soft solid elastomers used for gel pads and print rollers
 Hard solid plastics used as electronic instrument bezels and structural parts

Polyurethanes are widely used in high resiliency flexible foam seating, rigid foam insulation panels, microcellular
foam seals and gaskets, durable elastomeric wheels and tires, automotive suspension bushings, electrical potting
compounds, high performance adhesives and sealants, Spandex fibers, seals, gaskets, carpet underlay, and hard
plastic parts.

Polyurethane products are often called "urethanes". They should not be confused with the specific substance
urethane, also known as ethyl carbamate. Polyurethanes are not produced from ethyl carbamate, nor do they contain
it.
Urethane:

Urethane is not acutely toxic to humans, as shown by its use as a medicine. Acute toxicity studies show that the
lowest fatal dose in rats, mice, and rabbits equals 1.2 grams/kg. or more. When urethane was used medicinally, about
50 percent of the patients exhibited nausea and vomiting, and long time use led to gastro enteric hemorrhages. The
compound has almost no odor and a cooling, saline, bitter taste. Studies with rats, mice, and hamsters has shown that
urethane will cause cancer when it is administered orally, injected, or applied to the skin, but no adequate studies of
urethane-caused cancer in humans has been reported.