Polymers in
Concrete
Personal reflections on the edge of the new century
BY LECH CZARNECKI
T he 11th International Congress on Polymers in
Concrete (ICPIC 04) was held in June 2004 at the
headquarters of BAM (The Federal Institute for Materials
Research and Testing) in Berlin. Interestingly, BAMs
mission to promote development and to interconnect
materials, chemistry, environment and safety is very
similar to the guidelines for the ICPIC itself. It therefore
isnt surprising that the venue contributed to the favorable
climate for the conference.
The conference was held in cooperation with two
renowned universities, Catholic University of Leuven
(Belgium) and Warsaw University of Technology (Poland),
and had an outstanding group of scientific cosponsors:
the American Concrete Institute (ACI); the International
Union of Laboratories and Experts in Construction
Materials, Systems, and Structures (RILEM); European
Network of Building Research Institutes (ENBRI); and
Technical Academy Esslingeen (TAE). The stature of the
cooperating organizations provides strong evidence of
the significance of concrete-polymer composites (C-PC).
GLORY OF PAST AND FUTURE
The program information for the ICPIC 04 Berlin
contained the following bold pronouncement:
ICPIC has been the leading congress worldwide in the
interactive fields of polymers and concrete for more than
25 years. Following 10 successful conferences in London,
Austin, Koriyama, Darmstadt, Brighton, Shanghai,
Moscow, Oostende, Bologna and Honolulu, the 11th
Congress in Berlin will launch a new period of scientific
progress, innovation and development of application in
this fascinating area.1
As we continue our journey into a new century, I
believe these challenging assertions give us a good
opportunity to reflect on the past, mark the milestones,
and survey the achievements within the C-PC field.
The concept of using polymers in concrete is not new2
(certainly, its history comprises more than just the last
quarter of a century). In particular, polymer-modified
concrete (PMC) (see the sidebars on Types and Classification
of Concrete-Polymer Composites) has many ancestors
(Fig. 1). Only in the second half of the past century,
however, have these composites experienced true
industrial development. In the 1950s, polymer cement
concrete (PCC) and polymer concrete (PC) came into
very limited use. It was only in the 1970s, after polymer
impregnated concrete (PIC) was developed, that C-PCs
received significant publicity.3
Concrete international / AUGUST 2005 55
 TYPES OF CONCRETE-POLYMER COMPOSITES
In the broadest sense, C-PCs comprise aggregates
and, at least partially, chemicals (monomers, oligomers,
prepolymers, or polymers) that may be subjected to
polymerization and polycondensation by thermo-
catalytic or other systems. These chemicals
(polymers) are used to improve concrete properties.
For example, the addition of polymers to an existing
portland cement concrete mixture could provide
increased tensile strength, better adhesion, better
abrasion resistance, higher resistance to water and
vapor transmission, or greater resistance to frost
or chemical attacks. Depending on the chemical
nature of the components, their contents, and
their manufacturing processes, an infinite number
of different mixtures can be produced (Fig. A).
For this reason, it will be useful to review some
simple definitions:
Composite is any solid, polyphase material
with: 1) phases that cannot be mutually transformed
into each other by any treatment; 2) properties
that are not attainable by any one of its constitutive
phases alone; and 3) properties that are not
attainable by the simple sum of its constitutive phases.
Concrete is a composite material that essentially
consists of a binding medium with embedded
particles or fragments of aggregate, usually a
combination of fine aggregate and coarse aggregate;
in portland cement concrete, the binder is a mixture of
portland cement and water, with or without admixtures.
Fig. A: Schematic representation of C-PC
56 AUGUST 2005 / Concrete international
Concrete-polymer composites (C-PC) are concrete-like
polymer composites, that may contain portland cement.
Polymer-modified concrete (PMC)* is concrete
produced using a low dosage of polymer (5% by
weight) incorporated into portland cement concrete to
affect mainly, if not only, the rheological properties of
the mixture. This type of composite is also called latex-
modified concrete (LMC).
Polymer cement concrete (PCC)* is a composite
wherein either a nonreactive polymer (latex) or a
reactive monomer (resin) is added to a fresh portland
cement concrete mixture. More precisely, PCCs can be
described as follows:
Premix PCC, in which the modifying additive is
added to the fresh concrete in the form of complete
polymer (latexes, elastomers, or thermoplastics).
That is, the polymerization of the modifying
additive has taken place before addition to
the concrete; and
Post-mix PCC, in which polymerization components
(chemically reactive synthetic resins or prepolymers
and monomers) are mixed with fresh concrete,
and the polymerization is obtained by chemical
means inside the concrete, along with hydration of
the cement.
Polymer-impregnated concrete (PIC) is a composite
formed by infusion of polymers into the pores in
portland cement concrete (after it has hardened).
Polymer concrete (PC) is a composite formed using
aggregate and a polymer binder (no portland cement
is used).
*It should be noted that in recent ACI
documents such as Polymer-Modified
Concrete (ACI 548.3R-03), PMC and PCC
are placed in the same category,
polymer-modified concrete
CLASSIFICATION OF CONCRETE-POLYMER COMPOSITES
Within the framework of the RILEM Technical
Committee TC-105, a classification code for C-PC has
been developed, as shown in Fig. B (from Schorn, H.,
C-PC Classification in C-PC RILEM TC-105 Technical
Report, 1999 [unpublished]). Although the abbrevia-
tions PC, PCC, and PIC can be obtained using the
classification system, they are no longer simply the
combination of the first letters of technical terms, but
are also used to indicate particular material structures:
The first letter indicates the presence of polymers
in concrete:
P for polymer
The second letter defines the process used to
incorporate the polymers in concrete:
I for impregnated
C for mixed
In effect, PI indicates all C-PCs produced using an
impregnation process, while PC indicates all C-PCs
produced using a mixing process.
Fig. B: Classification code for C-PC
A third letter can provide information on the
binder action:
C for combined binder, with both portland
cement and polymer acting as binders.
M for modified binder, with portland cement as
the primary or sole acting binder.
P for polymer binder with polymer as the acting
binder. Usually, it is not necessary to use the third
letter P for the identification of polymer concrete.
An additional, but optional, uppercase letter can
be used to indicate the type of polymer used (for example,
E for epoxy or L for latex). Finally, a lower
case p with superscripts and subscripts (see Fig. B)
can provide additional information on the kind and
amount of porosity of the composite. For example,
PCCEpcl indicates polymer cement concrete with
epoxy resin and portland cement paste acting as
combined binders and with a low, mainly closed
pore content.
Concrete international / AUGUST 2005 57
 Now, however, a massive amount
of information is available on C-PCs.4
According to my estimates, dating
back to 1964, over 7000 papers
have been published, over
5000 patents have been awarded,
and 32 international seminars and
symposia have been held on this topic.
Further, it is important to note
that C-PCs are most commonly used
for reconstruction and repair. Its not
surprising then, that among eight
existing models applicable to
concrete repairs, two of them have
been developed by people from the
field of polymers, including D.W.
Fowler and L. Czarnecki. 5 How
important is this? Current estimates
indicate that over the next 20 years,
20 to 50% (by value) of existing
concrete structures will need to be
rebuilt. If even a small fraction of that
total involves polymers, C-PC will
have a huge impact.
One of the significant changes
in the development of C-PC is the
shift in material type most often
discussed at each of the ICPIC
congresses (Fig. 2). Until 1995, PC
was unquestionably the dominant
material, with nearly half of the
papers focused on PC.
Recently, however, the picture
has changed dramatically. In the last
four congresses, over 50% of the
papers have focused on PCC, about
Fig. 1: Timeline and ancestors of PMC 40% have focused on PC, and less than
10% have focused on PIC.
Fifteen years ago, I stated, After
more than 50 years of searching, the
least success has been attained with
PCC. However, PCC still could have the
greatest potential for field applications.
For these reasons, attempts to improve
our understanding of PCC must be
continued.6 The successful results,
particularly with epoxy cement and
acrylic cement are well known.7 It is
also worthy of note that some polymer-
containing concrete composites have
changed names and shifted to the other
families of building composites,
including high-performance and high-
Fig. 2: Number of papers involving PIC, PCC, and PC at ICPIC congresses strength concretes.

58 AUGUST 2005 / Concrete international

 In the near future, its unlikely well see a completely
new material concept in the C-PC domain. Rather,
the focus of new developments will be on better uses of
polymers, in more economical and synergistic ways.
More sophisticated formulation and preparation
methods will be developed, special modifiers will be
formulated, and cooperative systems (for example,
microfillers, microfibers, and polymers) will be employed.
The energy of manufacturing of C-PC will be treated as
a separate element of the material model, apart from its
Fig. 3: Progress of C-PC as indicated by ICPIC presentations
composition and properties. More attention will not only
be paid to the products final properties and usability,
but also to its processibility (for example, self-compacting Homeostasis (self-regulation of internal properties so
polymer cement concretes). as to maintain a stable condition);
The analysis of ICPIC output (Fig. 3) gives the Fractal analysis;
impression of very quick development in the 1970s Synergistic effect estimation; and
and the 1980s, but near stagnation in the early 1990s. Artificial intelligence.
Some optimistic signs of change, evident in the positive The answer to challenges for the development of new
turning point on the C-PC development curve, could be building materials and the continuous progress of C-PC
seen in the 1995 Congress in Oostende. The output should be to create knowledge management strategies on
of the Congresses in Bologna and Hawaii confirmed C-PC in the following areas:
the optimism.
It is also worthwhile to stress that the tenor of ICPIC
presentations has changed through the years. At the 1975
Congress, the basis for intellectual and technical
stimulation could be described as, Here is a concept
for a very new materiallike concrete, but much better.
What do we do with it? At the more recent congresses,
the emphasis has shifted to, A material with a unique
set of technical properties is required. How do we
formulate a suitable concrete-polymer composite that
meets these needs? In this regard, many successful
families of C-PC have already been created, including
composites for repair, composites for industrial floors
and anti-corrosion protection, and composites for
electrical insulators and machine framework.

PROMOTION THROUGH BETTER

UNDERSTANDING
Engineering activity on siteon a macroscopic level
can be thought of as the transformation from chaos to
order. In much the same way, progress in the development
of materialson the microscopic levelcan be thought
of as the transformation from mixture to composite.
A mixture is just a combination of ingredients, whereas a
composite is formulated in such a way that the properties
are different from, and often superior to, its constituents.
By definition, therefore, a composite is optimized.
There are many questions, new and old, that still must be
answered (Fig. 4). However, there are also new scientific
tools that can help us to answer these questions, including:
Theory of percolation;
Thermodynamics of unbalanced status and reversible
processes; CIRCLE READER CARD #13

Concrete international / AUGUST 2005 59

 Material design methods: linking components, structure,
and properties;
Durability: including aging mechanisms, service life,
and maintenance;
Selection procedure: ranking lists and expert systems;8
Concrete reinforcement: steel and nonmetallic;
Polymer coatings: for concrete and reinforcement;
PIC: both PC and PCC; and
Standards and test methods.
ONGOING RESEARCH
Several fields of research are attractive from both
a scientific and an engineering point of view. These include
using new resin binders (for example, vinylesters),9 as well
as modifying properties using adhesion promoters
(particularly silane) and microfillers.9, 10
One of polymer concretes advantages is the ability to
dampen vibrations. Until now, this was used mainly in
machine foundations. Currently, attempts are being made
Fig. 4: More questions than answers?
60 AUGUST 2005 / Concrete international
to take advantage of this feature for building structures to
resist dynamic loads.
Among other important and prominent fields of
research involving polymer concretes are attempts to
improve some of their unfavorable properties. Low fire
resistance has been investigated through trials conduct-
ed to diminish its flammability or combustibility.11
Sensitivity to the presence of moisture during hardening
(wet substrate or aggregate) has also been investigated.12
The possibility of new, unconventional applications of
polymer concrete continues to be a direction of study. Two
such applications include the manufacturing of void-free
concrete for use in nonceramic insulators,13 and the use of
polymer concretes for producing precast elements such as
artificial marble, containers for aggressive or dangerous
liquids or waste materials (including radioactive waste), and
electrolytic cells.
Basic research for polymer-cement concretes, containing
both premix and post-mix additives, is determining the
influence of the various modifiers on the structure and
properties of the composite. This is
also connected with the effect of
concrete curing conditions.14 In
addition, the presence of polymer in
the cement paste can influence the
process of the cement hydration,15
including self-curing concrete.
For concretes containing polymer
additives of the post-mix type, the
main field of research is developing
mixed polymer-cement binders
(epoxy-cement) including resin
binders that set in the alkaline
environment of portland cement
paste without hardeners.15
For concretes containing polymer
additives of the premix type, the more
important directions of research are
in determining the significance of the
minimum film-forming temperature
for the structure and properties of the
composite16 and manufacturing of
materials with decreased brittleness.17
GLORY OF THE FUTURE
During the past 50 years, concrete-
polymer composites have made
tremendous progress. They continue
to be very promising materials for
new applications and for stimulating
new research. For the future of C-PC,
neither optimists nor pessimists are
necessary. Rather, possibilists
are required.
Acknowledgments Improving the Ductility of High Performance Concrete Under
This work was partially supported by a grant from the Polish Compression, ibid., pp. 391-399.
Committee for Scientific Research, Project No. 4T07E00726.
Received and reviewed under Institute publication policies.
References
1. Press release for the 11th International Congress on Polymers
in Concrete (ICPIC04), BAM, Berlin, June 2004 (www.bam.de/
english/media_relations/press_releases/pm_32-e_02_i.htm).
2. Chandra, S., Historical Background of Polymers Used in
Concrete, Proceedings of the 8th International Congress on Polymers
in Concrete (ICPIC95), 1995, pp. 3-11. ACI member Lech Czarnecki is the Vice-
3. Fowler, D.W., Polymers in Concrete: a Vision for the 21st Century, Rector of Warsaw University of Technology
Cement and Concrete Composites, V. 21, No. 5-6, 1999, pp. 449-452. and Head of the Division of Building
4. Ohama, Y., Bibliography on Polymers in Concrete, Nihon Materials Engineering. He is a member of
University, Koriyama, 1990. ACI Committee 548, Polymers in Concrete;
5. Vaysburd, A.M.; Carino, N.J.; and Bissonette, B., Predicting former Secretary of RILEM Technical
the Performance of Concrete Repair Materials, National Institute Committee TC-105, Concrete-Polymer
of Standards and Technology Interagency Report 6402, 2000, 35 pp. Composites; as well as a member of RILEM
6. Czarnecki, L., The Status of Polymer Concrete, Concrete TC-52, Resin Composites Adhesion to
International, V. 7, No. 7, July 1985, pp. 47-53. Concrete; and TC-110, Test Methods for Concrete-Polymer
7. Beeldens, A.; Van Gemert, D.; Schorn, H.; Ohama, Y.; and Composites. He is also Vice President of the Directors Board of
Czarnecki, L., From Microstructure to Macrostructure: An Integrated the International Congresses on Polymers in Concrete.
Model of Structure Formation in Polymer-Modified Concrete, Materials
and Structures, V. 38, No. 280, 2005, pp. 601-607.
8. Czarnecki, L., and Van Gemert, D., Basis Approach for Expert
System on Polymer Concrete in Building, Proceedings of the 6th
International Congress on Polymers in Concrete (ICPIC 90), 1990,
pp. 87-91.
9. Czarnecki, L., and Chmielewska, B., The Influence of Microfillers
and Coupling Agents on the Selected Properties of Vinylester
Mortars, Proceedings of the 9th International Congress on Polymers in
Concrete (ICPIC 98), 1998, pp. 217-224.
10. Tu, L., and Kruger D., Effect of Increased Fiber Surface
Wettability on the Flexural Performance of Polypropylene Fiber
Reinforced Concrete, ibid., pp. 287-294.
11. Czarnecki, L., and Wiackowska, A., Non-Flammable
Unsaturated Polyester Mortars, Proceedings of the 7th International
Congress on Polymers in Concrete (ICPIC 92), 1992, pp. 378-388.
12. Czarnecki, L., and Osiecka, E., Durcissemenyt des Btons
Polyesters en Prsence dHumidit, Bull. liaison Laboratoires des
Ponts-et-Chausses, 108, 1980, pp. 29-36.
13. Vidaurre, V.; Dufeu, J.; and Bendek, W., Void and Gas
Occlusion Free Dielectric Polymeric Composite Materials and
Cost Effective Manufacturing Processes for Production of High
Reliability Electric Insulators, Proceedings of the 9th International
Congress on Polymers in Concrete (ICPIC 98), 1998, pp. 139-149.
14. Justnes, H.; Reynaers, T.; and Van Zundert, W., Influence of
Lattices and Redispersible Powders on Hydration and Strength
Development of Polymer Cement Mortars, ibid., pp. 225-238.
15. Ohama, Y., New Research and Development of Concrete-
Polymer Composites in Japan, ibid., pp. 1-20.
16. Puterman, M., and Malorny, W., Some Doubts and Ideas on
the Microstructure Formation of PCC, ibid., pp. 165-178.
17. Konig, G.; Deutschman, K.; Kutzing, L.; and Sicker, A., CIRCLE READER CARD #14

Concrete international / AUGUST 2005 61

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