1st International Conference on Engineering Materials and Metallurgical Engineering

22- 24 December, 2016 Bangladesh Council of Scientific and Industrial Research (BCSIR)

Dhaka, Bangladesh

PREPARATION AND CHARACTERIZATION OF POLYMER CONCRETE FROM

UNSATURATED POLYESTER RESIN REINFORCED WITH SAND

Muhtasim Kader Mukita*, M. A. Gafurb, Sajib Anindab Dhar, Aninda Nafis Ahmed and Muhammed Yusuf Miahc

aPilot Plant and Process Development Centre (PP&PDC), Bangladesh Council of Scientific and Industrial Research (BCSIR), E-

mail:muhtasimmukit@yahoo.com,Dhaka, Bangladesh. bPilot Plant and Process Development Centre (PP&PDC), Bangladesh Council of Scientific and Industrial Research (BCSIR), E-

mail:d_r_magafur@yahoo.com,Dhaka, Bangladesh cApplied Chemistry & Chemical Engineering Department, Noakhali Science and Technology University, E-mail:

yuri19742003@yahoo.com, Sonapur, Noakhali

Abstract Physical properties, optical properties and mechanical properties are the important material properties for engineering and analysis of polymer concrete (composite of unsaturated polyester resin & sand). Physical properties such as density & water absorption; optical properties such as optical microstructure; mechanical properties such as hardness, compressive strength, flexural strength have been studied of the polymer concrete at various compositions of unsaturated polyester resin & sand. Firstly, density is low of low percentage of sand in polymer concrete and secondly density is high of high percentages of sand in polymer concrete. In the study of water absorption, percentage of water absorption in polymer concrete is nearly zero. The optical microstructure of polymer concrete shows that proper composition of unsaturated polyester resin & sand. The hardness of polymer concrete (composite of unsaturated polyester resin & sand) is nearly high comparing with other polymer concretes. The compressive strength of polymer concrete is comparatively very understandable by comparing with others composites compressive strength. The flexural strength of polymer concrete (composite of unsaturated polyester resin & sand) is very good for completing the present world. Keywords – Density, Water absorption, Optical Microstructure, Hardness, Compressive Strength, Flexural Strength.

1. Introduction Polymer concrete is a composite material which results from polymerization of a monomer/aggregate

mixture. The polymerized monomer acts as binder for the aggregates and the resulting composite is called “Concrete”. Polymer concrete in which the binder is an organic polymer; a construction and structural material that is a solidified mixture of a macromolecular substance with a mineral aggregate. [1-2]Polymer and polymer-cement concretes are used for floors in industrial plants, garages, and hospitals. They are used in the production of high-quality road and airfield paving’s and for repairing damaged concrete surfaces and patching cracks. The overall goal of this thesis work has to investigate some physical, optical, mechanical and thermal properties of prepared polymer concrete from unsaturated polyester resin reinforced with sand (Both white & red sand). In order to study the possibility of superior performance, preventing the composite from water absorption and reducing the costs, polymer concrete has been prepared with different compositions. The following investigations have been performed on these composite samples. In view of the above consideration, the following work- plans have been undertaken :(1)Standardization of the experimental products.(2)Raw materials collection and preparation.(3)Production of different composition of polymer concrete from unsaturated polyester resin and sand.(4)Measurement of the density (BD) & water absorption of the products.(5)Measurement of the optical properties has been investigated.(6)Determination of mechanical properties such as flexural strength, compressive strength & hardness of the products.(7)Measurement of the thermal properties such as thermal conductivity, thermo-mechanical analysis & thermo-gravimetric analysis of the products. The physical, optical, mechanical, thermal behaviors of the composites (polymer concrete) have

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been analyzed to correlate the structure- property relation. This research work helps us to find the best suitable composites for some application in science and technology at the advance world.

2.Materials and Method

2.1 Materials Polymer concrete formulation has been prepared by mixing sand and unsaturated polyester resin. Two types

of sand has been used in polymer concrete formulation, one is white sand and second is red sand. Sand content in polymer concrete has been varied from 20% to 60% in the polymer concrete formulation. Methyl ethyl ketone peroxide (MEKP) is an organic, colorless and oily liquid which has been used as hardener in the polymer formulation. Methyl ethyl ketone peroxide (MEKP) has been used as 1% of unsaturated polyester resin in the polymer concrete formulation.

2.2 Equipments The equipments have been used here, such as Slide-calipers, Screw gauge, Vacuum dryer, Dryer, Digital

balance, Universal testing machine (UTM), Microscope and Leeb Rebound hardness machine. (ModeL??)

2.3Methods 2.3.1Collection of raw materials

Firstly, for the preparation of polymer concrete, the basic raw materials such as sand, unsaturated polyester resin and methyl ethyl ketone peroxide have been collected. To prepare polymer concrete from these raw materials following steps are involved:-

Washing of sand & purchasing of unsaturated polyester resin and methyl ethyl ketone peroxide from

the market. Weighing Mixing Molding

2.3.2 Method of density measurement The density, or more precisely, the volumetric mass density, of a substance is its mass per unit volume. The

symbol most often used for density is ρ. mathematically; density is defined as mass divided by volume. ρ =

௩

Where, ρ = Density of the sample m = Mass of the sample V = Volume of the sample Volume is the quantity of three-dimensional space enclosed by a closed surface, for example, the space that

a substance (solid, liquid, gas, or plasma) or shape occupies or contains. [3-4] Volume of prepared polymer concrete is defined as

V= గସ

×d2× ܶ Where, V = Volume of the sample d = Diameter of the sample T = Thickness of the sample

2.3.3.Method of water absorptive measurement To determine water absorptive of the sample, various composition of the sample is kept into water at

different intervals such as -20 minutes -One hours -Two hours

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-Five hours -23 hours -47 hours -96 hours

2.3.4 Method of flexural properties measurement Flexural strength of the sample is determined by using universal testing machine. For that the thickness of the sample is measured by screw gauge and width of the sample is measured by slide calipers.

2.3.5 Method of compressive properties measurement

Compressive properties of the sample are determined by using universal testing machine. For that the thickness of the sample is measured by screw gauge and width of prepared polymer concrete is measured by slide calipers.

2.3.6. Method of Leeb rebound hardness properties measurement

The sample has been sectioned and around 10mmx10mm cross-sectional area of sample has been prepared. Cleaning of the samples has been done after sectioning the samples. Sample has been kept upon solid surface where glycerin also applied before. After then Leeb rebound hardness measurement device has been applied on sample surface for obtaining data. [5-8]

2.3.7. Method of optical properties measurement The sample is sectioned and around 10mmx10mm cross-sectional area is prepared. After progressive polishing the samples are brought for fine polishing on a polishing wheel. The samples are thoroughly washed in water and dried by acetone. The samples are observed by an optical microscope and micrographs are recorded with a digital camera.

3. Results & Discussions The results of the work are as presented in the following

3.1 Density of the Polymer concrete

Figure-1: Density vs Percentage of red sand in sample (Polymer concrete). From above figure-1, it shows that density increases with increasing of red sand in sample (Polymer concrete).

Figure-2: Density vs Percentage of white sand in sample (Polymer concrete). From above figure-2, it shows that density increases with increasing of white sand in sample (Polymer concrete).

1.23 1.411 1.53 1.701 1.835

0

1

2

0 10 20 30 40 50 60 70

Den

sity,

g/cm

3

Percentage of red sand in sample

Density vs percentage of red sand in sample

1.23 1.38 1.53 1.703 1.877

00.5

11.5

2

0 10 20 30 40 50 60 70Den

sity,

g/c

m3

Percentage of white sand in sample

Density vs Percentage of white sand in sample

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Figure-3: Comparison between Density vs Percentage of red sand in sample (Polymer concrete) and Density vs Percentage of white sand in sample (Polymer concrete). From above figures, it shows that density variation of sample (Polymer concrete) from figure- 1 to figure- 3 is notified. Variation of density is observed with the change of composition of sand (Both white & red sand) in sample (Polymer concrete). High density is notified with the high percentage of sand (Both white & red sand) in the composites of unsaturated polyester resin and sand; besides low density is notified with the low percentage of sand (Both white & red sand) in the composites of unsaturated polyester resin and sand.

3.2. Water absorption of the Polymer concrete Water absorption of polymer concrete with various composition of sand (Both red and white sand) and unsaturated polyester resin is very nearly zero. Polymer concrete of different compositions has been contacted with water in the various period of time but water absorption is nearly zero.

3.3. Optical microstructure observation of the Polymer concrete The microstructure of different composition of polymer concrete under magnification of optical microscope is observed from microscopic view. Optical micrograph of samples from optical microscope shows that the density phase has been increased with increasing sand (Both red and white sand) amount in the polymer concrete besides the density phase has been decreased with decreasing sand (Both red and white sand) amount in the polymer concrete.

Figure-4: Optical micrograph of Sample view (20% red sand & 80% resin) & (40% red sand & 60% resin)

Figure-5: Optical micrograph of Sample view (50% red sand & 50% resin) &(60% red sand & 40% resin)

1.23 1.411 1.53 1.701 1.835

1.23 1.38 1.53 1.703 1.877

00.5

11.5

2

0 10 20 30 40 50 60 70D

ensi

ty, g

/cm

3

Percentage of sand in sample

Comparison of samples with red & white sand

sample with red sandsample with white sand

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Figure-6: Optical micrograph of Sample view (20% white sand & 80% resin) & (40% white sand & 60% resin)

Figure-7: Optical micrograph of Sample view (50% white sand & 50% resin) & (60% white sand & 40% resin)

3.4. Flexural strength of the Polymer concrete

Figure-8: Flexural strength of sample with red sand From above figure-4, it shows that flexural strength of polymer concrete decreases with increasing of red sand in sample. So it can say that sample containing high percentage of red sand behaves low flexural properties, besides sample containing low percentage of red sand behaves high flexural properties.

Figure-9: Flexural strength of sample with white sand From above figure-5, it shows that flexural strength of polymer concrete decreases with increasing of white sand in sample. So it can say that sample containing high percentage of white sand behaves low flexural properties, besides sample containing low percentage of white sand behaves high flexural properties.

80.37

42.13 36.56 32.23 24.390

20406080

100

0 10 20 30 40 50 60 70

Flex

ural

st

reng

th, M

pa

Percentage of red sand in sample

Flexural strength of sample with red sand

80.3757.9

46.23 40.14 37.48

020406080

100

0 10 20 30 40 50 60 70

Flex

ural

st

reng

th, M

pa

Percentage of white sand in sample

Flexural stength of sample with white sand

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Figure-10: Comparison between flexural strength of sample with red sand and flexural strength of sample with

white sand.

3.5. Compressive strength of the Polymer concrete

Figure-11: Compressive strength of sample with red sand From figure-7, it shows hat compressive strength of polymer concrete decreases with increasing of red sand in sample. So it can say that sample containing high percentage of red sand behaves low compressive properties, besides sample containing low percentage of red sand behaves high compressive properties.

Figure-12: Compressive strength of sample with white sand From figure-8, it shows that compressive strength of polymer concrete decreases with increasing of white sand in sample. So it can say that sample containing high percentage of white sand behaves low compressive properties, besides sample containing low percentage of white sand behaves high compressive properties.

Figure-13: Comparison between compressive strength of sample with red sand and compressive strength of sample with white sand.

80.37

42.13 36.56 32.23 24.39

80.3757.9 46.23 40.14 37.48

0

50

100

0 10 20 30 40 50 60 70

Flex

ural

st

reng

th, M

pa

Percentage of sand in sample

Comparison of samples with red & white sand sample with red sandsample with white sand

112 95 90 84 80

0

50

100

150

0 10 20 30 40 50 60 70

Com

pres

sive

st

reng

th, M

pa

Percentage of red sand in sample

Compressive strength of sample with red sand

11298 92 86 79

0

50

100

150

0 10 20 30 40 50 60 70

Com

pres

sive

stre

ngth

,Mpa

Percentage of white sand in sample

Compressive strength of sample with white sand

11295 90 84 80

112 98 92 86 79

0

50

100

150

0 10 20 30 40 50 60 70

Com

pres

sive

stre

ngth

, Mpa

Percentage of sand in sample

Comparison of sample with red & white sand sample with red sandsample with white sand

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3.6. Hardness of the Polymer concrete

Figure-14: Leeb rebound hardness of sample with red sand From above figure-10, it shows that Leeb rebound hardness of sample containing 20 & 40 percentage red sand increases with increasing red sand percentage but Leeb rebound hardness of sample containing 50 & 60 percentages red sand decreases with increasing red sand percentage.

Figure-15: Leeb rebound hardness of sample with white sand From above figure-11, it shows that Leeb rebound hardness of sample containing 20& 40 percentage white sand increases with increasing white sand percentage but Leeb rebound hardness of sample containing 50& 60 percentages white sand decreases with increasing white sand percentage.

Figure-16: Comparison between Leeb rebound hardness of sample with red sand and Leeb rebound hardness of sample with white sand.

4. Conclusions In this research work, the effect of polymer concrete prepared from unsaturated polyester resin and reinforced with sand has been analyzed. The density, water absorption, Optical microstructure observation, compressive strength, flexural strength and hardness behavior have been calculated and quantified. Water absorption is zero. Density phase of prepared polymer concrete is also nearly uniform over various compositions. Compressive strength, flexural strength and hardness behavior of polymer concrete is also within expectation level. So, at the end of research, it can say that polymer concrete from unsaturated polyester resin and sand will be found application in very specialized domains in the advance world.

769

751.8

774.8764

742.2740

760

780

0 10 20 30 40 50 60 70

Leeb

rebo

und

hard

ness

Percentage of red sand in sample

Hardness of sample with red sand

769 716 750.8 675.8 637.6

0200400600800

1000

0 10 20 30 40 50 60 70

Leeb

rebo

und

hard

ness

Percentage of white sand in sample

Hardness of sample with white sand

769 751.8 774.8 764 742.2

769 716 750.8 675.8 637.6

0200400600800

1000

0 10 20 30 40 50 60 70Leeb

rebo

und

hard

ness

Percentage of sand in sample

Comparison of samples with red & white sand sample with red sand

sample with white sand

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5. References 1. JUNG DO SUH, DAI GIL LEE, DESIGN AND MANUFACTURE OF HYBRID POLYMER CONCRETE BED FOR HIGH-SPEED CNC MILLING MACHINE, IDESIGN, VOLUME 4, ISSUE 2, PP 113-121, JUNE 2008. 2. Satalkin, A. V., V. A. Solntseva, and O. S. Popova, Tsementno-polimernye betony, Leningrad, The Great Soviet Encyclopedia, 3rd Edition (1970-1979). 3. The National Aeronautic and Atmospheric Administration's Glenn Research Center. "Gas Density Glenn research Center". grc.nasa.gov. 4. Hugh D. Young; Roger A. Freedman. University Physics with Modern Physics. Addison-Wesley; 2012. ISBN 978-0-321-69686-1. p. 374. 5. R. T. Mennicke, “Equotip Metal Hardness”, ICASI & CCATM 2008 congress proceedings (2008). 6. K. Herrmann et al. Härteprüfung an Metallen und Kunststoffen“ (“Hardness tests on metals and plastics”), Expert Verlag, Renningen, 2007. 7. M. Tietze, M. Kompatscher, “Predicative Hardness Testing for Production Control and Materials Design”, IMEKO-TC5-2002-027, 2002. 8. Wredenberg, Fredrik; PL Larsson (2009). "Scratch testing of metals and polymers: Experiments and numerics". Wear 266 (1–2): 76. Doi: 10.1016/j.wear.2008.05.014