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1、548.6R-1 Polymer concrete (PC) is used in the construction of structural elements. Applications include wall panels to carry wind and seismic loads; under- ground vaults that must resist lateral earth pressure; vault and utility box covers that are required to resist vehicle loads; machine tool comp
2、onents subject to a wide range of loadings; and railroad ties to resist static and dy- namic rail loads. Structural uses of PC components involve flexure, shear, bearing, and deflections. Creep, fatigue, and service temperature are im- portant aspects of these mechanisms. A need for defining and und
3、erstanding polymer concretes structural properties and behavior therefore exists. Standards and codes governing design with polymer concrete have not yet been developed. There is a need for more research on structural behavior before design criteria can be completed. Keywords: beams (supports); drai
4、nage; floors; insulating concretes; port- land cements; pipes (tubes); plastics, polymers, and resins; polymer con- crete; railroad ties; structural design; tools; walls CONTENTS Introduction, p. 548.6R-2 Chapter 1Historic development, p. 548.6R-2 Chapter 2Materials and properties, p. 548.6R-3 2.1Ma
5、terials for structural polymer concrete 2.2Polymer concrete types 2.3Mechanical properties 2.4Chemical and physical characteristics 2.5Standards and guides applicable to polymer concrete 2.6Safety 2.7Regulatory matters 2.8Materials research 2.9Suggested additional research ACI 548.6R-96 became effec
6、tive January 1, 1996. Copyright 1996, American Concrete Institute. All rights reserved including rights of reproduction and use in any form or by any means, including the making of copies by any photo process, or by electronic or mechanical device, printed, written, or oral, or recording for sound o
7、r visual reproduction or for use in any knowledge or retrieval system or device, unless permission in writing is obtained from the copyright proprietors. ACI 548.6R-96 Polymer ConcreteStructural Applications State-of-the-Art Report Reported by ACI Committee 548 D. Gerry Walters Chairman Paul D. Krau
8、ss Secretary John J. BartholomewArthur H. GerberRockwell T. Rookey Gary BilliardAlbert O. KaedingEmanuel J. Scarpinato W. Barry ButlerMohammed S. KhanErnest K. Schrader Robert R. CainLouis A. KuhlmanQizhong Sheng Paul D. CarterHenry N. MarshW. Glenn Smoak Frank ConstantinoStella L. MarusinJoe Solomo
9、n Glenn W. DePuyJoseph A. McElroyMichael J. Sprinkel Floyd E. DimmickPeter MendisCumaraswamy Vipulanandan William T. DohnerJohn R. MillironHarold H. Weber, Jr. Larry J. FarrellRichard MontaniRon P. Webster* Jack J. Fontana*Larry C. MuszynskiDavid P. Whitney* David W. Fowler*Michael J. OBrienYoga V.
10、Yogendran Sandor Popovics * Members of subcommittee who prepared report. Chairman of subcommittee who prepared report. ACI Committee Reports, Guides, Standard Practices, Design Handbooks, and Commentaries are intended for guidance in planning, designing, executing, and inspecting construction. This
11、document is intended for the use of individuals who are competent to evaluate the significance and limitations of its con- tent and recommendations and who will accept responsibility for the application of the material it contains. The American Con- crete Institute disclaims any and all responsibili
12、ty for the appli- cation of the stated principles. The Institute shall not be liable for any loss or damage arising therefrom. Reference to this document shall not be made in contract docu- ments. If items found in this document are desired by the Archi- tect/Engineer to be a part of the contract do
13、cuments, they shall be restated in mandatory language for incorporation by the Ar- chitect/Engineer. Copyright American Concrete Institute Provided by IHS under license with ACI Licensee=IHS Employees/1111111001, User=listmgr, listmgr Not for Resale, 03/05/2007 01:25:59 MSTNo reproduction or network
14、ing permitted without license from IHS -,-,- 548.6R-2ACI COMMITTEE REPORT Chapter 3Structural members, p. 548.6R-12 3.1Flexural members 3.2Compression members 3.3Reinforced polymer concrete 3.4Unreinforced polymer concrete 3.5Sandwich panels Chapter 4Applications in structures, p. 548.6R-13 4.1Archi
15、tectural panels and facades 4.2Transportation 4.3Electrical insulators 4.4Utility structures 4.5Hydraulic structures 4.6Hazardous waste containment 4.7Machine tools Chapter 5Glossary of terms, p. 548.6R-18 Chapter 6References, p. 548.6R-20 6.1Recommended references 6.2Reference organizations 6.3Cite
16、d references Appendix 1Example polymer concrete formulations, p. 548.6R-23 Appendix 2Typical polymer concrete properties, 548.6R-23 INTRODUCTION Polymer concrete (PC) is used for structural applications where strength, stiffness, durability, and ease in molding provide an advantage over alternate ma
17、terials. An additional attraction is that many types of reinforcement can be used with PC. This report presents the state of the art in structural uses of PC. The information herein is separated into six ma- jor sections. Chapter 1 outlines the historic development of PC used in structures. Chapter
18、2 presents a general description of PC and some of its properties. Chapter 3 deals with the de- sign implications for structural elements fabricated from PC. Chapter 4 describes structures that have been completed us- ing PC. A glossary of technical terms relating to PC is pro- vided in Chapter 5, a
19、nd Chapter 6 lists references that contain additional information and background for PC structures. CHAPTER 1HISTORIC DEVELOPMENT The use of polymers in concrete was developed in the United States under three general classifications, polymer- impregnated concrete (PIC), polymer modified concrete (PM
20、C), and polymer concrete (PC). Polymer-impregnated concrete is a hydrated portland cement concrete impregnated with a monomer and subsequently polymerized in situ. Large-scale research on PIC commenced in the United States in 1966. Polymer modified concrete is a premixed material in which either a m
21、onomer or polymer is added to a fresh concrete mixture in a liquid, powdery, or dispersed phase, and subsequently allowed to cure, and if needed, polymer- ize in place. PMC is covered by other documents prepared by ACI (ACI 548.3R) and others.1 PIC has not been used in commercial applications and is
22、 virtually nonexistent in the United States today. PC was first used commercially in the 1950s in the United States in the production of synthetic marble, followed by the manufacture of architectural fac- ing panels in the late 1950s. By the mid 1970s, PC was used as a repair material for Portland c
23、ement concrete structures, mainly on highways and bridges. The U.S. Federal High- way Administration, the Bureau of Reclamation, and the Department of Energy all sponsored materials research during the 1970s and the 1980s that included PC. In the United States in the 1980s, chemical companies develo
24、ped an increasing interest in specific materials and material properties required to produce PC. As a result, many en- hancements in the polymers used in PC were developed, and resins tailor-made for PC production began to be of- fered. This development continues, and material improve- ments are oft
25、en achieved by manufacturers. Information and technical papers concerning PC and its applications were published as the result of the First Inter- national Congress on Polymers in Concrete (ICPIC) held in England in 1975. Subsequent congresses were held in Aus- tin, Texas, U.S.A. (1978), Koriyama, J
26、apan (1981), Darm- stadt, Germany (1984), Brighton, England (1987), and Peoples Republic of China (1990). The Seventh Interna- tional Congress on Polymers in Concrete was held in Rus- sia in September 1992. All published proceedings include papers on several structural aspects of PC. Fatigue, impact
27、, abrasion, and flammability are discussed. Uses of PC in structures in the United States, Russia, India, Japan, Po- land, Germany, England and South Africa are described. The American Concrete Institute (ACI) formed Commit- tee 548, Polymers in Concrete, in 1971. Committee 548 has published proceed
28、ings of symposia held with American Concrete Institute conventions. The committee has also published Polymers in ConcreteState-of-the-Art Report (ACI 548R) and Guide for the Use of Polymers in Concrete (ACI 548.1R). Several test methods specific to PC were de- veloped and published by the Polymer Co
29、ncrete Committee of the Society of the Plastics Industry, Inc. (See Table 4). Today, a major part of PC application is in the form of precast elements. At first, the only precast elements were architectural building panels. Beginning in the 1970s, other structural products began to appear on the mar
30、ket, includ- ing floor drains, utility trenches, underground utility vaults and covers, high-voltage insulators, and highway median barrier shells. These products were followed by the intro- duction of manhole structures and machine tool bases. Re- search into the behavior of PC structures is contin
31、uing at the University of Texas (Austin), Brookhaven National Laboratory, the University of Houston, the Federal High- way Administration, and various state highway departments. It is anticipated that many new PC materials and innova- tive uses for these materials will be on the market by the Copyri
32、ght American Concrete Institute Provided by IHS under license with ACI Licensee=IHS Employees/1111111001, User=listmgr, listmgr Not for Resale, 03/05/2007 01:25:59 MSTNo reproduction or networking permitted without license from IHS -,-,- POLYMER CONCRETESTRUCTURAL APPLICATIONS548.6R-3 turn of the ce
33、ntury. Research is being conducted on such uses as ballistics panels, electric transmission poles, sand- wich panels, building blocks, utility trenches, utility covers, and insulation panels.2 CHAPTER 2MATERIALS AND PROPERTIES 2.1Materials for structural polymer concrete The general term, polymer co
34、ncrete, used in this report in- cludes polymer mortars, polymer grouts, and polymer con- cretes. Polymer mortars and grouts include materials with aggregate sizes smaller than 1/4 in. (6 mm). Differences be- tween mortars and grouts depend on the intended use and af- fect the fabricators formulation
35、 of the material. 2.1.1 PolymersThermosetting polymers are used as the binding matrix for structural PC applications. Frequently used polymers include those made from such monomers as methacrylates, epoxy, furan, styrene, trimethylopropane tri- methacrylate, unsaturated polyesters (UP), and vinyl es
36、ter. The monomers of these polymers, or a mixture of monomers and polymers in liquid form, are mixed with an aggregate system to produce the mixture. Polymerization promoters and initiators are also included in the mix proportioning to cross-link or complete the polymerization (hardening) of the mon
37、omers. There are several properties of the monomers or polymers typically used to define the characteristics of the uncured PC. Polymer concretes and mortars are usually clas- sified based on the properties of the uncured binder, the cured binder, and the cured PC or mortar. For most appli- cations,
38、 the properties of the cured binder will dominate ma- terial selection. The viscosity of the individual or mixed components may be specified to control the coating of the aggregates. Binder resins with low viscosity are more suitable for highly-filled mixtures. A gel time range may be specified to i
39、nsure that there is adequate time to place the fresh PC and that the cur- ing will be completed within the time allotted before demolding. Additional properties of the uncured binders, such as specific gravity, shelf life, component content, and flash point, are sometimes specified.3 Mixing procedur
40、es vary with the polymers selected. The combination of monomers, polymers, initiators, promoters, and chemical additives constitutes the binder system. Some binder systems may be formulated as two components where one component contains the monomers, polymers, promoters, and additives and the second
41、 contains the curing agent or initiator. Another common way to prepare the bind- er system is to premix the promoters and additives with part of the monomers and polymers (usually one-half) and to premix the initiators with the remaining portion. For a spe- cific binder system, the ingredient manufa
42、cturer or a chem- ist should be consulted to select the most appropriate way to mix the required chemicals. Particular care must be taken to avoid mixing promoters directly with initiators because the mixture can react explosively. Refer to Paragraph 2.6 for safety requirements. 2.1.2 AggregatesAggr
43、egates such as silica sand, gran- ite, river gravel, basalt, fly ash, calcium carbonate, and silica flour are generally acceptable for PC. Individual fly ashes should be tested before use since some may adversely affect the polymerization reaction. Most aggregates meeting the Standard Specification
44、for Concrete Aggregates, ASTM C 33, will provide adequate performance in PC. In addition, aggre- gates must be selected for chemical resistance if that is a fac- tor in the application.4 Aggregates are usually specified to be dry (less than 0.2 percent free moisture) and free from dirt, clay, asphal
45、t, and organic materials. Rounded river gravel up to 3/4 in. (20 mm) has been used for some overlays and is also suitable for precasting larger sections. The larger smooth ag- gregate provides a more workable mixture, and less resin can be used. Concern for the preservation of the environment and th
46、e conservation of natural resources has focused attention on the need to recycle waste materials such as plastics, glass, and incinerator ash to produce useful products for the public and private sectors. Waste glass is a major portion of all mu- nicipal waste, accounting for about 10.5 percent or 1
47、3.5 mil- lion tons (12.2 million Mg) in 1975. This glass fraction of municipal solid waste is an inert aggregate that may be used in PC composites. Examples of glass-polymer composites include sanitary pipe, culvert pipe, septic tanks, cesspools, and building blocks or brick. Municipal park benches
48、and tables and other decorative products normally made of portland ce- ment concrete can also be made of glass polymer composites.5 2.1.3 ReinforcementThere are many types of reinforce- ment available for PC: bars and rods made from steel or fi- berglass; fabrics made from steel wire, fiberglass, or
49、 polymers; and fibers made from steel, glass, carbon, or poly- mers. Ductile materials such as steel with high tensile strength and stiffness are generally preferred to provide the ductile behavior and high flexural strength for the compo- nent. Fiberglass cloth or mats are frequently used as rein- forcement due to the ease of its placement in molds and its durability, strength, and chemical resistance.5 The addition of various types of fibers can result in in-
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