Comparison of Mechanical Properties for Polymer Concrete

with Different Types of Filler

Marinela Bărbuţă1; Maria Harja2; and Irina Baran3

Abstract: Sustained research and development work on the utilization of waste 共fly ash and silica fume兲 for various productive uses have
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been carried out. In the construction industry, major attention has been devoted to the use of fly ash and silica fume in concrete as addition
to or as cement replacement. The utilization of a solid waste, fly ash and silica fume, in polymer concrete was reported in this paper
including the effects on the compressive strength, flexural strength, and split tensile strength. The results show the influence of fly ash and
silica fume content on the mechanical properties of polymer concrete with epoxy resin. The fillers improved the mechanical characteristics
of polymer concrete compared to that of polymer concrete without filler: the compressive strength of polymer concrete with fly ash
content was favorably influenced by the filler compound to polymer concrete with silica fume.
DOI: 10.1061/共ASCE兲MT.1943-5533.0000069
CE Database subject headings: Silica; Fly ash; Polymer; Concrete; Compressive strength.
Author keywords: Silica fume.

Introduction fume is largely used as an addition in cement concrete for im-

proving its properties 共de Souza Almeida and Sichieri 2006兲.
Industry development and electricity production lead to the gen- The formulation of high-performance materials that are stron-
eration of undesirable pollutants into the environment and it was ger and more durable than conventional cement-based materials
necessary to develop processes that would cause minimum pollu- has emerged as an issue of considerable importance in the con-
tion in the environment. The disposal of solid waste such as fly struction industry. In the past several decades new types of con-
ash or silica fume is a problem all around the world. Today, ther- crete such as high strength concrete, high performance concrete,
mal power plants exhaust large quantities of combusted waste in reactive powder concrete, and polymer concrete 共PC兲 were devel-
the form of bottom ash, fly ash, or slag 共Erol et al. 2007兲. Most of oped 共San-José et al. 2005, 2008; San-José and Frias 2007; San-
this ash is disposed in landfills at suitable sites 共Denver et al. José 2006; Ramirez and San-Jose 2001; Pardo et al. 1995兲.
2007兲. Landfilling is not a desirable option because of future en- Concrete-polymer composite materials can be classified into
vironmental protection costs and problems associated with land- three types: 共1兲 PC; 共2兲 polymer cement concrete 共PCC兲; and 共3兲
filling amendments 共Khale and Chaudhary 2007兲. polymer-impregnated concrete 共PIC兲 共Fowler 1999; Blaga and
In order to reduce the environmental pollution caused by Beaudoin 1985兲. PC is a composite material consisting of fine or
wastes and promote their comprehensive utilization, many areas coarse aggregates and microfiller that are bound together in a
of utilization were proposed in which the secondary raw materials matrix of polymer. The composite does not contain a hydrated
were reused in processing and recycling technologies 共Varughese cement paste. Fibers of different types 共carbon or glass fiber,
and Chaturvedi 1996; Rangan 2008兲. The research focused on polypropylene fibers, natural fibers, etc.兲 can be included 共Reis
fields such as building materials, chemical industry, agriculture, and Ferreira 2004; Reis 2006; San-José and Manso 2006兲 in the
and environmental protection. The utilization ratio of fly ash in polymer concrete matrix. The PCC is a modified concrete in
Romania increased from 16% in Year 1995 to 30% in 2002, which part 共10–15% by weight兲 of the cement binder is replaced
which is lower than that of developed countries 共70–80%兲. Im- by a synthetic organic polymer. The PIC is made by impregnation
proving the utilization of fly ash is still a difficult task. Also, silica of precast Portland cement concrete with low viscosity monomers
that are converted to a polymer under the influence of physical or
1
Associate Professor, Faculty of Civil Engineering, Technical Univ. chemical agents 共Blaga and Beaudoin 1985兲. Aggregates include
Gh. Asachi Iaşi, B-dul D. Mangeron 43, Iaşi 700050, Romania 共corre- silicate products, quartz, crushed stone, chalk, gravel, limestone,
sponding author兲. E-mail: [email protected] granite, clay, expanded glass, and metallic fillers 共Muthukumar et
2
Lecturer, Faculty of Chemical Engineering, Technical Univ. Gh. Asa- al. 2003兲.
chi Iaşi, B-dul D. Mangeron 71, Iaşi 700050, Romania. E-mail: maria_ From ecological reasons, the wastes such as recycled polyeth-
[email protected]
3
ylene terephthalate 共PET兲 and by-products 共silica fume, fly ash,
Lecturer, Faculty of Civil Engineering, Technical Univ. Gh. Asachi and slag兲 were used for producing new materials since they are
Iaşi, B-dul D. Mangeron 43, Iaşi 700050, Romania. E-mail: irina_ available in great quantities and pollute the environment 共Byung-
[email protected]
Wan et al. 2006; Bărbuţă et al. 2008; Srivastava and Shembekar
Note. This manuscript was submitted on September 22, 2008; ap-
proved on November 23, 2009; published online on November 25, 2009. 1990; Rebeiz et al. 2004; Varughese and Chaturvedi 1996; Ohama
Discussion period open until December 1, 2010; separate discussions 1996; Abul Bari et al. 2008兲.
must be submitted for individual papers. This paper is part of the Journal The final properties of PC depend on many factors including
of Materials in Civil Engineering, Vol. 22, No. 7, July 1, 2010. ©ASCE, the type and content of resin; type and particle size of aggregates;
ISSN 0899-1561/2010/7-696–701/$25.00. type of filler; type of fibers; dosage of components in the mixture;

696 / JOURNAL OF MATERIALS IN CIVIL ENGINEERING © ASCE / JULY 2010

J. Mater. Civ. Eng., 2010, 22(7): 696-701

 Table 1. Chemical Composition of Silica Fume 共%兲
SiO2 Fe2O3 Al2O3 CaO MgO MnO
91.07 1.83 4.63 0.5 0.5 1.04

• From scanning electron microscopy 共SEM兲 with particles ag-

glomeration 共Bărbuţă and Harja 2009兲;
• Specific surface 130, 000 m2 / kg; and
• Density 2 , 250 kg/ m3 共Bărbuţă 2007兲.
The chemical composition for dust with high content of SiO2
from filtering of burnt gases in the ferrosilicon process is given in
Table 1. Fly ash is one of the important source materials for
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construction materials. It is available worldwide, yet its utilization

is still limited. Fly ash consists of finely divided ashes produced
by burning pulverized coal in power plants.
The chemical composition depends on the mineral composi-
tion of the coal 共the inorganic part of the coal兲. Silica usually
Fig. 1. Particle-size distribution curves for fly ash 共filled circles兲 and varies from 40 to 60% and alumina from 20 to 30%. The iron
silica fume 共open circles兲 content varies quite widely. Alkalis are present in an appreciable
amount and potassium prevails over sodium. When CaO is greater
than 20% then it can be categorized as cementitious material.
curing temperature 共Abdel-Fattah and El-Hawary 1999; de Souza
When CaO varies between 10 and 20%, it is categorized as a
Almeida and Sichieri 2006兲; and manufacturing process.
cementitious and pozzolanic material. The chemical composition
This paper presents the results of experimental research on PC
of fly ash is presented in Table 2, where LOI represents the loss
made of epoxy resin, aggregates, and two types of fillers: silica
on ignition. Based on their chemical composition, these ashes are
fume and fly ash. The principal aim of this research was to inves-
classified as Class F 关Criado et al. 2007; Harja et al. 2008; ASTM
tigate the influence of each type of filler on the mechanical prop-
C 618 共ASTM 2007兲兴.
erties of PC.
Of all characteristics, the particle size distribution is very im-
portant. The particle size distribution was performed with a laser
diffraction particle size analyzer SALD-7001 equipped with vio-
Experimental Program
let laser. That measured particle size ranged from 15 nm
共0.015 ␮m兲 to 50 ␮m. Experimental data obtained for the par-
Materials ticle size distribution, for fly ash and silica fume, are presented in
Fifteen mixtures of PC were prepared having different dosages Fig. 1.
for all components: epoxy resin, aggregate, and filler. For statis- From Fig. 1 it can be observed that the fly ash had a median
tical optimization of the PC mixture, the design of the experimen- particle size of about 29.73 ␮m with a maximum of 49.5 ␮m,
tal method was used for establishing the mixtures, considering a and silica fume had a median particle size of about 0.49 ␮m with
limited domain of resin dosage between 12.4 and 18.8% 共the a maximum value of 5.82 ␮m. The filler dosage resulted from
minimum dosage was imposed from the workability condition the design of experiments between 6.4 and 12.8%.
and the maximum from the cost兲 共Bărbuţă and Lepădatu 2008兲. The aggregates were obtained from river gravel by crushing.
Two types of PC were studied: 共1兲 epoxy PC with silica fume as Two sorts were used: 0–4 mm, noted Sort I, and 4–8 mm, noted
filler 共BPS兲 and 共2兲 epoxy PC with fly ash as filler 共BPF兲. Sort II, both with continuous granulosity.
The polymer was an epoxy resin ROPOXID 701, a thermoset-
ting polymer that can be hardened with the polyamide curing Preparation of PC
agent 共ROMANID 407兲. The filler was used as addition to the
mixture and was considered as an independent component in the The 15 mixture combinations determined by the design of the
mixture design of the experiment. experiment’s method 共Bărbuţă and Lepădatu 2008兲 are given in
The silica fume used for the present study is a by-product of Table 3. The same mixtures were used for both types of PC, with
producing ferrosilicon alloys in smelters using electric arc fur- silica fume 共BPS兲 and fly ash 共BPF兲.
naces from a Romanian factory. The raw materials used for ob- The PC was prepared by mixing in a slow speed mechanical
taining the ferrosilicon are as follows: quartz 共with minimum mixer the required quantities of aggregate with epoxy resin com-
97.5% SiO2兲 as silicon source; metallurgic coke 共with minimum bined with hardener and the filler was slowly added. After the
82% C兲 as reducer; and iron wastes. The silica fume is collected complete mixing of PC, 70.7-mm cubes and 210⫻ 70⫻ 70 mm
from the off gases in very large filters in the baghouse. The quan- prisms were cast. For each composition a set of six cubes and
tity of dust involved by burnt gases from the furnace represents three prisms were cast. The specimens were tested at 14 days. For
about 35% of the end product quantity, that from a production the compressive test were tested three cubes; for the flexural
capacity means about 30,000 t per year.
The physical properties of the silica fume used in the experi-
mental program are as follows: Table 2. Chemical Composition of Fly Ash 共%兲
• Color: gray; SiO2 Al2O3 Fe2O3 CaO MgO SO3 LOI
• Distribution of particle sizes 共Fig. 1兲;
55.198 22.62 6.98 8.31 1.056 1.538 2.42
• Spherical particle shape 共Bărbuţă and Harja 2009兲;

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 Table 3. Mixture Design Combinations of PC
Epoxy Aggregate, Aggregate,
resin Filler Sort I 共0–4 mm兲 Sort II 共4–8 mm兲
Mixture 共%兲 共%兲 共%兲 共%兲
1 18.8 6.4 37.4 37.4
2 12.4 12.8 37.4 37.4
3 12.4 6.4 43.8 37.4
4 12.4 6.4 37.4 43.8
5 15.6 9.6 37.4 37.4
6 15.6 6.4 40.6 37.4
7 15.6 6.4 37.4 40.6
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8 12.4 9.6 40.6 37.4

9 12.4 9.6 37.4 40.6
10 12.4 6.4 40.6 40.6
11 16.4 7.2 38.2 38.2
12 13.2 10.4 38.2 38.2
13 13.2 7.2 41.4 38.2 Fig. 2. Compressive strength variations for PC BPS 共black兲 and BPF
14 13.2 7.2 38.2 41.4 共gray兲
15 14 8.0 39.0 39.0
Compressive Strength
The compressive strength test results are shown in Fig. 2 for the
strength were tested three prisms; and for the split tensile strength two types of epoxy PC 共BPS and BPF兲. From the experimental
were tested three cubes. The average result is reported. results the following observations can be made:
• The compressive strength values are more closely as values for
the PC with fly ash than in the case of concrete with silica
Experimental Results fume;
• For the same mixtures the compressive strengths for 12 com-
The samples were tested under identical conditions according to positions are larger for the PC with fly ash than for the PC
European Standard EN 12390/2001. The compressive strength, with silica fume;
flexural strength, and split tensile strength were determined ex- • The values of compressive strength in the case of PC with
perimentally adopting standard techniques EN 12390/2001 for all silica fume varied between 43.47 and 65.32 N / mm2;
combinations of both types of PC 共BPS and BPF兲. The experi- • The values of compressive strength in the case of the PC with
mental results obtained for the compressive strength 共f c兲, flexural fly ash varied between 57.96 and 69.82 N / mm2;
strength 共f ti兲, and split tensile strength 共f td兲 are the medium values • One mixture with silica fume BPS 13 had a larger value of
of the three tests for each mixture. The results are given in Table compressive strength; in this case the decrease in aggregate
4. Sort I and the increase of Sort II resulted in the smaller values
of compressive strength for both types of PC;
• The larger value of the compressive strength in the case of PC
with silica fume was obtained for a medium dosage of filler
共7.2–10.4%兲;
Table 4. Mechanical Properties Test Results
• The larger value of the compressive strength in the case of PC
fc f ti f td with fly ash was obtained for a maximum dosage of filler
共N / mm2兲 共N / mm2兲 共N / mm2兲 共12.8%兲;
Mixture BPS BPF BPS BPF BPS BPF • In the case of PC with silica fume the increase of the filler
dosage did not necessarily result in the increase of the com-
1 59.20 67.14 15.89 16.43 6.76 6.59 pressive strength; and
2 58.79 69.82 12.29 14.03 6.88 7.18 • In the case of PC with fly ash the increase of the filler dosage
3 59.59 57.96 16.79 16.67 7.67 5.77 resulted in the increase of the compressive strength.
4 57.61 60.62 15.59 15.77 6.11 5.67 The influence of filler content on the compressive strength is
5 64.08 67.22 15.81 14.73 7.62 7.19 presented in Fig. 3. Increasing the fly ash content increased the
6 58.62 64.49 17.57 16.79 6.27 7.25 compressive strength; increasing fly ash had more effect on in-
7 43.47 65.30 14.09 14.75 5.59 7.38 creasing strength than increasing silica fume.
8 45.95 64.89 14.30 16.85 6.88 7.15 The increase of the resin dosage resulted in an increase of the
9 55.21 62.86 13.49 15.59 5.72 6.89 compressive strength. This effect was more significant in the case
10 55.62 64.49 14.60 15.89 6.76 6.89 of concrete containing fly ash 共Fig. 4兲 in accordance with litera-
11 58.80 67.76 15.59 15.65 7.28 6.37 ture 共Pardo et al. 1995兲.
12 63.20 60.61 14.39 16.49 6.86 5.85
13 65.32 64.89 14.81 15.86 7.02 6.49 Flexural Behavior
14 57.61 62.45 14.39 14.99 6.18 6.72
The flexural strengths for the mixtures with silica fume and fly
15 57.75 61.06 14.87 13.70 6.49 7.93
ash are given in Fig. 5. The test results showed the following:

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Fig. 6. Influence filler dosage on flexural strength for 12.4% epoxy

Fig. 3. Influence of filler dosage on compressive strength for 12.4% resin
epoxy resin

• The largest value of flexural strength 共16.79 N / mm2兲; in the

• Generally, for the same mixtures, the flexural strength was case of PC with silica fume was obtained for mixtures with a
higher for the PC with fly ash than that with silica fume, ex- minimum content of epoxy resin and filler 共BPS3兲;
cepting Samples 3, 5, 6, and 15 共when the flexural strength is • The highest value of flexural strength in the case of PC with
higher for BPS兲; fly ash 共16.85 N / mm2兲 was obtained using a minimum dos-
• The values of the flexural strength in the case of PC with silica age of epoxy resin and medium content of filler 共BPF8兲; and
fume varied between 12.29 and 17.57 N / mm2; • The flexural strength was influenced by increasing the filler
• The values of the flexural strength in the case of PC with fly dosage.
ash varied between 13.70 and 16.85 N / mm2; The flexural strength decreased with the increase of filler con-
tent 共Fig. 6兲 and the decrease was more pronounced in the case of
the silica fume filler.

Split Tensile Strength

The values of the split tensile strength are shown in Fig. 7 for
both types of concrete. From experimental tests, the following
results can be determined:
• The maximum and minimum values of the split tensile
strength were higher in the case of PC with fly ash;
• The values of the split tensile strength in the case of PC with
silica fume varied between 5.59 and 7.67 N / mm2;
• The values of the split tensile strength in the case of PC with
fly ash varied between 5.67 and 7.93 N / mm2;
• The highest value of the split tensile strength 共7.67 N / mm2兲
in the case of PC with silica fume was obtained for the mixture
Fig. 4. Influence of epoxy resin dosage on compressive strength for with minimum content of epoxy resin and filler 共BPS3兲;
6.4% filler

Fig. 5. Flexural strength variations for PC, BPS 共black兲, and BPF Fig. 7. Split tensile strength variations for PC BPS 共black兲 and BPF
共gray兲 共gray兲

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