JPS6149261B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION This invention relates to polymer concrete, and more particularly to a method for making polymer concrete having very low polymer binder levels.

Concrete produced using synthetic organic binders is known. These non-hydraulic concretes have excellent properties once the binder has hardened and fused with the inorganic components to form a rigid body. these are,
Precast for construction, civil engineering or site casting where strength, water resistance, chemical resistance or curing speed is desired.
Used in the production of elements. The binder used is a catalyzed monomeric or resinous component, and various methods are known for mixing the binder with inorganic materials to achieve polymerization or curing.

Although polymer-bonded concretes (hereinafter referred to as polymer-bonded concretes) are currently well known, many of them have several drawbacks in their use. The main of these disadvantages are high cost, low elastic modulus,
It has poor fire resistance, has limited achievable surface effects for architectural purposes, and exhibits high shrinkage during curing, resulting in crimping and cracking. Highly exothermic reaction during curing, which can generate internal stresses; May be difficult to process due to the viscous properties of the liquid phase used;
etc. can be mentioned. Such drawbacks are that organic binder components can be added to concrete without causing other serious problems such as low compressive strength, low tensile strength, high abrasion resistance, and poor sensitivity to impact.
This is due to the fact that it is possible to suppress the content to a level of 10 to 15% by weight or less, especially in the case of large structures. Low levels of binder content have been disclosed in certain methods of making polymeric concrete, however, other disadvantages are associated with this. For example, some of these manufacturing methods have limited application, such as road repair.

Additionally, some have complex manufacturing methods and are limited to special conditions that are not commercially acceptable.

According to the present invention, it has been found that strong polymer bonded concrete with very low binder levels can be achieved by a specific method that is simple and efficient. The method can be used, for example, at a binder level of 6.7% by weight of the composition.
It has a wide range of applications as it can also be applied to very large polymer concrete moldings, such as manufacturing curved precast panels of (thickness).

The method utilizes special ingredients and a very specific sequence of steps.

Generally, the method involves mixing certain monomeric materials with inorganic components and a polymerization initiator and allowing polymerization to occur as a curing step.

The low viscosity of the liquid phase allows for the incorporation of sand, filler, and aggregate in amounts sufficient to obtain binder levels of 5-10% by weight and as low as 3% by weight. By applying strong vibrations to the mixed components, proper distribution of the bonding material can be achieved by closely packing the solids and separating the components during or before the curing process. , resulting in a high-strength concrete product.

Generally speaking, the polymeric concrete provided by the present invention comprises an aggregate consisting of sand, stone or gravel, or a mixture thereof, and about 30% of the concrete.
Polymeric concrete with high strength properties is provided, comprising ~10% by weight of an organic binder, the organic binder comprising (a) styrene, styrene derivatives, C _1-8 alkyl esters of acrylic acid or methacrylic acid, and divinyl. One or two selected from the group of benzene
one or more α/β-ethylenically unsaturated monomers, or
(b) consisting of a polymer formed in situ from a low viscosity solution of an unsaturated polyester in said monomer;
The solution here contains an amount of monomer in excess of that required for crosslinking the polyester.

The invention provides a method for producing polymer bonded concrete with a binder content of less than 10% by weight, characterized by the following production steps:

(1) A mixing step in which aggregate consisting of sand, stone, or gravel, or a mixture thereof, is mixed with a binder component to form a mixture of aggregate and binder component. wherein the binder component is any member of the group consisting of (a) styrene, styrene derivatives, C _1-8 alkyl esters of acrylic acid or methacrylic acid, or divinylbenzene;
a species or two or more α,β-ethylenically unsaturated monomers, or an unsaturated polyester dissolved in one or more of the monomers, where the solution of monomers and polyester is of low viscosity and (b) a free radical polymerization initiator; (2) casting the mixture; (3) subjecting the mixture to intense vibration; (4) polymerizing and curing the monomer to produce polymer bonded concrete.

In particular, the invention provides a method for producing polymer-bonded concrete with a content of from 3 to less than 10% of organic binder materials, characterized by the following steps: (1) sand, stone or gravel, or a mixture thereof; mixing an aggregate consisting of: (a) an unsaturated polyester resin dissolved in styrene monomer with a binder component to form a mixture of aggregate and binder component; having a low viscosity and comprising an additional monomer in excess of that required for crosslinking the polyester, said additional monomer being selected from the group consisting of styrene, methyl methacrylate and butyl acrylate; (b) free radical polymerization; an initiator; (2) shaping the mixture; (3) subjecting the mixture to intense vibration; and (4) polymerizing the monomers by heating to produce polymer-bonded concrete.

Further, the present invention provides a method in which the content of the organic bonding material is 3.
7% to less than 7% polymer-bonded concrete comprising the following steps: (1) mixing an aggregate consisting of sand, stone or gravel, or a mixture thereof, with a binder component as follows: forming a mixture of aggregate and binder components; (a) methyl methacrylate monomer; and (b) a free radical polymerization initiator; (2) shaping the mixture; and (4) polymerizing the monomers by heating to produce polymer bonded concrete.

When using monomers to polymerize in situ, one would expect a high degree of shrinkage to occur. This is because, for example, when a polyester resin is used alone as a binder, the shrinkage that occurs when the monomer used is polymerized is larger than the shrinkage of the polyester resin during curing. For example, the shrinkage rate when methyl methacrylate polymerizes to poly(methyl methacrylate) is 20
~22%. However, in reality, when using the method of the present invention, the expansion and contraction of concrete is
less than the expansion and contraction that occurs during the manufacture of conventional polymer-bonded concrete made from resin and aggregate. Additionally, there is no stress cracking associated with the heat generation that normally occurs when high resin concrete hardens. The concrete of the present invention can also be formed in forms as thin as 1/2 inch (1.27 cm) and can be formed better than hydraulic concrete. Additionally, standard concrete mixing and placing equipment may be used.

Due to the reduced level of binder that can be used in concrete according to the invention, the total cost of concrete can often be halved without any adverse effect on its mechanical properties. For example, unsaturated polyester dissolved in styrene/
The formulation contains 3.5% by weight styrene (72:28); 3.1% methyl methacrylate; 0.08% initiator; 93% graded silica filler, sand and aggregate with a flexural strength of 2750 psi and a compressive strength of 13500 psi has 0.1%
of water, thereby providing a concrete that can withstand at least 2500 freeze-thaw cycles with little loss of properties. The elastic modulus of 6.6×10 ⁶ is at least twice that of conventional polyester bonded concrete. A high modulus of elasticity is particularly important for large structural members such as plates, since the higher the elastic modulus of the plate, the greater the distance between the struts that the plate can cover. Weather resistance has also been improved, with concrete like the one shown above remaining unchanged in appearance after 2,500 hours in the Weather Ometer. Furthermore, such polymer concrete can have thermal linear expansion and contraction comparable to conventional hydraulic concrete or steel, for example 6.5×10 ⁻⁶ /〓.

On the other hand, the linear expansion and contraction of conventional polymer concrete with high binder levels is 2
It will double.

Since the binder is the only combustible component in polymer-bonded concrete and this binder component is considerably reduced according to the invention, the fire resistance is also greatly improved.

Additionally, the use of certain materials over conventional small size fills significantly improves fire resistance properties, as discussed below.

Aggregates that can be used in the production method of the invention are sand, stone and gravel, which are usually used in concrete production with hydraulic binders. The aggregate may be sieved or ground, but preferably it does not contain too much fines.

The filler, which is a ground solid, may be added to the actual aggregate as particulate material with a particle size smaller than that of the aggregate. Silica is advantageous to use because it is inexpensive, has few pores, and is relatively hard. Suitable types of silica include, for example, silica powder and Ottawa silica. Fillers that may be used include treated or untreated calcium carbide. The proportion of fillers or extenders used is determined for a given aggregate by methods similar to those used in the manufacture of hydraulic cements and mortars. This determination for a given aggregate is made by testing various proportions of aggregate and filler in the subject binder composition system. The amount of filler selected will be that amount corresponding to substantially maximum compression and deflection resistance.
The above-mentioned fillings are not restrictive; all known fillings in concrete manufacturing technology can be used.

Other materials may also be added, such as titanium dioxide or iron oxide or other materials for pigments.

By using certain compounds instead of relatively small particle size fillers (e.g. 44-220 microns), the fire protection of the product is greatly increased, and by reducing the amount of binder used. It was found that the fire resistance was improved more than the achieved fire resistance.

These compounds include, for example, alumina trihydrate,
It can be any powdered material that releases water of crystallization at high temperatures, such as tricalcium aluminate hexahydrate, and zinc borate. The amount of such material required to provide maximum fire protection is approximately twice the amount of commonly used resin binders.

Thus, whereas in conventional polymer concretes these materials must be used in excess of prohibited amounts, concretes with low polymer binder content according to the present invention provide the necessary fire protection for maximum fire protection. The amount of chemical compound is reduced correspondingly to the amount of resin binder.

Generally 20-200% by weight based on binder
level greatly improves the fire resistance of concrete.

As already outlined, monomers that can be used are α,β ethylenically unsaturated monomers, namely styrene and styrene derivatives, divinylbenzene and C _1-18 alkyl esters of acrylic acid and methacrylic acid. Examples of these monomers include:
Styrene itself; lower alkyl-substituted styrenes such as α-methylstyrene and vinyltoluene; divinylbenzene; methyl acrylate; ethyl acrylate; isopropyl acrylate; butyl acrylate; 2-ethylhexyl acrylate; methyl methacrylate; ethyl methacrylate; Isopropyl acid; butyl methacrylate, etc.

These monomers can be used alone or in combination, and preferred monomers, particularly from a cost standpoint, are styrene, methyl methacrylate, and butyl acrylate. Other monomers may be advantageously used in combination with the preferred monomers mentioned above to modify the properties of the binder, and such may be used in small amounts.

In addition to the above monomers, other monomers and crosslinking agents may also be used to change the properties of the binder.
They may be included in relatively small amounts, for example to improve adhesion or improve glass transition temperature. Examples of these monomers and crosslinkers are acrylic acid, methacrylic acid, 1,3-butylene dimethacrylate, trimethylolpropane, trimethacrylate, diethyl phthalate, dibutyl phthalate and diallyl phthalate.

The above monomers can be used as such or to dissolve a proportion of the unsaturated polyester. These unsaturated polyesters are condensates of polyalcohols and unsaturated dibasic acids, and are general-purpose medium-reactive resins conventionally used as binders in the polymer concrete and glass fiber fields. For example, Palatal(TM) H-170 (Canada's
available from BASF) and Laminac (trademark)
4193 (available from Cyanamid, Canada), which are unsaturated polyester resins dissolved in styrene;
Maleic anhydride is added in a ratio of about 1 part to 1 part. Paraplex™ P-444A (available from Rohm & Haas, Canada) is a similarly advantageous unsaturated polyester.

It is known to add materials such as styrene to unsaturated polyester resins, and in practice these are commercially available by the chemical supplier diluted with sufficient styrene for crosslinking of the polyester to occur. There is. The usual proportion of commercially available
About 70 parts by weight of polyester and 30 parts by weight of styrene. The viscosity of the resin thus diluted is still greater than 1000 cps.

By further diluting the above monomers based on the process of the present invention, viscosities of perhaps 50 cps to less than 1 cps are obtained. The polyester thus diluted provides an amount of monomer in excess of that required for crosslinking the polyester, and when used in accordance with the present invention, polymerization of that monomer occurs together with the crosslinking reaction. It is clear that if no unsaturated polyester resin is used, the viscosity of the monomer component is negligible compared to the preformed resin binder and no crosslinking is involved.

For purposes of this invention, it has been found that various proportions of unsaturated polyester resin dissolved in the monomer may be used as long as the viscosity of the monomer solution does not exceed about 50 cps. Expressed as a percentage by weight, the polyester resin accounts for approximately
It can account for up to 50% by weight, preferably 40% by weight or less.

As previously mentioned, the amount of binder component that may be used in accordance with the manufacturing method of the present invention generally ranges from 5 to 50% of the composition.
The content is 10% by weight, but lower proportions up to about 3% are suitable. When the liquid organic phase has a low viscosity,
High levels of aggregates, fillers, sand, and other inorganic components can be incorporated and the surface tension of the liquid phase is low.
Provides intimate contact between organic particles. Due to the low proportion of liquid used, the liquid phase does not play a very decisive role with respect to the curing properties and properties of the final product; rather, the product provided is made up of bones that are tightly adhered to each other. It is a mostly mineral product with an almost monolithic structure consisting of grains of wood and sand. In fact, the final product has more properties of granite or stone than of plastic, and therefore even of hydraulic concrete.

The amount of binder can be increased somewhat above 10%, but increasing it too much may cause problems in obtaining good quality concrete, sacrificing the improved properties obtained with lower binder levels. be sexualized.

The polymerization initiator added according to the production method of the present invention is suitable for polymerization of monomers and, if applicable, for
It is a free-radical initiator that causes crosslinking of the polyester resin used.

These initiators may be either those that exhibit activity at room temperature or those that exhibit activity at high temperatures.
Examples for use at room temperature include benzoyl peroxide in combination with nitrogen-containing promoters such as N.N-diethyl-m-toluidine and N.N-dimethylaniline. An example of an initiator used at elevated temperatures is bis-4-tert.-butyl-cyclohexyl peroxydicarbonate. The use of heat-activated initiators and heating during concrete hardening has the advantage that the pot life of the fresh concrete mix is extended. Examples of other suitable initiators will readily occur to those skilled in the art. The proportion of initiator is generally from 0.1 to 5% by weight of the other binder components.

As previously mentioned, standard concrete mixing and pouring equipment can be used with concrete based on the manufacturing method of the present invention. For precast concrete components, the formwork used is preferably a closed formwork, but open formwork can also be used. One reason for this is that the monomer, which is typically heated to cure, is volatile, and the use of closed molds allows the heat to be applied from both sides, resulting in a more uniform polymerization. Therefore, warping and distortion are prevented. When using closed formwork, the formwork does not have to be completely closed;
The term closed formwork refers to the concrete surface of 10~
This includes formwork with up to 30% exposed.

In the production of regular precast concrete, it is common practice to vibrate the concrete in order to drive air entrained in the concrete to the surface during mixing or pouring. The use of vibration in the present invention is essential for these reasons, and another reason is to minimize the volume occupied by the aggregate or to fill it without gaps. By reducing the viscosity of the liquid phase, preferably on the order of less than 1 centipoise, and the concomitant reduction in surface tension, the vibrations allow the aggregate to fill freely, resulting in the aggregate itself being most compact. Needless to say, this cannot be achieved with highly viscous binders. This operation brings the solids into close contact with each other so that the shrinkage associated with increased monomer levels and conversion of monomer to polymer is not observed. In the case of hydraulic concrete, excessive vibration causes undesirable mix separation.

On the contrary, in the manufacturing method according to the present invention,
Excessive vibrations are required to cause separation and are referred to herein by the term "strong vibrations." This is done by subjecting the formwork of a precast article to general rather than small vibrations, for example in a closed formwork, where excess liquid or binder rises to the top and inch to 2 inches)
It is determined empirically that the vibration of the entire formwork is sufficient to form a layer with a thickness of . When horizontal open formwork or cast-in-place is applied, the top surface area is much larger than in the case of closed vertical formwork, and the thickness of the layer accumulated on top due to strong vibrations is reduced, e.g.
It may be as thin as 0.16 cm (1/16 inch). The accumulation layer from the vertical closed formwork can be removed by cutting off the edges of even very large panels, if necessary or desired. The upper resin layer formed by open molding, a method suitable for making furniture or other similar articles, is not visually significant as it can be placed on the underside or back of the furniture, and the furniture is not subjected to significant stress. Therefore, there is no need to remove it.

The above-mentioned strong vibrations that cause "separation" also remove a significant amount of voids in the mix, i.e.
Spaces or interstices between aggregate particles are reduced to a minimum.

Various vibratory devices may be used depending on the concrete manufacturing method. For example, table vibrators can be used for precast concrete formwork, while internal vibrators are suitable for pour-in-place methods. In fact, any type of vibration, any frequency, or even mechanical shock can cause
They may be used if they have sufficient strength to accomplish the degree of component separation or "settling" of the aggregates described above. However, preferably
High amplitude, low frequency vibrations may be used to promote separation, and vibrations may generally be applied for longer periods of time compared to those practiced in other concrete techniques. As an example of suitable conditions,
A closed formwork containing a 909 kg (2000 lb) panel is vibrated for 5 minutes using a 6 horsepower vibrator operating at 1750 cycles per minute. A suitable frequency range is about 1700 to 3600 cycles per minute.

Once the concrete mixture has been shaped and subjected to vibration, the time required for curing will, of course, depend on the particular initiator used and the presence or absence of heating. The time required may be approximately 5 minutes to 3 hours, or more. Temperatures may range from room temperature to 95°C or higher.

Reinforcing materials used in conventional concrete mixes may also be used in accordance with the present invention. These may be reinforcing bars or steel mesh, for example. Steel fibers may also be used in the compositions of the present invention and can simply be mixed with the other ingredients, unlike in hydraulic concrete, where mixing tends to result in agglomeration of steel fibers. Such reinforcement improves the tensile strength and impact resistance of the concrete.

The polymer bonded concrete according to the invention comprises:
The appearance of the surface can be varied for various architectural purposes.
The surface of the concrete can be treated or etched with a solution of polymer binder to obtain exposed aggregate. polymethacrylate,
A particularly effective solvent for polyacrylate or polystyrene is methylene chloride. This type of surface treatment is usually carried out in hydraulic concrete by acid etching, retarding the surface hardening of the concrete and/or sand blasting.

The plastic-like finish on concrete is
It is obtained by applying a coating of colored resin to the precast structure in the formwork before pouring the concrete. This surface coating permanently adheres to the concrete product. For example, such resins include
Palatal(TM) H-170 and Gel-Kote(TM)
(available from Gritsdon).

The following examples are illustrative and do not limit the scope of the invention.

In all examples, the aggregate used was placed in a conventional pan mixer, then the liquid ingredients except the initiator were added, then the dry ingredients were added, and finally the initiator was added. Mixing was done for 2 minutes and then the mixture was transferred to a 30 square foot closed mold. Vibration is 3450rpm
The test was carried out for 2 minutes using a 11/2 horsepower reciprocating vibrator operating at a frequency of . Curing conditions are described in detail in each example.

Example 1 A polymer concrete according to the invention was produced using the following ingredients.

Polyester resin 72% styrene 28% (palatal
(Trademark) H-170) 3.5% Methyl methacrylate 3.1% Bis-4-tert.-butylcyclohexyl peroxydicarbonate 0.08% Silica powder (>200 mesh) 12.6% Ottawa Silica (27 mesh)
21.2% Round quartz aggregate (1/8″-3/8″) 58.8% Titanium dioxide 0.8% Organic matter%: 6.7 Heat curing: (1/2 hour at 175〓=79℃) Thickness of molded product: 3/4″ Compressive strength: 13500 psi (ASTM C39-73) Flexural strength: 2750 psi (ASTM C78-75) Elastic modulus: 6.6×10 ⁶ psi (ASTM C469-65) Example 2 Polymer concrete according to the present invention The following ingredients were used in the manufacture:

Methyl methacrylate 5.7% Bis-4-tert.-butylcyclohexyl peroxydicarbonate 0.05% Titanium dioxide 0.25% Calcium carbonate 250 mesh + 12.00% Calcium carbonate 50-500 mesh 14.00% Aggregate 1/8″-1″ 67.20% Organic matter %: 5.8% Heat curing: (1 hour at 160°C = 7.1°C) Thickness of molded product: 2″ Example 3 The following ingredients were used.

72% polyester resin, 28% styrene (palatal
(Trademark) H-170) 3.20% Butyl acrylate 1.60% Methyl methacrylate 1.60% Silica powder (7.8% is 200 mesh, 12.9% is
270 meshes, 11.1% held above 325 meshes,
Total: 66.7%) (200 mesh) 12.00% Otsutawa Silica (27 mesh) 32.00% Round quartz aggregate (1/8″-3/4″) 49.00% Titanium dioxide 0.13% N-N-diethyl-m-toluidine 0.04 % N・N-dimethylaniline 0.08% Benzoyl peroxide 70% (granular) 0.25% Organic matter %: 6.77 Room temperature curing: (70 = 3 hours at 21°C) Thickness of molded product: 2″ Example 4 This concrete was manufactured using the following:

72% polyester resin, 28% styrene (palatal
H-170) 2.5% Methyl methacrylate 2.5% Bis-4-tert.-butylcyclohexyl peroxydicarbonate 0.1% Silica powder (>200 mesh) 12.9% Otsutawa powder (27 mesh) 21.9% Round quartz aggregate (1/ 8″−3/4″) 59.7% Titanium dioxide 0.4% Organic matter %: 5.1 Heat curing: (3/4 hour at 175 = 79°C) Thickness of molded product: 2″ This example can be used instead of methyl methacrylate. When repeated using styrene alone, comparable results were obtained.

Example 5 The following was used to produce concrete mixes.

72% polyester resin, 28% styrene (palatal
H-170) 3.3% Methyl methacrylate 2.7% Bis-4-tert.-butylcyclohexyl peroxydicarbonate 0.6% Silica powder (>200 mesh) 10.0% Otsutawashi silica (27 mesh) 15.0% Round quartz aggregate (1/8 ″−3/8″) 68.5% Iron oxide pigment 0.5% Organic matter %: 6.1 Heat curing: (200〓 = 15 minutes at 93°C) Thickness of molded product: 1″ Example 6 The following raw materials were mixed and Processed.

72% polyester resin, 28% styrene (palatal
H-170) 2.9% Methyl methacrylate 2.9% Bis-4-tert.-butylcyclohexyl peroxydicarbonate 0.06% Silica powder (>200 mesh) 3.8% Aluminum hydrate (average 100 mesh) 10.0% Otsutawa silica (27 mesh) 16.2% Round quartz aggregate (1/8″-1/2″) 64.0% Titanium dioxide 0.2% Organic matter%: 5.9 Heat curing: (1 hour at 165〓=73.9℃) Thickness of molded product: 2″ Example 7 Concrete was produced from the following:

72% polyester resin, 28% styrene (palatal
H-170) 3.3% Methyl methacrylate 3.3% Bis-4-tert.-butylcyclohexyl peroxydicarbonate 0.1% Silica powder (>200 mesh) 6.0% Aluminum hydrate (average 100 mesh) 13.4% Otsutawa silica (27 mesh) 15.2% Round quartz aggregate (1/8″-1/2″) 57.46% Titanium dioxide 0.14% Molybdenum red 1.12% Organic matter%: 6.7 Heat curing: (1/2 hour at 175〓=79.4℃) Molded product Thickness: 2" The polymer concretes of Examples 2-7 had properties very similar to those of the concrete of Example 1. For example, the compressive strength was 13500 psi.
It was moderately hot.

It was found that the properties of the concrete of the above examples did not change appreciably with respect to the specified binder ratio.

As an indication of the fire resistance of the polymer concretes exemplified in Examples 6 and 7, concrete made with the ingredients listed in Example 7 but excluding molybdenum red showed a high temperature resistance during decomposition by a heat source of 2500°C (1427°C). It was found that neither smoke nor flame was emitted.
Smoke emissions per ASTM D2843 are 1%;
Meanwhile, the fire resistance test (ASTM D2863) showed an oxygen index of 80 or higher.

All of the above embodiments of polymer bonded concrete according to the invention are precast panels for architectural fascia panels with a thickness of 3/8 to 4";
Patio slabs, concrete flower pots, garden furniture, load-bearing type or non-load-bearing using urethane foam sandwiched between two mechanically and chemically bonded polymer concrete slabs type of sanderch panels and 3/8 thickness to replace traditional wood chip systems, stucco systems, plywood and aluminum and steel siding
Can be used for ~1 inch (0.95~2.54 cm) wall cladding, etc.

The polymer bonded concretes of Examples 1, 3, 4 and 5 are particularly suitable for drain, sewer and other pipe manufacturing due to their chemical and abrasion resistance. These polymer concretes can also be used in pump motor boxes, storage tanks, and chemically resistant articles such as foundations, floor slabs and tiles.

Because of its very high chemical resistance, the polymer concrete of Example 1 has been used in the form of panels to protect the sides, undersides, or supports of elevated highways. This concrete is also used as permanent, white, impermeable forms for highway median strips, which consist of thin shells that utilize hydraulic concrete as filler. ).

The polymer concrete of Example 4 is abrasion resistant and is particularly suitable for the production of railway sleepers and tracks for rubber-tired subway vehicles.

The polymer concretes of Examples 6 and 7 have a low binder content and contain hydrated aluminum, and are therefore particularly suitable for producing fire-resistant panels and the like.

Claims (1)

[Claims] 1. Aggregate consisting of sand, stone, or gravel, or a mixture thereof, made of (a) styrene, styrene derivatives, C _1-8 alkyl esters of acrylic acid and methacrylic acid, and divinylbenzene; selected α/β-ethylenically unsaturated monomers, or unsaturated polyesters dissolved in one or more of said monomers, where the solution consisting of said monomers and polyester is of low viscosity and contains the amount necessary for cross-linking. (b) a free radical polymerization initiator, forming a mixture of the aggregate and the binder component, forming the mixture, subjecting the mixture to vibrations strong enough to separate the material from the binder and cause a layer of liquid binder to form on the upper surface of the molding mixture; and polymerizing the monomers to produce polymer-bonded concrete. A method for producing polymer-bonded concrete containing less than 10% by weight of an organic binder, characterized by the steps described above. 2. The method of claim 1, wherein the binder component has a viscosity of less than 50 CPS. 3. said binder component comprises (a) an unsaturated polyester dissolved in styrene monomer, said solution having a low viscosity and containing an amount of additional monomer in excess of the amount necessary for crosslinking said polyester; The monomer is styrene,
3. A method according to claim 1 or 2, characterized in that it comprises: (a) a free radical polymerization initiator (selected from the group consisting of methyl methacrylate and butyl acrylate); and (b) a free radical polymerization initiator. 4. The method according to claim 1 or 2, wherein the binder component comprises: (a) methyl methacrylate monomer; and (b) a free radical polymerization initiator. 5. Process according to claim 1, characterized in that the polymerization is carried out by heating to a temperature of up to 200 °C. 6. Process according to claim 1, characterized in that a filler is also mixed with the aggregate and binder components. 7. According to any one of claims 1 to 3, 5 and 6, characterized in that the polyester solution in monomer has a polyester content of not more than 50% by weight of the binder Method described. 8. Process according to claim 7, characterized in that the polyester solution in monomer has a polyester content of not more than 40% by weight of the binder. 9. Process according to any one of claims 1 to 8, characterized in that the initiator is bis-4-tert-butylcyclohexyl peroxydicarbonate. 10 The binder component accounts for about 3 to 10 of the total composition.
A method according to claim 1, characterized in that less than % by weight. 11 The binder component accounts for about 5 to 10 of the total composition.
A method according to claim 3, characterized in that less than % by weight. 12 The binder component accounts for about 3 to 7 of the total composition.
5. Process according to claim 4, characterized in that less than % by weight. 13 The initiator is added to about 0.1-5% of the other binder components.
Process according to claim 1, characterized in that it is used in an amount of % by weight. 14 Fire retardant material 20 to 200 based on binder
2. Process according to claim 1, characterized in that it is added in an amount of % by weight. 15. The method of claim 14, wherein the fire retardant material is selected from the group consisting of alumina trihydrate and zinc borate. 16. The method according to claim 1, characterized in that the mixture is molded in a closed mold that covers 70% or more of the surface of the mixture. 17. Method according to claim 1, characterized in that the strong vibrations are of high amplitude and low frequency.