Chapter 5

High Performance Polymer Cement

Concrete
5.1 Introduction
High Performance Concrete (HPC) represents a significant
development in concrete technology, aiming to overcome the
limitations of conventional concrete in terms of strength,
durability, and long-term performance. Traditional concrete,
although widely used, often suffers from issues such as low tensile
strength, cracking, permeability, and poor resistance to aggressive
environmental conditions. These limitations have encouraged
researchers and engineers to develop modified concrete systems
with enhanced properties.
One of the most effective approaches to improve concrete
performance is the incorporation of polymer materials into
cement-based composites. Polymer Cement Concrete (PCC), also
known as Polymer Modified Concrete (PMC), is produced by
partially replacing cement hydration products with polymer films,
leading to improved bonding, flexibility, and impermeability.
According to ACI 548R, polymer-modified concrete exhibits
superior mechanical and durability properties compared to
ordinary Portland cement concrete.
High Performance Polymer Cement Concrete combines the
advantages of high-performance concrete and polymer
modification. This type of concrete is characterized by high
compressive strength, enhanced tensile and flexural strength,
reduced permeability, improved chemical resistance, and better
adhesion to existing concrete substrates. These properties make it
suitable for demanding structural and non-structural applications.
The use of polymers in concrete alters the microstructure of the
cement matrix. Polymer particles form continuous films within
the cement paste and at the interfacial transition zone between
cement paste and aggregates. This film formation enhances stress
distribution and reduces microcracking, which significantly
improves the overall performance of the concrete. Studies
reported by Mehta and Monteiro indicate that polymer-modified
systems show better crack resistance and toughness than
conventional concrete.
From an economic and practical perspective, polymer cement
concrete allows for thinner sections, longer service life, and
reduced maintenance costs. Although the initial material cost may
be higher, the long-term benefits often justify its use, especially in
aggressive environments. Consequently, polymer-modified
concrete has gained wide acceptance in repair works, bridge
decks, industrial floors, and marine structures.
In Egypt, the increasing demand for durable infrastructure under
harsh climatic and environmental conditions has led to growing
interest in advanced concrete technologies. The Egyptian Code of
Practice (ECP 203) recognizes the importance of improving
concrete durability and encourages the use of suitable admixtures
and advanced materials to enhance concrete performance.
Polymer cement concrete aligns well with these objectives and
represents a promising solution for modern construction needs.
5.2 Polymer Modified Concrete
Polymer Modified Concrete is a composite material in which
polymers are incorporated into a cementitious matrix to improve
its engineering properties. The polymers are usually added in the
form of latexes, redispersible powders, or liquid resins. Common
polymer types include styrene-butadiene rubber (SBR), acrylic
polymers, polyvinyl acetate (PVA), and epoxy resins. These
polymers interact with cement hydration products to form a co-
matrix system.
According to ACI 548R, the performance of polymer-modified
concrete depends on the type of polymer, polymer content, curing
conditions, and compatibility between polymer and cement.
When properly designed, polymer modification significantly
enhances tensile strength, flexural strength, impact resistance,
and bonding characteristics. This improvement is mainly
attributed to the polymer film formation within the cement
matrix.
During the hydration process, cement particles react with water to
form calcium silicate hydrate (C-S-H) and other hydration
products. Simultaneously, polymer particles dispersed in the mix
gradually coalesce as water is consumed or evaporates. This
coalescence leads to the formation of a continuous polymer film
that fills capillary pores and microcracks. Neville reported that this
mechanism reduces porosity and improves resistance to water
and chemical ingress.
One of the most important benefits of polymer modification is the
improvement of the interfacial transition zone (ITZ) between
cement paste and aggregates. In conventional concrete, the ITZ is
considered the weakest zone due to higher porosity and
microcracking. The presence of polymers strengthens this zone by
enhancing adhesion and reducing stress concentrations, resulting
in improved mechanical performance.
Polymer modified concrete also exhibits improved deformation
capacity and ductility. Unlike ordinary concrete, which fails in a
brittle manner, polymer-modified systems show more gradual
failure behavior. This property is particularly beneficial in
structures subjected to dynamic loads, vibrations, or thermal
movements. Experimental studies have demonstrated that
polymer-modified concrete can sustain higher strains before
failure compared to normal concrete.
From a durability standpoint, polymer modified concrete shows
excellent resistance to freeze-thaw cycles, chemical attack, and
abrasion. The reduced permeability limits the penetration of
harmful substances such as chlorides and sulfates, which are
major causes of reinforcement corrosion. According to ASTM and
ACI guidelines, polymer modification is especially recommended
for structures exposed to aggressive environments.
In repair and rehabilitation applications, polymer modified
concrete provides superior bonding to old concrete surfaces. This
property ensures monolithic behavior between new and existing
concrete layers, reducing the risk of debonding. As a result,
polymer-modified concrete is widely used in overlays, patch
repairs, and protective coatings.
5.3 Materials Used
The performance of High Performance Polymer Cement Concrete
is highly dependent on the quality and characteristics of its
constituent materials. Proper selection and proportioning of these
materials are essential to achieve the desired mechanical and
durability properties. The main materials used in polymer cement
concrete include cement, aggregates, polymers, mixing water, and
chemical admixtures.
5.3.1 Cement
Ordinary Portland Cement (OPC) is the most commonly used
cement in polymer-modified concrete. Cement must comply with
the requirements of ASTM C150 or BS EN 197. In Egypt, cement
should conform to the Egyptian Standard Specifications and ECP
203. The fineness, chemical composition, and strength class of
cement play a crucial role in the hydration process and polymer
interaction.
Cement hydration products form the primary binding matrix in
concrete. In polymer-modified systems, cement hydration occurs
simultaneously with polymer film formation. A balanced
hydration process is necessary to ensure proper bonding between
cement paste and polymer particles. Excessive cement content
may increase shrinkage, while insufficient cement content may
lead to poor strength development.
5.3.2 Aggregates
Aggregates constitute the largest volume fraction of concrete and
significantly influence its mechanical properties. Both fine and
coarse aggregates used in polymer cement concrete must satisfy
the requirements of ASTM C33 and BS 812. According to the
Egyptian Code (ECP 203), aggregates should be clean, hard,
durable, and free from harmful materials such as clay, silt, and
organic impurities.
Well-graded aggregates are preferred to achieve dense packing
and reduce voids in the concrete matrix. Angular aggregates
improve mechanical interlock, while rounded aggregates enhance
workability. In polymer-modified concrete, good aggregate
gradation helps improve polymer distribution and reduces
segregation.
5.3.3 Polymers
Polymers are the key component that distinguishes polymer
cement concrete from conventional concrete. Commonly used
polymers include styrene-butadiene rubber (SBR), acrylic
polymers, polyvinyl acetate (PVA), and epoxy resins. These
polymers are usually added in the form of latex emulsions or
redispersible powders.
According to ACI 548R, SBR and acrylic polymers are widely used
due to their excellent compatibility with cement and their ability
to improve bonding, flexibility, and impermeability. The polymer-
cement ratio is a critical parameter that affects strength,
durability, and workability. Typical polymer contents range from
5% to 20% by weight of cement, depending on the intended
application.
5.3.4 Mixing and Curing Water
Water used in polymer cement concrete should meet the same
quality requirements as water used in conventional concrete, as
specified in ASTM C1602 and ECP 203. Clean potable water is
generally suitable. Water plays a dual role by enabling cement
hydration and assisting in polymer dispersion.
The water-cement ratio must be carefully controlled. Excess water
can delay polymer film formation and reduce strength, while
insufficient water may hinder cement hydration. Proper curing
conditions are essential to allow both hydration and polymer film
formation to occur effectively.
5.3.5 Chemical Admixtures
Chemical admixtures such as superplasticizers, air-entraining
agents, and retarders may be used to enhance the performance of
polymer cement concrete. Superplasticizers conforming to ASTM
C494 are commonly used to improve workability without
increasing water content. The compatibility between admixtures
and polymers must be verified to avoid adverse effects on
concrete performance.
5.4 Mix Proportions and Design Concept
The mix design of High Performance Polymer Cement Concrete
differs from that of conventional concrete due to the presence of
polymers and the need to balance cement hydration with polymer
film formation. The primary objective of mix design is to achieve
the required strength, durability, and workability while ensuring
economic efficiency.
According to ACI 211 and ACI 548R, the mix design process begins
with the selection of suitable materials and determination of
target performance requirements. These requirements include
compressive strength, workability, durability, and exposure
conditions. The polymer content is selected based on the desired
improvement in properties and the type of polymer used.
The water-cement ratio is one of the most important parameters
affecting concrete performance. In polymer-modified concrete, a
lower water-cement ratio is generally preferred to achieve high
strength and reduced permeability. However, sufficient water
must be available to allow proper cement hydration and polymer
dispersion. Superplasticizers are often used to maintain
workability at low water-cement ratios.
The polymer-cement ratio significantly influences mechanical and
durability properties. Increasing polymer content generally
improves tensile strength, flexural strength, and bonding
characteristics. However, excessive polymer content may reduce
compressive strength and increase cost. Therefore, an optimum
polymer content must be determined through experimental
studies.
Aggregate proportioning aims to achieve dense packing and
minimize voids. Well-graded aggregates reduce the demand for
cement and polymer, improving both performance and economy.
Fine aggregate content is carefully adjusted to enhance
workability and polymer distribution.
Curing conditions play a vital role in achieving the desired
properties of polymer cement concrete. Unlike conventional
concrete, which requires continuous moisture curing, polymer-
modified concrete often benefits from a combination of moist and
air curing. According to ACI recommendations, initial moist curing
allows cement hydration, followed by air curing to promote
polymer film formation.
5.5 Advantages and Properties of Polymer Cement Concrete
High Performance Polymer Cement Concrete offers several
advantages over conventional concrete due to the combined
action of cement hydration products and polymer films. This
composite microstructure results in superior mechanical, physical,
and durability properties, making it suitable for advanced
construction applications.
One of the most significant advantages of polymer cement
concrete is its enhanced mechanical performance. The presence
of polymers improves tensile strength and flexural strength by
bridging microcracks within the cement matrix. According to ACI
548R, polymer-modified concrete typically exhibits higher tensile-
to-compressive strength ratios compared to ordinary concrete,
which contributes to improved crack resistance.
The compressive strength of polymer cement concrete is
influenced by polymer type and dosage. While moderate polymer
contents can enhance compressive strength, excessive polymer
addition may lead to a reduction due to increased flexibility of the
matrix. However, the overall performance remains superior due to
improved ductility and energy absorption capacity. This behavior
is well documented in experimental studies reported by Mehta
and Monteiro.
Another important property is the significant reduction in
permeability. Polymer films block capillary pores and microvoids,
limiting the penetration of water and aggressive chemicals. This
reduced permeability enhances resistance to chloride ingress,
sulfate attack, and carbonation, which are major causes of
reinforcement corrosion. According to ASTM durability studies,
polymer-modified concrete demonstrates superior long-term
performance in aggressive environments.
Polymer cement concrete also shows excellent bonding
characteristics. The adhesion between concrete layers and
between concrete and reinforcement is greatly improved due to
polymer presence. This property is particularly advantageous in
repair and overlay applications, where strong bonding to existing
concrete is essential to ensure structural integrity and durability.
From a deformation standpoint, polymer cement concrete
exhibits improved ductility and toughness. Unlike conventional
concrete, which fails in a brittle manner, polymer-modified
systems show gradual failure with higher strain capacity. This
characteristic is beneficial in structures subjected to dynamic
loads, thermal movements, and impact forces.
Shrinkage behavior is another important aspect influenced by
polymer modification. Polymers reduce drying shrinkage by
improving internal cohesion and reducing moisture loss. This
reduction in shrinkage minimizes cracking and enhances
serviceability. According to ACI guidelines, polymer-modified
systems show better dimensional stability than ordinary concrete.
In terms of durability, polymer cement concrete provides excellent
resistance to freeze-thaw cycles, abrasion, and chemical attack.
These properties make it suitable for industrial floors, bridge
decks, and marine structures. The improved durability contributes
to longer service life and reduced maintenance costs, which
offsets the higher initial material cost.
5.6 Applications of High Performance Polymer Cement Concrete
The superior properties of High Performance Polymer Cement
Concrete have led to its widespread use in various structural and
non-structural applications. Its ability to provide high strength,
durability, and excellent bonding makes it an ideal material for
demanding construction environments.
One of the most common applications of polymer cement
concrete is in repair and rehabilitation works. It is extensively
used for patch repairs, overlays, and resurfacing of deteriorated
concrete structures. The enhanced bonding characteristics ensure
monolithic action between the repair material and the existing
concrete, reducing the risk of delamination and premature failure.
In bridge engineering, polymer cement concrete is widely used in
bridge deck overlays and protective layers. The reduced
permeability and high resistance to chloride penetration make it
particularly suitable for bridge decks exposed to de-icing salts and
marine environments. According to ACI recommendations,
polymer-modified overlays significantly extend the service life of
bridge structures.
Polymer cement concrete is also used in industrial floors and
pavements where high abrasion resistance and chemical
resistance are required. The improved toughness and impact
resistance make it suitable for heavy-duty applications such as
factories, warehouses, and loading areas.
In marine and hydraulic structures, polymer cement concrete
provides excellent resistance to water penetration, chemical
attack, and cyclic wetting and drying. These properties are
essential for structures such as piers, docks, and water tanks. The
use of polymer-modified systems in such environments enhances
durability and reduces maintenance requirements.
Architectural and decorative applications also benefit from
polymer cement concrete due to its improved surface finish and
adhesion. It is used in thin sections, façade elements, and precast
components where conventional concrete may not provide
adequate performance.
In Egypt, polymer cement concrete is increasingly used in
infrastructure projects, particularly in repair works and protective
coatings for reinforced concrete structures. The harsh climatic
conditions and exposure to aggressive environments necessitate
the use of durable materials. The Egyptian Code of Practice
encourages the use of advanced materials, including polymer-
modified systems, to improve the performance and sustainability
of concrete structures.
References
1. ACI Committee 548, Guide for the Use of Polymer in Concrete
(ACI 548R), American Concrete Institute.
2. Neville, A.M., Properties of Concrete, Pearson Education.
3. Mehta, P.K. and Monteiro, P.J.M., Concrete: Microstructure,
Properties, and Materials, McGraw-Hill.
4. ASTM C150 – Standard Specification for Portland Cement.
5. ASTM C33 – Standard Specification for Concrete Aggregates.
6. ASTM C494 – Standard Specification for Chemical Admixtures
for Concrete.
7. ACI 211 – Standard Practice for Selecting Proportions for
Normal, Heavyweight, and Mass Concrete.
8. Egyptian Code of Practice ECP 203 – Design and Construction
of Reinforced Concrete Structures.