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Polymer Concrete Pipe Technology
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Polycrete polymer concrete is a composite material consisting of polyester resin, quartz sand, silicate aggregate and quartz filler. As Portland cement performs poorly in an acidic environment, it is not used as a binding agent. Polycrete polymer concrete uses a polyester resin to bond the kiln-dried silicate aggregate, thereby creating a dense, corrosion-resistant matrix. For special industrial applications where added chemical resistance may be required, Polycrete can be produced using a vinyl ester resin.

Polymer concrete pipes are produced using a vertical casting process, very similar to concrete pipe. Exact amounts of the materials are pre-mixed, with the raw material quantities, mixing sequence and material feeds controlled by a computer. Then, the mixed material is loaded into vertical molds where vibratory compaction is used to ensure a dense, void-free composite structure. The polymer concrete pipe is initially cured in the molds. Once a rigid structure has set, the molds are stripped and the pipe is post-cured in a tunnel kiln.

Manufacturing in dimensionally accurate steel casting molds produces pipe with very tight dimensional tolerances, circular over the entire length. Using this same process, non-circular pipes and special structures (e.g. manholes and wet-wells), elliptical, semi-elliptical and egg-shaped pipes can be manufactured.

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