Grantee Research Project Results
Melt Recyclable Polymer Concrete Using Recovered Concrete Aggregate and Unique Thermosetting Thermoplastic Polycarbonate
EPA Contract Number: 68HERC20C0036Title: Melt Recyclable Polymer Concrete Using Recovered Concrete Aggregate and Unique Thermosetting Thermoplastic Polycarbonate
Investigators: Cameron, Randy E.
Small Business: Instrumental Polymer Technologies, LLC
EPA Contact: Richards, April
Phase: I
Project Period: March 1, 2020 through August 31, 2020
Project Amount: $100,000
RFA: Small Business Innovation Research (SBIR) - Phase I (2020) RFA Text | Recipients Lists
Research Category: Small Business Innovation Research (SBIR) , SBIR – Sustainable Materials Management
Description:
This project will develop a new type of polymer concrete using recycled concrete aggregate (RCA) and a proprietary sustainable and biodegradable thermosetting thermoplastic polycarbonate that has the performance properties of current polymer concrete, but can be melt processed and recycled like asphalt. Consequently it will be more practical than current polymer concrete in large scale applications like roadways and structures. In so doing it will accomplish two goals, it will become a large user of RCA, but will also make high performing polymer concrete even more environmentally friendly than cement concrete. It's performance and easy moldability will also help designers continue their introduction of concrete in household applications like countertops, tables and tiles that currently use marble, granite, steel, etc. but in an environmentally friendly way.
Concrete is the single most widely used manufactured material in the world, with over 10 billion tons being produced each year. Currently 60% of interstate roads in the U.S. are paved with concrete, in lieu of asphalt. Finding use for RCA is essential, not only to minimize spent concrete' s volume in landfills, but also to minimize the amount of mining for aggregate. But during the last 30 years, polymer concrete, in which polymer binds aggregate rather than cement, is becoming more popular and is replacing cement concrete in many applications. Though its growth is strong, it' s being hindered by the fact that all polymer concrete systems are two component systems with a very short work life. Unfortunately polymer concrete is also an environmental burden. The polymers used are generally epoxy, polyesters and styrene that are toxic and have unsustainable roots.
The project will develop and utilize a new version of a thermosetting thermoplastic invented by Instrumental Polymer Technologies, LLC, (IPTECH) that is a rigid, crosslinked plastic under ambient conditions, however, has a chemical functionality built in so that upon heating to a certain temperature the resin fragments and becomes a liquid. Upon cooling the plastic once again crosslinks. Consequently the plastic processes like a thermoplastic, but performs like a thermoset plastic. This project will meet the worlds needs for higher performing concrete, but with a system that is recyclable , sustainable and capable of absorbing the worlds supply of spent cement concrete. IPTECH will produce and sell their polymer technology and RCA to manufacturers of polymer concrete using IPTECH's current distribution network.
Progress and Final Reports:
The perspectives, information and conclusions conveyed in research project abstracts, progress reports, final reports, journal abstracts and journal publications convey the viewpoints of the principal investigator and may not represent the views and policies of ORD and EPA. Conclusions drawn by the principal investigators have not been reviewed by the Agency.