Polyplex™ is a specifically formulated, all-acrylic polymer emulsion, which
can be used in GFRC mixes to eliminate the necessity for seven-day wet cure.
Advantages
Until the introduction of the acrylic polymer GFRC products required a
seven-day cure in over 95 percent humidity in order to insure full curing of
the Portland cement. This usually meant building wet rooms where the product
could be stored in the required wet environment.
Where manufacturing was done in an enclosed building, the provision of a
curing area resulted in the loss of valuable production space. Where
manufacturing was essentially performed outside, the provision of a
satisfactory curing area was difficult, if not impossible.
Polyplex™ polymer eliminated the need for the wet curing period and the
associated costs of curing areas and lost production space. These cost savings
more than offset the added cost of incorporating Polyplex in the mix.
Polyplex™ provides added workability to the GFRC mix and , particularly better
adherence to vertical mold surfaces, so reducing the tendency of the wet mix to
slide. It is suitable for use with both white and gray Portland cements.
Polyplex™ does not yellow when weathered, and is it will not discolor panel
finishes, as some acrylic polymers can do.
Principals of the Polyplex™ polymer curing effect
Because it is thin, compared to conventional concrete (one half inch
compared to three inches or thicker), GFRC without polymer can lose water by
evaporation too quickly. GFRC composites had to be stored in a wet environment
to maintain sufficient water in the composite and ensure complete hydration of
the cement.
Polyplex™ when added to GFRC mixes at the recommended level, does not change the
hydration process of Portland cement. It’s the function is to reduce
permeability during the first few hours of cure, first on the surface by
forming a sealing film and then within the composite. This reduced permeability
in the composite significantly lessens the loss of water by evaporation,
facilitating the full hydration and cure of the Portland cement.
Excessive loss of water during curing, to such an extent that there’s not
sufficient water remaining to fully hydrate the Portland cement, will result in
low cement and composite strengths. Further , there are no remedial procedures
that will retrieve the composite strengths if the initial cure is not done
correctly.
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