Melt Recyclable Polymer Concrete Using Recovered Concrete Aggregate and Unique Thermosetting Thermoplastic Polycarbonate

This project will develop a new type of polymer concrete using recycled concrete aggregate (RCA) and a proprietarysustainable and biodegradable thermosetting thermoplastic polycarbonate that has the performance properties ofcurrent polymer concrete, but can be melt processed and recycled like asphalt. Consequently it will be morepractical than current polymer concrete in large scale applications like roadways and structures. In so doing it willaccomplish 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 helpdesigners continue their introduction of concrete in household applications like countertops, tables and tiles thatcurrently 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 beingproduced 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 amountof 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 pplications. Though its growth isstrong, 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 generallyepoxy, 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.