Why Choose Polymer Modified Mortar For Construction Projects?

What is Polymer Modified Mortar?

Polymer-modified mortar is a compound construction material that blends polymers with the regular cement mortar.

Traditional mortars are the formulation of sand, cement & water in a specific ratio. Conversely, polymer-modified mortar has an additional ingredient, the polymers, into the mix.

Common polymers include redispersible polymer powders and polymer emulsions like acrylic emulsions and styrene-acrylic emulsions.

The polymers are uniformly distributed within the system of bricks and mortar, and work jointly with sand, cement, and other components to give the material enhanced and unique properties.

How to Make Polymer-Modified Mortar?

Preparing of Material

Cement- It should be a good cement, like Portland cement or any ordinary Portland cement, which provides fundamental strength to the mortar.

Polymers- Selection can be made between the two types of polymers

• Redispersible Polymer Powder –It is suitable as it can be redispersed into an emulsion on mixing with water.
• Polymer Emulsion- Polymer Emulsions, like acrylic emulsions, can be directly blended with mortars.

Aggregates

• Clean, naturally manufactured sand should be used.
• Oversized particles and fine sand should be removed.
• If it is not removed, proper grain gradation will not be done, which can impact the final output.
• Granulated Sand is harder, and fine silt demands more water.
• So, medium sand is Ideal.

Additives

To enhance the workability and water water-reducing agents and deformers should be used.

• Defoamers- Prevent the formation of air bubbles during the mixing process & give a thicker finish.
• Water Reducing Agent- Makes it easy to mix and apply with reduced water.

How to Mix Polymer-Modified Mortar?

Dry mixing for Redispersible Polymer Powder

Firstly, cement, sand, and polymer powder need to be added to a clean mixing container.

With the help of a low-speed mixer, mix it for 3-5 minutes so that all the dry components are mixed evenly.

This is an important step, as if it is not done properly, then it will be difficult to get that consistency after the water is added.

Wet Mixing For Polymer Emulsion

• Add cement and sand to get a consistent dry mix.
• Slowly mix the polymer emulsion and a specific amount of water.
• Continuously stir in a medium speed mixer for 5-10 minutes.
• Continue the same until you get a smooth, lump-free mortar with the expected thickness.

Usage & Storage

Usage

• To restore uniformity, stir before use properly.
• The Mortars should be applied as per the construction’s needs, like masonry, plastering, and patching.

Storage

• If the polymer-modified mortar is not put to use immediately, store it in a cool and dry place.
• Cover the material with plastic sheets to avoid contamination or risk of damage due to moisture.
• If stored properly, PMM can last for 6 to 12 months
• It is recommended to see the expiry date on the pack.

Comparison Points	Traditional mortars	PMM
Adhesion	The adhesion with the material is relatively less and is more likely to crack, chip, or flake, especially on harder or smoother surfaces like metals, concrete, or tiles	Due to polymers, there is improved adhesion that fills the gap between mortar with the groundwork, efficiently bonding with the dense material and preventing the risk of peeling, flaking.
Composition	They consist of sand, cement, and water in some ratio. Where cement is a binder and sand fills the gaps	It is a composition of traditional mortar with the addition of a polymer ingredient.E.g., redispersible polymer powder or polymer emulsion
Elasticity	Has Limited flexibility and is not fit for bearing structural movements. Even though there are shrinkages due to changes in temperature or humidity. This often results in cracking.	Excellent Flexibility, inclusion of polymer gives a more flexible network that resists cracking. Ideal for substrates with minor deformations.
Water Proofing	Water penetration becomes easier due to low-quality internal waterproofing. Poor water resistance leads to seepage and durability issues in the long run.	Due to polymer modification, there is improved waterproofing, which almost resists water seepage. It is the best choice for applications demanding powerful waterproofing.
Durability	It is helpless in chemical erosion, weathering, and thawing/freezing cycles. Exposure to a harsh environment for a longer time can lead to devaluing its properties.	Has high chemical and environmental damage resistance, like UV radiation, alkali, and acid. Provides stable performance with longevity.
Workability	Rather difficult to use as it requires careful adjustments in terms of water range. Improper leveling and finishing can result in cracks and uneven surfaces.	Enhanced workability, polymer transformation improves flowability, & adaptability, which makes it easy to coat, spread, and get a smooth finish.
Applications	It is ideal for low-demand environments with steady conditions like basic construction work or simple repairs.	Generally used in building repairs, decorative finishes,  renovations, and waterproofing, bridge-road constructions, and many other high-demand cases.

Polymer Modified Repair Mortars

Building Construction Repairs

In various buildings, slabs, concrete beams, columns, and even walls, cracks and holes start developing due to exterior impact and ageing. 

Polymer-modified repair mortar gives supreme bonding and firmly binds the existing base, such as the masonry and concrete to fix the damaged area. 

The addition of polymers gives elasticity, which makes the material resistant to stress caused by temperature changes and structural settlements.

Thus, the life span of the building structure expands, and stability is there, and  the risk of cracking in the repaired area is reduced.

Industrial Structure Maintenance

For Industrial structures, like equipment foundations or bases of storage tanks that bear constant material impact or vibrations, face damage over time. 

This repair mortar helps in an easy, targeted, and fast fixing solution. Restoring usefulness and reducing layoff time.

Thus, the regular operations are not disturbed, and the maintenance cost is also reduced with efficient working.

Polymer Modified Thinset Mortar 

Indoor Fine Decorative           

For Interior wall renovation and decorative projects, polymer-modified thinset mortar is very useful.

Its outstanding rheology and workability make it best for applications demanding an extra-thin, smooth, and thin layer.

This gives a graceful and even base for the next decoration step, like artistic paint finish, wallpaper installation.

It enhances the overall decorative look. Also the due to the reduced thickness of material, the cost is saved.

Preservation of Cultural Roots

To safeguard the ancient buildings and antiques, polymer-modified thinset plays a key role.

One of the benefits of using this type of mortar is that it fixes minor flaws without changing the original appearance.

It is suitable for flaking masonry or painting, thereby avoiding secondary damage.

Polymer Modified Concrete Repair Mortar

Water Conservancy Infrastructure Repairs 

In structures like dams and canals, damage occurs on the concrete surface due to the continuous flow of water.

This mortar not only fixes the damage but also gives excellent waterproofing and seepage properties.

Restricts water infiltration, resulting in the safe operation of water conservancy infrastructure. 

Bridge and Road Repairs

Gaps or potholes on road surfaces and spalling in bridge segments can impact traffic.

This repair mortar can be prepared quickly and applied, and can achieve the strength within a short period. 

This can help to meet the load-bearing and traffic requirements without any disturbance.

The superior durability and weather resistance give long-lasting repairs and resist vehicle load and environmental decay.

Sakshi Chem Sciences Polymer for PMM

Sakshi Chemi Sciences Pvt Ltd, Nagpur, Maharashtra, is one of the leading manufacturers and suppliers of construction chemicals. 

It has a specialization in polymers, which are used in polymer-modified mortars.

These include redispersible polymer powders like  AKULPOL-9192, AKULPOL–3032, and also hydrophobic RD 1112 that enhances flexibility, bonding, and water resistance in mortars.

Also, they have Hydroxypropyl Methyl Cellulose HPMC and its brand name of AKULCEL.

It enhances water resistance and workability.

The Polycarboxylate ether PCE 811 helps in reducing water without impacting workability.

With their consistent commitment towards quality and creativity, they give a customized solution to meet the complex need of modern construction.

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