Polymer concrete (PC) has been used to replace cement concrete when harsh service conditions exist. Polymers have a high carbon footprint when considering their life cycle analysis, and with increased climate change concerns and the need to reduce greenhouse gas emission, bio-based polymers could be used as a sustainable alternative binder to produce PC. This paper examines the development and characterization of a novel bio-polymer concrete (BPC) using bio-based polyurethane used as the binder in lieu of cement, modified with benzoic acid and carboxyl-functionalized multi-walled carbon nanotubes (MWCNTs). The mechanical performance, durability, microstructure, and chemical properties of BPC are investigated. Moreover, the effect of the addition of benzoic acid and MWCNTs on the properties of BPC is studied. The new BPC shows relatively low density, appreciable compressive strength between 20–30 MPa, good tensile strength of 4 MPa, and excellent durability resistance against aggressive environments. The new BPC has a low carbon footprint, 50% lower than ordinary Portland cement concrete, and can provide a sustainable concrete alternative in infrastructural applications.
One of the main challenges of using a high fiber volume content in a cement composite is the narrow margin of fiber volume content beyond which fibers can cause an adverse effect on the mechanical properties. In this paper, the significance of fiber size distribution and fiber volume content of different proportions of chopped and milled carbon microfibers are investigated. The mixes’ flowability showed improvement with altering the fiber size distribution despite having a high fiber content. Uniaxial compression cylinders and unnotched and notched beams were cast and then tested at 7 and 28 days of age. It was found that the compressive strength is significantly affected by fiber size distribution more than fiber volume content. On the other hand, the modulus of rupture and fracture toughness are proportional to the fiber volume content with little effect of fiber size distribution. Finally, neither high fiber volume content nor altered fiber size distribution significantly affected the elastic modulus of the fiber cement composites.
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