Polymer-cement composites and methods of making same

A polymer-cement composite comprising:

• silica sand;
• latex including polymer solids;
• portland cement, the ratio of polymer solids in the latex to cement (ls/c) being between 0.3 and 0.6;
• a mixture of ground silica and precipitated silica;
• water;
• and
• optionally, additives.

A method of making a polymer-cement composite comprising the steps of:

• (a) dry mixing the powdered components of a polymer-cement composite having the following composition, by weight percent:
• 40% to 50% inert, inorganic filler material;
• 12% to 23% latex including polymer solids;
• 20% to 25% cement the ratio of polymer solids in the latex to cement (ls/c) being between 0.3 and 0.6;
• 7% to 13% reactive silica;
• optional additives;
• and
• water;
• (b) adding the liquid components;
• (c) wet mixing of the powdered and liquid components to form the green body;
• (d) forming the green body into the desired shape of a product;
• (e) curing the product;
• and
• (f) drying the product.

A method of making a polymer-cement composite comprising the steps of:

• (a) dry mixing in a high intensity mixer, until homogeneous, the powered components of the polymer-cement composite having the following composition, by weight percent:
• 40% to 50% inert, inorganic filler material;
• 12% to 23% latex including polymer solids;
• 20% to 25% cement, the ratio of polymer solids in the latex to cement (ls/c) being between 0.3 and 0.6;
• 7% to 13% reactive silica;
• optional additives;
• and
• water;
• (b) adding the liquid components under vacuum;
• and
• (c) wet mixing the powered and liquid components at medium intensity to form a thoroughly mixed batch of green body which is subsequently de-aired.