Method of forming a product for use as a concrete substitute

A method of forming a product which method comprises the steps of

• (A) preparing a water in resin emulsion by mixing
• (i) water with
• (ii) a mixture consisting essentially of (a) an unsaturated polyester resin having a molecular weight from about 3100 to 3600 formed by a condensation polymerization reaction, which is allowed to proceed until the polyester has an acid number of no more than about 25, between polyhydric and polycarboxylic compounds or derivatives thereof, said polyhydric compounds being present in excess over stoichiometric requirements, at least one of said compounds being unsaturated, the remainder being saturated;
• and (b) an unsaturated monomer;
• the mixture (ii) containing no more than about 30% by weight of the unsaturated monomer (b);
• wherein said emulsion is so stable that demulsification does not occur when a setting agent of the kind hereinafter defined is added thereto;
• (B) mixing the water in resin emulsion of step (A) with a setting agent of a kind which sets by hydration thereof to form a hardenable mixture;
• (C) causing an addition polymerization reaction to occur between said unsaturated polyester resin and said unsaturated monomer;
• and
• (D) allowing the hardenable mixture to harden thereby forming a product, wherein the quantity of emulsion mixed with the setting agent is such that sufficient water is provided by said emulsion to allow said hydration to occur.