Process for filling space in a structure with a polyurethane composite in the presence of water

A process for filling space in a structure with a polyurethane composite having a compressive strength of at least 2,000 p.s.i. which comprises

• (a) adding a wet, coarse aggregate to said space of said structure, and
• (b) adding a polyurethane binder to said aggregate wherein said binder comprises a mixture of
• i. a phenolic resin component, which is denser than water, comprising
• 1. a phenolic resole resin, and
• 2. a hydrophobic solvent system in which water is not significantly soluble;
• ii. an isocyanate component which is denser than water comprising
• 1. an aromatic polyisocyanate selected from the group consisting of diphenylmethane diisocyanates, oligomeric derivatives of diphenylmethane diisocyanates, and mixtures thereof, and
• 2. a hydrophobic solvent in which water is not significantly soluble;
• iii. a liquid urethane promoting catalyst;
• wherein the amounts of said components are as follows:
• 1. the weight ratio of the binder to the aggregate is from about 9:92 to about 50:50;
• 2. the isocyanate is used in an amount sufficient to cause the curing of the phenolic resin when reacted in the presence of the curing catalyst;
• 3. the urethane catalyst is used in an amount such that the binder is essentially nonfoaming and the composite is capable of being formed with wet aggregate;
• and
• wherein said process is carried out under conditions such that water is present in an amount of at least one percent by weight based upon the weight of said aggregate.