POLYMER-CEMENT COMPOSITES AND METHODS OF MAKING SAME

A polymer-cement composite comprises, by weight percent, about 40% to 50% inert, inorganic filler material, such as silica sand; about 12% to 23% latex, preferably in aqueous suspension; about 20% to 25% hydraulic cement; and reactive silica in an amount of at least about 6 weight percent. The reactive silica is a pozzolanic material, and in preferred embodiments, where the cement is portland cement, comprises an advantageous mixture of precipitated and ground silica. All solid components have a particle size of less than about 300 microns. The polymer-cement composite is preferably made by dry mixing of the powdered components throughly in a high intensity mixer, adding the liquid components, and wet mixing to form a thoroughly blended, de-aired green mixture. The green mixture is formed into any desired shape, cured, and dried. Preferably, the product is cured in a warm, moist environment.