ABSTRACT The use of polymer modified concrete dates back to the 1920s, in the UK, which have been

used because of general improvements in some structural performance of concrete, such as higher tensile strength and ductility, and as repair material where it acts as a sealant and filler of pores and cracks. Also, it is claimed that polymers improve the performance of concretes in chloride environments, by creating a barrier to the incoming chloride ions, which is obviously a very positive factor against corrosion of reinforced concrete. However, there are a number of different types of polymers, and all of them play an important role in the fresh and hardened properties of concrete. Most research have been carried out in emulsion, however, there has not been much research addressing the effect of polymers powders in concrete, specially regarding durability and chemical stability performance. This research was designed to investigate whether the performance of cement replacement materials in concrete, such as limestone filler and metakaolin in polymer-modified concrete would help to overcome possible limitations of polymer-modified mixes. To achieve these objectives, performance of OPC mixes incorporating polymer powder and metakaolin was investigated for engineering and durability properties in ambient dry conditions. To investigate the resistance to sulfate attack of polymer-modified concrete mixes containing ordinary Portland cement (C3S 49.4, C2S.22.4. and C3A 10.5), limestone filler (CaO 53.6%) and metakaolin were tested by immersing the concrete in 1.8%(MgSO4) for 18 months at 200C and 50C. The mineralogy of deterioration products was tested by means of X-ray diffraction (XRD), Infrared spectroscopy. Visual examinations, dynamic modulus of elasticity, pulse velocity and length change were recorded on a regular bases and strength loss was also monitored. Regarding fresh concrete properties, the data shows that re-dispersible powder reduced workability when compared to all mixes without polymer. Also, the use of polymer remarkably increased setting time in all mixes, except with limestone filler, which is attributed to the plasticising properties of limestone. Indeed, the early strength development of polymer-modified mixes was low. Again, this factor can be attributed to chemical interactions within dispersion agents and cement paste. In fact, it seems that this polymer offers site for nucleation for some hydrated products, mainly calcium hydroxide, which may bring problems in sulfate environments. As far as engineering properties are concerned, re-dispersible polymer powders behave as conventional polymers in ambient laboratory conditions in all mixes with and without cement replacement materials, by increasing flexural strength. However, its performance on durability was quite remarkable. Indeed, it reduced carbonation and water permeability, since it positively refined the pore structure of concrete. Indeed, to the best knowledge of this research, there are no published data regarding the behaviour of re-dispersible powders in sulfate environments. Despite the general improvements on the cement matrix found in dry conditions, there seems

to be a strong chemical interaction between such polymer, cement matrix and sulfate ions. It is suggested that this interaction is rather negative with respect to the stability of the hydrated products. In fact, the use of re-dispersible polymer increased the susceptibility to sulfate attack, which was markedly evident by the formation of gypsum at room temperature and both, gypsum and thaumasite at 50C. This trend was found even in composite cement containing limestone filler and metakaolin. This study emphasizes that, although it does not seem to bring durability problems when exposed to dry conditions, extreme caution should be taken in the use of redispersible polymers whenever chemical attack is expected. Indeed, more research is needed to quantify at what extent the proportions of each co-polymer and the composition of the surfactants affect the overall performance in concrete.