Development of polymer films by the coalescence of polymer particles in powdered and aqueous polymer-modified mortars

This paper evaluates and compares the coalescence of polymer particles (continuous polymer films formation) in powdered polymer-modified mortars (PPMMs) and aqueous polymer-modified mortars (APMMs). Polymer-modified mortars (PMMs) using various redispersible polymer powders (powdered cement modifiers) and polymer dispersions (aqueous cement modifiers) were prepared by varying the polymer-cement ratio (P/C) and were tested for the characterization of polymer films using a scanning electron microscope (SEM) after curing for 28 days. It is concluded from the test results that mortar constituents of unmodified mortar (UMM) are loosely joined with each other due to the absence of polymer films, thus having a structure with comparatively lower mechanical and durability characteristics. By contrast, mortar constituents in PPMMs and APMMs are compactly joined with each other due to the presence of interweaving polymer films, thereby forming a monolithic structure with improved mechanical and durability characteristics. However, the results make obvious the poor coalescence of polymer particles or development of inferior quality polymers films in PPMMs as compared to that observed in APMMs. Moreover, PPMMs show less uniform distribution of polymer films as compared to that in APMMs. Different powdered cement modifiers have different film-forming capabilities. However, such difference is hardly recognized in aqueous cement modifiers. The polymer films in PPMMs and APMMs may acquire different structures. They may appear as mesh-like, thread-like, rugged, dense or fibrous with fine or rough surfaces. Development of coherent polymer films is not well pronounced at a P/C of 5% in PPMMs, whereas sometimes coherent polymer films are observed at a P/C of 5% in APMMs. At a P/C of 10% or more, fully developed, coherent polymer films are observed in both PPMMs and APMMs.