What are polymer CONCRETE manholes and structures made of?
Polymer concrete has 5 ingredients:
1. Polyester Resin
In lieu of using cement as our binder, or “glue”, we are using a polyester based resin to make the structure impervious to sewer gases. Our sand and aggregate used in the structures are also corrosion proof.
How long has polymer concrete been around? Is it new?
Polymer Concrete has been manufactured since the 1960’s, mostly in Europe. The most common polymer concrete structure has been large diameter sewer interceptor pipe.
How come I’m only hearing about polymer concrete structures and manholes now?
The product up to this point has been used mostly in pipe application. Also, up to this point, polymer concrete has been too expensive to be considered on everyday structures. Armorock's focus and initiative was to bring the price point down on polymer concrete that it was a viable option for all collection system manholes and structures requiring corrosion protection. We’ve done that through a variety of innovations. Also, we just really like to market and tell people about our solution, so we are much more aggressive than previous manufacturer's have been.
Is there an ASTM for polymer concrete structures?
Currently, there is no ASTM for polymer concrete structures. We pull from ASTM D 6783 for rigid polymer concrete pipe, as well as ASTM C478 for precast concrete manholes. Mix design comes from ASTM D6783, and loading baseline criteria from ASTM C478. Currently, to help inspire customer confidence, as well as improve our systems, we are ISO 9001:2015 certified to help keep us in line with our own standard operating procedures and ensure we’re providing the customer a uniform product.
Who are you guys?
We branched off from Geneva Pipe, a precaster in the Mountain West who has been in the underground construction business manufacturing a wide variety of concrete products since 1956. We’ve brought some of our expertise over to polymer concrete to assist in all that we are creating.
Do you know what you’re doing?
Yes We do. We’ve been casting polymer concrete manholes and structures since 2007, and are continually tweaking and improving our process. our background is from precast concrete and being a producer in this space since 1956.
What do you need to apply in the field to make this corrosion resistant?
Nothing. The product comes to the jobsite prefabricated to be corrosion proof
What does a 50 year corrosion warranty mean?
Armorock™ pays for a insurance policy on our product. We insure that the polymer concrete manholes and structures will be resistant to sewer gases and corrosive environments for 50 years from installation. Our warranty is more than a piece of paper, as we pay a policy for each structure that we produce.
What kind of loads can polymer concrete structures and manholes carry?
Armorock ™ Polymer concrete manholes and structures are certified to carry both H-20 and HL-93 Traffic Rated loads. They are a rigid and structural product.
Do you need to cast a ballast slab to help with buoyancy concerns?
Ballast slabs and support slabs are not needed in general application. However, if dealing with a high groundwater table, then calculations can be reviewed if a ballast slab helps anchor the polymer structure. if needed, we will make it.
What does polymer concrete weigh?
Polymer concrete weighs approximately 140 pounds per foot. Traditional concrete weighs approximately 150 pounds per foot. The reason our product weighs significantly less is utilizing different wall design.
How do I core a new connection or line into the polymer concrete structure after it’s been set in the field?
You would put a new lateral line into a polymer concrete structure the same way you do traditional concrete. Call your local coring company, or use a wetsaw/diamond blade to core it yourself in the field. Anything that you do to work with traditional concrete in the field you do can do with polymer concrete.
Is polymer concrete brittle?
What reinforcement do you use in your product?
STEEL REBAR CORRODES. THat's why We utilize fiberglass rebar reinforcement rather than steel like traditional concrete. another reason being is that polymer has a higher rate of expansion that steel, so we use fiberglass rebar that expands and contracts at relatively the same rate as the polymer. It eliminates a potential problem area. Polymer manufacturers can cast steel rebar into the product, we have chosen to use fiberglass rebar. if you're the corrosion proof manhole, every part of our structure is truly corrosion proof. including our reinforcement. steel reinforced polymer concrete presents its own issues which we are happy to discuss.
How many people make polymer concrete?
More than one. Owners need not to worry about sole specification on bidding, as competitive bidding is achieved every day with polymer concrete. With that being said, Armorock™ produces more polymer concrete structures than anyone in the country by a wide margin.
How do you know your product is “corrosion resistant”?
We have third party testing done to prove our mix design is made out of non-corroding material. Test was done in accordance with the California Green Book Standard of Engineering. Results are readily available if requested. We also consistently test our product and all ingredients following ISO 9001 guidelines so that we are providing the same quality and corrosion resistance that you've come to expect from our structures.
Aren’t polymer concrete structures and fiberglass structures the same?
No. Polymer concrete structures are rigid and carry structure on their own. The same cannot be said for fiberglass structures, as they recommend ballast slabs and load DISBURSEMENT material to assist the structure carrying traffic rated loads.
How do I estimate installing a polymer concrete structure? are there any secrets?
No secrets. Many contractors utilize their same estimate for installing a concrete storm drain manhole. The idea with polymer concrete, is set the manhole, stack it, BACK FILL, and move on. It is a much quicker installation than any other sewer manhole products currently available.
When are you building a plant in my area?
Armorock is looking at an aggressive growth schedule, and as the market dictates, more facilities will be brought online to meet the growing demand. Currently, all material is fabricated in Las Vegas, Nevada, AND SULPHUR SPRINGS, TX. Other plants will become operational as to meet demand.
Sounds exciting. Where do I sign up?
We’ll get you as many armorock polymer concrete structures as quickly as you need them. We are here and happy to be of assistance in providing you sustainable sewer infrastructure.