Formula Used
Converted volume: Project volume × unit conversion factor.
Design volume: Converted volume × (1 + waste allowance ÷ 100).
Base premix mass: Design volume × target cured density.
Component mass: Base premix mass × component percentage ÷ 100.
Hardener mass: Resin mass × hardener percentage ÷ 100.
Wet aggregate mass: Dry aggregate mass × (1 + moisture percentage ÷ 100).
Exact bags: Total batch mass ÷ selected bag size.
Total cost: Sum of each component mass × its unit price.
How to Use This Calculator
Enter the required project volume and choose the correct unit.
Add a waste allowance for trimming, spillage, and surface variation.
Enter the target cured density from supplier data or trial batching.
Set aggregate, filler, resin, and additive shares so they total 100%.
Enter hardener as a percentage of resin mass only.
Use actual unit prices to estimate material cost and ordering needs.
Press calculate to show results above the form.
Use the CSV or PDF buttons to save the calculation.
Premixed Polymer Concrete Design Guide
Polymer concrete uses resin as the main binder. It does not rely on cement hydration. This makes the material useful for fast repairs, chemical areas, precast drains, machine bases, and thin overlays. A good design starts with volume. The calculator converts project volume into design volume. Waste allowance is then added. That step protects the order from trimming loss, spillage, and rough surface variation.
Material Balance
The target density controls total batch mass. Dense aggregate increases weight and stiffness. Resin improves bond, wetting, and chemical resistance. Filler improves packing and can reduce resin demand. Hardener is normally based on resin weight, not total mix weight. The tool keeps that rule clear. Additives are included for pigments, fibers, defoamers, or flow agents. Aggregate moisture is also shown because water can reduce bonding in many resin systems.
Cost And Bags
After each mass is calculated, the unit prices create a cost estimate. This helps compare rich resin mixes with leaner repair mixes. Bag count is based on total batch mass and selected bag size. It is rounded up for ordering, while exact bags show the theoretical demand. The resin to mineral ratio is also useful. It shows whether the mix is binder rich or aggregate rich.
Quality Checks
Polymer concrete is sensitive to proportion errors. Small resin shortages can leave dry pockets. Too much resin can raise cost and shrinkage. Very fine filler can improve finish, yet it may reduce workability. Trial batches are wise for new aggregates. Test flow, setting time, surface finish, and early strength. Keep materials clean and dry. Store resin away from heat. Use gloves, ventilation, and supplier safety guidance during every batch. Document temperatures for better field quality control.
Practical Use
Use measured densities when possible. Supplier data is better than a guess. Check the allowed resin and hardener range from the product sheet. Do not exceed working time in warm weather. Mix dry minerals first when site practice allows it. Then add resin and hardener as directed. Scrape container sides during mixing. Place the material before it thickens. Compact or vibrate only when the product permits it. Finally, record the batch values. Clear records help repeat strong results on later repairs.
FAQs
What is premixed polymer concrete?
It is a resin-bound concrete blend made with aggregates, fillers, resin, hardener, and additives. It is often used for fast repairs, overlays, drains, machine bases, and chemical-resistant work.
Why is density important?
Density converts project volume into total material mass. A wrong density can understate or overstate every component, including aggregate, filler, resin, hardener, bags, and cost.
Why is hardener based on resin mass?
Many reactive resin systems dose hardener against resin weight. This calculator follows that rule, so hardener is not treated as a percentage of the whole mineral blend.
What happens if mix percentages do not total 100%?
The calculator still gives results, but it shows a warning. For clean batch control, aggregate, filler, resin, and additive percentages should normally total exactly 100%.
Can wet aggregate be used?
Some systems tolerate very small moisture levels, but many resin systems need dry aggregate. Always check supplier guidance before mixing damp minerals with resin binder.
How should bags be ordered?
The calculator shows exact bags and rounded bags. Rounded bags are better for ordering because suppliers sell whole bags, and site work often needs a small reserve.
Is the cost result final?
No. It is a material estimate only. It does not include labor, equipment, surface preparation, freight, primer, taxes, testing, or site delays.
Can this replace supplier mix design?
No. Use it for planning and checking quantities. Final designs should follow product sheets, resin limits, curing conditions, safety guidance, and project specifications.