Critical review of polymer concrete: From origin, mix design, performance characteristics, to multidisciplinary applications

Polymer concrete (PC) is an advanced composite whose engineered combination of synthetic resins and aggregates yields markedly improved mechanical performance and durability versus ordinary Portland cement systems. This review synthesises findings to (1) trace the historical development of PC, (2) categorise common resin classes (epoxy, polyester, vinyl ester, furan, polyurethane), (3) consolidate mix-design principles and additive/fibre strategies, and (4) quantify static and dynamic mechanical behaviour (compressive, tensile, flexural strength, fracture toughness, damping and strain-rate sensitivity) under varied curing and environmental exposures. Key outcomes include identification of an optimal resin-content window (≈12–17 wt%) that balances strength and cost, documented trade-offs between resin type and thermal/chemical durability, and the pronounced superiority of PC in impact and vibration-damping applications. The review critically examines sustainability challenges (embodied energy, recyclability, and life cycle impacts) and surveys mitigation pathways such as recycled fillers, bio-based resins, and circular economy practices. Finally, it maps future research priorities: standardised testing protocols for structural use, development of low-carbon and recyclable polymer matrices, and deployment of machine learning for mix design and property prediction. This integrated roadmap informs engineers and researchers seeking to deploy PC in structural, marine, transportation and defence applications while guiding research toward sustainable, data-driven innovation.