The durability of building composites with polymer matrix, such as polymer concretes, is considered high or excellent. However, very few studies are available that show the properties of such composites tested long after the specimens’ preparation, especially composites with fillers other than traditional rock aggregates. The paper presents the long-term compressive strength of polymer concrete containing common and alternative fine fillers, including quartz powder (ground sand) and by-products of the combustion of Polish fossil fuels (coal and lignite), tested nine or 9.5 years after preparation. The results were compiled with the data for respective specimens tested after 14 days, as well as 1.5 and 7 years. Data analysis confirmed the excellent durability of concrete-like composites with various fillers in terms of compressive strength. Density measurements of selected composites showed that the increase in strength was accompanied by an increase in volumetric density. This showed that the opinion that the development of the strength of composites with polymer matrices taking place within a few to several days was not always justified. In the case of a group of tested concrete-like composites with vinyl-ester matrices saturated with fly ashes of various origins, there was a further significant increase in strength over time.

NASA has revealed that they plan to resume manned missions and ensure the permanent presence of people in the so-called habitats on the Moon by 2024. Moon habitats are expected to be built using local resources—it is planned to use lunar regolith as aggregate in lunar concrete. Lunar concrete design requires a new approach in terms of both the production technology and the operating conditions significantly different from the Earth. Considering that more and more often it is assumed that the water present on the Moon in the form of ice might be used to maintain the base, but also to construct the base structure, the authors decided to investigate slightly more traditional composites than the recently promoted sulfur and polymer composites thermally hardened and cured. Numerous compositions of cement “lunar micro-mortars” and “lunar mortars” were made and tested to study rheological properties, namely, the consistency, which largely depend on the morphology of the fine-grained filler, i.e., regolith. For obvious reasons, the lunar regolith simulant (LRS) was used in place of the original Moon regolith. The used LRS mapped the grain size distribution and morphology of the real lunar regolith. It was created for the purpose of studying the erosive effect of dusty regolith fractions on the moving parts of lunar landers and other mechanical equipment; therefore, it simulated well the behavior of regolith particles in relation to cement paste. The obtained results made it possible to develop preliminary compositions for “lunar mortars” (possible to apply in, e.g., 3D concrete printing) and to prepare, test, and evaluate mortar properties in comparison to traditional quartz mortars (under the conditions of the Earth laboratory).

The paper focuses on optimizing the elastic polymer-cement protection coating composition using material model. The material model consists of mathematical relations between composition and technical features demanded for protection, which are: flexibility, waterproofness and vapor permeability. The optimization that enabled obtaining the desirable values of features was proceeded by using statistical experimental design. Taking data from tests and choosing material variables, a material model based on quadratic functions was determined and in consequence three top rank compositions – each for a given feature – have been formulated. Evaluation of compositions was done using the desirability function approach. The individual desirability functions for the particular feature and the combined overall desirability function were treated as additional properties of the coating. Also, after defining the relation between desirability and composition, the overall desirability was enclosed in the material model as its generalization. High values of overall desirability confirmed the usefulness of compositions. The investigation proved that material models based on statistical methods are efficient tools for designing polymer-cement protective coatings.