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Polymer concrete has shown a number of promising applications in building and construction, but its mix design process remains arbitrary due to lack of understanding of how constituent materials influence performance. This paper investigated the effect of resin-to-filler ratio and matrix-to-aggregate ratio on mechanical and durability properties of epoxy-based polymer concrete in order to optimise its mix design. A novel combination of fire-retardant, hollow microsphere and fly ash fillers were used and specimens were prepared using resin-to-filler ratios by volume from 100:0 to 40:60 at 10% increment. Another group of specimens were prepared using matrix-to-aggregate ratios from 1:0 decreasing to 1:0.45, 1:0.90 and 1:1.35 by weight at constant resin-to-filler ratio. The specimens were inspected and tested under compressive, tensile and flexural loading conditions. The epoxy polymer matrix shows excellent durability in air, water, saline solution, and hygrothermal environments. Results show that the resin-to-filler ratio has significant influence on the spatial distribution of aggregates. Severe segregation occurred when the matrix contained less than 40% filler while a uniform aggregate distribution was obtained when the matrix had at least 40% filler. Moreover, the tensile strength, flexural strength and ductility decreased with decrease in matrix-to-aggregate ratio. Empirical models for polymer concrete were proposed based on the experimental results. The optimal resin-to-filler ratio was 70:30 and 60:40 for non-uniform and uniform distribution of aggregates, respectively, while a matrix-to-aggregate ratio of 1:1.35 was optimal in terms of achieving a good balance between performance and cost.

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