CN106966687A - 一种无流动性速凝强粘结力磷酸盐水泥修补材料及其制备方法 - Google Patents

一种无流动性速凝强粘结力磷酸盐水泥修补材料及其制备方法 Download PDF

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CN106966687A
CN106966687A CN201710223266.6A CN201710223266A CN106966687A CN 106966687 A CN106966687 A CN 106966687A CN 201710223266 A CN201710223266 A CN 201710223266A CN 106966687 A CN106966687 A CN 106966687A
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patching material
phosphate cement
water
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magnesia
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俞家欢
陈小琳
刘永年
白晓彤
闫林伟
金子辉
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Shenyang Jianda Taibo Technology Co.,Ltd.
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Abstract

本发明属于复合材料领域,尤其涉及一种无流动性速凝强粘结力磷酸盐水泥修补材料及其制备方法。其原料按重量百分比配比如下:砂子20%‑40%、磷酸二氢铵5%‑12%、氧化镁10%‑25%、粉煤灰2%‑8%、胶粉30%‑60%、硅灰6%‑10%、聚羧酸高效减水剂0.35%‑0.6%、硅酸钠1%‑5%、聚丙烯纤维1.5%‑2%、缓凝剂0.5%‑2%、水8%‑10%。该材料用作桥梁底板或建筑物立面特殊位置出现病害后的修补材料,修补效果显著。

Description

一种无流动性速凝强粘结力磷酸盐水泥修补材料及其制备 方法
技术领域
本发明属于复合材料领域,尤其涉及一种无流动性速凝强粘结力磷酸盐水泥修补材料及其制备方法。
背景技术
近年来,大量钢筋混凝土结构建筑物拔地而起,随之出现了各种混凝土结构耐久性病害,当病害出现在桥梁底板或建筑物立面时,需要及时修复,由于修补部位的特殊性使得修补难度增大,就要求修补材料必须具有无流动性、强粘结力、速凝、无收缩、抗裂、早期强度高的特点。
许多研究人员对磷酸镁水泥基材料进行了研究开发,例如杨楠在《磷酸镁水泥基材料粘结性能研究》中系统地研究水灰比、养护条件、界面湿度、界面处理方式、界面剂以及基体强度等各种因素,对磷酸镁水泥修补材料与老硅酸盐水泥砂浆粘结强度的影响;雒亚莉在《新型早强磷酸镁水泥的试验研究和工程应用》中采用正交试验方法,分析讨论了MgO与 KH2PO4的摩尔比值、水胶比和硼砂掺量等因素对磷酸镁水泥强度的影响规律。上述修补材料都具有凝结时间短、早期强度高、干缩小(体积稳定性好)、与旧混凝土之间的性能匹配好、粘结强度高的特点;但是,对于桥梁底板或建筑物立面特殊位置出现病害后,修补材料需要克服自身重力并与原有修补面很好的粘结、抗裂性能好、无流动性、无收缩、快凝快硬等,到目前为止还没有一种修补材料能够实现这种特殊位置的修补,其根本原因是在于没有一种性能理想,工艺合理的修补材料来应对桥梁底板或建筑物立面病害问题。
发明内容
针对上述问题,本发明将现有建筑材料普遍存在的问题结合国家对新型建筑材料的要求,提供了一种成本低、便于加工、储存和运输,具有无流动性、快凝快硬、无收缩、抗裂性能好、强粘结力的水泥修补材料,将该材料用作桥梁底板或建筑物立面特殊位置出现病害后的修补材料,修补效果显著。
为了实现上述目的,本发明提供的水泥修补材料,其原料按重量百分比配比如下:砂子20%-40%、磷酸二氢铵5%-12%、氧化镁10%-25%、粉煤灰2%-8%、胶粉30%-60%、硅灰6%-10%、聚羧酸高效减水剂0.35%-0.6%、硅酸钠1%-5%、聚丙烯纤维1.5%-2%、缓凝剂0.5%-2%、水8%-10%。
所述的砂子采用中砂,其细度模数为2.5,含泥量为0.8%,无泥块,表观密度为2700kg/m3
所述的聚丙烯纤维优选空心聚丙烯纤维;所述的缓凝剂为硼砂。
为了实现上述目的,本发明还提供该修补材料的制备方法,具体为按原料所需重量配比依次称取磷酸二氢铵、氧化镁、粉煤灰、胶粉、硅灰、聚羧酸高效减水剂、硅酸钠、缓凝剂、砂子添加到搅拌机的搅拌筒内,以匀速搅拌5-10分钟,直至这九种材料搅拌均匀为止;将所需重量的水缓慢加入到搅拌筒内,然后持续搅拌1-2分钟,直到形成均匀的流动性较好的糊状浆体为止,然后加入所需重量的空心聚丙烯纤维搅拌30s,即可制备成磷酸盐水泥快速修补材料。
本发明的有益效果。
本发明为了能够彻底解决桥梁底板及建筑物立面的特殊位置病害,提出了一种无流动性速凝无收缩抗裂强粘结力快硬磷酸盐水泥修补材料,充分发挥其无流动性、快凝快硬、无收缩、抗裂性能好、强粘结力等优点,其性能比水泥行业中的其他修补材料优异。这种修补材料普遍使用后,既解决了在桥梁底板及建筑物立面处粘结强度不足问题又保证了修复厚度要求,带来显著的经济效益和社会效益。
本发明所选用的各原料的特性要求及分析如下:氧化镁为菱镁矿(MgCO3)经过1700℃左右的高温煅烧后破碎形成,通常制备水泥所用MgO为晶体磨制的粉末(220目),颜色显棕黄色,比表面积为2700cm2/g,其活性与比表面积对磷酸盐水泥的水化反应速率、水化放热量、工作性能和强度有着决定性作用,为了减缓磷酸盐水泥的水化速率,使用高温煅烧过的氧化镁,在表面形成一层惰性膜来降低氧化镁的活性,此外,氧化镁的比表面积也是控制水化速率的一个重要方面;水泥水化的凝结时间主要取决于两个因素:一是早期水化产物的多少,二是颗粒之间的空隙;水泥越细,水化越快,水化产物越多,凝结时间越短;水泥颗粒之间的空隙越大,填充包裹所需要的水化产物就越多,凝结时间相对延长;合适的氧化镁颗粒细度和级配可以达到良好的工作性能;磷酸二氢铵采用普通磷酸二氢铵,它是一种白色结晶性粉末,在空气中稳定,作用是提供一个碱性环境,磷酸盐水泥水化反应的本质属于酸碱反应,其反应的程度受到两种反应物的物质的量的影响较大;本发明严格控制磷酸二氢铵和氧化镁的配比,只有磷酸二氢铵和氧化镁在一定比例(1/4~3/4)下,才能充分反应,形成致密的水化产物;若磷酸盐过多,整个水化体系中磷酸盐过量,由于磷酸盐本身强度较低,而且极易溶于水,会造成水化体系中磷酸盐的大量溶出,形成较大的孔隙率,影响强度;氧化镁比例过高,反应速率过快,成型效果差,也会影响强度;粉煤灰为灰色粉状物,主要对磷酸镁水泥起增强作用和改善水泥浆流动性及旧的混凝土的粘结性能;胶粉是由高分子乳液与水泥或其他无机添加剂加工制成的双组份水性防水涂料,可达到抗渗、防潮、粘结和抗裂等效果,具有防水装饰双重功能,属于无毒、无害绿色环保产品,起到强粘结力作用;硅灰是外观为灰色或灰白色粉末,耐火度大于1600℃,可以提高抗折、抗压、耐磨等性能,用来控制减少流动性;聚羧酸高效减水剂用来控制水泥浆体的流动性,其流动性随着聚羧酸高效减水剂掺量的增大而减小;聚丙烯纤维主要是由丙烯聚合而成的高分子化合物,外观为白色无味、无毒、轻质、半透明、手感柔和,在成型混凝土的表面类似毛发,控制干缩率,增强抗裂性能;硅酸钠粘结性强,强度较高,用于配制速凝减水剂;缓凝剂硼砂白色结晶粉末,无臭,味咸,相对密度1.73,微溶于水,水溶液呈碱性,在空气中可缓慢风化,熔融时成无色玻璃状物质,主要调节水泥的凝结时间;所用的水为无杂质的自来水。
本发明与现有技术相比,具有的优点为:(1)速凝快硬早强,该修补材料短时间可达到一定强度,且1小时抗压强度超过30 MPa,中后期强度可更高,各项性能指标均达到行业标准要求;(2)无流动性无收缩,由于病害位于建筑物立面或桥梁底板顶面,要求修补材料必须具有无流动性和高粘结性,且修补后不收缩,满足各项工作性能要求;(3)抗裂性能好,粘结性能强,增加了结构的整体刚度;(4)磷酸盐水泥快速修补材料是一种新型的建筑材料,就其工艺和原理而言,可以利用生产企业的常用设备,在不需要添加其它设备的情况下,可以进行规模生产,成本低,原料充足,选购方便,加工、储存、运输都十分便利,是目前建筑行业的一种理想的快速修补材料产品。
具体实施方式
下面结合具体实施例对本发明做进一步的说明。
实施例1。
磷酸盐水泥基快速修补材料,先将5%的磷酸二氢铵、20%的氧化镁、2%的粉煤灰、30%的胶粉、6%的硅灰、0.4%的聚羧酸高效减水剂、1.6%的硅酸钠、0.5%的缓凝剂投入混合机搅拌均匀,然后将25%的砂子投入混合机中搅拌均匀,接着把8%的水加入到搅拌筒内,加入要缓慢,待水全部加入之后持续搅拌1-2分钟,直到形成均匀的流动性较好的糊状浆体为止,然后加入1.5%的聚丙烯纤维搅拌30s,即可制备成磷酸盐水泥基快速修补材料。
所述的粉煤灰检测结果,见表1。
表1粉煤灰检测结果。
一、磷酸盐水泥基快速修补材料的性能测试结果。
1.凝结时间。
实验仪器采用GB1346《水泥标准稠度用水量、凝结时间、安定性检测方法》中所规定的仪器及器具。
将300g磷酸盐水泥快速修补料倒入拌合锅内,加入30g自来水,迅速搅拌均匀,并立即放入圆模,振动数次,刮去多余稠浆,抹干后,测定初凝时间为10分钟,终凝时间为16分钟。
2.抗压强度。
将磷酸盐水泥快速修补料按实例1的比例称量好,然后分别倒入搅拌锅内迅速搅拌,出锅立即倒入4×4×16cm³试模中,用捣棒夯实20次,并将试模在地面振动2-3分钟,同时用抹子抹去表面漫出的修补料,将同一试模中的三个试件条编号,标记龄期等;由于修补料为空气养护,不需洒水;1h,3h,1d,7d,28d,60d,90d后分别测试强度,结果见表2;结果取三个试件的平均值。
表2 力学性能测试。
测得其一小时强度已经达到了32.2MPa,抗折强度达到5.3MPa,28天强度已经达到了72.3MPa和10.9MPa,且60天、90天强度均缓慢增长,没有强度倒缩现象;由此可见,在气温零下环境中,使用该材料修补墙外立面后,修补材料表现出无流动性、快凝快硬、强粘结力等明显性能,并测得其一小时强度已经达到30MPa以上,抗折强度达到5MPa以上,具体实验数据见表2。
实施例2。
磷酸盐水泥基快速修补材料,砂子20%、磷酸二氢铵6%、氧化镁18%、粉煤灰3%、胶粉32%、硅灰7%、聚羧酸高效减水剂0.5%、硅酸钠1.5%、聚丙烯纤维2%、缓凝剂1%、水9%。

Claims (6)

1.一种无流动性速凝强粘结力磷酸盐水泥修补材料,其特征在于,其原料按百分比配比如下:砂子20%-40%、磷酸二氢铵5%-12%、氧化镁10%-25%、粉煤灰2%-8%、胶粉30%-60%、硅灰6%-10%、聚羧酸高效减水剂0.35%-0.6%、硅酸钠1%-5%、聚丙烯纤维1.5%-2%、缓凝剂0.5%-2%、水8%-10%。
2.如权利要求1所述的磷酸盐水泥修补材料,其特征在于,所述的砂子采用中砂,其细度模数为2.5,含泥量为0.8%,无泥块,表观密度为2700kg。
3.如权利要求1所述的磷酸盐水泥修补材料,其特征在于,所述的缓凝剂为硼砂。
4.如权利要求1所述的磷酸盐水泥修补材料,其特征在于,其原料按重量百分比配比如下:砂子25%、磷酸二氢铵5%、氧化镁20%、粉煤灰2%、胶粉30%、硅灰6%、聚羧酸高效减水剂0.4%、硅酸钠1.6%、聚丙烯纤维1.5%、缓凝剂5%、水8%。
5.如权利要求1所述的磷酸盐水泥修补材料,其特征在于,其原料按重量百分比配比如下:砂子20%、磷酸二氢铵6%、氧化镁18%、粉煤灰3%、胶粉32%、硅灰7%、聚羧酸高效减水剂0.5%、硅酸钠1.5%、聚丙烯纤维2%、缓凝剂1%、水9%。
6.如权利要求1-5任一所述的磷酸盐水泥修补材料,其特征在于,具体为按原料所需重量配比依次称取磷酸二氢铵、氧化镁、粉煤灰、胶粉、硅灰、聚羧酸高效减水剂、硅酸钠、缓凝剂、砂子添加到搅拌机的搅拌筒内,以匀速搅拌5-10分钟,直至这九种材料搅拌均匀为止;将所需重量的水缓慢加入到搅拌筒内,然后持续搅拌1-2分钟,直到形成均匀的流动性较好的糊状浆体为止,然后加入所需重量的空心聚丙烯纤维搅拌30s,即可制备成磷酸盐水泥快速修补材料。
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