CN112930329A - Alkali-activated dry-mixed repair mortar with low shrinkage - Google Patents
Alkali-activated dry-mixed repair mortar with low shrinkage Download PDFInfo
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- CN112930329A CN112930329A CN202080005791.0A CN202080005791A CN112930329A CN 112930329 A CN112930329 A CN 112930329A CN 202080005791 A CN202080005791 A CN 202080005791A CN 112930329 A CN112930329 A CN 112930329A
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- China
- Prior art keywords
- repair mortar
- alkali
- dry
- activated
- portland cement
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- 230000008439 repair process Effects 0.000 title claims abstract description 94
- 239000004570 mortar (masonry) Substances 0.000 title claims abstract description 93
- 239000003513 alkali Substances 0.000 title claims abstract description 47
- 239000000203 mixture Substances 0.000 claims abstract description 52
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 52
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims abstract description 30
- 239000000463 material Substances 0.000 claims abstract description 27
- 239000000377 silicon dioxide Substances 0.000 claims abstract description 21
- KWYUFKZDYYNOTN-UHFFFAOYSA-M Potassium hydroxide Chemical compound [OH-].[K+] KWYUFKZDYYNOTN-UHFFFAOYSA-M 0.000 claims abstract description 19
- 238000001035 drying Methods 0.000 claims abstract description 18
- 239000011398 Portland cement Substances 0.000 claims abstract description 17
- 239000002253 acid Substances 0.000 claims abstract description 14
- 239000002893 slag Substances 0.000 claims abstract description 13
- 239000012190 activator Substances 0.000 claims abstract description 11
- 239000010881 fly ash Substances 0.000 claims abstract description 11
- NNHHDJVEYQHLHG-UHFFFAOYSA-N potassium silicate Chemical class [K+].[K+].[O-][Si]([O-])=O NNHHDJVEYQHLHG-UHFFFAOYSA-N 0.000 claims abstract description 11
- 239000002585 base Substances 0.000 claims abstract description 10
- 230000004580 weight loss Effects 0.000 claims abstract description 9
- 239000000945 filler Substances 0.000 claims abstract description 5
- 229910052681 coesite Inorganic materials 0.000 claims abstract description 4
- 229910052906 cristobalite Inorganic materials 0.000 claims abstract description 4
- 229910052682 stishovite Inorganic materials 0.000 claims abstract description 4
- 229910052905 tridymite Inorganic materials 0.000 claims abstract description 4
- 239000004576 sand Substances 0.000 claims description 14
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 claims description 9
- 239000000835 fiber Substances 0.000 claims description 6
- 239000001866 hydroxypropyl methyl cellulose Substances 0.000 claims description 3
- 229920003088 hydroxypropyl methyl cellulose Polymers 0.000 claims description 3
- UFVKGYZPFZQRLF-UHFFFAOYSA-N hydroxypropyl methyl cellulose Chemical compound OC1C(O)C(OC)OC(CO)C1OC1C(O)C(O)C(OC2C(C(O)C(OC3C(C(O)C(O)C(CO)O3)O)C(CO)O2)O)C(CO)O1 UFVKGYZPFZQRLF-UHFFFAOYSA-N 0.000 claims description 3
- 235000010979 hydroxypropyl methyl cellulose Nutrition 0.000 claims description 3
- 239000000654 additive Substances 0.000 claims description 2
- 230000035699 permeability Effects 0.000 claims description 2
- 230000000996 additive effect Effects 0.000 claims 1
- 239000002699 waste material Substances 0.000 abstract description 7
- 239000000126 substance Substances 0.000 description 12
- 239000000843 powder Substances 0.000 description 11
- 238000009472 formulation Methods 0.000 description 8
- UIIMBOGNXHQVGW-UHFFFAOYSA-M sodium bicarbonate Substances [Na+].OC([O-])=O UIIMBOGNXHQVGW-UHFFFAOYSA-M 0.000 description 8
- 238000002156 mixing Methods 0.000 description 7
- 239000000758 substrate Substances 0.000 description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 6
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 5
- 239000004111 Potassium silicate Substances 0.000 description 5
- 238000001994 activation Methods 0.000 description 5
- 239000000853 adhesive Substances 0.000 description 5
- 230000001070 adhesive effect Effects 0.000 description 5
- 229910000323 aluminium silicate Inorganic materials 0.000 description 5
- 239000011575 calcium Substances 0.000 description 5
- 229910052791 calcium Inorganic materials 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 5
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 5
- 230000010220 ion permeability Effects 0.000 description 5
- 238000000034 method Methods 0.000 description 5
- 235000019353 potassium silicate Nutrition 0.000 description 5
- 229910052913 potassium silicate Inorganic materials 0.000 description 5
- 235000012239 silicon dioxide Nutrition 0.000 description 5
- 229910000030 sodium bicarbonate Inorganic materials 0.000 description 5
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- 229920000642 polymer Polymers 0.000 description 4
- 238000012360 testing method Methods 0.000 description 4
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 3
- 239000004927 clay Substances 0.000 description 3
- 239000000499 gel Substances 0.000 description 3
- 239000011159 matrix material Substances 0.000 description 3
- 235000017557 sodium bicarbonate Nutrition 0.000 description 3
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 2
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- 229910002808 Si–O–Si Inorganic materials 0.000 description 2
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- 230000004913 activation Effects 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 description 2
- 239000000292 calcium oxide Substances 0.000 description 2
- 238000005266 casting Methods 0.000 description 2
- 239000004568 cement Substances 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 239000007795 chemical reaction product Substances 0.000 description 2
- 239000003245 coal Substances 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- 239000004615 ingredient Substances 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 238000012423 maintenance Methods 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- -1 polyethylene Polymers 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 239000006254 rheological additive Substances 0.000 description 2
- 239000002562 thickening agent Substances 0.000 description 2
- 239000005995 Aluminium silicate Substances 0.000 description 1
- 208000009043 Chemical Burns Diseases 0.000 description 1
- 208000018380 Chemical injury Diseases 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 1
- 229910003849 O-Si Inorganic materials 0.000 description 1
- 229910003872 O—Si Inorganic materials 0.000 description 1
- 229910020489 SiO3 Inorganic materials 0.000 description 1
- 229910002800 Si–O–Al Inorganic materials 0.000 description 1
- 229920002472 Starch Polymers 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000002378 acidificating effect Effects 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical group [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 description 1
- 150000004645 aluminates Chemical class 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- 238000004082 amperometric method Methods 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 239000006172 buffering agent Substances 0.000 description 1
- 230000003139 buffering effect Effects 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- 238000001354 calcination Methods 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000002734 clay mineral Substances 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 238000013329 compounding Methods 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000004090 dissolution Methods 0.000 description 1
- 229920000876 geopolymer Polymers 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 229910001387 inorganic aluminate Inorganic materials 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 229910052744 lithium Inorganic materials 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 1
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 235000010755 mineral Nutrition 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000003607 modifier Substances 0.000 description 1
- 239000000178 monomer Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000000171 quenching effect Effects 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 238000009418 renovation Methods 0.000 description 1
- 238000000518 rheometry Methods 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000008107 starch Substances 0.000 description 1
- 235000019698 starch Nutrition 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000009628 steelmaking Methods 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- 239000004408 titanium dioxide Substances 0.000 description 1
- 239000012855 volatile organic compound Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/24—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing alkyl, ammonium or metal silicates; containing silica sols
- C04B28/26—Silicates of the alkali metals
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/006—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing mineral polymers, e.g. geopolymers of the Davidovits type
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/10—Compositions or ingredients thereof characterised by the absence or the very low content of a specific material
- C04B2111/1037—Cement free compositions, e.g. hydraulically hardening mixtures based on waste materials, not containing cement as such
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/34—Non-shrinking or non-cracking materials
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/72—Repairing or restoring existing buildings or building materials
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P40/00—Technologies relating to the processing of minerals
- Y02P40/10—Production of cement, e.g. improving or optimising the production methods; Cement grinding
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Structural Engineering (AREA)
- Inorganic Chemistry (AREA)
- Materials Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Organic Chemistry (AREA)
- Life Sciences & Earth Sciences (AREA)
- Environmental & Geological Engineering (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Geology (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
Abstract
The invention provides a repair mortar with low drying shrinkage without the addition of ordinary portland cement, which contains a relatively high proportion of waste. The alkali activated dry mix repair mortar comprises between 32% and 37% by weight of a base material selected from ground granulated blast furnace slag, fly ash or mixtures thereof. The weight percentage of metakaolin is between 3% and 8%. Modified potassium silicate is used as alkali activator, the modified potassium silicate has been modified by potassium hydroxide to make K2O and SiO2Is between 1.8 and 2.2. The filler is used in the weight percentageThe ratio is between 50% and 54%. The repair mortar has a drying shrinkage of 0.06% or less and a bond strength of 0.5MPa or more, an acid resistance of 3.4% or less as measured by calculating the weight loss after 28 days of acid exposure, and a setting time of 60 minutes or more.
Description
Cross Reference to Related Applications
This application claims priority from hong kong patent application No. 19121825.4 filed on 3/4/2019, the disclosure of which is incorporated herein by reference.
Technical Field
The invention relates to alkali-activated dry-mixed repair mortar. More particularly, the present invention relates to an alkali-activated dry-mixed repair mortar having an extremely low shrinkage and excellent chemical resistance to the working environment.
Background
Repairing concrete structures is a large percentage of all the construction work done. Maintenance and renovation of aged infrastructure places high demands on repair materials that need to adhere well to the concrete substrate while having sufficient strength to restore the structure to near its original load-bearing capacity. Concrete repair is typically performed in areas of the structure that are subjected to harsh chemical or mechanical environments and must be highly durable. Originally, repair mortars were based on ordinary portland cement, but many of these repair mortars lacked volumetric stability, chemical resistance, strength and adhesion to the original concrete structure. Newer repair mortars include various polymers, such as epoxy, acrylic or polyurethane; these materials may increase strength and adhesion. However, volatile organic compounds emitted from the repair material may raise concerns for the operator, and organic based materials are not compatible with cement matrix based substrates.
Since a large amount of carbon dioxide is generated during the production of ordinary portland cement, the use of cement substitutes as environmentally friendly substitutes for repair has been studied. Thus, different recycled materials or waste materials will be considered for use in the repair mortar. Recyclates and waste materials have been added to concrete compositions in the past, but as mentioned above, repair mortars have special requirements with regard to mechanical and chemical resistance, in particular the requirements such as volume stability, very low shrinkage, high chemical resistance and a strong bond to the concrete substrate to be repaired are very much required for repair mortars. Accordingly, there is a need in the art for an environmentally friendly, portland cement-free repair mortar that exhibits good bond strength and low dry shrinkage. Furthermore, there is a need in the art for repair mortars having a high resistance to chemical attack.
Therefore, in order to solve the above problems, a novel dry-mixed repair mortar which has a low shrinkage ratio, is free from addition of ordinary portland cement, and is activated by alkali has been developed.
Disclosure of Invention
The invention provides a repair mortar which has a low drying shrinkage, high chemical resistance and is free of ordinary portland cement, and which contains a relatively high proportion of waste. The alkali activated dry mix repair mortar comprises between 32% and 37% by weight of a base material selected from ground granulated blast furnace slag, fly ash or mixtures thereof. The weight percentage of metakaolin is between 3% and 8%. Modified potassium silicate is used as alkali activator, the modified potassium silicate has been modified by potassium hydroxide to make K2O and SiO2Is between 1.8 and 2.2. The different types of fillers are used in amounts of 50 to 54% by weight. A dry shrinkage of 0.06% or less and a bond strength of 0.5MPa or more, an acid resistance of 3.4% or less as measured by calculating a weight loss after 28 days of acid exposure, and the repair mortarHas a setting time of 60 minutes or more.
Detailed Description
The environmentally friendly repair mortar of the present invention comprises recycled or waste base aluminosilicate materials. Such recycled or waste material may be selected from granulated blast furnace slag (or similar slag) or fly ash. Slag refers to the material remaining after one metal has been separated (e.g., smelted) from its corresponding metal ore. Granulated blast furnace slag is produced by quenching and grinding molten iron slag (a by-product of iron and steel making) in a blast furnace. The main components of the granulated blast furnace slag are calcium oxide (30-50%), silica (28-38%), alumina (8-24%) and magnesium oxide (1-18%).
Fly ash is the residual product of coal combustion. The range of composition depends on the composition of the coal being burned and is often zone specific. The main component of the fly ash comprises silicon dioxide (SiO) with the content of 45-60 percent by weight2) Alumina (Al) with the content of 18-32 percent by weight2O3) And calcium oxide (CaO) with the content of 2-10 percent by weight. It should be noted that the substrate material must contain variable components, as it is a recycled material or waste material, which may come from a variety of sources. Therefore, the above composition is only one example of the composition of the base material. The content of the slag micro powder (GGBS) and/or the fly ash in the repair mortar is 22-33% by weight.
Metakaolin is also used in the repair mortar of the invention. Metakaolin is formed from calcined kaolin and is a clay mineral. It has low calcium content and is mainly composed of silicon dioxide (SiO) with content of 48-58 wt%2) And alumina with a content of 40-50% by weight, and containing small amounts of iron oxide, calcium oxide and titanium dioxide. In particular, metakaolin produced by calcination at a temperature in the range from 750 to 800 ℃ is selected for use in the repair mortar. The content of the metakaolin in the repair mortar composition is 3-8% by weight.
Metakaolin has been used as an alternative material in conventional concrete mixes, particularly in environments that may be subject to chemical attack (e.g., chloride-induced chemical attack). However, it was determined in the present invention that the use of metakaolin in a repair mortar would result in a very low dry shrinkage. The low dry shrinkage allows the repair mortar to be applied to concrete structures, bond to the area requiring repair, and not crack upon drying and curing. It has been determined that metakaolin in combination with GGBS or fly ash produces a sufficiently strong binder phase with good adhesion to the structure to be repaired and high durability.
Metakaolin is an aluminate rich material. SiO is generated due to alkali activation4And AlO4Tetrahedral frameworks linked together by shared oxygen in the form of polysialic acid or polysialic acid-siloxane or polysialic acid-disiloxane, so that the addition of metakaolin results in an improved structure with a dense amorphous phase, including a semi-crystalline 3-D aluminosilicate microstructure. The dense 3-D structure is volume stable and has very low dry shrinkage.
Base-activated substrate materials will produce a variety of reaction products that are bonded together. During alkali activation of the low calcium content material, a reaction occurs that causes the aluminosilicate material to be dissolved by the alkali material. That is, the minerals are "depolymerized" into their constituent monomers by condensation of basic materials. Dissolution will result in the formation of reactive units of covalently bonded Si-O-Si and Al-O-Si units. The aluminum atoms enter the Si-O-Si units, forming an aluminosilicate gel. After the gel is formed, a condensed structure is created and crystallized into a polymer network. Some base-activated materials are referred to as "geopolymers" because of the formation of a polymer network.
With respect to the alkali activation process of the higher calcium content raw material, calcium silicate-like hydrate phases are formed as reaction products. Similar to the alkali activation process of low calcium content materials, aluminosilicate gels are formed and the hardened polymer network forms the binder phase of the repair mortar.
In the present invention, potassium silicate (K) is modified2SiO3) Can be used as an alkali activator. The potassium silicate is modified with potassium hydroxide (KOH) to make SiO2And K2The molar ratio of O is between 1.8 and 2.2. The modifier exists in the form of dry powder, so that the use of a liquid alkali activator is avoidedMultiple potential safety hazards (transportation problems, chemical burn problems, etc.). Alternatively, other modified base activators may be used, such as sodium-based activators or lithium-based activators. In the repair mortar, the modified alkali activator is present in an amount of 5 to 6% by weight.
Other materials may be added to the repair mortar to improve mechanical properties such as workability and set time. For example, a retarder such as NaHCO may be added in an amount between 0.01% and 0.2% by weight3. Retarder NaHCO3Controlled setting time is achieved by a buffering action in the alkali activated mortar. In fresh mixed base, NaHCO3Is a buffering agent used to balance the alkalinity of the matrix. It can help counteract and limit the increase in alkalinity in the matrix and slow down early base-activated chemical reactions. Thus, the setting and hardening process of the alkali-activated material can be well controlled. In particular, the setting time of the repair mortar may be controlled to be greater than 60 minutes, and in some cases may exceed 90 minutes or more. In a maintenance environment, longer set times are important because the applied mortar may need to be shaped into a complex structure, which takes time to form.
A thickener, such as starch ether, may be added in an amount between 0% and 0.1% by weight. Rheology modifiers such as hydroxypropyl methylcellulose (HPMC) may be added in a weight percentage between 0% and 0.01%. The rheology may be selected for different applications. For example, in horizontal applications, a repair mortar may be used that is less viscous than a repair mortar suitable for vertical surface or overhead applications.
Between 0% and 0.2% by weight of fibres may be added to the repair mortar. Glass fibers can be used as fiber additives. Since mortar generally has a weak tensile property, the fiber strengthening can improve the tensile strength. The fibers may help reduce shrinkage and cracking during drying of the repair structure, may act as an anti-cracking agent, as the fibers may prevent crack propagation by bonding various portions of the repair mortar to one another.
The filler provides compressive strength and bulk to the repair mortar, which may be selected according to the desired durability, strength and workability of the repair mortar. The repair mortar of the present disclosure may include different amounts of sand and/or lightweight aggregate. The aggregate is in the range of 50 to 54% by weight, with sand content between 50 and 52% by weight and lightweight aggregate between 0 and 2% by weight. In particular, different grades of sand may be used. For example, graded silica sand having a diameter of 0.5 mm or less in an amount of 20 to 21% by weight may be used, and graded silica sand having a diameter of 0.5 mm to 1.2 mm in an amount of 30 to 31% by weight may be used.
During mixing, water is added in an amount of between 15 and 18% by weight, more preferably between 16 and 17% by weight. Due to the alkali activator already present in the dry-mixed repair mortar, no further liquid is required to prepare the repair mortar. By adding the alkali activator as a dry ingredient to the dry mix repair mortar, a precise amount of activation uniformly distributed throughout the mixture can be ensured since the mixture is prepared in a controlled environment rather than on the job site. In addition, the use of dry compounding ensures that the proper amount is between batches. The repair mortar of the invention exhibits excellent chemical resistance and can be used in repairs where corrosion resistance is required (for example resistance to chloride penetration to reduce corrosion of steel reinforcement). The repair mortar also exhibits excellent acid resistance. Particular applications requiring chemical resistance include concrete structures in contact with contaminated sources of acidic chemicals. The repair mortar also exhibits a very low drying shrinkage, less than 600 microstrain (i.e. less than or equal to 0.06% or 0.6 mm/m). The setting time is controllable and may be controlled to be set at 60 minutes or longer, and in some embodiments, at 90 minutes or longer. The repair mortar of the invention also showed high compressive strengths at 7 days and 28 days, 30MPa and 35MPa, respectively. The intensity may be selectively varied depending on the repair application. In order to ensure excellent adhesion to existing concrete structures, the repair mortar of the invention has a good bond strength of at least 0.5MPa, more preferably at least 2.0 MPa. The repair mortar of the present invention can partially penetrate and chemically react with the concrete substrate to be repaired, thereby providing good bonding strength.
Examples
The alkali-activated dry-mix repair mortar samples in the examples were prepared and processed according to the following procedure:
1) a quantity of dry powder ingredients was mixed homogeneously in an M-tec MS 1.1N dry powder mixer for 120 seconds and then an alkali activated dry mix repair mortar was obtained and activated.
2) Water was added to the alkali activated dry mix repair mortar in powder form and the water was mixed with the dry mortar in a Hobart mixer at 140 revolutions per minute for 120 seconds. The mixing speed was then changed to a higher speed of 285 rpm for 120 seconds. After the above mixing procedure is complete, the mixture is ready for casting or testing operations.
3) The alkali activated repair mortar mixture was cast in a mold to form different test specimens for testing.
4) The casting in the mold was wrapped with a polyethylene film and moisture cured at room temperature of 23 + -2 deg.C and relative humidity of 60 + -5% for 24 hours.
5) After 24 hours of cure, the samples were demolded and wrapped with polyethylene sheeting under the previous conditions of temperature and humidity to further cure until the indicated test age.
Fresh mixing properties, mechanical properties and durability properties of the alkali activated dry mix repair mortar mixture were measured. The setting time of the mortar was measured by vicat needle, the fluidity was measured by ASTM standard flow meter, the compression strength results and the modulus of elasticity at different curing ages of 1, 7 and 28 days were obtained by a universal tester, and the bond strength was measured using a tensile tester. In addition to the durability performance, properties such as drying shrinkage were measured according to the linear length change method, and the acid resistance was measured by measuring the weight loss by immersing the cylindrical sample in a 5% sulfuric acid solution. Chloride permeability is determined by rapid amperometry.
Example 1 (comparative example without metakaolin)
| Composition of alkali-activated Material | Ratio of |
| Slag of mine | 0.28 |
| Fly ash | 0.12 |
| Metakaolin clay | 0 |
| Potassium silicate powder | 0.0453 |
| Potassium hydroxide powder | 0.0046 |
| Sodium bicarbonate | 0.0020 |
| Grading silica sand (0 to 0.5 mm) | 0.2 |
| Grading silica sand (0.5 to 1.2 mm) | 0.3 |
| Mixing ratio | 5 kg of mortar and 615 kg of water |
Example 2 (comparative example with 2% metakaolin)
| Composition of alkali-activated Material | Ratio of |
| Slag of mine | 0.28 |
| Fly ash | 0.10 |
| Metakaolin clay | 0.02 |
| Potassium silicate powder | 0.0453 |
| Potassium hydroxide powder | 0.0046 |
| Sodium bicarbonate | 0.0020 |
| Grading silica sand (0 to 0.5 mm) | 0.2 |
| Grading silica sand (0.5 to 1.2 mm) | 0.3 |
| Mixing ratio | 5 kg of mortar and 615 kg of water |
Example 3 (inventive composition with 3.2% metakaolin)
Example 4 (inventive composition with 6% metakaolin)
| Composition of alkali-activated Material | Ratio of |
| Slag of mine | 0.28 |
| Fly ash | 0.06 |
| Metakaolin clay | 0.06 |
| Potassium silicate powder | 0.0453 |
| Potassium hydroxide powder | 0.0046 |
| Sodium bicarbonate | 0.0020 |
| Grading silica sand (0 to 0.5 mm) | 0.2 |
| Grading silica sand (0.5 to 1.2 mm) | 0.3 |
| Mixing ratio | 5 kg of mortar and 615 kg of water |
Example 5 (inventive composition with 4.8% metakaolin)
Properties of example 1
Example 1 is a comparative formulation that does not contain metakaolin. The setting time was about 90 minutes and the compressive strength at day 7 and day 28 was 29.3 and 30MPa, respectively. However, the drying shrinkage of 28 days is as high as 0.333%, which is too large for repair mortars. The weight loss in the acid solution after 28 days was 3.5%, the chloride ion permeability was low, and the adhesive strength was higher than 0.5 MPa. As a result, it was found that, without metakaolin in the formulation of the repair mortar of this comparative example, drying shrinkage would be a serious problem, and thus it was not suitable for use as a repair mortar.
Properties of example 2
Example 2 is a comparative formulation containing only 2% metakaolin. The setting time was about 47 minutes and the compressive strength at day 7 and day 28 was 43.4 and 46.5MPa, respectively. However, the 28-day drying shrinkage was as high as 0.113%, although less than example 1, but still unacceptable for repair mortars. The weight loss in the acid solution after 28 days was 3.6%, the chloride ion permeability was low, and the adhesive strength was higher than 0.5 MPa. Although metakaolin helps to reduce drying shrinkage, this level of drying shrinkage is still unacceptable for repair mortars.
Properties of example 3
Example 3 (composition of the invention) is a formulation with 3.2% metakaolin. The setting time was about 46 minutes and the compressive strength at day 7 and day 28 was 42.3 and 43.6MPa, respectively. The 28-day drying shrinkage was 0.052%, which is acceptable for repair mortars. Generally, low shrinkage repair mortars require a dry shrinkage of less than or equal to 0.06%. The weight loss in the acid solution after 28 days was 3.6%, the chloride ion permeability was low and the adhesive strength was higher than 0.5 MPa. In such low shrinkage alkali activated dry mix repair mortar formulations, a higher metakaolin content of 3.2% helps to further control the drying shrinkage to acceptable levels.
Properties of example 4
Example 4 is a formulation containing 6% metakaolin within the scope of the present invention. The setting time was about 60 minutes and the compressive strength at day 7 and day 28 was 41.4 and 46.8MPa, respectively. The drying shrinkage in 28 days was 0.048%. The weight loss in the acid solution after 28 days was 3.8%, the chloride ion permeability was low and the adhesive strength was higher than 0.5 MPa. In the formulation of the low shrinkage alkali-activated dry-mixed repair mortar, the higher metakaolin content of 6% can reduce the drying shrinkage to 0.048%. However, the workability of the repair mortar can be further improved by using other functional mixtures.
Properties of example 5
Example 5 is a formulation of a low shrinkage alkali activated dry mix repair mortar of the present invention to which thickeners, rheology modifiers and fibers have been added to adjust workability and durability. Setting times of more than 90 minutes, compressive strengths at 7 th and 28 th days of 34.6 and 36.8MPa, respectively, are sufficient for use in repair mortars. The drying shrinkage in 28 days was 0.048%. The weight loss in the acid solution after 28 days was 3.4%, the chloride ion permeability was low and the adhesive strength was higher than 0.5 MPa.
From the foregoing description, those skilled in the art will appreciate that the broad techniques of the embodiments can be implemented in a variety of forms. Therefore, while this embodiment has been described in connection with particular examples thereof, the true scope of the invention should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, the specification and the following claims.
Claims (14)
1. An alkali-activated dry-mixed repair mortar with low shrinkage and without adding ordinary portland cement is characterized by comprising the following components:
a base material selected from ground granulated blast furnace slag, fly ash or mixtures thereof in a weight percent of between 32% and 37%;
metakaolin in a weight percentage between 3% and 8%;
a modified potassium silicate as an alkali activator, said modified potassium silicate having been modified with potassium hydroxide to provide K2O and SiO2Is between 1.8 and 2.2;
a filler in an amount between 50% and 54% by weight,
wherein the repair mortar has a drying shrinkage of 0.06% or less and a bond strength of 0.5MPa or more, an acid resistance of 3.4% or less as measured by calculating a weight loss after 28 days of acid exposure, and a setting time of 60 minutes or more.
2. The alkali-activated, dry-mix repair mortar with low shrinkage and without the addition of Portland cement according to claim 1, wherein the metakaolin is calcined at a temperature ranging from 750 to 800 ℃.
3. The low shrinkage, portland cement-free, alkali-activated dry mix repair mortar of claim 1, wherein the repair mortar further comprises less than or equal to 0.02% by weight of a fiber additive.
4. The alkali-activated dry mix repair mortar with low shrinkage without the addition of Portland cement according to claim 1, wherein the bond strength is at least 2 MPa.
5. The alkali-activated, dry-mix repair mortar with low shrinkage without the addition of Portland cement according to claim 1, wherein the repair mortar has low chloride permeability.
6. The low shrinkage, portland cement-free, alkali-activated dry-mix repair mortar of claim 1, wherein the repair mortar further comprises less than or equal to 0.008% by weight of hydroxypropyl methylcellulose.
7. The alkali-activated, dry-mix repair mortar with low shrinkage without the addition of Portland cement according to claim 1, wherein the filler is graded silica sand.
8. The alkali-activated, dry-mix repair mortar with low shrinkage without the addition of Portland cement according to claim 7, wherein a portion of the silica sand is less than 0.5 mm.
9. The alkali-activated, dry-mix repair mortar with low shrinkage without the addition of Portland cement according to claim 7, wherein a portion of the silica sand is between 0.5 mm and 1.2 mm.
10. The alkali-activated, dry-mix repair mortar with low shrinkage without the addition of Portland cement according to claim 1, wherein the repair mortar has a 7-day compressive strength of at least 30MPa after curing.
11. The alkali-activated, dry-mix repair mortar with low shrinkage without the addition of Portland cement according to claim 1, wherein the repair mortar has a 28-day compressive strength of at least 35MPa after curing.
12. The low shrinkage, non-additivated portland cement, alkali-activated dry mix repair mortar of claim 1, wherein the repair mortar has a dry shrinkage of less than or equal to 0.048%.
13. The alkali-activated, dry-mix repair mortar with low shrinkage without the addition of Portland cement according to claim 1, wherein the repair mortar has a 28-day compressive strength of at least 46MPa after curing.
14. The alkali-activated dry mix repair mortar with low shrinkage without the addition of Portland cement according to claim 1, wherein the setting time of the repair mortar is greater than or equal to 90 minutes.
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| CN113387635B (en) * | 2021-05-11 | 2022-10-11 | 贵州省公路工程集团有限公司 | Preparation method of tunnel tailing concrete with high stone powder content |
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| CN104478324A (en) * | 2014-11-26 | 2015-04-01 | 华南理工大学 | High-temperature-resisting geopolymer based reinforcing and repairing mortar as well as preparation method and application of high-temperature-resisting geopolymer based reinforcing and repairing mortar |
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| WO2010085537A2 (en) * | 2009-01-22 | 2010-07-29 | The Catholic University Of America | Tailored geopolymer composite binders for cement and concrete applications |
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| CN104478324A (en) * | 2014-11-26 | 2015-04-01 | 华南理工大学 | High-temperature-resisting geopolymer based reinforcing and repairing mortar as well as preparation method and application of high-temperature-resisting geopolymer based reinforcing and repairing mortar |
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