DE202021103918U1 - Layered surface protection system - Google Patents

Abstract

Layered surface protection system (1) to protect concrete components from penetrating liquids and chlorides with the following ingredients:
• a matrix material (3) - such as concrete or mortar - which preferably comprises mineral substances,
• at least one sealant (4) which is contained in at least a partial volume (17) of the surface protection system (1),
• wherein the at least one sealing means (4) is designed in such a way that it increases the solid volume of the layered surface protection system (1) when it comes into contact with typical environmental substances such as water and / or air,
And wherein the layered surface protection system (1) extends predominantly in a first main direction of extent (X) and a second main direction of extent (Y), which are perpendicular to one another and preferably run parallel to a surface (5) to be protected, characterized by
• a reinforcement system (6) comprising long fibers (7) which have a length of at least 100 mm, but preferably at least 200 mm, the reinforcement system (6) being enclosed by the matrix material (3).

Description

It has been known for many years to use concrete components, in particular concrete components with steel reinforcement, in structures (including buildings, bridges, roads). With increasing age of the structures, however, these concrete components have the disadvantage that cracks form in the concrete and water or moisture can penetrate as far as the steel reinforcement. As a result, the steel reinforcement corrodes and the load-bearing capacity of the concrete component decreases. This problem occurs particularly strongly with concrete components that are exposed to corrosive media (e.g. chlorides, salt water) due to their location. An example of this are surfaces that can be driven on (road surfaces) on streets or underground garages made of a concrete component, which are exposed to an increased amount of de-icing salts, especially in winter at temperatures below freezing point. In addition, road surfaces are exposed to high mechanical loads due to the dynamic loads exerted by the vehicles - for example braking and acceleration - which increases their susceptibility to cracks. A large number of surface protection systems are therefore already known to protect the steel reinforcement in concrete components from corrosion. The German Committee for Reinforced Concrete (DAfStb) provides with its guideline "Protection and repair of concrete components" an approach to divide surface protection systems into protection classes. Reinforced concrete floor slabs in underground garages, for example, are usually covered with surface protection systems of protection class OS 8th or OS 11 fitted. Surface protection systems of protection class OS 8th are very strong and can withstand high mechanical loads, but they are prone to cracking and cannot bridge cracks. Well-known surface protection systems of protection class OS 11 on the other hand, cracks that occur in the concrete component can be bridged by a soft floating layer, but they age under heavy mechanical loads - e.g. when used on a roadway - and must be replaced at regular intervals due to wear. In addition to surface protection systems, concrete components are also known which have sealants evenly distributed in the concrete, which have a sealing effect on contact with water. They close the cracks that arise in the concrete directly after the crack formation by increasing the volume. Such sealants are intended to prevent corrosion by preventing the steel reinforcement of the reinforced concrete component from coming into contact with water. A disadvantage of these sealants, however, is that they can only close small cracks. In this context, the statements made by experts about the crack width up to which cracks can still be closed with such a sealant are different. In most cases, however, a crack width of 0.3 to 0.5 mm can be read, which can still be closed at most (cf. “A Review of Self-Healing for Damage Management of Structures,” De Belie et al., Advanced Material Interfaces, May 2018 ). The sealants can extend the service life of mechanically heavily stressed or driven concrete components, but do not prevent the corrosion of the steel reinforcement through cracks with larger crack widths (> 0.5 mm).

the AT521434B1 shows a road surface made of concrete which contains a crystal-forming sealant which crystallizes on contact with water with an increase in volume. In this way, cracks and cavities in the concrete are to be closed. It is proposed to add glass composite fibers with a length of 43 mm to the concrete in order to prevent cracks that have already been closed from opening again. Such a road surface, however, cannot prevent the occurrence of cracks with crack widths of more than 0.5 mm and, with increasing age, will have cracks that cannot be closed by the crystal-forming sealant. In addition, when the road surface is used in tunnels, under bridges and in underground garages, the layer thickness of the road surface (up to 20 cm) reduces the headroom for vehicles.

The object of the invention is therefore to provide a layered surface protection system, a reinforced concrete component and a method for applying a layered surface protection system for mechanically strong and drivable surfaces, which can heal cracks itself and, compared to the prior art, a smaller layer thickness and a less material used with a comparable protective effect.

• - einem Matrixmaterial - wie Beton oder Mörtel -, das vorzugsweise mineralische Stoffe umfasst,
• - zumindest einem Dichtmittel, das zumindest in einem Teilvolumen des Oberflächenschutzsystems enthalten ist,
• - wobei das zumindest eine Dichtmittel derart beschaffen ist, dass es bei Kontakt mit typischen Umgebungsstoffen wie Wasser und/oder Luft das Festkörpervolumen des schichtförmigen Oberflächenschutzsystems steigert (dadurch können Risse im schichtförmigen Oberflächenschutzsystem verschlossen bzw. geheilt werden),
• - und wobei das schichtförmige Oberflächenschutzsystem sich vorwiegend in einer ersten Haupterstreckungsrichtung und einer zweiten Haupterstreckungsrichtung, die senkrecht zueinander und parallel zu einer zu schützenden Oberfläche verlaufen, erstreckt, weist erfindungsgemäß zusätzlich ein Bewehrungssystem auf, das Langfasern umfasst, welche eine Länge von zumindest 100 mm, vorzugsweise jedoch von zumindest 200 mm, aufweisen, wobei das Bewehrungssystem von dem Matrixmaterial umschlossen ist. Langfasern im Sinne dieser Schutzrechtsanmeldung können Fasern jeglicher Art (z.B. Glasfasern, Kohlenstofffasern, Aramidfasern, Naturfasern, etc.) sein, die zumindest die vorgenannte Länge aufweisen. Besonders vorteilhaft sind jedoch Langfasern, die eine Länge von zumindest 1000 mm, vorzugsweise jedoch zumindest 5000 mm, aufweisen. Vorzugsweise handelt es sich bei den Langfasern um Filamente, bzw. Endlosfasern. Das Matrixmaterial erstreckt sich vorzugsweise vorwiegend in der ersten und der zweiten Haupterstreckungsrichtung und bildet eine Schicht mit im Wesentlichen gleichmäßiger Schichtdicke in einer Dickenrichtung, die senkrecht zu der ersten und der zweiten Haupterstreckungsrichtung verläuft. In dieser Schicht ist auch das Bewehrungssystem angeordnet. Eine Schicht oder etwas schichtförmiges im Sinne dieser Schutzrechtsanmeldung ist eine flächenhaft ausgebreitete Masse (z.B. Matrixmaterial oder Dichtmittel) mit einer im Vergleich zu ihrer Erstreckung in Richtung der Haupterstreckungsrichtungen geringen Schichtdicke in Dickenrichtung. Die Schichten des schichtförmigen Oberflächenschutzsystems erstrecken sich also vorteilhafterweise vorwiegend in Richtung der ersten und der zweiten Haupterstreckungsrichtung. Einzelne Schichten des schichtförmigen Oberflächenschutzsystems sind durch Grenzflächen, die vorzugsweise im Wesentlichen parallel zu der zu schützenden Oberfläche verlaufen, voneinander getrennt. Das Teilvolumen, welches das Dichtmittel enthält, enthält vorteilhafterweise mineralische Stoffe. Besonders vorteilhaft ist es, wenn das Teilvolumen, das das Dichtmittel enthält, ein Beton oder Mörtel ist. Das Matrixmaterial und/oder das Teilvolumen, das das Dichtmittel enthält, enthalten vorteilhafterweise Bindemittel. Besonders vorteilhaft sind dabei alkalisch aktivierte Bindemittel. Das genannte Dichtmittel ist vorteilhafterweise derart mit einem Teilvolumen vermengt, dass das Dichtmittel im Wesentlichen gleichmäßig in diesem Teilvolumen verteilt ist. Dabei kann das Dichtmittel auch in Partikeln enthalten sein, die im Wesentlichen gleichmäßig in dem Teilvolumen verteilt sind. Wenn das Dichtmittel in Partikeln enthalten ist, wird das Dichtmittel vorteilhafterweise beim Entstehen eines Risses in dem Teilvolumen freigesetzt, wenn der Riss durch einen Partikel verläuft. Das Matrixmaterial und ein Teilvolumen, das das Dichtmittel enthält, können unterschiedliche stoffliche Zusammensetzungen (z.B. unterschiedliche Gewichtsanteile der Inhaltsstoffe) haben. In einer möglichen Ausführungsform enthält das Matrixmaterial kein Dichtmittel. Genauso ist aber auch eine Ausführungsform denkbar, bei der das Matrixmaterial selbst ein Teilvolumen ist, dass das Dichtmittel enthält.

The object is achieved by a surface protection system with the features of claim 1. A layered surface protection system for protecting reinforced concrete components from penetrating liquids and chlorides with the following ingredients:

• - a matrix material - such as concrete or mortar - that preferably comprises mineral substances,
• - at least one sealant that is contained in at least a partial volume of the surface protection system,
• - the at least one sealant being such that it increases the solid volume of the layered surface protection system when it comes into contact with typical environmental substances such as water and / or air (this allows cracks in the layered surface protection system to be closed or healed),
• - and wherein the layered surface protection system is predominantly in a first Main direction of extent and a second main direction of extent, which extend perpendicular to each other and parallel to a surface to be protected, according to the invention additionally has a reinforcement system that comprises long fibers which have a length of at least 100 mm, but preferably of at least 200 mm, wherein the Reinforcement system is enclosed by the matrix material. Long fibers within the meaning of this patent application can be fibers of any kind (eg glass fibers, carbon fibers, aramid fibers, natural fibers, etc.) that have at least the aforementioned length. However, long fibers which have a length of at least 1000 mm, but preferably at least 5000 mm, are particularly advantageous. The long fibers are preferably filaments or continuous fibers. The matrix material preferably extends predominantly in the first and the second main direction of extent and forms a layer with a substantially uniform layer thickness in a thickness direction which runs perpendicular to the first and the second main direction of extent. The reinforcement system is also arranged in this layer. A layer or something in the form of layers in the sense of this patent application is a mass spread out over a large area (eg matrix material or sealant) with a small layer thickness in the direction of thickness compared to its extent in the direction of the main directions of extent. The layers of the layered surface protection system thus advantageously extend predominantly in the direction of the first and the second main direction of extent. Individual layers of the layered surface protection system are separated from one another by interfaces which preferably run essentially parallel to the surface to be protected. The partial volume which contains the sealant advantageously contains mineral substances. It when the partial volume that contains the sealant is a concrete or mortar is particularly advantageous. The matrix material and / or the partial volume which contains the sealant advantageously contain binders. Alkaline-activated binders are particularly advantageous. Said sealant is advantageously mixed with a partial volume in such a way that the sealant is distributed essentially uniformly in this partial volume. The sealant can also be contained in particles that are distributed essentially uniformly in the partial volume. If the sealant is contained in particles, the sealant is advantageously released when a crack occurs in the partial volume when the crack runs through a particle. The matrix material and a partial volume that contains the sealant can have different material compositions (eg different weight proportions of the ingredients). In one possible embodiment, the matrix material does not contain any sealant. However, an embodiment is also conceivable in which the matrix material itself is a partial volume that contains the sealant.

Even if the layered surface protection system extends predominantly in the first main direction of extent and the second main direction of extent, it is nevertheless layered, that is, it extends (to a significantly lesser extent than in the main direction of extent) in a thickness direction that is perpendicular to the first and second main direction of extent runs. By increasing the solid volume when the sealant comes into contact with typical environmental materials, cracks can be closed again immediately after they have formed. The sealant thus enables the surface protection system to heal itself. Such sealants can be special mineral additives (e.g. fly ash, quartz dust, blast furnace slag, calcined kaolin), crystal-forming substances, superabsorbent plastics and / or polymer additives (e.g. epoxy resin in combination with calcium hydroxide). Superabsorbent plastics can advantageously be in the form of a hydrogel. Such a hydrogel can contain polar crosslinked polymers (for example polyacrylimide, polyvinylpyrrolidone). However, the hydrogel can also contain copolymers (for example a copolymer of sodium acrylate and acrylamide). Furthermore, the sealant can be contained in particles which envelop the sealant with a capsule and only release the sealant when the capsule is damaged, for example by a crack. The capsule can be a polymer capsule made of a plastic. The capsule advantageously comprises at least one of the following plastics: polystyrene, polylactide, polymethyl methacrylate, polyethylene glycol, polyethylene terephthalate, polypropylene, polyethylene. The sealant can advantageously be a bacterium. The publication "A Review of Self-Healing for Damage Management of Structures" ( De Belie et al., Advanced Material Interfaces, May 2018 ) gives an overview of possible sealants in chapters 1 to 3.2. All of the sealing means described there can advantageously be combined with the exemplary embodiments disclosed in this patent application.

It is advantageous if the layered surface protection system has at least two preferably layered partial volumes with different material compositions. At least one of the two preferably layer-shaped partial volumes is a partial volume that contains the sealant. Advantageously, both of the two contain preferably layer-shaped partial volume the sealant. Further advantages result if the at least two layered partial volumes have different concentrations of sealant. In a further advantageous embodiment, the surface protection system has three or more layered partial volumes, of which at least two, but preferably each partial volume, contain the sealant.

The sealant is advantageously mixed with the matrix material. The matrix material is then, in the sense of this patent application, a partial volume that contains the sealant. It is particularly advantageous if the sealant is mixed essentially uniformly with the matrix material. A layered surface protection system with at least one second partial volume, which has a higher concentration of sealant than the matrix material, is also advantageous.

The long fibers of the surface protection system advantageously extend essentially in a plane that is spanned by the first and second main directions of extent. The long fibers preferably run parallel to a surface to be protected. At points where individual long fibers cross, it may be that at least one of the long fibers has a fiber course that also runs in the direction of the thickness in order to "avoid" another crossing long fiber. Despite this “evasion”, such a long fiber then runs in the sense of this property right essentially in a plane that is spanned by the first and the second main direction of extent.

Further advantages result if the long fibers are surrounded at every point along their length by a layer of the matrix material that is at least 5 mm, preferably at least 10 mm, thick. It has been shown that the load introduction into the fibers can be improved in this way. Furthermore, the fibers are protected and cannot be damaged, especially when driving on the surface protection system. In this way, over the long fibers, there is also an edge layer with a thickness of at least 5 mm, preferably at least 10 mm, in the direction of the thickness, but the matrix material does not contain any long fibers. This edge layer can be subject to wear without the function of the surface protection system being impaired by the exposure of long fibers.

The long fibers can have a coating that includes protrusions. The projections advantageously have a size of 0.1 mm to 3 mm, but preferably of 0.2 mm to 1 mm. The protrusions are raised in a direction perpendicular to the surface of the long fibers opposite a majority of the coating. The projections improve the connection of the reinforcement system to the matrix material. In this way, the formation of large cracks can be avoided or at least delayed.

The long fibers can have a coating containing a bulk material. For this it is sufficient if the surface of at least a subset of the long fibers is at least partially coated with the bulk material. The bulk material serves to form the projections that protrude perpendicular to the surface of the long fibers. Such a coating is suitable for increasing the surface roughness of the reinforcement system. As a result of the improved connection of the reinforcement system to the matrix material, the protective effect of the surface protection system against the penetration of water and chlorides through cracks can be improved in comparison to previously known surface protection systems. A bulk material within the meaning of this patent application is a powdery, granular or lumpy mixture of a material - it is therefore a material that is present in a pourable form.

The bulk material advantageously comprises sand, preferably quartz sand. A quartz sand is sand that contains quartz grains. The quartz sand advantageously comprises at least 50% (weight) quartz grains. The bulk material can advantageously also contain any other bulk material, in particular mineral substances.

The bulk material advantageously has a grain size of 0.1 to 1 mm. A bulk material which has a grain size of 0.2 to 0.5 mm is particularly preferred. Surprisingly, in this selection area, in combination with the other features according to the invention, a positive effect has been established which can no longer be significantly increased with increasing grain size.

Further advantages result if the sealant forms crystals on contact with the typical surrounding substances, preferably water (or moisture) and / or oxygen. Such sealants are known, for example, under the product names “Xypex Admix” from Xypex Chemical Corporation or “Krystaline Add1” from wba Abdichtungssysteme GmbH. The teaching according to the invention can, however, also be carried out advantageously with all other sealants which form crystals on contact with the typical surrounding substances. Typical environmental substances in the context of this invention are to be understood as substances that usually occur in and / or on concrete components. These are, for example, water, air or mineral substances from the concrete itself. The sealant, which forms crystals on contact with the typical surrounding substances, makes use of the structure of the matrix material: it promotes the swelling of unhydrated components of the matrix material and forms additional solid material in cracks through crystallization. These processes advantageously take place until the sealant is no longer in contact with water and are continued as soon as water comes into contact with the sealant again. In this way, defects in the matrix material, such as cracks, can be closed in a watertight manner immediately after their formation and even after many years. The layered surface protection system effectively protects a surface to be protected by the surface protection system from moisture and corrosive substances that are transported with the moisture.

The sealant can advantageously comprise at least one bacterium which, on contact with at least one typical ambient substance, forms a solid, preferably calcium carbonate CaCO ₃ - that is, limestone - in the protective layer. Such a sealant is known, for example, under the product name “Green Basilisk” from wba Abdichtungssysteme GmbH. Such a sealant advantageously uses biochemical processes to form limestone. It can be advantageous if, in addition to the at least one bacterium, the sealant contains a nutrient solution which, in addition to the typical ambient substances, includes all substances that are required for the formation of a solid by the bacterium. The nutrient solution advantageously comprises calcium carbonate. In this way, defects in the layered surface protection system - for example cracks - can be closed in a watertight manner immediately after their formation.

It has proven to be particularly advantageous if the at least one bacterium comes from one of the genera Bacillus, Planococcus or Sporosarcina. With bacteria from these genera, in combination with the features according to the invention, particularly good crack healing on contact with the typical surrounding substances has been shown.

Further advantages result if the long fibers of the reinforcement system comprise at least one carbon fiber and / or at least one glass fiber. In such a layered surface protection system, the high chemical resistance and the good mechanical properties of these fibers are particularly advantageous. However, other types of fibers can also be advantageously combined with all of the design variants disclosed above, for example aramid fibers or natural fibers such as hemp and flax.

The reinforcement system advantageously comprises a polymer matrix which envelops the long fibers and contains at least one thermoset resin, preferably epoxy resin or vinyl ester resin. For the purposes of this property right, a polymer matrix that envelops the long fibers is also to be understood as a polymer matrix with which the long fibers are impregnated or infiltrated. The polymer matrix is advantageously part of the coating of the long fibers. With a polymer matrix of this type, the mechanical properties of the long fibers can be used in a targeted manner and a large number of long fibers can be materially bonded to one another. The polymer matrix can advantageously envelop a large number of long fibers and fill free spaces between the long fibers in order to form an integral connection between the long fibers. Long fibers with a polymer matrix are also generally known as fiber-reinforced plastics or fiber-reinforced plastics.

In an advantageous embodiment, the reinforcement system has fiber strands each comprising a plurality of the long fibers, the fiber strands being arranged with respect to one another in such a way that the fiber strands cross at nodes, and the fiber strands are connected to one another at the nodes. Fiber strands that cross each other are fiber strands whose fiber direction runs in different directions. The fiber strands are preferably arranged perpendicular to one another. The fiber strands are preferably connected to one another in a form-fitting and / or cohesive manner (for example by a polymer matrix). Further advantages result if the long fibers are arranged in a stretched manner - that is, form a scrim. Non-woven fabrics are flat textile structures that have no meshes or fiber undulations (fiber waviness). As a scrim, they differ from textiles, in which the fibers are usually not stretched, but rather have fiber undulations (fiber waviness) - that is, flat textile structures such as woven, knitted, braided, stitched, nonwovens, mats or felts. It is particularly advantageous if the reinforcement system is a rigid solid body. It is particularly advantageous if a first amount of fiber strands run in a first direction (i.e. parallel to one another in this direction) and a second amount of fiber strands in a second direction, so that the fiber strands of the first set and the fiber strands of the second set run in Cross nodal points, the fiber strands being connected to one another at the nodal points and forming a lattice with a preferably uniform lattice spacing. It can be advantageous to add further quantities of fiber strands which run in further directions to this lattice. In this way, a reinforcement system is formed in which “fiber strands” that are essentially aligned or stretched run in two or more directions. If the fiber strands are encased in a polymer matrix, it is a grid Fiber reinforced plastic. The lattice is advantageously formed by arranging a plurality of fiber strands next to one another in the respective directions and connecting them to one another. The distance between the fiber strands forms the grid spacing of the grid and describes the size of the grid openings. Advantageously, several fiber strands lie next to one another in at least two different directions. It is also advantageous if several fiber strands are arranged next to one another in one direction and are stabilized and connected in their position by auxiliary threads. In this case, the nodes would arise between the fiber strands and the auxiliary threads. The fiber strands can comprise various fiber materials. For example, the fiber strands pointing in a first direction can comprise glass fibers and the fiber strands pointing in a second direction can comprise carbon fibers. For example, fiber strands made of glass fibers and fiber strands made of carbon fibers, which point in the same direction, can be arranged alternately next to one another. Further advantages result if the fiber strands are initially formed from uncoated long fibers and the long fibers of the respective fiber strands are then coated together in such a way that all long fibers of the respective fiber strand are covered by a coating. The coating advantageously fills the spaces between the long fibers.

The modulus of elasticity of at least one of the long fibers is at least 70,000 MPa, but preferably at least 200,000 MPa. With such long fibers, the protective effect of the layered surface protection system against penetrating water can be improved by counteracting the formation of cracks.

Further advantages result if the layered surface protection system has a layer thickness of a maximum of 50 mm, but preferably a maximum of 20 mm, the layer thickness being the extent of the surface protection system in a thickness direction which is perpendicular to the first main direction of extent and the second main direction of extent. The thickness direction thus points in the direction of the surface normal of the surface to be protected. Due to the low layer thickness, such layered surface protection systems are particularly suitable in underground garages and tunnels, where the low layer thickness means that the greatest possible headroom is maintained for vehicles.

Additional advantages result from a layered surface protection system which comprises short fibers which have a maximum length of 50 mm and which are mixed with the matrix material. The matrix material can be additionally reinforced with the short fibers in order to reduce the layer thickness while maintaining the load-bearing capacity of the surface protection system and to prevent the formation of large cracks.

• - einer Tragschicht, die sich schichtförmig vorwiegend in einer ersten Haupterstreckungsrichtung und einer zweiten Haupterstreckungsrichtung erstreckt und mineralische Stoffe umfasst, (z.B. Beton oder Mörtel)
• - einer Hauptbewehrung, die vorzugsweise zumindest ein metallisches Material umfasst und vorzugsweise als Gitter in der Tragschicht angeordnet ist,
• - einem schichtförmigen Oberflächenschutzsystem, das ein Matrixmaterial - wie Beton oder Mörtel - vorzugsweise aus mineralischen Stoffen umfasst, und das sich schichtförmig vorwiegend in einer ersten und einer zweiten Haupterstreckungsrichtung erstreckt,
• - zumindest einem Dichtmittel, das zumindest in einem Teilvolumen des schichtförmigen Oberflächenschutzsystems enthalten ist,
• - wobei das zumindest eine Dichtmittel derart beschaffen ist, dass es bei Kontakt mit typischen Umgebungsstoffen wie Wasser oder Luft das Festkörpervolumen des Oberflächenschutzsystems steigert,

wobei das bewehrte Betonbauteil zusätzlich ein Bewehrungssystem aufweist, das in dem schichtförmigen Oberflächenschutzsystem angeordnet und von dem Matrixmaterial umschlossen ist, und das Langfasern umfasst, welche zumindest eine Länge von 100 mm aufweisen. Mineralische Stoffe in der Tragschicht können vorteilhafterweise Beton und/oder Mörtel sein. Die Hauptbewehrung in der Tragschicht kann zum Beispiel Stahl enthalten, wobei der Stahl in Form von Bewehrungsstäben vorzugsweise in einem zweidimensionalen und/oder dreidimensionalen Gitter angeordnet ist. Das Betonbauteil ist ein mit dem schichtförmigen Oberflächenschutzsystem in Verbindung stehendes Erzeugnis. Alle in den vorstehenden Abschnitten offenbarten Merkmale eines schichtförmigen Oberflächenschutzsystem sind vorteilhaft mit dem Betonbauteil kombinierbar. Die in den vorigen Abschnitten eingeführten begrifflichen Definitionen gelten auch im Zusammenhang mit dem Betonbauteil.The object of the invention is also achieved by a reinforced concrete component with the following features:

• - a base course, which extends in layers predominantly in a first main direction of extent and a second main direction of extent and comprises mineral substances (e.g. concrete or mortar)
• - a main reinforcement, which preferably comprises at least one metallic material and is preferably arranged as a grid in the base layer,
• - a layered surface protection system which comprises a matrix material - such as concrete or mortar - preferably made of mineral substances, and which extends in layers predominantly in a first and a second main direction of extent,
• - At least one sealant that is contained in at least a partial volume of the layered surface protection system,
• - the at least one sealant being such that it increases the solid volume of the surface protection system when it comes into contact with typical environmental substances such as water or air,

wherein the reinforced concrete component additionally has a reinforcement system which is arranged in the layered surface protection system and enclosed by the matrix material, and which comprises long fibers which have a length of at least 100 mm. Mineral substances in the base course can advantageously be concrete and / or mortar. The main reinforcement in the base layer can contain steel, for example, the steel preferably being arranged in the form of reinforcing bars in a two-dimensional and / or three-dimensional grid. The concrete component is a product associated with the layered surface protection system. All of the features of a layered surface protection system disclosed in the preceding sections can advantageously be combined with the concrete component. The conceptual definitions introduced in the previous sections also apply in connection with the concrete component.

In an advantageous embodiment of the reinforced concrete component, the sealant is mixed with the matrix material. The material matrix is then, in the sense of this property right, a partial volume of the layered surface protection system that contains the Contains sealant. The sealant is advantageously mixed with the material matrix essentially uniformly.

Further advantages result if a preferably layer-shaped partial volume is arranged between the support layer and the matrix material, which partial volume contains the at least one sealing means. A layered partial volume, which contains the at least one sealing means, preferably connects the layered surface protection system between the matrix material and the support layer in a materially bonded manner to the support layer. The weight fraction of the sealant in the layered partial volume containing the sealant is preferably at least twice as great as the weight fraction of a sealant in the matrix material if the matrix material also contains a sealant. Such layered partial volumes offer increased protection against penetrating moisture or penetrating water - in particular between the matrix material and the surface to be protected.

• - Aufbringen zumindest eines ersten Anteils eines Matrixmaterials - wie Beton oder Mörtel -, das vorzugsweise mineralische Stoffe umfasst, auf zumindest einer zu schützenden Oberfläche derart, dass eine sich vorwiegend in einer ersten Haupterstreckungsrichtung X und einer zweiten Haupterstreckungsrichtung Y, die senkrecht zueinander und parallel zu der zu schützenden Oberfläche verlaufen, erstreckende Schicht gebildet wird,
• - Aufbringen zumindest eines Dichtmittels,
• - wobei das zumindest eine Dichtmittel derart beschaffen ist, dass es bei Kontakt mit typischen Umgebungsstoffen wie Wasser und/oder Luft das Festkörpervolumen des Oberflächenschutzsystems steigert.

Zusätzlich wird ein Bewehrungssystem, das Langfasern umfasst, welche zumindest eine Länge von 100 mm aufweisen, in das Matrixmaterial eingelegt, wobei das Bewehrungssystem vorzugsweise vollständig von dem Matrixmaterial umgeben ist, und das Matrixmaterial wird anschließend ausgehärtet. Das Bewehrungssystem wird also vor dem Aushärten des Matrixmaterials in dieses eingelegt. Bevorzugterweise umfasst das Einlegen eine Positionierung des Bewehrungssystems in einer vorbestimmten Position, die vorzugsweise parallel zu der zu schützenden Oberfläche ist. Vorteilhafterweise wird das Bewehrungssystem derart eingelegt, dass es mindestens um 5 mm von der zu schützenden Oberfläche beabstandet ist. Alle in den vorstehenden Abschnitten offenbarten Merkmale eines schichtförmigen Oberflächenschutzsystem und eines Betonbauteils können vorteilhafterweise Bestandteil des Verfahrens sein. Die in den vorigen Abschnitten eingeführten begrifflichen Definitionen gelten auch im Zusammenhang mit dem Verfahren. Das Bewehrungssystem umfasst vorteilhafterweise Kohlenstofffasern und/oder Glasfasern. Besonders bevorzugt ist ein gitterförmiges Bewehrungssystem, das einen Verbundwerkstoff aus Kohlenstofffasern und/oder Glasfasern und einer Polymermatrix - also einen Faserverbundkunststoff - umfasst.The object of the invention is also achieved by a method for applying a layered surface protection system with the following method steps:

• - Application of at least a first portion of a matrix material - such as concrete or mortar -, which preferably comprises mineral substances, on at least one surface to be protected in such a way that one extends predominantly in a first main direction of extent X and a second main direction of extent Y which extend perpendicular to each other and parallel to the surface to be protected is formed,
• - applying at least one sealant,
• - wherein the at least one sealant is designed in such a way that it increases the solid body volume of the surface protection system when it comes into contact with typical environmental substances such as water and / or air.

In addition, a reinforcement system comprising long fibers which have a length of at least 100 mm is inserted into the matrix material, the reinforcement system preferably being completely surrounded by the matrix material, and the matrix material is then cured. The reinforcement system is therefore inserted into the matrix material before it hardens. The insertion preferably includes positioning the reinforcement system in a predetermined position, which is preferably parallel to the surface to be protected. The reinforcement system is advantageously inserted in such a way that it is at least 5 mm away from the surface to be protected. All of the features of a layered surface protection system and a concrete component disclosed in the preceding sections can advantageously be part of the method. The conceptual definitions introduced in the previous sections also apply in connection with the procedure. The reinforcement system advantageously comprises carbon fibers and / or glass fibers. Particularly preferred is a grid-shaped reinforcement system which comprises a composite material made of carbon fibers and / or glass fibers and a polymer matrix - that is to say a fiber composite plastic.

Further advantages result if the long fibers of the reinforcement system are at least partially coated with at least one bulk material before the reinforcement system is inserted into the matrix material. The advantages of coating with a bulk material have already been explained in the previous sections. The bulk material advantageously comprises sand. It is particularly advantageous if the bulk material comprises quartz sand. The bulk material is advantageously applied to the long fibers with the aid of an adjustable spreading device. The scattering device comprises a container with at least one hole, the bulk material being applied falling through the hole onto the long fibers, preferably by the action of gravity. The spreading device can comprise an adjusting device with which the cross section of the hole can be partially covered in order to regulate the amount of the bulk material. Alternatively, the coating with a bulk material can be applied to the long fibers in such a way that the long fibers, in contact with the bulk material, are guided through a container which is filled with the bulk material. For this purpose, the long fibers are advantageously impregnated with a polymer matrix that has not yet hardened.

It has proven to be advantageous if the long fibers are impregnated for coating with a curable polymer matrix, which preferably comprises a thermoset. After coating with the at least one bulk material, the polymer matrix is advantageously cured before the reinforcement system is inserted into the matrix material. In this way, the bulk material is firmly connected to the reinforcement system and can be integrated into existing manufacturing processes without the use of an additional adhesive.

Further advantages result if the sealant is mixed with the matrix material before the application of the at least one first portion of the matrix material and the sealant is applied together with the matrix material. The two previously described method steps of applying the first portion of the matrix material and the In this way, the sealant can be applied in a common process step. The sealant is then preferably contained uniformly in a layer formed by the matrix material.

Advantageously, after the reinforcement system has been placed in the matrix material, a second portion of the matrix material is applied to the first portion of the matrix material and the reinforcement system. In this way it can be ensured on the one hand that the reinforcement system is spaced apart from the surface to be protected and is nevertheless surrounded on all sides with a sufficiently large amount of the matrix material.

In a particularly advantageous embodiment of the method, a layer containing the at least one sealant is applied before the matrix material is applied, the layer preferably comprising mineral substances. The layer advantageously contains concrete or mortar. The sealant is advantageously distributed essentially uniformly in the layer. Such a layer, which is applied to the surface to be protected before the matrix material is applied, creates a material connection between the surface to be protected and the matrix material and offers additional protection against water penetration between the surface to be protected and the matrix material. For the purposes of this property right, the layer is a partial volume of the layered surface protection system that contains a sealant.

• 1 1 zeigt ein Betonbauteil (2) mit einem schichtförmigen Oberflächenschutzsystem (1), das ein Bewehrungssystem (6) umfasst.
• 2 2 zeigt eine Langfaser (7), die eine Beschichtung (9) mit einem Schüttgutmaterial (8) und einer Polymermatrix (10) aufweist.
• 3 3 zeigt ein Betonbauteil (2) mit einem schichtförmigen Oberflächenschutzsystem (1), Kurzfasern (14) und einem Teilvolumen (17), das ein Dichtmittel (4) enthält.
• 4 4 zeigt das Betonbauteil (2) aus 1, das einen Riss (18) aufweist.
• 5 5 zeigt das Betonbauteil (2) aus 4, wobei der Riss (18) verschlossen ist.

Advantages also result if the method additionally has the following steps: before the application of the at least one first portion of the matrix material, material of a concrete component is at least partially removed, and the surface to be protected is created by removing this material. The concrete component preferably has reinforcement. These process steps can be added to the process, for example in the course of a concrete repair. The material removed from the concrete component is then advantageously a concrete cover layer that covers the reinforcement of the concrete component. The concrete cover layer can contain defects, such as cracks or flaws, which are removed by removing the material in order to subsequently produce a high-quality and fault-free component with a long service life again with the layered surface protection system. In addition, the material removal creates a component with the lowest possible layer thickness, which is of great importance, for example, when the component is used as a roadway in an underground car park.

• 1 1 shows a concrete component ( 2 ) with a layered surface protection system ( 1 ), which has a reinforcement system ( 6th ) includes.
• 2 2 shows a long fiber ( 7th ) that have a coating ( 9 ) with a bulk material ( 8th ) and a polymer matrix ( 10 ) having.
• 3 3 shows a concrete component ( 2 ) with a layered surface protection system ( 1 ), Short fibers ( 14th ) and a partial volume ( 17th ), which is a sealant ( 4th ) contains.
• 4th 4th shows the concrete component ( 2 ) the end 1 that has a crack ( 18th ) having.
• 5 5 shows the concrete component ( 2 ) the end 4th , where the crack ( 18th ) is closed.

the 1 shows a concrete component 2 , which is predominantly in a first main direction of extent X and a second main direction of extent Y extends, with a layered surface protection system 1 , which is also predominantly in the first main direction of extent X and the second main direction of extent Y extends. In one direction of thickness Z that are perpendicular to the first and second main directions of extent X , Y runs, has the layered surface protection system 1 an essentially uniform layer thickness 13th on. The layered surface protection system 1 is on a surface to be protected 5 a base course 15th arranged. In the base course 15th is a main reinforcement 16 arranged, which consists of a metallic material and two reinforcing bars 20th of the metallic material includes. In an advantageous embodiment, there are a large number of such reinforcing bars 20th grid-like in the base course 15th arranged. The metallic material can corrode on contact with water, for example as a result of cracks. The layered surface protection system 1 serves to prevent the metallic material from coming into contact with water and thus preventing its corrosion. For this purpose, the layered surface protection system includes 1 a reinforcement system 6th that consists of several fiber strands 11 is composed, and a matrix material 3 that evenly with a sealant 4th is mixed up and the reinforcement system 6th surrounds. The reinforcement system 6th is particularly in the thickness direction Z on both sides of the matrix material 3 covered and is thus protected from environmental influences and abrasion. In the sense of this patent application, the matrix material is 3 in this embodiment a partial volume 17th the layered surface protection system 1 that the sealant 4th contains. The sealant 4th is in the form of particles. The particles are in 1 shown enlarged for better representation. The distribution of the sealant 4th in the matrix material 3 is in 1 shown by way of example and takes place essentially randomly by mixing the sealant 4th with the Matrix material 3 to a mass that is as homogeneous as possible. The sealant 4th reacts on contact with water with an increase in volume and closes defects in the layered surface protection system 1 . This creates the surface to be protected 5 protected from water and moisture. The reinforcement system 6th increases the sealing effect of the sealant 4th . The fiber strands 11 the reinforcement system can use a variety of long fibers 7th include, which are exemplified in 2 are shown. In the in 1 illustrated embodiment are a plurality of fiber strands 11 , their grain direction 21 (see. 2 ) in the direction of the second main direction of extent Y runs in the direction of the first main direction of extent X arranged side by side. These strands of fiber 11 are shown in section and can be recognized by their exemplary oval cross-section. For the sake of clarity, however, these fiber strands have been hatched 11 waived. There is also a fiber strand in the figure 11 shown, its grain direction 21 in the direction of the first main direction of extent X runs. Parallel to this fiber strand 11 are further fiber strands 11 arranged whose grain direction 21 also in the direction of the first main direction of extent X run and which are covered in this representation and therefore not visible. The fiber strands 11 of the reinforcement system 6th intersect at junctions 12th , are at these junctions 12th firmly connected to each other and form a reinforcement system 6th in the form of a lattice, which lies essentially in a plane that of the two main directions of extent X , Y is stretched.

the 2 shows a long fiber 7th which are essentially in one grain direction 22nd extends and a coating 9 having, the coating 9 a polymer matrix 10 and a variety of protrusions 22nd covering the surrounding areas of the coating 9 in a direction perpendicular to the fiber direction 21 tower above, includes. In this exemplary embodiment, the projections are made up of grains of a bulk material 8th educated. The long fiber 7th is greatly enlarged and not shown in full, which is made clear by the break lines on both sides. A multitude of such long fibers 7th can become a fiber strand 11 (see. 1 ) summarized and as part of a reinforcement system 6th (see. 1 ) can be used. The grain direction 21 of the fiber strand 11 in this case corresponds to the grain direction 21 its long fibers 7th . Instead of a polymer matrix 10 could the coating 9 also include an adhesive securing the bulk material 8th cohesively with the long fiber 7th connects. In 2 becomes an example of a long fiber 7th with a coating 9 shown. It is also conceivable that a large number of long fibers 7th who have favourited a fiber strand 11 form a common coating 9 exhibit.

the 3 shows a concrete component 2 with the same characteristics as the concrete component 2 the end 1 . In addition to the exemplary embodiment from 1 includes the layered surface protection system 1 of the concrete component 2 a variety of short fibers 14th that evenly with the matrix material 3 are mixed up. In the sense of this patent application, the matrix material is 3 in this embodiment a first partial volume 17th the layered surface protection system 1 that the sealant 4th contains. The short fibers 14th enable an even thinner layer 13th in the thickness direction Z with constant mechanical load capacity. Furthermore is between the base course 15th and the layered surface protection system 1 a second partial volume 17th that the sealant 4th contains, arranged. The sealant 4th is even in this second partial volume 17th distributed. However, there are also designs of the layered surface protection system without the second partial volume 17th and / or without the short fibers 14th possible.

the 4th shows the concrete component 2 the end 1 that also has a crack 18th has, which is so through the matrix material 3 the layered surface protection system 1 and the base course 15th of the concrete component 2 that extends the main reinforcement 16 is exposed in sections. The reinforcement system 6th also remains in the place of the crack 18th intact and stabilizes the crack 18th or a reduced crack growth. Usually through such a crack 18th Moisture in the base course 15th occur and lead to corrosion of the main reinforcement 16 to lead.

In a concrete component according to the invention 2 becomes the crack 18th but as in 5 represented by the reaction of the sealant 4th with its typical surrounding substances - in this case water (H ₂ O) and oxygen (O ₂ ) - sealed. This is done in the crack 18th additional solid volume 19th that formed the crack 18th completely fills up. Water and oxygen are in 5 exemplified by their chemical formula. The water can be contained in the form of moisture together with the oxygen in the ambient air or through precipitation in the crack 18th reach.

List of reference symbols

1

Layered surface protection system

2

Concrete component

3

Matrix material

4th

sealant

5

surface to be protected

6th

Reinforcement system

7th

Long fiber

8th

Bulk material

9

Coating

10

Polymer matrix

11

Fiber strand

12th

Junction

13th

Layer thickness of the layered surface protection system ( 1 )

14th

Short fiber

15th

Base course of the concrete component ( 2 )

16

Main reinforcement of the base course ( 15th )

17th

Partial volume

18th

Crack

19th

additional solid volume

20th

Rebar

21

Grain direction

22nd

head Start

X

First main direction of extent

Y

Second main direction of extent

Z

Thickness direction

QUOTES INCLUDED IN THE DESCRIPTION

This list of the documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent literature cited

• AT 521434 B1 [0002]

Non-patent literature cited

• "A Review of Self-Healing for Damage Management of Structures", De Belie et al., Advanced Material Interfaces, May 2018 [0001]
• De Belie et al., Advanced Material Interfaces, May 2018 [0005]

Claims (21)

Layered surface protection system (1) to protect concrete components from penetrating liquids and chlorides with the following ingredients: • a matrix material (3) - such as concrete or mortar - that preferably comprises mineral substances, • at least one sealant (4), at least in part (17) of the surface protection system (1) is included, • the at least one sealant (4) being such that it increases the solid volume of the layered surface protection system (1) on contact with typical environmental substances such as water and / or air, • and where the layered surface protection system (1) extends predominantly in a first main direction of extent (X) and a second main direction of extent (Y), which are perpendicular to one another and preferably run parallel to a surface (5) to be protected, characterized by • a reinforcement system (6) which comprises long fibers (7) which have a length of at least 100 mm, but preferably at least 200 mm, the reinforcement system (6) being enclosed by the matrix material (3). Layered surface protection system (1) according to the preceding claim, characterized in that the layered surface protection system (1) has at least two preferably layered partial volumes (17) with different material compositions. Layered surface protection system (1) according to one of the preceding claims, characterized in that the sealing means (4) is mixed with the matrix material (3). Layered surface protection system (1) according to one of the preceding claims, characterized in that the long fibers (7) extend essentially in a plane which is spanned by the first and second main direction of extension (X, Y). Layered surface protection system (1) according to one of the preceding claims, characterized in that the long fibers (7) are surrounded at each point of their length by an at least 5 mm, preferably at least 10 mm, layer of the matrix material (3). Layered surface protection system (1) according to one of the preceding claims, characterized in that the long fibers (7) have a coating (9) which comprises projections (23). Layered surface protection system (1) according to the preceding claim, characterized in that the coating (9) contains a bulk material (8). Layered surface protection system (1) according to the preceding claim, characterized in that the bulk material (8) comprises sand, preferably quartz sand. Layered surface protection system (1) according to one of the Claims 7 or 8th characterized in that the bulk material (8) has a grain size of 0.1 to 1 mm. Layered surface protection system (1) according to one of the preceding claims, characterized in that the sealant (4) forms crystals on contact with the typical surrounding substances, preferably water and / or oxygen. Layered surface protection system (1) according to one of the preceding claims, characterized in that the sealant (4) comprises at least one bacterium which forms a solid, preferably calcium carbonate, in the layered surface protection system (1) on contact with at least one typical ambient substance. Layered surface protection system (1) according to the preceding claim, characterized in that the at least one bacterium comes from one of the genera Bacillus, Planococcus or Sporosarcina. Layered surface protection system (1) according to one of the preceding claims, characterized in that the long fibers (7) comprise at least one carbon fiber and / or at least one glass fiber. Layered surface protection system (1) according to one of the preceding claims, characterized in that the reinforcement system (6) comprises a polymer matrix (10) which envelops the long fibers (7) and contains at least one thermoset resin, preferably epoxy resin or vinyl ester resin. Layered surface protection system (1) according to one of the preceding claims, characterized in that • the reinforcement system has a plurality of fiber strands (11) each comprising a large number of the long fibers (7), • wherein the fiber strands (11) are arranged in relation to one another, that the fiber strands (11) intersect at nodes (12) and wherein the fiber strands (11) are connected to one another at the node points (12). Layered surface protection system (1) according to one of the preceding claims, characterized in that the modulus of elasticity of at least one of the long fibers (7) is at least 70,000 MPa, but preferably at least 200,000 MPa. Layered surface protection system (1) according to one of the preceding claims, characterized in that the layered surface protection system (1) has a layer thickness (13) of a maximum of 50 mm, but preferably a maximum of 20 mm, the layer thickness (13) the extension of the surface protection system (1 ) in a thickness direction (Z) which runs perpendicular to the first main direction of extent (X) and the second main direction of extent (Y). Layered surface protection system (1) according to one of the preceding claims, characterized by short fibers (14) which have a maximum length of 50 mm and are mixed with the matrix material (3). Reinforced concrete component (2) with the following features: • a base layer (15), which extends in layers predominantly in a first main direction of extent (X) and a second main direction of extent (Y) and comprises mineral substances, • a main reinforcement (16), which preferably at least comprises a metallic material and is preferably arranged as a grid in the base layer (15), • a layered surface protection system (1) which comprises a matrix material (3) - such as concrete or mortar - preferably made of mineral substances, and which is layered predominantly in the first and second main direction of extent (X, Y), • at least one sealant (4) which is contained in at least a partial volume (17) of the layered surface protection system, • wherein the at least one sealant (4) is such that it is at Contact with typical ambient substances such as water and / or air, the solid volume of the layered surface protection system (1), characterized by a reinforcement system (6) which is arranged in the layered surface protection system (1) and enclosed by the matrix material (3), and which comprises long fibers (7) which have a length of at least 100 mm. Reinforced concrete component (2) according to one of the preceding claims, characterized in that the sealing means (4) is mixed with the matrix material (3). Reinforced concrete component (2) according to the preceding claim, characterized in that a preferably layered partial volume (17) containing the at least one sealing means (4) is arranged between the base layer (15) and the matrix material (3).

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