JP2002054273A - Composite covering structural body and its execution method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a new composite covering structural body excellent in waterproofness, durability, and beautiful appearance and having a gravel layer at the uppermost layer and to provide its execution method. SOLUTION: This composite covering structural body is provided with (A) the gravel layer fixed with natural stones and/or artificial stones by a resin composition, (B) a waterproof layer hardened with a fiber-reinforced thermosetting resin composition containing a thermosetting resin and a fiber reinforcement, (C) a primer layer, and (D) a substrate from above. Projections of natural stones and/or artificial stones are formed on the (A) gravel layer.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composite covering structure and a method for constructing the same.

[0002]

2. Description of the Related Art In recent years, the multifunctionality of architectural spaces has been actively promoted. For example, the rooftop of a building is required to function not only as a roof but also as a walking space and a design space. More. That is, it is required to have both waterproofness, which is a main function as a roof, and durability and aesthetics, which are main functions as a walking space and a design space.

[0003]

As a method for providing a function as a walking space in an architectural space, there has been proposed a method of forming a gravel layer by spreading natural stones such as cobblestones. However, in the conventional method of simply laying natural stones such as gravel or the like, there is a problem that a crack occurs in a waterproof layer below the gravel layer due to the weight of the gravel layer or the impact of walking. Further, in the conventional gravel layer, there is also a problem that stones move or fly due to wind, rain, walking, or the like. The problem to be solved by the present invention is to provide a novel composite covering structure having a gravel layer as the uppermost layer and having an excellent waterproofness, durability, and aesthetics, and a method of constructing the same.

[0004]

Means for Solving the Problems The present inventor has made intensive studies to solve the above-mentioned problems. As a result, according to the composite covering structure using the FRP resin layer as the waterproof layer, and further using the layer formed by fixing the natural stone and / or the artificial stone with the resin composition in a specific fixing form as the gravel layer. It has been found that the above problem can be solved. That is, it was found that by using the FRP resin layer as the waterproof layer, excellent waterproofness can be exhibited, and the durability against mechanical damage due to the gravel layer built thereon is also excellent. In addition, by using a layer in which natural stones and / or artificial stones are fixed with a resin composition in a specific fixing form as a gravel layer, movement and scattering of the gravel can be suppressed, and the original texture of the gravel can be obtained. I found that I could do it.

Accordingly, the composite coated structure according to the present invention is
From the top, (A) a gravel layer in which natural stones and / or artificial stones are fixed by a resin composition, and (B) a fiber-reinforced thermosetting resin composition containing a thermosetting resin and a fiber reinforcing material, (C) a primer layer and (D) a substrate, wherein the (A) layer has a protruding portion made of natural stone and / or artificial stone formed on the layer. It is characterized by becoming.

[0006] A method for applying a composite covering structure according to the present invention is a method for applying a composite covering structure according to the present invention, comprising:
A natural stone and / or artificial stone is laid on the layer (B), and a liquid resin composition is applied and solidified to fix the natural stone and / or the artificial stone with the resin composition, and The projection is formed on the layer (A) by the natural stone and / or the artificial stone.
Further, another method for applying a composite coating structure according to the present invention is a method for applying a composite coating structure according to the present invention, wherein a liquid resin composition is applied on the layer (B). A natural stone and / or an artificial stone is laid before the resin composition is solidified, and the natural stone and / or the artificial stone is fixed by the resin composition by solidifying the resin composition, and the natural stone and / or the artificial stone is A protruding portion made of artificial stone is formed on the layer (A).

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION The composite coated structure according to the present invention comprises:
From the top, (A) a gravel layer in which natural stones and / or artificial stones are fixed by a resin composition, and (B) a fiber-reinforced thermosetting resin composition containing a thermosetting resin and a fiber reinforcing material, (C) a primer layer and (D) a substrate, wherein the (A) layer has a protruding portion made of natural stone and / or artificial stone formed on the layer. It is characterized by becoming.

Hereinafter, the present invention will be described in detail, including details of the above-mentioned components. In the present invention, the gravel layer (A) in which natural stone and / or artificial stone is fixed by the resin composition is a layer in which natural stone and / or artificial stone is fixed by the resin composition. The thickness of the gravel layer (A) is not particularly limited, but is 5 to 100 m.
m, preferably 20 to 70 mm. As the natural stone and / or artificial stone,
It is not particularly limited, and a stone having a corner shape may be used,
A stone having no corner may be used, but a stone having no corner such as a sphere or an oval sphere is preferable from the viewpoint of walking property and workability. By using a stone having no corners, walking on the gravel layer becomes comfortable, and it is easy to spread the natural stone and / or the artificial stone to a uniform thickness when forming the gravel layer.

The particle size of the natural stone and / or artificial stone is not particularly limited, but is preferably in the range of 5 to 100 mm, and more preferably in the range of 5 to 50 mm. If the particle size is less than 5 mm, the particles will be buried in the layer of the resin composition used for fixing, and the texture inherent in gravel cannot be obtained, and a sufficient landscape cannot be provided. Further, if the particle size exceeds 100 mm, even if the resin composition is fixed, the adhesive area may be easily dropped due to a small bonding area. The natural stone that can be used in the present invention is not particularly limited, for example, granite,
Igneous rocks such as andesite, sedimentary rocks such as sandstone and tuff, marble,
Modified rocks such as slate and serpentine are exemplified.

The artificial stone usable in the present invention is not particularly limited. For example, a pulverized product of an inorganic material such as ceramic or a thermosetting resin such as urea resin, melamine resin and unsaturated polyester resin is used. And a stone-shaped molded article of a thermoplastic resin. The resin used in the resin composition used for fixing the natural stone and / or the artificial stone is not particularly limited, and examples thereof include an epoxy resin, a urethane resin, a urea resin, a melamine resin, a phenol resin, an acrylic resin, and an unsaturated polyester resin. , A vinyl ester resin, a urethane (meth) acrylate resin, and the like. These solvent dilution type and emulsion type resins can also be used.

The content of the resin in the resin composition is not particularly limited, but may be, for example, 40 to 100% by weight.
Is more preferable, and the range of 60 to 100% by weight is more preferable. In the above resin composition, in addition to the above resin, if necessary, a curing agent, a curing accelerator, a life stabilizer, a filler, a pigment, a defoaming agent, a surfactant, a silane coupling agent, a plasticizer And auxiliary materials such as thermoplastic resins and elastomers. In the present invention,
(A) The layer is characterized in that a protruding portion made of the natural stone and / or the artificial stone is formed on the layer. That is, when the (A) layer is viewed from above, the portion where the natural stone and / or the artificial stone itself protrudes can be recognized, or in a state where the natural stone and / or the artificial stone is covered with the resin composition, There are cases where a protrusion derived from the shape of the natural stone and / or the artificial stone can be recognized. In addition, not only the form in which a projection is formed on the (A) layer by a part of all of the used natural stones and / or artificial stones, but also some of the used natural stones and / or artificial stones Although it is completely buried, some of the others include a form in which a protrusion is formed on the layer.

In the present invention, the waterproof layer (B) obtained by curing the fiber-reinforced thermosetting resin composition containing the thermosetting resin and the fiber reinforcing material is a so-called FRP waterproof layer.
By combining the (B) layer, which is the FRP waterproof layer, with the gravel layer (A), excellent waterproofness can be exhibited, and the durability against mechanical damage due to the gravel layer (A) built on the top is improved. Will also be excellent. Examples of the fiber reinforcing material used in the fiber-reinforced thermosetting resin composition include glass fibers; organic fibers such as amide, aramid, vinylon, polyester, and phenol; carbon fibers; metal fibers; ceramic fibers; And the like. Among these, glass fibers and organic fibers are preferable in consideration of workability and economic efficiency.

The fiber may be in the form of plain weave, satin weave, mat or the like, but is preferably mat in view of workability and thickness maintenance. In addition, glass roving 20 ~ 100m
It is also possible to cut it to about m and use it as a chopped strand. The content of the fiber reinforced material in the fiber reinforced thermosetting resin composition is not particularly limited, but is preferably in the range of 5 to 60% by weight, and more preferably in the range of 10 to 40% by weight. The tensile elongation (JIS-K-7113) of the cured product of the thermosetting resin is not particularly limited, but is preferably 20 to 200%, more preferably 20 to 150%, and still more preferably 30 to 150%.
120%. If it is less than 20%, the ability to follow the movement of the underlying substrate will be poor. If it is more than 200%, calcium chloride resistance, water resistance, alkali resistance, and oil resistance will be poor.

The method of forming the waterproof layer (B) is not particularly limited. For example, a hand lay-up method, a spray-up method, a method of laying a resin-impregnated mat-like fiber reinforcement, Casting method and the like can be mentioned. The thickness of the waterproof layer (B) is not particularly limited,
Usually preferably 0.5-5 mm, more preferably 1-2.
mm. The thermosetting resin used in the waterproof layer (B) is not particularly limited, and examples thereof include an unsaturated polyester resin, a vinyl ester resin, an epoxy resin, a phenol resin, and an acrylic resin. Preferred are unsaturated polyester resins and vinyl ester resins.

The content of the thermosetting resin in the fiber-reinforced thermosetting resin composition is not particularly limited, but is preferably 40 to
It is preferably in the range of 95% by weight, more preferably in the range of 60 to 90% by weight. Examples of the unsaturated polyester resin preferably used in the present invention include, for example, polycondensation of α, β-unsaturated dibasic acid or acid anhydride thereof, aromatic saturated dibasic acid or acid anhydride thereof, and glycols. 30 to 80 parts by weight of an unsaturated polyester produced by the combined use of an aliphatic or alicyclic saturated dibasic acid as an acid component in some cases, a polymerizable unsaturated monomer 70 to
Those obtained by dissolving in 20 parts by weight are exemplified.

The vinyl ester resin preferably used in the present invention is, for example, a vinyl ester in which the carboxyl terminal or the hydroxyl terminal of an unsaturated polyester is vinyl-modified with an epoxy compound having an unsaturated group or an isocyanate compound having an unsaturated group. And those obtained by dissolving 30 to 80 parts by weight of a vinyl ester obtained by adding an unsaturated monobasic acid to an epoxy group of a polyfunctional epoxy resin in 70 to 20 parts by weight of a polymerizable unsaturated monomer. . If necessary, a thickener, a filler, a curing agent, a curing accelerator, a low-shrinking agent, a thixotropic agent, a paraffin wax and the like can be added. In particular, it is preferable to add a curing agent and a curing accelerator.

The α, β-unsaturated dibasic acid or anhydride thereof includes, for example, maleic acid, maleic anhydride, fumaric acid, itaconic acid, citraconic acid and esters thereof. As the basic acid or its acid anhydride, phthalic acid, phthalic anhydride, isophthalic acid,
Terephthalic acid, and esters thereof, etc., as aliphatic or alicyclic saturated dibasic acids, oxalic acid, malonic acid, succinic acid, adipic acid, sebacic acid, azelaic acid, glutaric acid, tetrahydrophthalic anhydride, Hexahydrophthalic anhydride and esters thereof. These can be used alone or in combination.

The glycols include ethylene glycol, propylene glycol, diethylene glycol, dipropylene glycol, 1,3-butanediol,
4-butanediol, 2-methylpropane-1,3-diol, neopentyl glycol, triethylene glycol, tetraethylene glycol, 1,5-pentanediol, 1,6-hexanediol, bisphenol A, hydrogenated bisphenol A, etc. Is mentioned. These can be used alone or in combination. In addition, oxides such as ethylene oxide and propylene oxide can also be used. Polycondensates such as polyethylene terephthalate can also be used as part of the glycols and the acid component.

As the polymerizable unsaturated monomer, styrene,
Vinyl toluene, α-methylstyrene, methyl (meth)
Unsaturated compounds such as vinyl compounds such as acrylate, ethyl (meth) acrylate, methoxydiethylene glycol (meth) acrylate, phenoxyethyl (meth) acrylate and diethylene glycol di (meth) acrylate; and allyl compounds such as diallyl phthalate and triallyl cyanurate Examples include a vinyl monomer crosslinkable with polyester or vinyl ester. These can be used alone or in combination. The filler is not particularly limited, for example, calcium carbonate powder,
Clay, alumina powder, silica stone powder, talc, barium sulfate,
Known materials such as silica powder, glass powder, glass beads, mica, aluminum hydroxide, cellulose thread, silica sand, river sand, cold water stone, marble chips, and crushed stone are exemplified.

The curing agent is generally used for curing a thermosetting resin such as an unsaturated polyester resin. Specific examples thereof include an azo compound such as azoisobutyronitrile, tertiary butyl perbenzoate, and tertiary butyl perbenzoate. Organic peroxides such as reaper octoate, benzoyl peroxide, methyl ethyl ketone peroxide, dicumyl peroxide and the like can be mentioned. The amount of the curing catalyst used is not particularly limited, but for example, can be generally used in the range of 0.3 to 3 parts by weight based on 100 parts by weight of a thermosetting resin such as an unsaturated polyester resin. As the curing accelerator, metal salts of organic acids, particularly, cobalt salts,
For example, but not limited to, cobalt naphthenate, cobalt octylate, acetylacetocobalt and the like are used.

The primer layer (C) in the present invention is a layer for the purpose of bonding the substrate (D) and the waterproof layer (B). As the primer layer (C), a material having good adhesion to a thermosetting resin is desired. For example, a low-viscosity concrete-impregnated product (viscosity of 300 mPa · s or less) is preferable. Urethane primers, bisphenol A epoxy / polyamine primers, unsaturated polyester resin primers, vinyl ester resin primers and the like can be used.
The coating amount of the primer is 50 to 500 g / m ^{2 in} solution,
Preferably 70 to 300 g / m ² , more preferably 10 g / m ²
0 to 200 g / m ² . As a means for applying, a brush, a roll, a spray gun, or the like is used.

The substrate (D) in the present invention is not particularly limited. For example, the substrate (D) is applied to the surfaces of roofs, rooftops, intermediate floors, ground floors, verandas, basements and the like of buildings and structures, and the surfaces thereof. Existing waterproof surfaces are listed, and the materials are cement concrete, asphalt concrete, mortar, asbestos straight, ALC board, PC board, F
RP materials, plastics, wood materials, metals, and the like.
In the method for applying a composite coated structure according to the present invention, for example, first, a primer is applied to a substrate (D) to form a primer layer (C). Subsequently, a fiber reinforced material is laid on the primer layer and then impregnated with a thermosetting resin, or a fiber reinforced material impregnated with a thermosetting resin is laid to form a waterproof layer (B). Let it form.

The method of forming the gravel layer (A) in which natural stones and / or artificial stones are fixed by a resin composition on the layer (B) is not particularly limited. A method of laying a natural stone and / or an artificial stone on a layer and further applying a liquid resin composition or solidifying it by injecting, constructing, or the like, or applying a liquid resin composition on the layer (B) And further laying natural stones and / or artificial stones before the resin composition solidifies,
A method of solidifying the resin composition is preferred. According to the above method, one of the features of the present invention, a natural stone and / or an artificial stone is fixed by a resin composition, and
The layer (A) in which a projection made of natural stone and / or artificial stone is formed on the layer can be constructed.

In the above method, the amount of the resin composition to be applied is not particularly limited, but is preferably in the range of 0.3 to 3.0 kg per m ² , and more preferably in the range of 0.6 to 2.0 kg. More preferably, it is within the range of 0 kg. 0.3 kg of resin composition per 1 m ²
If it is less than 3, the fixation of the natural stone and / or the artificial stone may be insufficient, and the applied amount is 3.0 kg per 1 m ^2.
If it exceeds 3, natural stones and / or artificial stones will be buried in the layer of the resin composition, and the texture inherent in the gravel cannot be obtained, and a sufficient landscape cannot be provided. The use of the composite covering structure according to the present invention is not particularly limited, and examples thereof include a rooftop of a building, a middle floor, a ground floor, a veranda, a road, a sidewalk, and an underpass.

[0025]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described more specifically below with reference to the drawings, but the present invention is not limited to these embodiments. (Example 1) substrate in a building roof 1 liquid type urethane primer on concrete (trade name: NS-YP, manufactured by Nippon Shokubai Co., Ltd.) about 200g was uniformly applied per 1 m ² and allowed to stand for 3 hours, touch It was dried to the extent of drying to form a primer layer. Next, a curing agent (trade name: Kayamec M, manufactured by Kayaku Akzo Co., Ltd.) was added to the accelerator-added soft unsaturated polyester resin (trade name: Epolac N-5553, manufactured by Nippon Shokubai Co., Ltd.).
About 4% by weight per 1 m ²
00g uniformly, followed by a glass mat #
380, 2 plies were impregnated with the same curing agent-added resin so that the glass content was about 23% by weight, and left for 3 hours to cure to the extent of touch-drying to form a waterproof layer.

[0026] Further, about 6 to 6
Acrylic resin emulsion (trade name: Acryset EMN-1)
29E, manufactured by Nippon Shokubai Co., Ltd.) was applied in an amount of about 1 kg per 1 m ² , and allowed to stand for 6 hours to fix the gravel and form a gravel layer. The layer form is as shown in FIG. 1 when the application of the acrylic resin emulsion is performed so as to cover also the upper part of the gravel, and when the coating is performed so as not to cover the upper part of the gravel. It looked like 2. After construction,
One year later, it was confirmed that there was no water leakage due to exposure of the waterproof layer due to falling of the gravel from the gravel layer and damage to the waterproof layer, and that it could be used without any problem.

Example 2 In the same manner as in Example 1, a primer layer and a waterproof layer were formed on a concrete on a rooftop of a building. Next, a vinyl ester resin containing an accelerator (trade name:
RF-9100, manufactured by Nippon Shokubai Co., Ltd.) and a curing agent (trade name: 3)
28E, manufactured by Kayaku Akzo Co., Ltd.) is applied uniformly at a rate of about 1 kg per 1 m ^{2 of} a curing agent-added resin containing 1% by weight of a resin. The pieces were laid side by side and left for 4 hours to fix the gravel and form a gravel layer.

The layer configuration was as shown in FIG. After construction,
One year later, it was confirmed that there was no water leakage due to exposure of the waterproof layer due to falling of the gravel from the gravel layer and damage to the waterproof layer, and that it could be used without any problem.

[Brief description of the drawings]

FIG. 1 is a schematic view of an example of a layer form in an embodiment of the present invention.

FIG. 2 is a schematic view of an example of a layer form in an embodiment of the present invention.

FIG. 3 is a schematic view of an example of a layer form in an embodiment of the present invention.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Substrate 2 Primer layer 3 Waterproof layer which hardened | cured the fiber reinforced thermosetting resin composition containing a thermosetting resin and a fiber reinforcement 4 Gravel layer which natural stone and / or artificial stone are fixed by the resin composition 4a Gravel 4b Solidified resin composition

According to the present invention, waterproofness, durability and aesthetics are all excellent, and a non-slip effect can be exhibited.
A novel composite covering structure having a gravel layer as the uppermost layer and a method for constructing the same can be provided.

Claims (3)

[Claims] 1. From the top, (A) a gravel layer in which natural stone and / or artificial stone is fixed by a resin composition, and (B) a fiber-reinforced thermosetting resin composition containing a thermosetting resin and a fiber reinforcing material. (C) a primer layer, (D) a substrate, a composite coating structure having the following constitution: wherein the (A) layer has a layer formed of a natural stone and / or an artificial stone. A composite coated structure characterized by being formed thereon. 2. The method according to claim 1, wherein a natural stone and / or an artificial stone is laid on the layer (B), and a liquid resin composition is applied. By solidifying, the natural stone and / or the artificial stone is fixed with the resin composition, and a projection made of the natural stone and / or the artificial stone is formed on the layer (A). Body construction method. 3. The method according to claim 1, wherein a liquid resin composition is applied on the layer (B).
A natural stone and / or an artificial stone is laid before the resin composition is solidified, and the natural stone and / or the artificial stone is fixed by the resin composition by solidifying the resin composition. Alternatively, a method for constructing a composite covering structure, wherein a projecting portion made of artificial stone is formed on the layer (A).