JP2003120009A - Repair floor and its construction method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To solve a problem of no repair construction method existing for a hard finished floor due to incapability of acquiring the adhesion of a repair floor because of its hard and nonporous properties in repair when damaged under the long-term use of the hard finished floor formed by scattering a mixture obtained by mixing wear-resistant aggregate such as natural stone, artificial aggregate or carborundum, with a hydraulic binding material such as Portland cement, on the surface of unhardened concrete or mortar, and absorbing excess moisture in the concrete or mortar to harden it. SOLUTION: Resin mortar comprising water polyol, an isocyanate compound, hydraulic cement and further aggregate mixed if necessary can be reused as the repair floor because of its excellent adhesion to the existing hard finished floor and its excellent floor performance such as wear resistance.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a repair floor for various building structures such as factories, warehouses and parking lots and a construction method therefor, and more particularly to a repair floor for an existing hard finish floor and a construction method therefor.

[0002]

2. Description of the Related Art As a floor for various building structures such as factories, warehouses, and parking lots, in order to improve slip resistance and wear resistance, there is disclosed in Japanese Patent Application Laid-Open No. 11-293901 "Water-resistant non-slip floor and its forming method" Such hard finished floors have been proposed. Such hard finishing floor is hard aggregate on the surface of uncured concrete or mortar immediately after casting, for example, river sand, mountain sand, natural aggregate such as river gravel, mountain gravel, artificial aggregate such as crushed stone,
Blast furnace slag, some water is an aggregate with excellent wear resistance such as emery, carborundum, and alundum, or a mixture of these and a hydraulic binder, such as Portland cement, gypsum, and a spray powder that is a mixture of hydraulic slag. Then, the sprayed hydraulic bond aggregate is absorbed by absorbing excess water of the uncured concrete or mortar and hardened, and then further coated with a synthetic resin top coat if necessary. Although the hard finish floor has excellent characteristics such as slip resistance and abrasion resistance, it is used for a long period of time, and cracks, scratches, abrasion, etc. may occur due to the transportation of heavy objects, and the temperature difference between the base and the floor is repeated. If cracks are generated due to dimensional changes due to, repair is required. However, since such a hard finish floor absorbs excess water in the hardening process of concrete or mortar as described above, there is almost no void created by the evaporation of water on the surface or inside of concrete or mortar. It has become. For this reason, when the repair floor is constructed without pretreatment, the resin, mortar, etc. used for the repair material cannot penetrate, resulting in incomplete adhesion of the repair material to the foundation and peeling after construction. It had been. Also, as a base treatment, the floor surface was mechanically blasted or the like to give an uneven state to the surface, or an acid such as sulfamic acid was used to form voids on the surface and then the repair floor was constructed.
There were problems such as increased cost and longer construction period.

The present invention has been made in view of the above problems.
It was made as a result of diligent examination, it has excellent adhesion to the surface of the hard finish floor, the construction period is short, and the heat resistance,
The purpose of the present invention is to provide a repair floor that can be expected to have surface properties such as chemical resistance, water resistance, heat resistance, and abrasion resistance, and a construction method therefor.

[0004]

DISCLOSURE OF THE INVENTION The present invention provides the above-mentioned problems, namely, the improvement of the adhesion to an existing hard finish floor and the surface performance such as heat resistance, water resistance, chemical resistance and abrasion resistance. (EN) A construction method which is provided and which solves the problems of construction period and construction management, which have been problems of the conventional construction method for flooring materials.

[0005]

SUMMARY OF THE INVENTION In order to solve the above problems, the present invention solves the conventional problems by applying urethane resin mortar to an existing hard finish floor. The resin mortar composition comprises an aqueous polyol as a main component, an isocyanate compound as a curing agent, preferably a polymeric MDI, a hydraulic cement, and optionally an aggregate, and the composition is an existing hard finish. It was constructed on the floor.

Among the resin components of the composition used for the resin mortar layer, an aqueous polyol or a water-dispersible follyol can be used as the main component, an aqueous polyol, and the aqueous polyol is ethylene glycol as a polyhydroxy compound,
Ester compound obtained from polyhydric alcohol or oxyalkylene derivative such as diethylene glycol, butanediol, propylene glycol, hexanediol glycerin, pentaerythritol and polyvalent carboxylic acid, polyvalent carboxylic acid anhydride, or polyvalent carboxylic acid ester, polycarbonate polyol , Polycaprolactone polyols, polyester polyols, polyacetal polyols, castor oil polyols, and other polyol compounds, and modified products thereof.

The water-dispersible polyol is a resin having a hydroxyl group and dispersible in water, and examples of the hydroxyl group-containing component include methacrylic acid 2-hydroxyethyl ester, methacrylic acid 2-hydroxypropyl ester and methacrylic acid 2-hydroxypropyl ester. Acrylic copolymer-based polyol prepared by emulsion-polymerizing at least one kind of unsaturated compound such as acrylonitrile, methacrylic acid, and alkyl methacrylic acid ester containing at least one kind of ester Or aromatic, aliphatic, or alicyclic diisocyanates or isocyanate oligomers using them and polyhydric alcohols such as polyethylene glycol, polypropylene glycol, trimethylolpropane, pentaerythrit, sorbitol, or bisphenols. Urethane-forming reaction of at least one alcohol compound selected from hydroxycarboxylic acids such as roxypropionic acid and hydroxyacetic acid, and if necessary neutralize carboxylic acid, such as urethane polyol, other polyetherols, polyester Examples thereof include polyols. These can be dispersed in water by utilizing the emulsifying action of the surfactant. In addition,
Aqueous dibutyltin diuret as a curing aid is added to the main agent as a curing agent.
By adding 01 to 0.2% by weight, the time until tack free can be shortened.

The isocyanate compound of the curing agent is a polymeric diisocyanate having two or more functional groups, preferably polymeric diphenylmethane diisocyanate M.
DI is preferably 15 to 32% NCO. Polymeric MDI is a polymeric MDI "PAPI2027" manufactured by Dow Chemical Co., a polymeric MDI "rubinate M" manufactured by ICI Polyurethanes, or a polymeric MDI "MONDUR XP7" manufactured by Bayer.
00 "or the like can be used. Such a polymeric MD
The purpose of using I is to eliminate the above-mentioned various problems associated with the use of solvents, and the purpose of the present invention cannot be achieved without the use of this type of curing agent.

Examples of the hydraulic cement used in the present invention include Portland cement, white Portland cement, and fast-setting cement containing high alumina.

Aggregates optionally incorporated into the resin mortar layer of the present invention include recycled powder of insulator, silica sand, calcium carbonate, kaolin, clay, iron dust, other glass, crushed ceramics and slaked lime. . These aggregates are used alone, or a plurality of components are appropriately mixed and used. The particle size of the aggregate is 0.0
Particle sizes of 5 to 3 mm, preferably 0.1 to 1.5 mm are suitable for use. If it is less than 0.05 mm, the workability is deteriorated, which is not preferable. When it is 3 mm or more, workability is poor and the finish is not good, which is not preferable.

A preferred blending ratio of these blending materials is 5 parts hydraulic cement to 100 parts by weight aqueous polyol.
0 to 300 parts by weight, isocyanate compound 100 to 12
In addition to 0 parts by weight, 0 to 300 parts by weight of aggregate is mixed.
If the hydraulic cement content is 50 parts by weight or less, the water absorption by the hydraulic cement is reduced, and the tendency of foaming due to the reaction between the isocyanate compound and the water is increased, which is not suitable. Three
If it is more than 100 parts by weight, the composition for mortar floor becomes too hard and the workability is deteriorated, and since there are many hydraulic cements, the chemical resistance tends to be poor, which is not preferable. When the amount of the isocyanate compound is 100 parts by weight or less, the curability is poor, which is not preferable. On the other hand, if it is more than 120 parts by weight, it tends to react with water and foam, which is not suitable. By blending the aggregate, it is possible to obtain a coating film having a uniform thickness, improve workability, and reduce costs.

Next, a floor repairing method according to the present invention will be described. When applying to an existing hard finish floor, it is preferable that conditions such as no stain, no cracks, and no impregnation of vegetable oil, mineral oil, etc. are satisfied as a base. When it is dirty, it can be adjusted by washing with a detergent, when it is cracked, it is filled with putty or a resin mortar mixture, and when it is oil, it can be adjusted by washing with a neutral detergent. A resin mortar layer is prepared by applying the composition for resin mortar on the thus prepared underlayer using an applicator such as a flat trowel, a comb trowel, or a roller to a thickness of about 0.5 to 1.5 mm and curing it. Is formed. The curing of the resin mortar layer will vary depending on the resin component, but it will take about 2 to 10 hours at room temperature. In applying the resin mortar composition, there is no particular problem with drying the base, and the resin mortar layer may be applied to the base even when it is in an undried state.

The cured resin mortar layer can be used as it is as a repair floor. However, when it is desired to further improve the performance such as walking property or waterproof property, the surface of the resin mortar is coated with urethane resin or the like. It is also possible to apply and finish the coated flooring material, or to apply a reinforced resin layer in which glass fiber and thermosetting resin are combined. In this way, when applying another finishing layer on the resin mortar, the adhesion may be insufficient. In such a case, a primer can be used to improve the adhesion. As an example of the primer, a one-component moisture-curable urethane primer, 2
A liquid urethane resin primer, an epoxy resin primer, an unsaturated polyester resin primer, etc. can be used.

Specific examples will be described below. Example 1 Dismophen 1 which is a water-dispersible polyol as a main agent
50 parts by weight of 150 (Bayer) and 5 parts by weight of Rebenol (Kao Co., Ltd.) in 45 parts by weight of water, 100 parts by weight of a water-based oil / polyol polyol, Sumidure 44V20 of Polymeric MDI as a curing agent 100 parts by weight of chlorinated Bayer), 100 parts by weight of cement, and 100 parts by weight of cement in a container and thoroughly stirred with a hand mixer.
200 parts by weight of silica sand was added and further stirred to prepare a resin mortar formulation 1 of Example 1. The resin mortar formulation 1 was applied to the surface of an existing hard finish floor (water content 4.8%) with a trowel to a thickness of 2 mm and cured to complete the repair floor of Example 1 consisting of a resin mortar layer.

Example 2 As an adhesive (urethane resin-based adhesive) on the surface of the floor constructed in Example 1, (Aika Joliace JU-1
270) was applied at 0.15 Kg / m 2 and dried, and then a fiber-reinforced thermosetting resin layer was applied as follows. 450 kg / m 2 of glass mat was applied as a fiber to 1 ply of unsaturated polyester resin (Aica Jollyace JE-2000) as a thermosetting resin so that the glass content rate was about 25%, laminated and cured. . Next, as an intermediate coating, unsaturated polyester resin (Aika Joliace JE-
2000) was coated with a roller at 0.4 kg / m 2 and cured. Furthermore, 0.4K of unsaturated polyester resin (Aika Joliace JE-2080) is used as a top coat with a roller.
The repair floor of Example 2 was constructed by applying g / m 2 and curing.

Example 3 The surface of an existing hard finish floor with a part of oil adhering thereto was washed with washing water containing a neutral detergent mixed with water, and the washing water remaining on the surface was wiped off with a waste cloth, With the surface of the hard finish floor of No. 2 being wet, the resin mortar formulation 1 of Example 1 was applied in the same manner as in Example 1 to construct the repair floor of Example 3.

Comparative Example 1 An epoxy resin-based primer (Joliace JE-2) was used as a primer on the surface of the hard finish floor used in Example 1.
570) is applied at 0.15 Kg / m 2 and after drying, an epoxy solvent-free casting floor material Joliace JE-2520
Was applied at 1.0 kg / m2 and cured to complete the repair floor of Comparative Example 1.

Comparative Example 2 0.6 kg of epoxy resin emulsion mortar (JE-2371) was applied to the surface of the hard finish floor used in Example 1.
/ M2 applied and dried, then water-based primer (JE-7
71) 0.15 Kg / m2, and then 1.0 Kg / m of epoxy resin coating floor (JE-2520) as the top coat.
2 was applied to finish the repair floor of Comparative Example 2.

Comparative Example 3 The repair floor of Comparative Example 3 was finished in the same manner as Comparative Example 1 except that the existing damp, hard finished floor used in Example 3 was used.

The results of performance evaluation of the floors of Examples and Comparative Examples are shown in Table 1.

[Table 1] Evaluation Method Plane Tensile Strength A test piece in which an iron jig having an adhesion area of 4 cm is adhered to the surface of the repair floor is prepared on a construction floor 7 days after construction, and a plane tensile test is performed to measure the adhesion strength. Forced peeling test 7 days after construction, put a peel on the adhesive surface of the repair floor and observe the peeled state.

[0021]

According to the repair floor and its construction method of the present invention,
The resin mortar according to the present invention has excellent adhesion even to the surface of the existing hard finish floor, which could not be completely adhered by the conventional construction method, and can be applied without problems even when the base is insufficiently dried. It can be reused as a repair floor in a short period of time. Therefore, the method for constructing a repair floor according to the present invention is most suitable for repairing a floor in a place such as a factory or a warehouse where daily use is required and a short work period is strongly required. Further, the repair floor according to the present invention is composed of a urethane resin, a hydraulic cement, and an aggregate compounded in a timely manner, which is hardened by being compounded and hardened, so that the wear resistance, heat resistance, water resistance and resistance It excels in chemical properties and is robust because the base is integrally supported by the existing hard finish floor, and can be reused for a long period of time.

Claims (2)

[Claims] 1. A repair, characterized in that a resin mortar layer is formed by applying a resin mortar consisting of an aqueous polyol, an isocyanate compound, a hydraulic cement and an aggregate optionally mixed to an existing hard finish floor. floor. 2. A repair floor characterized by forming a resin mortar layer by applying a resin mortar consisting of an aqueous polyol, an isocyanate compound, a hydraulic cement and an aggregate optionally mixed to an existing hard finish floor. Construction method.