JP2004210585A

JP2004210585A - Noncombustible spraying material

Info

Publication number: JP2004210585A
Application number: JP2002381667A
Authority: JP
Inventors: Koji Nishimuta; 幸治西牟田; Yasumasa Tanaka; 泰正田中
Original assignee: Taiheiyo Materials Corp
Current assignee: Taiheiyo Materials Corp
Priority date: 2002-12-27
Filing date: 2002-12-27
Publication date: 2004-07-29

Abstract

<P>PROBLEM TO BE SOLVED: To provide a noncombustible spraying material which is low in bulk specific gravity after spraying, does not generate droops even when sprayed thickly at a time, and further has acoustic performance in addition to heat insulating capability. <P>SOLUTION: This noncombustible spraying material comprises, by pts.wt. based on 100 pts.wt. of the spraying material except water, 20-70 cement and 0.1-4.5 resin binder in terms of solid content both as the binder components, 10-60 lightweight aggregate, 0.1-1 foam-producing agent, 0.1-1 foaming agent comprising two or more agents different in foaming time, 0.5-5 fiber and 0.1-1.5 viscosity modifier. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

【０００１】
【発明が属する技術分野】
本発明は、構造物の壁面や天井面等に施工される不燃性吹付け材に係り、特に、断熱性能及び防音性能を有する不燃性吹付け材に関する。
【０００２】
【従来の技術】
従来から、構造物の壁面や天井面等に施工される断熱性を有する不燃性吹付け材として、セメントと軽量骨材を含む不燃性吹付け材がある（例えば、特許文献１及び特許文献２参照。）。また、セメントと軽量骨材に更に起泡剤を含むことにより気泡モルタルにする不燃性吹付け材が、提案されている（例えば、特許文献３参照。）。しかし、これらの不燃性吹付け材は、吹付けた後の不燃性吹付け材のかさ比重が大きいために、５０ｍｍ以上の吹付け厚さになるように一度に吹付けると垂れを生じてしまうので、５０ｍｍ以上の吹付け厚さになるように一度に吹付けることができない。５０ｍｍ以上の吹付け厚さが要求される場合は、二層以上に重ねて吹付けて厚みを出さねばならず、多大な手間と時間がかかると共に、層間剥離を起こし易く一体化し難いという問題があった。特に、建築基準法第２条第９号で云う不燃性能を有する従来の不燃性吹付け材では、一度に吹付けられる厚さは、せいぜい１０ｍｍ程度であった。また、起泡剤により気泡モルタルとした不燃性吹付け材でも、モルタルポンプ等による圧送や吹付けノズルにおいて使用される圧縮空気により、相当量の気泡が消失するため吹付け後の不燃性吹付け材のかさ比重が増大し、５０ｍｍ以上の吹付け厚さになるように一度に吹付けることができない。また、吸音材としての性能も持ち合わせる不燃性吹付け材は、知られていない。
【０００３】
【特許文献１】
特開平５−３１９９４２号公報
【特許文献２】
特開平４−３４２９８号公報
【特許文献３】
特開平７−４８１８４号公報
【０００４】
【発明が解決しようとする課題】
本発明は、前記実情に鑑みてなされたもので、吹付けた後のかさ比重が小さく、且つ一度に例えば５０ｍｍ以上の吹付け厚さになるように厚く吹付けても垂れを生じない不燃性吹付け材を提供すること、更に、断熱性能を有し、且つ吸音材としての性能も持ち合わせる前記不燃性吹付け材を提供することを目的とする。
【０００５】
【課題を解決するための手段】
即ち、本発明は、以下の（１）〜（３）で表す不燃性吹付け材である。
（１）結合成分、軽量骨材、気泡剤及び発泡剤を含む不燃性吹付け材。（２）発泡剤が、発泡時期の異なる２種以上の発泡剤からなることを特徴とする前記（１）の不燃性吹付け材。（３）水を除いた不燃性吹付け材１００重量部に対し、結合成分として２０〜７０重量部のセメントと固形分換算で０．１〜４．５重量部の樹脂結合材、軽量骨材１０〜６０重量部、起泡剤０．１〜１重量部、発泡剤０．１〜１重量部、繊維０．５〜５重量部、粘度調整剤０．１〜１．５重量部を含む不燃性吹付け材。
【０００６】
【発明の実施の形態】
本発明でいう不燃性とは、建築基準法第２条第９号で云う不燃性能のことを云う。
【０００７】
本発明の不燃性吹付け材に必須に含有される結合成分とは、少なくともセメントを含むもので、更に結合・接着能を有する樹脂（以下、樹脂結合材と称す。）を含むものでも良い。本発明で用いるセメントは、水硬性セメントであれば特に何れのものでも用いることができ、例えば、ポルトランドセメント、混合セメント、アルミナセメント、石膏等が挙げられ、これらを併用しても良い。また、本発明で用いる樹脂結合材は、天然ゴム，スチレン・ブタジエン共重合体，クロロプレンゴム，アクリロニトリル・ブタジエン共重合体及びメチルメタクリレート・ブタジエン共重合体等のゴムラテックス、ポリプロピレン，ポリクロロピレン，ポリ酢酸ビニル，ポリアクリル酸エステル，スチレン・アクリル共重合体，酢酸ビニル・アクリル共重合体，エチレン・酢酸ビニル共重合体，エチレン・酢酸ビニル・塩化ビニル共重合体，酢酸ビニルビニルバーサテート共重合体，不飽和ポリエステル樹脂，ポリウレタン樹脂，アルキド樹脂及びエポキシ樹脂等の合成樹脂のエマルション、アスファルト，ゴムアスファルト等の瀝青質等の樹脂エマルションが挙げられ、これらの２種以上を混合して用いることもできる。また、粉末状にした再乳化型粉末樹脂であってもよい。結合成分の量は、水を除いた不燃性吹付け材１００重量部に対し、２０〜７５重量部とすることが好ましく、セメント２０〜７０重量部且つ固形分換算で樹脂結合材０．１〜４．５重量部であると、硬化後の不燃性吹付け材の強度が高く、硬化後の不燃性吹付け材にひび割れが発生し難いので、更に好ましい。
【０００８】
本発明の不燃性吹付け材に必須に含有される軽量骨材は、無機質軽量骨材や有機質軽量骨材の何れでも良く、併用することもできる。無機質軽量骨材は、例えば天然鉱物の発泡又は膨張した物質である膨張バーミキュライト，パーライト，膨張頁岩，軽石，シラスバルーン等の他、シリカゲルを発泡させた物，各種のスラグを造粒して発泡させた物，ガラス屑を造粒して発泡させた物，粘土粉体を造粒して発泡させた物等のような人工軽量骨材が使用できる。これらの内、膨張又は発泡した物質が結晶的にみてさほどガラス化が進んでいないもので且つかさ比重の小さいものが好ましく、例えば膨張バーミキュライト，パーライト，軽石，シラスバルーンが良い。有機質軽量骨材は、合成樹脂又はゴム等のかさ比重２以下である固形の有機質が使用でき、その例としてはポリスチレン，ポリエチレン，ポリエチレン−酢酸ビニル共重合物，ポリプロピレン，ポリウレタン，ポリ塩化ビニル，ポリ塩化ビニリデン，天然ゴム，合成ゴム等がある。また、これらのうち、ポリスチレン，ポリエチレン，ポリエチレン−酢酸ビニル共重合物，ポリ塩化ビニル等の熱可塑性樹脂が、加熱された時の硬化体の温度上昇を抑制するので好ましい。その形状は、粒状物、発泡体などが使用できる。尚、発泡体でなくとも、かさ比重が２以下の固形物であれば使用可能であり、例えば繊維状や不織布状の有機質も使用できる。軽量骨材の量は、水を除いた不燃性吹付け材１００重量部に対し、１０〜６０重量部とすることが好ましい。１０重量部未満であると不燃性吹付け材の硬化体の強度が小さいので好ましくなく、６０重量部を超えると圧送ホース等の圧送経路内で材料分離を起こし易く、圧送経路内で材料が閉塞することがあるので好ましくない。
【０００９】
本発明の不燃性吹付け材に必須に含有される起泡剤とは、界面活性作用を有し、攪拌等の物理的作用により水を加えて練り混ぜた不燃性吹付け材中に安定な気泡を多量に混入するための混和剤で、例えば、ポリオキシエチレン系界面活性剤等のノニオン系合成界面活性剤、アルキルスルホン酸系界面活性剤等のアニオン系合成界面活性剤、ロジンセッケン等の樹脂セッケン系起泡剤、加水分解タンパク系起泡剤等が挙げられる。また、市販のセメント用起泡剤及びＡＥ剤も、本発明で云う起泡剤として用いることができる。これらの起泡剤の多くは液体であるが、多孔質の鉱物に吸着させることで、粉末状にして用いることもできる。また、液体で用いる場合は、水にこれらの起泡剤を希釈して用いると、計量誤差が小さくなるので好ましい。
【００１０】
本発明の不燃性吹付け材に必須に含有される発泡剤とは、不燃性吹付け材中の物質と反応し気体を発生することにより不燃性吹付け材の体積を膨張させる物質をであれば特に限定されず、例えば、アゾ化合物、スルフォニルヒドラジド、イソシアネート化合物、金属アルミニウム等が挙げられ、発泡時期を自在に調整し易いことから金属アルミニウム粉末が好ましい。金属アルミニウム粉末は、粉末度、表面を被覆している成分の種類や量により、発泡時期を自在に調整することが容易である。金属アルミニウム粉末を細かくすることで発泡時期が早まり、金属アルミニウム粉末の表面を例えば水溶性高分子やオレイン酸等で被覆することで発泡時期が遅くなる。本発明で使用する発泡剤が、発泡時期の異なる２種以上の発泡剤からなる発泡剤であると、不燃性吹付け材を練り混ぜてから吹付けまでの時間を長くした場合においても、垂れが生じ難いので好ましい。
【００１１】
本発明の不燃性吹付け材は、前記起泡剤と前記発泡剤を必須に含有する。起泡剤のみでは、モルタルポンプ等による圧送や吹付けノズルにおいて使用される圧縮空気により、相当量の気泡が消失して吹付け後の不燃性吹付け材のかさ比重が増大し、５０ｍｍ以上の吹付け厚さになるように一度に吹付けることができない。圧送等により消失する容量の気泡を圧送前の不燃性吹付け材に多く混入するように起泡剤の配合量を増やすと、作業効率が低下するばかりでなく、場合によっては圧送して吹付けることができなくなることもあるので好ましくない。また、発泡剤のみでは、吹付けを行う時点の不燃性吹付け材のかさ比重が大きいため、硬化後の吹付け厚さが５０ｍｍ以上になるように吹付けると垂れを生じるので、硬化後の吹付け厚さが５０ｍｍ以上になるように吹付けることができない。その上、発泡剤による発泡機構が化学反応によるものであるために、吹付け時の不燃性吹付け材のかさ比重が小さくなるように発泡剤の配合量を増やすと、使用温度の影響が大きくなり、硬化後の不燃性吹付け材のかさ比重が安定せず、硬化後の強度も小さくなる。起泡剤と発泡剤の量は、水を除いた不燃性吹付け材１００重量部に対し、起泡剤０．１〜１重量部及び発泡剤０．１〜１重量部が好ましい。ここで、起泡剤の量は、水や多孔質鉱物を除いた、ポリオキシエチレン系界面活性剤等の有効成分の量である。
【００１２】
本発明の不燃性吹付け材には、結合成分、軽量骨材、起泡剤及び発泡剤以外に、砕砂，陸砂，川砂，石粉等の軽量骨材以外の細骨材、流動化剤、収縮低減剤、防錆剤、硬化促進剤、遅延剤、膨張材、流動性調整剤、吸熱物質、繊維、防水材、フライアッシュ、スラグ粉末、シリカフューム、保水剤等の各種混和剤（材）を適宜含むものであっても良い。ここで、吸熱物質とは、加熱された時に、熱分解することにより吸熱する物質を云い、水酸化アルミニウム，ギブザイトミネラル，ボーマイト，ジアスポールなどの酸化アルミニウムの水和物や、斜方沸石，ヒューランダイト，モルデナイトなどのゼオライト物質や、アロファン，ハロイサイト，非発泡ひる石などのシリカ−アルミナ物質や、ブルサイト及びアタパルジャイトなどのマグネシア物質や、サテンホワイト，エトリンガイト，及び硼酸などの熱分解する物質が例示される。
【００１３】
本発明で使用する繊維は、ガラス繊維，炭素繊維，炭化ケイ素繊維，マイカ等の無機繊維、ナイロン繊維，ポリエステル繊維，ポリプロピレン繊維，ポリエチレン繊維，ビニロン繊維等の有機繊維、ステンレス鋼繊維，アモルファス合金繊維，鋼繊維等の金属繊維が挙げられる。耐熱性が高いことから、無機繊維又は金属繊維を用いることが好ましい。繊維の量は、水を除いた不燃性吹付け材１００重量部に対し、０．５〜５重量部であることが好ましい。
【００１４】
本発明で使用する流動性調整剤とは、練り混ぜた不燃性吹付け材の流動性を増大又は減少させる作用をもたらすもので、例えば、ヒドロキシプロピルメチルセルロース等のセルロ−ス系、ポリエチレングリコ−ル系、エチレンオキサイド系、ポリアクリルアマイド等のアクリル系、ポリビニルアルコ−ル系、ウェランガム等の微生物醗酵多糖類系等の水溶性高分子の増粘剤、ナフタリン系、メラミン系、ポリカルボン酸系、アミノスルホン酸系等の減水剤等が挙げられ、これらの１種又は２種以上を組み合わせたものが使用できる。流動性調整剤の量は、水を除いた不燃性吹付け材１００重量部に対し、０．１〜２重量部であることが好ましい。
【００１５】
また、本発明の不燃性吹付け材は、水を除いた不燃性吹付け材１００重量部に対し、結合成分として２０〜７０重量部のセメントと固形分換算で０．１〜４．５重量部の樹脂結合材、軽量骨材１０〜６０重量部、起泡剤０．１〜１重量部、発泡剤０．１〜１重量部、繊維０．５〜５重量部、流動性調整剤０．１〜１．５重量部を含むものからなる。このような成分を含有してなる不燃性吹付け材は、吹付け厚さが５０ｍｍ以上になるように吹付けても垂れを生じず、硬化後のかさ比重が０．６未満となり、断熱性能及び防音性能を有する不燃性吹付け材となる。
【００１６】
本発明の不燃性吹付け材に用いる水は特に限定されないが、例えば水道水、起泡剤等の混和剤中の水分、樹脂エマルション等の樹脂結合材中の水分等を単独で、又は組み合わして用いることができる。水の量は、セメント１００重量部に対し、５０〜２００重量部であることが好ましい。５０重量部より少ないと、練り混ぜた不燃性吹付け材の流動性が悪いので吹付け作業が行い難く、２００重量部より多いと不燃性吹付け材の硬化体の強度が低いので、それぞれ好ましくない。更に、吹付け時の作業性と硬化体の強度を勘案すると、８０〜１８０重量部であることが好ましい。
【００１７】
次に、本発明の不燃性吹付け材の製造方法を説明する。本発明の不燃性吹付け材は主に建築工事現場や土木工事現場で使用されるため、これらの工事現場で各材料を計量することは、作業が煩雑となるので好ましくない。水を含まない材料を予め工場で乾式混合したプレミックス粉体を製造し、工事現場でこのプレミックス粉体に水及び水を含む材料を加え、ミキサにより機械混合する方法が好ましい。ミキサは通常のセメント組成物を練り混ぜる時に用いられるものが使用でき、例えばグラウトミキサ、ハンドミキサ、左官ミキサ、コンクリートミキサ等が挙げられる。起泡剤として多孔質の鉱物に液体の起泡剤を吸着させた粉末状起泡剤を用い、且つ結合材としてセメント又はセメントと再乳化型粉末樹脂を用いた場合は、水以外の材料を予め工場で乾式混合したプレミックス粉体を製造できるので、工事現場ではこのプレミックス粉体に水を加えて混合するだけで本発明の不燃性吹付け材を製造できるので、より好ましい。
【００１８】
本発明の不燃性吹付け材の吹付けは、セメントモルタルや耐火被覆材等を吹付ける方法により、行うことができる。
【００１９】
【実施例】
以下、実施例により本発明を説明する。表１に示す配合の不燃性吹付け材を製造した。なお、表１中の各成分は、以下に示す材料を使用した。
＜使用材料＞
セメントＡ：太平洋セメント株式会社製普通ポルトランドセメント。
セメントＢ：吉野石膏株式会社製無水石膏（平均粒径１５０μｍ）。
セメントＣ：吉野石膏株式会社製半水石膏（平均粒径３０μｍ）。
樹脂結合材Ａ：日本エヌエスシー株式会社製酢酸ビニル・アクリル樹脂系再乳化型粉末樹脂（商品名「エロッテクス」）。
樹脂結合材Ｂ：ガンツ化成株式会社製アクリル樹脂変性ＳＢＲ系ゴムラテックス（商品名「クロスレン」、固形分５０重量％）。
軽量骨材Ａ：日商岩井ケミカル株式会社製焼成バーミュキライト（商品名「バーミュキライト焼成品（２号品）」）。
軽量骨材Ｂ：発泡性ポリスチレンビーズ発泡成形品をリサイクル回収し粉砕したもの（粒径１〜２ｍｍ、かさ比重０．０３）。
軽量骨材Ｃ：太平洋マテリアル株式会社製パーライト（商品名「太平洋パーライト」）。
起泡剤Ａ：第一工業製薬株式会社製ポリエチレンオキサイド系ノニオン界面活性剤（有効成分２０重量％、水８０重量％）。
起泡剤Ｂ：起泡剤Ａ１００重量部を、多孔質鉱物であるセピオライト粉末１００重量部に添加混合後、低温で乾燥させ、更に市販の粉砕機により粉砕した粉末。
発泡剤Ａ：東洋アルミニウム株式会社製アルミニウム粉末（商品名「アルペースト」（無処理タイプ））。
発泡剤Ｂ：発泡剤Ａ１００重量部に８重量部のオレイン酸を添加し、ヘンシェルミキサで混合することで、表面をオレイン酸で被覆したアルミニウム粉末。
流動性調整剤Ａ：信越化学工業株式会社製ヒドロキシプロピルメチルセルロース（商品名「ｈｉメトローズ９０ＳＨ−１５０００」）。
流動性調整剤Ｂ：太平洋セメント株式会社製ポリカルボン酸系粉末高性能ＡＥ減水剤（商品名「コアフローＮＦ−１００」）。
繊維Ａ：日本電気硝子株式会社製ガラス繊維（繊維長３ｍｍ）。
繊維Ｂ：日本電気硝子株式会社製ガラス繊維（繊維長６ｍｍ）。
水：水道水。
シリカフューム：ＳＫＷカナダ社製シリカフューム。
【００２０】
【表１】

【００２１】
＜吹付け試験＞
モルタルミキサで各配合の不燃性吹付け材を練り混ぜた。製造した不燃性吹付け材をスネーク式モルタルポンプにより吹付けノズルまで圧送し、別経路より吹付けノズルに送られた圧縮空気（５ｋｇｆ／ｃｍ^２）を用いて、垂直に立てたベニヤ板（厚さ１３ｍｍ）に吹付け厚さが５０ｍｍになるように吹付けて、垂れが起こるか否かを確認した。吹付け厚さが５０ｍｍになるように吹付けて垂れが生じなかったものを○、吹付け厚さが５０ｍｍになるように吹付けて垂れが生じたもの又は吹付け厚さが５０ｍｍになる前に垂れが生じたものを×と判断した。
【００２２】
＜かさ比重測定＞
モルタルミキサから製造した不燃性吹付け材を採取し、容積４００ｍｌの容器に詰め、この時の不燃性吹付け材の重量をグラム単位で測定し、不燃性吹付け材の重量（グラム単位の値）を４００で除した値を、圧送前のかさ比重とした。吹付けノズルから吐出した不燃性吹付け材を前記容積４００ｍｌの容器に詰め、同様に、不燃性吹付け材の重量（グラム単位の値）を４００で除した値を求め、吹付け直後のかさ比重とした。また、コンクリートの圧縮強度試験用金属製簡易型枠（内径１００ｍｍ×高さ２００ｍｍ）に吹付けノズルから吐出した不燃性吹付け材を詰め、発泡剤による体積膨張で前記簡易型枠の上部から盛り上がった分の不燃性吹付け材を定木により擦り切った。翌日脱型した後７日間気中養生し、硬化した不燃性吹付け材の体積と重量から比重を求め、硬化後のかさ比重とした。
【００２３】
吹付け試験及びかさ比重測定の試験結果を表２に示す。
【００２４】
【表２】

【００２５】
＜不燃性試験及び熱伝導率試験＞
実施例１の不燃性吹付け材を型枠に吹付けて成形し、１００ｍｍ×２００ｍｍ×５１．５ｍｍの不燃性吹付け材硬化体の板を作製した。この不燃性吹付け材硬化体の板を７日間気中養生した後、１００ｍｍ×２００ｍｍの面の一方に火炎を当て、加熱側の不燃性吹付け材硬化体の板表面の温度が８３０℃になるように加熱して１２時間保持した。この時、熱伝導率を測定したところ、０．１２Ｗ／ｍ・Ｋ（試験体温度５０℃）、０．１１Ｗ／ｍ・Ｋ（試験体温度９６℃）、０．２２Ｗ／ｍ・Ｋ（試験体温度８３０℃）であったので、この不燃性吹付け材硬化体が断熱性能を有していることが確認できた。試験後、幅１ｍｍのクラックが数本入ったが形状は保持していたので、この不燃性吹付け材硬化体が不燃性の被覆材としての性能を有していることが確認できた。
【００２６】
＜吸音率測定試験＞
実施例１の不燃性吹付け材を型枠に吹付けて成形し、２５０ｍｍ×２５０ｍｍ×２０ｍｍの不燃性吹付け材硬化体の板を作製した。この不燃性吹付け材硬化体の板を７日間気中養生した後、ＪＩＳＡ１４０５に準じた方法で、６３Ｈｚ、１２５Ｈｚ、２５０Ｈｚ、５００Ｈｚ、１０００Ｈｚ、及び２０００Ｈｚについて吸音率を測定した。比較として、大建工業株式会社製吸音用壁材（商品名「オトカベＳ−１」）及びフジ化成工業株式会社製断熱・防音パネル（商品名「ＥＭパネル」）も同様に吸音率を測定した。その結果を図１に示す。
【００２７】
吸音率測定試験の結果から、本発明の不燃性吹付け材の硬化体は、市販品の吸音用壁材と略同等の吸音性能を有していることがわかる。したがって、本発明の不燃性吹付け材の硬化体は、吸音材としての性能も持ち合わせる。
【００２８】
【発明の効果】
本発明によれば、吹付けた後のかさ比重が小さく、且つ一度に例えば５０ｍｍ以上の吹付け厚さになるように厚く吹付けても垂れを生じない不燃性吹付け材が得られる。更に、この不燃性吹付け材は、優れた断熱性能及び吸音性能を有するため、断熱用及び／又は吸音用の不燃性吹付け材として用いることができる。
【図面の簡単な説明】
【図１】吸音率測定試験の試験結果を示すグラフである。[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a non-combustible spray material applied to a wall surface or a ceiling surface of a structure, and more particularly to a non-combustible spray material having heat insulation performance and soundproof performance.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, as a non-combustible spraying material having a heat insulating property applied to a wall surface or a ceiling surface of a structure, there is a non-combustible spraying material containing cement and lightweight aggregate (for example, Patent Document 1 and Patent Document 2). reference.). Further, a non-combustible spraying material has been proposed in which a foam mortar is formed by further adding a foaming agent to cement and lightweight aggregate (for example, see Patent Document 3). However, since these non-combustible spray materials have a large bulk specific gravity after spraying, if they are sprayed at a time so as to have a spray thickness of 50 mm or more, dripping occurs. Therefore, it cannot be sprayed at a time so as to have a spray thickness of 50 mm or more. When a spray thickness of 50 mm or more is required, the thickness must be obtained by spraying two or more layers, and it takes a great deal of time and labor, and it is easy to cause delamination and it is difficult to integrate. there were. In particular, with a conventional non-combustible spraying material having non-combustible performance referred to in Article 2, Item 9 of the Building Standards Law, the thickness sprayed at a time was at most about 10 mm. In addition, even with non-combustible spraying materials made of foam mortar with a foaming agent, a considerable amount of air bubbles are lost due to the compressed air used in the blasting nozzle or the compressed air used by the mortar pump. The bulk specific gravity of the material increases, and it cannot be sprayed at a time so as to have a spray thickness of 50 mm or more. Further, there is no known non-combustible spraying material which also has performance as a sound absorbing material.
[0003]
[Patent Document 1]
JP-A-5-319942 [Patent Document 2]
JP-A-4-34298 [Patent Document 3]
JP-A-7-48184
[Problems to be solved by the invention]
The present invention has been made in view of the above-mentioned circumstances, and has a low bulk specific gravity after spraying, and a non-flammable material that does not sag even when sprayed at a time so as to have a spray thickness of 50 mm or more at a time. An object of the present invention is to provide a spraying material, and further to provide the non-combustible spraying material having heat insulation performance and also having performance as a sound absorbing material.
[0005]
[Means for Solving the Problems]
That is, the present invention is a non-combustible spraying material represented by the following (1) to (3).
(1) A non-combustible spray containing a binding component, a lightweight aggregate, a foaming agent and a foaming agent. (2) The non-combustible spraying material according to the above (1), wherein the foaming agent comprises two or more kinds of foaming agents having different foaming times. (3) 20 to 70 parts by weight of cement and 0.1 to 4.5 parts by weight of a resin binder in terms of solid content, and a lightweight aggregate, based on 100 parts by weight of the non-combustible spraying material excluding water. 10 to 60 parts by weight, 0.1 to 1 part by weight of foaming agent, 0.1 to 1 part by weight of foaming agent, 0.5 to 5 parts by weight of fiber, 0.1 to 1.5 parts by weight of viscosity modifier Non-combustible spraying material.
[0006]
BEST MODE FOR CARRYING OUT THE INVENTION
The non-combustibility referred to in the present invention refers to the non-combustibility described in Article 2, Item 9 of the Building Standards Act.
[0007]
The binding component essentially contained in the non-combustible spraying material of the present invention contains at least cement, and may further contain a resin having a binding / adhering ability (hereinafter, referred to as a resin binding material). As the cement used in the present invention, any cement can be used as long as it is a hydraulic cement, and examples thereof include Portland cement, mixed cement, alumina cement, gypsum and the like, and these may be used in combination. The resin binder used in the present invention includes natural rubber, rubber latex such as styrene / butadiene copolymer, chloroprene rubber, acrylonitrile / butadiene copolymer and methyl methacrylate / butadiene copolymer, polypropylene, polychloropyrene, and polyacetic acid. Vinyl, polyacrylate, styrene / acrylic copolymer, vinyl acetate / acrylic copolymer, ethylene / vinyl acetate copolymer, ethylene / vinyl acetate / vinyl chloride copolymer, vinyl acetate vinyl versatate copolymer, Examples thereof include emulsions of synthetic resins such as unsaturated polyester resins, polyurethane resins, alkyd resins, and epoxy resins, and bituminous resin emulsions such as asphalt and rubber asphalt. Two or more of these may be used in combination. Further, it may be a re-emulsifiable powder resin in the form of a powder. The amount of the binding component is preferably 20 to 75 parts by weight based on 100 parts by weight of the non-combustible spraying material excluding water, 20 to 70 parts by weight of cement and 0.1 to 0.1 parts by weight of resin binder in terms of solid content. If the amount is 4.5 parts by weight, the strength of the cured non-combustible spray material is high, and the cured non-combustible spray material is less likely to crack.
[0008]
The lightweight aggregate that is essentially contained in the non-combustible spray material of the present invention may be any of an inorganic lightweight aggregate and an organic lightweight aggregate, and may be used in combination. Inorganic lightweight aggregates are, for example, expanded vermiculite, perlite, expanded shale, pumice, shirasu balloon, etc., which are expanded or expanded substances of natural minerals, as well as foamed silica gel and various slags which are granulated and foamed. Artificial lightweight aggregates can be used, such as waste, glass dust granulated and foamed, and clay powder granulated and foamed. Among these, the expanded or foamed material is preferably one whose crystallinity has not progressed so much in terms of crystallinity and whose bulk specific gravity is small. For example, expanded vermiculite, perlite, pumice stone, and shirasu balloon are preferable. As the organic lightweight aggregate, a solid organic substance having a bulk specific gravity of 2 or less such as synthetic resin or rubber can be used, and examples thereof include polystyrene, polyethylene, polyethylene-vinyl acetate copolymer, polypropylene, polyurethane, polyvinyl chloride, and polyvinyl chloride. Examples include vinylidene chloride, natural rubber, and synthetic rubber. Of these, thermoplastic resins such as polystyrene, polyethylene, polyethylene-vinyl acetate copolymer, and polyvinyl chloride are preferable because they suppress the temperature rise of the cured product when heated. The shape can be a granular material, a foam, or the like. In addition, even if it is not a foam, a solid substance having a bulk specific gravity of 2 or less can be used, and for example, a fibrous or nonwoven fabric organic substance can also be used. The amount of the lightweight aggregate is preferably 10 to 60 parts by weight based on 100 parts by weight of the non-combustible spray material excluding water. If the amount is less than 10 parts by weight, the strength of the cured body of the non-combustible spraying material is low, which is not preferable. If the amount is more than 60 parts by weight, material separation easily occurs in a pressure feeding path such as a pressure feeding hose and the material is blocked in the pressure feeding path. It is not preferable because it may be performed.
[0009]
The foaming agent essentially contained in the non-combustible spray material of the present invention has a surfactant activity, and is stable in a non-combustible spray material mixed by adding water by a physical action such as stirring. An admixture for mixing a large amount of air bubbles, for example, a nonionic synthetic surfactant such as a polyoxyethylene surfactant, an anionic synthetic surfactant such as an alkylsulfonic acid surfactant, and a rosin soap. Resin soap-based foaming agents, hydrolyzed protein-based foaming agents, and the like. Further, commercially available foaming agents for cement and AE agents can also be used as the foaming agent in the present invention. Many of these foaming agents are liquids, but can be used in powder form by adsorbing them on porous minerals. In addition, when used as a liquid, it is preferable to use these foaming agents after diluting them in water, because measurement errors are reduced.
[0010]
The blowing agent that is essentially contained in the non-combustible spray material of the present invention is a substance that expands the volume of the non-combustible spray material by reacting with a substance in the non-combustible spray material to generate gas. If it is not particularly limited, for example, an azo compound, a sulfonyl hydrazide, an isocyanate compound, metal aluminum and the like can be mentioned, and a metal aluminum powder is preferable because the foaming time can be easily adjusted. It is easy to freely adjust the foaming time of the metal aluminum powder depending on the degree of fineness and the type and amount of the component covering the surface. The foaming time is advanced by making the metal aluminum powder finer, and the foaming time is delayed by coating the surface of the metal aluminum powder with, for example, a water-soluble polymer or oleic acid. When the foaming agent used in the present invention is a foaming agent composed of two or more foaming agents having different foaming times, even when the time from mixing of the non-combustible spraying material to spraying is increased, dripping occurs. Is less likely to occur.
[0011]
The non-combustible spraying material of the present invention essentially contains the foaming agent and the foaming agent. With only the foaming agent, a considerable amount of air bubbles disappears due to the compressed air used in the blasting nozzle and the blasting nozzle and the like, and the bulk specific gravity of the non-combustible sprayed material after spraying increases, and 50 mm or more. It cannot be sprayed all at once to achieve the spray thickness. Increasing the blending amount of the foaming agent so that a large amount of bubbles that disappear by pressure feeding or the like is mixed into the non-combustible spraying material before the pressure feeding not only lowers the working efficiency but also in some cases presses and blows. This is not preferable because it may not be possible to do so. Also, with the foaming agent alone, since the bulk specific gravity of the incombustible spraying material at the time of spraying is large, spraying occurs so that the sprayed thickness after curing becomes 50 mm or more. It cannot be sprayed so that the spray thickness becomes 50 mm or more. In addition, since the foaming mechanism of the blowing agent is due to a chemical reaction, the effect of the operating temperature increases when the blending amount of the blowing agent is increased so that the bulk specific gravity of the incombustible spraying material at the time of spraying is reduced. As a result, the bulk specific gravity of the non-combustible spray material after curing is not stable, and the strength after curing is low. The amounts of the foaming agent and the foaming agent are preferably 0.1 to 1 part by weight of the foaming agent and 0.1 to 1 part by weight of the foaming agent with respect to 100 parts by weight of the nonflammable spraying material excluding water. Here, the amount of the foaming agent is the amount of an active ingredient such as a polyoxyethylene surfactant excluding water and porous minerals.
[0012]
The non-combustible spraying material of the present invention includes, in addition to the binding component, the lightweight aggregate, the foaming agent and the foaming agent, fine aggregates other than lightweight aggregates such as crushed sand, land sand, river sand, and stone powder; Various admixtures (materials) such as shrinkage reducing agents, rust inhibitors, hardening accelerators, retarders, swelling agents, flow control agents, endothermic substances, fibers, waterproofing materials, fly ash, slag powder, silica fume, and water retention agents It may be appropriately included. Here, the endothermic substance refers to a substance that absorbs heat by being thermally decomposed when heated, and is a hydrate of aluminum oxide such as aluminum hydroxide, gibbsite mineral, boehmite, and diaspol; Examples include zeolite substances such as daite and mordenite; silica-alumina substances such as allophane, halloysite and non-expanded vermiculite; magnesia substances such as brucite and attapulgite; and thermally decomposable substances such as satin white, ettringite, and boric acid. Is done.
[0013]
The fibers used in the present invention include inorganic fibers such as glass fibers, carbon fibers, silicon carbide fibers, and mica, organic fibers such as nylon fibers, polyester fibers, polypropylene fibers, polyethylene fibers, and vinylon fibers, stainless steel fibers, and amorphous alloy fibers. And metal fibers such as steel fibers. It is preferable to use inorganic fibers or metal fibers because of their high heat resistance. The amount of the fiber is preferably 0.5 to 5 parts by weight based on 100 parts by weight of the non-combustible spray material excluding water.
[0014]
The fluidity modifier used in the present invention is a substance having an effect of increasing or decreasing the fluidity of a non-combustible sprayed material which has been kneaded, and is, for example, a cellulose-based material such as hydroxypropylmethylcellulose, or polyethylene glycol. System, ethylene oxide system, polyacrylamide and other acrylic system, polyvinyl alcohol system, microbial fermentation polysaccharide system such as welan gum, water-soluble polymer thickener, naphthalene system, melamine system, polycarboxylic acid system, etc. Examples thereof include aminosulfonic acid-based water reducing agents and the like, and one or a combination of two or more thereof can be used. The amount of the fluidity adjusting agent is preferably 0.1 to 2 parts by weight based on 100 parts by weight of the nonflammable spraying material excluding water.
[0015]
In addition, the non-combustible spray material of the present invention is used in an amount of 20 to 70 parts by weight of cement and 0.1 to 4.5 parts by weight in terms of solid content based on 100 parts by weight of the non-combustible spray material excluding water. Parts by weight of resin binder, 10 to 60 parts by weight of lightweight aggregate, 0.1 to 1 part by weight of foaming agent, 0.1 to 1 part by weight of foaming agent, 0.5 to 5 parts by weight of fiber, fluidity modifier 0 .1 to 1.5 parts by weight. A non-combustible spray material containing such a component does not sag even when sprayed so that the spray thickness is 50 mm or more, and has a bulk specific gravity of less than 0.6 after curing, and a heat insulating performance. And a non-combustible spray material having soundproofing performance.
[0016]
Water used for the non-combustible spraying material of the present invention is not particularly limited, for example, tap water, water in an admixture such as a foaming agent, water in a resin binder such as a resin emulsion alone or in combination. Can be used. The amount of water is preferably 50 to 200 parts by weight based on 100 parts by weight of cement. If the amount is less than 50 parts by weight, it is difficult to perform the spraying operation because the fluidity of the mixed incombustible spraying material is poor, and if the amount is more than 200 parts by weight, the strength of the cured body of the incombustible spraying material is low. Absent. Further, considering the workability at the time of spraying and the strength of the cured body, the amount is preferably 80 to 180 parts by weight.
[0017]
Next, a method for producing the nonflammable spray material of the present invention will be described. Since the non-combustible spraying material of the present invention is mainly used at a construction site or a civil engineering site, weighing each material at these sites is not preferable because the operation becomes complicated. It is preferable to prepare a premix powder in which a water-free material is dry-mixed in a factory in advance, add water and a water-containing material to the premix powder at a construction site, and mechanically mix the mixture using a mixer. As the mixer, those used when kneading an ordinary cement composition can be used, and examples thereof include a grout mixer, a hand mixer, a plaster mixer, and a concrete mixer. When a powdered foaming agent in which a liquid foaming agent is adsorbed on a porous mineral is used as a foaming agent, and cement or cement and a re-emulsifying powder resin are used as a binder, materials other than water are used. Since a premix powder which has been dry-mixed in advance at a factory can be produced, the incombustible spray material of the present invention can be produced at a construction site simply by adding water and mixing the premix powder, which is more preferable.
[0018]
The spraying of the non-combustible spraying material of the present invention can be performed by a method of spraying a cement mortar, a refractory coating material or the like.
[0019]
【Example】
Hereinafter, the present invention will be described with reference to examples. A non-combustible spray material having the composition shown in Table 1 was produced. In addition, each component in Table 1 used the material shown below.
<Material used>
Cement A: ordinary Portland cement manufactured by Taiheiyo Cement Corporation.
Cement B: Anhydrite made by Yoshino Gypsum Co., Ltd. (average particle size 150 μm).
Cement C: Hemihydrate gypsum manufactured by Yoshino Gypsum Co., Ltd. (average particle size: 30 μm).
Resin binder A: A vinyl acetate / acrylic resin-based re-emulsifying powder resin (trade name "Erotex") manufactured by NSC Japan, Ltd.
Resin binder B: Acrylic resin-modified SBR-based rubber latex (trade name "Crosslen", solid content 50% by weight) manufactured by Ganz Chemical Co., Ltd.
Light aggregate A: Nissho Iwai Chemical Co., Ltd. fired vermiculite (trade name "burned vermiculite (No. 2)").
Light-weight aggregate B: foamed polystyrene bead foam molded product recycled and collected and pulverized (particle diameter: 1 to 2 mm, bulk specific gravity: 0.03).
Light aggregate C: Perlite manufactured by Taiheiyo Materials Co., Ltd. (trade name "Taiwan Perlite").
Foaming agent A: a polyethylene oxide nonionic surfactant manufactured by Daiichi Kogyo Seiyaku Co., Ltd. (active ingredient 20% by weight, water 80% by weight).
Foaming agent B: Powder obtained by adding and mixing 100 parts by weight of foaming agent A to 100 parts by weight of sepiolite powder as a porous mineral, drying at a low temperature, and further pulverizing with a commercially available pulverizer.
Foaming agent A: Aluminum powder manufactured by Toyo Aluminum Co., Ltd. (trade name “Alpaste” (untreated type)).
Foaming agent B: Aluminum powder whose surface was coated with oleic acid by adding 8 parts by weight of oleic acid to 100 parts by weight of foaming agent A and mixing with a Henschel mixer.
Fluidity adjusting agent A: hydroxypropyl methylcellulose manufactured by Shin-Etsu Chemical Co., Ltd. (trade name "hi Metroze 90SH-15000").
Fluidity modifier B: High performance AE water reducing agent of polycarboxylic acid powder manufactured by Taiheiyo Cement Co., Ltd. (trade name "Coreflow NF-100").
Fiber A: glass fiber manufactured by Nippon Electric Glass Co., Ltd. (fiber length 3 mm).
Fiber B: Nippon Electric Glass Co., Ltd. glass fiber (fiber length 6 mm).
Water: tap water.
Silica fume: SKW Canada silica fume.
[0020]
[Table 1]

[0021]
<Spray test>
The incombustible spraying material of each composition was kneaded with a mortar mixer. The manufactured non-combustible spray material is pressure-fed to the spray nozzle by a snake mortar pump, and the compressed air (5 kgf / cm ² ) sent to the spray nozzle from another path is used to vertically stand a plywood (thickness). 13 mm) so as to have a spray thickness of 50 mm, and it was confirmed whether or not sagging would occur. The one that was sprayed so that the sprayed thickness was 50 mm and did not sag was evaluated as 、, the one that was sprayed so that the sprayed thickness was 50 mm and sagged or before the sprayed thickness became 50 mm Was determined to be x when sagging occurred.
[0022]
<Bulk specific gravity measurement>
The non-combustible spray material produced from the mortar mixer is collected, packed in a 400 ml container, the weight of the non-combustible spray material at this time is measured in grams, and the weight of the non-combustible spray material (value in grams) ) Divided by 400 was defined as the bulk specific gravity before pumping. The non-combustible spray material discharged from the spray nozzle is packed in the above-mentioned container having a capacity of 400 ml, and similarly, a value obtained by dividing the weight (value in gram) of the non-combustible spray material by 400 is obtained, and the bulk immediately after spraying is obtained. Specific gravity. In addition, a non-combustible spray material discharged from a spray nozzle is packed in a metal simple mold (inner diameter 100 mm × height 200 mm) for concrete compressive strength test, and swells from the top of the simple mold by volume expansion due to a foaming agent. The incombustible spraying material was scraped off with wood. After demolding the next day, cured in air for 7 days, the specific gravity was determined from the volume and weight of the cured non-combustible spraying material, and the bulk specific gravity after curing was determined.
[0023]
Table 2 shows the test results of the spray test and the bulk specific gravity measurement.
[0024]
[Table 2]

[0025]
<Non-flammability test and thermal conductivity test>
The non-combustible spray material of Example 1 was sprayed onto a mold and molded to produce a 100 mm × 200 mm × 51.5 mm cured non-combustible spray material plate. After curing the plate of the incombustible spray material in the air for 7 days, a flame is applied to one of the surfaces of 100 mm × 200 mm, and the temperature of the plate surface of the heated incombustible spray material at 830 ° C. And kept for 12 hours. At this time, when the thermal conductivity was measured, 0.12 W / m · K (test piece temperature of 50 ° C.), 0.11 W / m · K (test piece temperature of 96 ° C.), 0.22 W / m · K (test piece) (Body temperature 830 ° C.), it was confirmed that the cured body of the nonflammable spraying material had heat insulation performance. After the test, several cracks having a width of 1 mm were formed, but the shape was maintained. Therefore, it was confirmed that the cured body of the nonflammable sprayed material had performance as a nonflammable coating material.
[0026]
<Sound absorption coefficient measurement test>
The non-combustible spray material of Example 1 was sprayed on a mold to form a 250 mm × 250 mm × 20 mm cured non-combustible spray material plate. After curing the plate of the incombustible sprayed material in the air for 7 days, the sound absorption coefficient was measured at 63 Hz, 125 Hz, 250 Hz, 500 Hz, 1000 Hz, and 2000 Hz by a method according to JIS A1405. As a comparison, the sound absorption coefficient of a sound absorbing wall material (trade name "Otokabe S-1") manufactured by Daiken Kogyo Co., Ltd. and a heat insulating and soundproofing panel (trade name "EM panel") manufactured by Fuji Kasei Kogyo Co., Ltd. were similarly measured. . The result is shown in FIG.
[0027]
From the results of the sound absorption coefficient measurement test, it is understood that the cured body of the nonflammable spraying material of the present invention has sound absorption performance substantially equivalent to that of a commercially available sound absorbing wall material. Therefore, the cured body of the non-combustible spray material of the present invention also has performance as a sound absorbing material.
[0028]
【The invention's effect】
ADVANTAGE OF THE INVENTION According to this invention, the bulk specific gravity after spraying is small, and the nonflammable spraying material which does not generate dripping even if it is sprayed so thick as to have a spray thickness of 50 mm or more at a time is obtained. Further, since this non-combustible spray material has excellent heat insulating performance and sound absorbing performance, it can be used as a non-combustible spray material for heat insulation and / or sound absorption.
[Brief description of the drawings]
FIG. 1 is a graph showing test results of a sound absorption coefficient measurement test.

Claims

Non-combustible spray containing binder, lightweight aggregate, foaming agent and foaming agent.

The non-combustible spray material according to claim 1, wherein the foaming agent comprises two or more foaming agents having different foaming times.

20 to 70 parts by weight of cement and 0.1 to 4.5 parts by weight of a resin binder in terms of solid content, and lightweight aggregate of 10 to 60 parts by weight, based on 100 parts by weight of the non-combustible spray material excluding water. Non-combustible spray containing 0.1 parts by weight of a foaming agent, 0.1 to 1 parts by weight of a foaming agent, 0.5 to 5 parts by weight of a fiber, and 0.1 to 1.5 parts by weight of a viscosity modifier. Additives.