JP2005053717A - Premix mortar for being filled into window frame gap part - Google Patents
Premix mortar for being filled into window frame gap part Download PDFInfo
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- JP2005053717A JP2005053717A JP2003206465A JP2003206465A JP2005053717A JP 2005053717 A JP2005053717 A JP 2005053717A JP 2003206465 A JP2003206465 A JP 2003206465A JP 2003206465 A JP2003206465 A JP 2003206465A JP 2005053717 A JP2005053717 A JP 2005053717A
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- 239000004570 mortar (masonry) Substances 0.000 title claims description 89
- 238000011049 filling Methods 0.000 claims abstract description 84
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 29
- 229920005989 resin Polymers 0.000 claims abstract description 24
- 239000011347 resin Substances 0.000 claims abstract description 24
- 239000002002 slurry Substances 0.000 claims abstract description 19
- 229920003023 plastic Polymers 0.000 claims abstract description 17
- 239000004033 plastic Substances 0.000 claims abstract description 17
- 239000000843 powder Substances 0.000 claims abstract description 14
- 230000005484 gravity Effects 0.000 claims abstract description 12
- 239000011396 hydraulic cement Substances 0.000 claims abstract description 12
- DQXBYHZEEUGOBF-UHFFFAOYSA-N but-3-enoic acid;ethene Chemical compound C=C.OC(=O)CC=C DQXBYHZEEUGOBF-UHFFFAOYSA-N 0.000 claims abstract description 7
- 239000005038 ethylene vinyl acetate Substances 0.000 claims abstract description 7
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 claims abstract description 7
- 238000004898 kneading Methods 0.000 claims abstract description 6
- 239000006260 foam Substances 0.000 claims abstract description 5
- 239000011521 glass Substances 0.000 claims abstract description 5
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 claims abstract description 4
- -1 Shirasu balloon Substances 0.000 claims abstract description 4
- 229910001562 pearlite Inorganic materials 0.000 claims abstract description 4
- 239000010802 sludge Substances 0.000 claims abstract description 4
- 239000010455 vermiculite Substances 0.000 claims abstract description 4
- 235000019354 vermiculite Nutrition 0.000 claims abstract description 4
- 229910052902 vermiculite Inorganic materials 0.000 claims abstract description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 21
- 239000004576 sand Substances 0.000 claims description 11
- 239000000463 material Substances 0.000 claims description 10
- 238000000034 method Methods 0.000 claims description 10
- 238000004078 waterproofing Methods 0.000 claims description 10
- 238000010276 construction Methods 0.000 claims description 8
- 239000004925 Acrylic resin Substances 0.000 claims description 5
- NJVOHKFLBKQLIZ-UHFFFAOYSA-N (2-ethenylphenyl) prop-2-enoate Chemical compound C=CC(=O)OC1=CC=CC=C1C=C NJVOHKFLBKQLIZ-UHFFFAOYSA-N 0.000 claims description 3
- HDERJYVLTPVNRI-UHFFFAOYSA-N ethene;ethenyl acetate Chemical group C=C.CC(=O)OC=C HDERJYVLTPVNRI-UHFFFAOYSA-N 0.000 claims description 3
- 239000000377 silicon dioxide Substances 0.000 claims description 3
- 239000004794 expanded polystyrene Substances 0.000 claims 1
- 238000007665 sagging Methods 0.000 abstract description 5
- 239000000839 emulsion Substances 0.000 abstract description 3
- 229920006248 expandable polystyrene Polymers 0.000 abstract description 3
- 230000001459 mortal effect Effects 0.000 abstract 5
- 238000005429 filling process Methods 0.000 abstract 1
- 238000002156 mixing Methods 0.000 description 10
- 238000009413 insulation Methods 0.000 description 8
- 239000011398 Portland cement Substances 0.000 description 7
- 239000003795 chemical substances by application Substances 0.000 description 7
- 238000001035 drying Methods 0.000 description 7
- 230000000052 comparative effect Effects 0.000 description 6
- 238000013329 compounding Methods 0.000 description 4
- 239000004567 concrete Substances 0.000 description 4
- 239000011800 void material Substances 0.000 description 4
- 238000009833 condensation Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 239000010881 fly ash Substances 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 239000002893 slag Substances 0.000 description 3
- 239000006004 Quartz sand Substances 0.000 description 2
- 238000010521 absorption reaction Methods 0.000 description 2
- 239000004568 cement Substances 0.000 description 2
- 230000005494 condensation Effects 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- 230000002708 enhancing effect Effects 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 230000014759 maintenance of location Effects 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 239000011150 reinforced concrete Substances 0.000 description 2
- 235000019738 Limestone Nutrition 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 1
- 125000005396 acrylic acid ester group Chemical group 0.000 description 1
- 239000008186 active pharmaceutical agent Substances 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 239000002518 antifoaming agent Substances 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 239000003638 chemical reducing agent Substances 0.000 description 1
- 239000011362 coarse particle Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000007720 emulsion polymerization reaction Methods 0.000 description 1
- 230000008595 infiltration Effects 0.000 description 1
- 238000001764 infiltration Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 239000004816 latex Substances 0.000 description 1
- 229920000126 latex Polymers 0.000 description 1
- 239000006028 limestone Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 239000010451 perlite Substances 0.000 description 1
- 235000019362 perlite Nutrition 0.000 description 1
- 229920006327 polystyrene foam Polymers 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000005871 repellent Substances 0.000 description 1
- 230000002940 repellent Effects 0.000 description 1
- 229910021487 silica fume Inorganic materials 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 239000000057 synthetic resin Substances 0.000 description 1
- 239000002562 thickening agent Substances 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
Classifications
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
Landscapes
- Curing Cements, Concrete, And Artificial Stone (AREA)
Abstract
Description
【０００１】
【発明の属する技術分野】
本発明は、鉄筋コンクリート造等の建設工事において、スチールサッシ、アルミサッシ又はプラスチックサッシなどの窓枠と壁部コンクリート躯体の間隙部を充填するためのモルタルに関するものであり、施工時において、注入器による充填抵抗が低く充填性が良好で、さらに充填後はダレが少なく保形性が良好で、スラリーが軽量で施工性に優れ、また、断熱性、結露防止性、水密性、躯体との接着性に優れ、クラック発生の少ない窓枠空隙部充填用プレミックスモルタル及びそれを用いた窓枠空隙部充填工法に関する。
【０００２】
【従来の技術】
鉄筋コンクリート造等の建設工事における窓枠の取り付け工事は、一般的にコンクリートを打設し躯体を形成した後、窓枠より大きめに躯体を切削し、その開口部に溶接などにより窓枠を取り付ける。その際、壁部のコンクリート躯体と窓枠に間隙ができるので、その間隙部をモルタルで充填する。間隙部の大きさは、建物の構造と窓枠取り付け位置により異なるが、通常、幅３０〜１００ｍｍ、奥行き５０〜２００ｍｍ程度であり、この間隙部に手動式モルタル注入器（たとえば、友定建機社製「つまーる」）でモルタルを充填する場合がほとんどである。このような空隙充填材としては、軽量モルタル、凝結促進剤及び急結剤を配合した軽量空隙充填材（たとえば特許文献１参照）、発泡状樹脂断熱材を使用した建物の開口部の断熱構造（たとえば特許文献２参照）あるいは窓枠周辺の充填用モルタルとして石灰質原料にガラス粉末を主成分とする造粒焼成物及び珪砂を混合した軽量モルタル（たとえば特許文献３参照）等の提案がなされている。
【０００３】
窓枠空隙部充填用モルタルに求められる性能としては、
（１）充填作業に於ける作業効率が良いこと（スラリーが軽量で、注入器による充填時の抵抗が低く、充填後の手直しが不要なこと）
（２）充填性が良いこと（間隙部の隅々まで充分に充填され、充填後のダレ［モルタル充填後固化までの間に重力により上部側のモルタルが下部側に移動し、上部側が薄く、下部側が厚くなる現象］が少ないこと）。
（３）モルタル硬化体の収縮率が低く、クラックの発生や躯体との界面剥離がないこと。
（４）モルタル硬化体の防水性能が高いこと。
（５）モルタル硬化体の断熱性能が高いこと。
（６）モルタル硬化体が必要最低限の強度（一般的に、２８日後の圧縮強度で１５Ｎ／ｍｍ２ 程度）を有していること。等が挙げられる。
【０００４】
従来の窓枠空隙部充填用モルタルは、一般的に施工現場において、たとえばポルトランドセメントに対し、川砂、山砂、海砂、砕砂等の細骨材を調合後（配合比は容積比でセメント１に対し、細骨材２〜３）、水を添加し混練して調製していた。この場合、防水性を確保するために水系防水剤をさらに配合するケースが多い。また、充填時の流動性を確保するために、無機系の微粉末、例えば高炉スラグ、フライアッシュ等を配合する場合もある。
しかし、これら従来の窓枠空隙部充填用モルタルは手動式モルタル注入器による充填時の抵抗が大きく、スラリー比重が高いことにより、作業効率、施工性の面で満足できるものではなかった。また、空隙部の隅々まで充填されないという問題があり、充填作業後に未充填部を再度鏝塗り等により手直しする必要があった。さらに、充填時の抵抗を低下させ、充填性を高めるために混練時に加える水の量を増やすと、ダレが生じるということが問題であった。
【０００５】
この様に調製された従来の現場調合の窓枠空隙部充填用モルタル硬化体は、打設後の乾燥収縮が大きいため、クラックを多く生じたり、壁部コンクリート躯体との間に間隙を生じたりしたため、雨水の浸入、躯体との接着の面で問題があった。さらに、硬化体の熱伝導率が高いため、断熱性が低く、壁面に結露ができやすいという問題があった。
【０００６】
【特許文献１】
特開平１１−１００２８５号公報
【特許文献２】
特開２０００−２４０３５７号公報
【特許文献３】
特許第３２２２３９０号公報
【０００７】
【発明が解決しようとする課題】
本発明は、モルタルとしたとき、スラリー比重と塑性粘度が低く、軽量で注入器による充填抵抗が低く、充填性が良好でありながら、充填用モルタルとして充填したときに降伏値が大でダレが生じにくい、作業性、施工性、充填性の面で優れ、さらにそのモルタル硬化体は、クラック発生による雨水浸入、躯体との接着不良、低断熱性、結露発生等のない窓枠空隙部充填用プレミックスモルタル及びそれを用いた窓枠空隙部充工法の提供を目的とする。
【０００８】
【課題を解決するための手段】
本発明において、
［１］ 水硬性セメント１００重量部、細骨材２０〜６０重量部、無機系軽量細骨材２０〜７０重量部、発泡樹脂系軽量骨材０．１〜３重量部、再乳化形粉末樹脂０．０３〜３重量部からなることを特徴とする窓枠空隙部充填用プレミックスモルタル、
［２］ 水比２０〜２６％で水を添加後、混練して調整したフレッシュモルタルの塑性粘度が４５００ｍＰａ・ｓ以下で、かつ降伏値が０．３５ｇ／ｃｍ２以上となるようにした請求項１に記載の窓枠空隙部充填用プレミックスモルタル、
【０００９】
［３］ 細骨材が珪砂からなる上記［１］または［２］に記載の窓枠空隙部充填用プレミックスモルタル、
［４］ 無機系軽量骨材が、パーライト、バーミキュライト、シラスバルーン、ガラス発泡体、パルプスラッジからなる群から選ばれた上記［１］または［２］に記載の窓枠空隙部充填モルタル用プレミックス、
［５］ 発泡樹脂系軽量骨材が、発泡ポリスチレン系軽量骨材、発泡エチレン酢酸ビニル系軽量骨材、発泡ウレタン系軽量骨材からなる群から選ばれた上記［１］または［２］に記載の窓枠空隙部充填用プレミックスモルタル、
【００１０】
［６］ 再乳化形粉末樹脂が、エチレン酢酸ビニル系樹脂、酢酸ビニルエチレンバーサテート系樹脂、スチレンアクリル酸エステル系樹脂、ポリアクリル酸エステル系樹脂からなる群から選ばれた上記［１］または［２］に記載の窓枠空隙部充填用プレミックスモルタル、
［７］ 上記［１］または［２］のプレミックスモルタルに、さらに珪酸質系塗布防水材０．５〜５重量部を配合した窓枠空隙部充填用プレミックスモルタル、
［８］ 上記［１］または［７］に記載のプレミックスモルタルに、水比２０〜２６％で水を配合して塑性粘度が４５００ｍＰａ・ｓ以下で、かつ降伏値が０．３５ｇ／ｃｍ２以上としたことを特徴とする窓枠空隙部充填用モルタル、
［９］ 上記［１］または［７］に記載の窓枠空隙部充填用プレミックスモルタルに水を添加して混練し、スラリー比重１．０〜１．８ｋｇ／リットル、フロー値１３０〜２００ｍｍとした［８］に記載の窓枠空隙部充填用モルタル、
【００１１】
［１０］ 施工現場において、上記［１］または［７］に記載の窓枠空隙部充填用プレミックスモルタルに水を添加して混練し、スラリー比重１．０〜１．８ｋｇ／リットル、フロー値１３０〜２００ｍｍとした窓枠空隙部充填用モルタルを建物壁部と窓枠の間の空隙部に充填することを特徴とする窓枠空隙部充填工法、及び
［１１］ 施工現場において、上記［１］または［７］に記載の窓枠空隙部充填用プレミックスモルタルに水を添加・混練し、フレッシュモルタルの塑性粘度が４５００ｍＰａ・ｓ以下、降伏値が０．３５ｇ／ｃｍ２以上である窓枠空隙部充填用モルタルを建物壁部と窓枠の間の空隙部に充填することを特徴とする窓枠空隙部充填工法、を開発することにより上記の課題を解決した。
【００１２】
【発明の実施の形態】
本発明は、軽量であって、モルタルとしたときに塑性粘度が低くそれでいて充填後は降伏値が高く保形性に優れると言う、相反する要求に応えることができる窓枠空隙部充填用プレミックスモルタルの開発に成功したものである。
本発明において使用する水硬性セメントとしては、普通ポルトランドセメント、早強ポルトランドセメント、低熱ポルトランドセメント、中庸熱ポルトランドセメント等のポルトランドセメント、およびこれらポルトランドセメントに高炉スラグ、フライアッシュ等を混合した混合セメントが使用できる。
【００１３】
本発明において使用する細骨材としては、川砂、山砂、海砂、砕砂、珪砂等が使用可能であり、品質の一定性、硬化物の強度などからみて珪砂が好ましい。細骨材の配合量は、水硬性セメント１００重量部に対して、２０〜６０重量部であり、好ましくは３０〜５０重量部の範囲である。２０重量部未満の場合は、相対的に水硬性セメントの配合比率が高くなるため、硬化時の乾燥収縮が大きくなり、クラック発生、躯体との間隙発生が問題となる。また、６０重量部を越える場合は、相対的に水硬性セメントの配合比率が低くなるため、硬化体の強度低下が問題となる。
【００１４】
本発明において使用する無機系軽量骨材としては、パーライト、バーミキュライト、シラスバルーン、ガラス発泡体、パルプスラッジ等が使用でき、品質の一定性、入手の容易性などからみてパーライトが好ましい。無機系軽量骨材の配合量は、水硬性セメント１００重量部に対して、２０〜７０重量部であり、好ましくは３５〜５５重量部の範囲である。２０重量部未満の場合は、スラリー軽量化による作業効率の向上が十分図れず、硬化体の断熱性が十分に発揮できず、さらに乾燥収縮が大きくなる。７０重量部を越える場合は、硬化体の強度低下が問題となる。
【００１５】
本発明において使用する発泡樹脂系軽量骨材としては、発泡ポリスチレン系軽量骨材、発泡エチレン酢酸ビニル系軽量骨材、発泡ウレタン系軽量骨材等が使用でき、手動式モルタル注入器による充填時の抵抗を低く保つという観点から、発泡ポリスチレン系軽量骨材が好ましい。発泡樹脂系軽量骨材の配合量は、水硬性セメント１００重量部に対して、０．１〜３重量部であり、好ましくは０．５〜２重量部の範囲である。０．１重量部未満の場合は、スラリー軽量化による作業効率の向上が十分図れず、硬化体の断熱性が十分に発揮できない。３重量部を越える場合は、硬化体の強度低下が問題となる。
【００１６】
本発明において使用する再乳化形粉末樹脂は、乳化重合によって製造した合成樹脂エマルジョンを粒子状態で乾燥して得られた微粉末樹脂であり、水を添加して撹拌すると再乳化するものである。モルタルに少量配合することにより、モルタル硬化体の吸水性を低下させ、雨水の浸透防止に効果を発揮する。なお、他の撥水剤を併用するときは、その添加量を低減することができ、樹脂の種類としては、エチレン酢酸ビニル系樹脂、酢酸ビニルバーサテート系樹脂、スチレンアクリル酸エステル系樹脂、ポリアクリル酸エステル系等が使用できる。再乳化形粉末樹脂の配合量は、水硬性セメント１００重量部に対して、０．０３〜３重量部であり、好ましくは０．０５〜０．５重量部の範囲である。０．０３未満の場合は、モルタル硬化体の防水性能が不十分となり、雨水が建物内部に浸透することが問題となる。３重量部を越える場合は、スラリーの粘性が上がって、充填性が悪化する。
【００１７】
本発明におけるプレミックスモルタルに、防水性を強化する目的で、さらに珪酸質系塗布防水材を配合することができる。珪酸質系塗布防水材の配合量は、０．５〜５重量部が好ましく、１〜３．５重量部がさらに好ましい。０．５重量部未満の場合は、防水材による防水性付与効果がほとんど現れない。５重量部以上の場合は、硬化体が緻密化しすぎるため、乾燥収縮によるクラック発生が問題となる。
【００１８】
本発明におけるプレミックスモルタルに、スラリーの流動性を改善し、充填性を強化する目的で、さらに高炉スラグ、フライアッシュ、シリカヒューム、石灰石微粉末から選ばれる無機系微粉末を使用することができる。無機系微粉末の配合量は、水硬性セメント１００重量部に対して、５０重量部以下であり、好ましくは３０重量部以下の範囲である。５０重量部を越える場合は、相対的に組成物全体に対する水硬性セメントの配合比率が低くなるため、硬化体の強度低下が問題となる。
【００１９】
本発明におけるプレミックスモルタルの製造方法は特に限定されないが、通常は、各材料を計量後、一般的な混合装置で均一混合することにより製造される。混合装置としては、傾胴ミキサー、ナウターミキサー、ヘンシェルミキサー、Ｖ型ミキサー、オムニミキサー等が挙げられる。
【００２０】
本発明におけるプレミックスモルタルは、必要に応じ、凝結促進剤、凝結遅延剤、急結剤、膨張材、防水材、減水剤、ＡＥ剤、増粘剤、高分子エマルジョン、高分子ラテックス、収縮低減剤、消泡剤などを併用することができる。
【００２１】
本発明におけるプレミックスモルタルを用いて、窓枠空隙部の充填施工を行う場合、窓枠空隙部充填用プレミックスモルタルに添加する水の量は、プレミックスモルタルの重量に対して、２０〜２６％の範囲とするのが好ましく、２２〜２５％の範囲とするのがさらに好ましい。２０％未満の場合は、注入器による充填抵抗が高く、充填性も悪化することが問題となる。２６％を越える場合は、乾燥収縮が大きくなり、クラック発生、躯体との間隙発生が問題となり、硬化体の強度低下も問題となる。
【００２２】
また、本発明におけるスラリー比重は、１．０〜１．８ｋｇ／リットルの範囲とするのが好ましく、１．２〜１．６ｋｇ／リットルの範囲とするのがさらに好ましい。１．０ｋｇ／リットル未満の場合は、硬化体の強度低下が問題となる。
１．８ｋｇ／リットルを越える場合は、スラリー軽量化による作業効率の向上が十分図れず、硬化体の断熱性が十分に発揮できず、さらに乾燥収縮が大きくなり、クラック発生、躯体との間隙発生が問題となる。
【００２３】
また、本発明におけるフレッシュモルタルの塑性粘度と降伏値は、外筒回転式粘度計（たとえば、共和科学社製ＤＰＶ−１）にて、ローターＢ、最高回転数：３０ｒｐｍ、測定時間：３分で測定した値であり、塑性粘度が４５００ｍＰａ・ｓ以下で、かつ降伏値が０．３５ｇ／ｃｍ２以上とすることが好ましく、塑性粘度が４０００ｍＰａ・ｓ以下で、かつ降伏値が０．４ｇ／ｃｍ２以上とすることがさらに好ましい。塑性粘度が４５００ｍＰａ・ｓを越える場合は、注入器による充填抵抗が高く、充填性も悪化することが問題となる。降伏値が０．３５ｇ／ｃｍ２未満の場合は、スラリー充填後にダレの発生が問題となる。
【００２４】
また、本発明におけるフロー値は、ＪＩＳ Ｒ ５２０１に準拠した方法によって測定した値であり、１３０〜２００ｍｍの範囲とするのが好ましく、１５０〜１８０ｍｍの範囲とするのがさらに好ましい。フロー値が１３０ｍｍ未満の場合は、注入器による充填抵抗が高く、充填性も悪化することが問題となる。２００ｍｍを越える場合は、スラリー充填後にダレの発生が問題となる。
【００２５】
上記の方法により得られた窓枠空隙部充填用プレミックスモルタルは、施工時において、低スラリー比重で、注入器による充填抵抗が低く、充填したときにはダレや未充填部が生じにくく、モルタル硬化体は、クラック発生が少なく、躯体との接着性良好で、断熱性が高く、作業性、施工性、充填性、硬化体特性の面で優れたものである。
【００２６】
（実施例１〜５）
表１の配合表のとおり材料を調合し、Ｖブレンダーで各材料が均一になるよう混合し、実施例１〜５のプレミックスモルタルを調製した。
【００２７】
【表１】
２） 粒子経：０．１５〜２．５ｍｍ，単位容積重量：０．４８ｋｇ／Ｌ
３） 粒子径：２ｍｍ以下，単位容積重量：０．０４ｋｇ／Ｌ
４） 酢酸ビニルエチレンバーサテート系樹脂
５） 昭和電工建材社製「セレシット・ＤＳ」
６） マノール社製「マノール防水剤」
【００２８】
実施例１〜５のプレミックスモルタルについて、ＪＩＳ Ｒ ５２０１に準拠した方法により練り混ぜ、フレッシュモルタル及びそのモルタル硬化体の物性を測定した。その結果を表２に示す。
【００２９】
（比較例１）
ＪＩＳ Ｒ ５２０１に準拠した方法により、表１の配合表のとおりセメントと砂を調合し、水粉体比１３．５％で水を加え、マノール防水剤を加えて練り混ぜ、フレッシュモルタル及びそのモルタル硬化体の物性を測定した。その結果を表２に示す。
【００３０】
【表２】
【発明の効果】
本発明のプレミックスモルタルは、比較例のプレミックスモルタルと比べスラリー比重が低く、軽量化されている。また、フレッシュモルタルにおいて塑性粘度が低いことより充填時における注入器の充填抵抗が低くなることを表しており、それにもかかわらず降伏値が高いことより充填後のダレが少ないことを示している。
実施例のプレミックスモルタルは、比較例のプレミックスモルタルと比べ曲げ強度および圧縮強度は低い値であるが、窓枠空隙部充填用モルタルとして要求される強度は充分に満たしているレベルである。
長さ変化率が比較例より低いことから、クラック発生や躯体との接着不良が起こりにくく、熱伝導率も比較例より低いことから、モルタル硬化体として断熱性に優れていると言える。さらに、吸水量と透水量が比較例より低いことより、防水性が高いことを示している。
以上のように本発明の窓枠空隙部充填用プレミックスモルタル、及びそのモルタルは、従来のモルタルに比べ、軽量で塑性粘度が低く、降伏値が高く、作業性、施工性、充填性が良好で、クラック発生や躯体との接着不良が少なく、さらに断熱性、防水性に優れたものであることがわかる。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a mortar for filling a gap between a window frame such as a steel sash, an aluminum sash, or a plastic sash and a wall concrete frame in a construction work such as a reinforced concrete structure. Low filling resistance, good fillability, less sag after filling, good shape retention, lightweight slurry, excellent workability, heat insulation, anti-condensation, water tightness, adhesion to the housing The present invention relates to a premix mortar for filling a window frame gap with excellent crack generation and a window frame gap filling method using the same.
[0002]
[Prior art]
In the installation work of a window frame in a construction work such as a reinforced concrete structure, after concrete is cast and a housing is formed, the housing is cut larger than the window frame, and the window frame is attached to the opening by welding or the like. At that time, since a gap is formed between the concrete frame and the window frame of the wall, the gap is filled with mortar. The size of the gap varies depending on the structure of the building and the window frame mounting position, but is usually about 30 to 100 mm in width and 50 to 200 mm in depth. In most cases, the mortar is filled with “Tsumaru”). As such a void filler, a lightweight mortar, a lightweight void filler containing a setting accelerator and a quick setting agent (see, for example, Patent Document 1), a heat insulating structure of a building opening using a foamed resin heat insulating material ( For example, as a mortar for filling around a window frame, a light weight mortar (for example, see Patent Document 3) in which a calcined raw material, a granulated fired product containing glass powder as a main component, and silica sand is proposed. .
[0003]
As performance required for window frame gap filling mortar,
(1) Good work efficiency in filling work (slurry is lightweight, resistance during filling with an injector is low, and no rework after filling is required)
(2) Good filling properties (filled to every corner of the gap, and after filling, the mortar on the upper side moves to the lower side due to gravity between mortar filling and solidification, the upper side is thin, The phenomenon that the lower side becomes thick] is small).
(3) The shrinkage rate of the mortar cured body is low, and there is no generation of cracks or interfacial peeling from the housing.
(4) The waterproof performance of the cured mortar is high.
(5) The heat insulation performance of the mortar cured body is high.
(6) The mortar cured body has the minimum necessary strength (generally, the compressive strength after 28 days is about 15 N / mm 2). Etc.
[0004]
Conventional window frame gap filling mortars are generally prepared at the construction site after blending fine aggregates such as river sand, mountain sand, sea sand, and crushed sand with Portland cement. On the other hand, fine aggregates 2 to 3) were prepared by adding water and kneading. In this case, there are many cases in which a water-based waterproofing agent is further blended to ensure waterproofness. Moreover, in order to ensure the fluidity | liquidity at the time of filling, an inorganic type fine powder, for example, blast furnace slag, a fly ash, etc. may be mix | blended.
However, these conventional window frame gap filling mortars are not satisfactory in terms of work efficiency and workability due to their high resistance during filling with a manual mortar injector and high slurry specific gravity. In addition, there is a problem that the entire space is not filled, and it is necessary to rework the unfilled portion again by glazing after the filling operation. Furthermore, when the amount of water added at the time of kneading is increased in order to reduce the resistance at the time of filling and improve the filling property, there has been a problem that sagging occurs.
[0005]
The mortar hardened body for filling window frame gaps prepared in this way, prepared in this way, has a large shrinkage after drying, so it causes many cracks and gaps with the wall concrete frame. As a result, there were problems in terms of infiltration of rainwater and adhesion to the housing. Furthermore, since the heat conductivity of the cured body is high, there is a problem that heat insulation is low and condensation is easily formed on the wall surface.
[0006]
[Patent Document 1]
Japanese Patent Application Laid-Open No. 11-1000028 [Patent Document 2]
JP 2000-240357 A [Patent Document 3]
Japanese Patent No. 3222390 [0007]
[Problems to be solved by the invention]
In the present invention, when the mortar is used, the slurry specific gravity and plastic viscosity are low, the weight is low, the filling resistance by the injector is low, and the filling property is good. Excellent in workability, workability, and filling properties, which are hard to occur, and the mortar hardened body is used for filling window frame voids without intrusion of rainwater due to cracks, poor adhesion to the housing, low heat insulation, condensation, etc. An object is to provide a premix mortar and a window frame void filling method using the same.
[0008]
[Means for Solving the Problems]
In the present invention,
[1] Hydraulic cement 100 parts by weight, fine aggregate 20-60 parts by weight, inorganic lightweight fine aggregate 20-70 parts by weight, foamed resin lightweight aggregate 0.1-3 parts by weight, re-emulsified powder resin A premix mortar for filling a window frame gap, characterized by comprising 0.03 to 3 parts by weight,
[2] A fresh mortar prepared by kneading after adding water at a water ratio of 20 to 26% has a plastic viscosity of 4500 mPa · s or less and a yield value of 0.35 g / cm 2 or more. The premix mortar for filling the window frame gap according to 1,
[0009]
[3] The premix mortar for filling a window frame gap according to the above [1] or [2], wherein the fine aggregate is made of silica sand.
[4] The premix for window frame void filling mortar according to [1] or [2], wherein the inorganic lightweight aggregate is selected from the group consisting of perlite, vermiculite, shirasu balloon, glass foam, and pulp sludge. ,
[5] The above-mentioned [1] or [2], wherein the foamed resin-based lightweight aggregate is selected from the group consisting of a foamed polystyrene-based lightweight aggregate, a foamed ethylene-vinyl acetate-based lightweight aggregate, and a foamed urethane-based lightweight aggregate. Premixed mortar for filling window frame voids,
[0010]
[6] The above [1] or [6] wherein the re-emulsifying powder resin is selected from the group consisting of ethylene vinyl acetate resin, vinyl acetate ethylene versatate resin, styrene acrylate resin, and polyacrylate resin. 2], a premix mortar for filling a window frame gap,
[7] A premix mortar for filling a window frame gap, in which 0.5 to 5 parts by weight of a siliceous coated waterproofing material is further blended with the premix mortar of [1] or [2] above,
[8] The premixed mortar according to the above [1] or [7] is mixed with water at a water ratio of 20 to 26% to have a plastic viscosity of 4500 mPa · s or less and a yield value of 0.35 g / cm 2. Mortar for filling window frame voids characterized by the above,
[9] Water is added to the premix mortar for filling the window frame voids according to the above [1] or [7] and kneaded to obtain a slurry specific gravity of 1.0 to 1.8 kg / liter and a flow value of 130 to 200 mm. [8] the window frame gap filling mortar according to the above,
[0011]
[10] At the construction site, water is added to the premix mortar for filling a window frame gap described in the above [1] or [7] and kneaded to obtain a slurry specific gravity of 1.0 to 1.8 kg / liter, a flow value. A window frame gap filling method characterized by filling a gap between a building wall and a window frame with a mortar for filling a window frame gap of 130 to 200 mm, and [11] In the construction site, [1 ] Or premixed mortar for filling window frame voids according to [7], wherein water is added and kneaded, and the plastic viscosity of the fresh mortar is 4500 mPa · s or less and the yield value is 0.35 g / cm 2 or more. The above-mentioned problems have been solved by developing a window frame gap filling method characterized by filling a gap between a building wall and a window frame with a mortar for filling the window.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
The present invention is a premix for filling window frame gaps that is light in weight and has a low plastic viscosity when it is made into a mortar, yet has a high yield value after filling and excellent shape retention. Successful development of mortar.
Examples of the hydraulic cement used in the present invention include ordinary Portland cement, early strength Portland cement, low heat Portland cement, Portland cement such as moderately hot Portland cement, and mixed cement obtained by mixing these Portland cements with blast furnace slag, fly ash, and the like. Can be used.
[0013]
As fine aggregates used in the present invention, river sand, mountain sand, sea sand, crushed sand, quartz sand and the like can be used, and quartz sand is preferred from the viewpoint of the constant quality and the strength of the cured product. The compounding amount of the fine aggregate is 20 to 60 parts by weight, preferably 30 to 50 parts by weight, based on 100 parts by weight of the hydraulic cement. When the amount is less than 20 parts by weight, the blending ratio of the hydraulic cement is relatively high, so that the drying shrinkage at the time of curing becomes large, and the generation of cracks and the gap with the casing becomes a problem. On the other hand, when the amount exceeds 60 parts by weight, the blending ratio of the hydraulic cement becomes relatively low, so that the strength of the cured body is lowered.
[0014]
As the inorganic lightweight aggregate used in the present invention, pearlite, vermiculite, shirasu balloon, glass foam, pulp sludge and the like can be used, and pearlite is preferable from the viewpoint of constant quality and availability. The compounding amount of the inorganic lightweight aggregate is 20 to 70 parts by weight, preferably 35 to 55 parts by weight with respect to 100 parts by weight of the hydraulic cement. When the amount is less than 20 parts by weight, the work efficiency cannot be sufficiently improved by reducing the weight of the slurry, the heat insulating property of the cured body cannot be sufficiently exhibited, and the drying shrinkage is further increased. When the amount exceeds 70 parts by weight, a decrease in strength of the cured body becomes a problem.
[0015]
As the foamed resin-based lightweight aggregate used in the present invention, foamed polystyrene-based lightweight aggregate, foamed ethylene vinyl acetate-based lightweight aggregate, foamed urethane-based lightweight aggregate, etc. can be used, and when filled with a manual mortar injector From the viewpoint of keeping the resistance low, a polystyrene foam lightweight aggregate is preferable. The amount of the foamed resin-based lightweight aggregate is 0.1 to 3 parts by weight, preferably 0.5 to 2 parts by weight, based on 100 parts by weight of the hydraulic cement. When the amount is less than 0.1 parts by weight, the work efficiency cannot be sufficiently improved by reducing the weight of the slurry, and the heat insulating property of the cured body cannot be sufficiently exhibited. When the amount exceeds 3 parts by weight, a decrease in strength of the cured product becomes a problem.
[0016]
The re-emulsified powder resin used in the present invention is a fine powder resin obtained by drying a synthetic resin emulsion produced by emulsion polymerization in a particle state, and re-emulsifies when water is added and stirred. By blending a small amount with mortar, the water absorption of the cured mortar is lowered, and the effect of preventing rainwater penetration is exhibited. When other water repellents are used in combination, the amount added can be reduced. The types of resins include ethylene vinyl acetate resin, vinyl acetate versatate resin, styrene acrylate resin, Acrylic acid ester type can be used. The compounding amount of the re-emulsifying powder resin is 0.03 to 3 parts by weight, preferably 0.05 to 0.5 parts by weight, with respect to 100 parts by weight of the hydraulic cement. If it is less than 0.03, the waterproof performance of the mortar hardened body becomes insufficient, causing a problem that rainwater penetrates into the building. When it exceeds 3 parts by weight, the viscosity of the slurry is increased and the filling property is deteriorated.
[0017]
The premixed mortar in the present invention can be further blended with a siliceous coated waterproofing material for the purpose of enhancing waterproofing. 0.5-5 weight part is preferable and, as for the compounding quantity of a siliceous-type application | coating waterproofing material, 1-3.5 weight part is more preferable. In the case of less than 0.5 part by weight, the waterproofing effect by the waterproof material hardly appears. In the case of 5 parts by weight or more, since the cured body is too dense, cracking due to drying shrinkage becomes a problem.
[0018]
In the premix mortar of the present invention, an inorganic fine powder selected from blast furnace slag, fly ash, silica fume, and limestone fine powder can be used for the purpose of improving the fluidity of the slurry and enhancing the filling property. . The blending amount of the inorganic fine powder is 50 parts by weight or less, preferably 30 parts by weight or less with respect to 100 parts by weight of the hydraulic cement. When the amount exceeds 50 parts by weight, the blending ratio of the hydraulic cement relative to the entire composition is relatively low, so that the strength of the cured body is reduced.
[0019]
Although the manufacturing method of the premix mortar in this invention is not specifically limited, Usually, after measuring each material, it manufactures by uniformly mixing with a general mixing apparatus. Examples of the mixing apparatus include a tilting cylinder mixer, a Nauter mixer, a Henschel mixer, a V-type mixer, and an omni mixer.
[0020]
The premix mortar according to the present invention includes a setting accelerator, a setting retarder, a rapid setting agent, an expansion material, a waterproofing material, a water reducing agent, an AE agent, a thickening agent, a polymer emulsion, a polymer latex, and a shrinkage reduction as necessary. An agent, an antifoaming agent, etc. can be used together.
[0021]
When filling the window frame gap using the premix mortar in the present invention, the amount of water added to the window frame gap filling premix mortar is 20 to 26 with respect to the weight of the premix mortar. %, Preferably in the range of 22-25%. If it is less than 20%, the filling resistance by the injector is high, and the filling property is deteriorated. When it exceeds 26%, drying shrinkage becomes large, and cracks and gaps with the casing are problematic, and the strength of the cured body is also problematic.
[0022]
The specific gravity of the slurry in the present invention is preferably in the range of 1.0 to 1.8 kg / liter, and more preferably in the range of 1.2 to 1.6 kg / liter. When the amount is less than 1.0 kg / liter, a decrease in strength of the cured body becomes a problem.
If it exceeds 1.8 kg / liter, the work efficiency cannot be improved sufficiently by reducing the weight of the slurry, the heat insulation of the cured body cannot be fully exerted, and the drying shrinkage becomes larger, cracks are generated, and gaps with the housing are generated. Is a problem.
[0023]
Moreover, the plastic viscosity and yield value of the fresh mortar in the present invention are the rotor B, the maximum rotation speed: 30 rpm, and the measurement time: 3 minutes using an outer cylinder rotary viscometer (for example, DPV-1 manufactured by Kyowa Kagaku Co., Ltd.). The measured values are preferably a plastic viscosity of 4500 mPa · s or less and a yield value of 0.35 g / cm 2 or more, a plastic viscosity of 4000 mPa · s or less and a yield value of 0.4 g / cm 2. More preferably, it is 2 or more. When the plastic viscosity exceeds 4500 mPa · s, there is a problem that the filling resistance by the injector is high and the filling property is deteriorated. When the yield value is less than 0.35 g / cm 2 , the occurrence of sagging after slurry filling becomes a problem.
[0024]
Moreover, the flow value in this invention is a value measured by the method based on JISR5201, It is preferable to set it as the range of 130-200 mm, and it is more preferable to set it as the range of 150-180 mm. When the flow value is less than 130 mm, the filling resistance by the injector is high, and the filling property is deteriorated. When it exceeds 200 mm, the occurrence of sagging after slurry filling becomes a problem.
[0025]
Premix mortar for filling window frame voids obtained by the above method has low slurry specific gravity and low filling resistance by an injector at the time of construction. Has less cracking, good adhesion to the casing, high heat insulation, and is excellent in terms of workability, workability, fillability, and cured body characteristics.
[0026]
(Examples 1-5)
The materials were blended as shown in the recipe of Table 1, and mixed with a V blender so that each material was uniform, to prepare premix mortars of Examples 1 to 5.
[0027]
[Table 1]
2) Particle diameter: 0.15 to 2.5 mm, unit volume weight: 0.48 kg / L
3) Particle size: 2 mm or less, unit volume weight: 0.04 kg / L
4) Vinyl acetate ethylene versatate resin 5) “Cerecit DS” manufactured by Showa Denko Construction Materials Co., Ltd.
6) “Manol waterproofing agent” manufactured by Manor
[0028]
About the premix mortar of Examples 1-5, it knead | mixed by the method based on JISR5201, and measured the physical property of the fresh mortar and its mortar hardening body. The results are shown in Table 2.
[0029]
(Comparative Example 1)
Cement and sand are prepared according to the method of JIS R 5201 as shown in the composition table of Table 1, water is added at a water powder ratio of 13.5%, a manol waterproofing agent is added and kneaded, and fresh mortar and its mortar The physical properties of the cured product were measured. The results are shown in Table 2.
[0030]
[Table 2]
【The invention's effect】
The premix mortar of the present invention has a lower slurry specific gravity and is lighter than the premix mortar of the comparative example. Moreover, it shows that the filling resistance of the injector at the time of filling becomes low because the plastic viscosity is low in the fresh mortar, and nevertheless shows that the sagging after filling is small because the yield value is high.
The premix mortars of the examples have lower bending strength and compressive strength than the premix mortars of the comparative examples, but the strength required as the window frame gap filling mortar is sufficiently satisfied.
Since the rate of change in length is lower than that of the comparative example, cracks and poor adhesion to the housing are less likely to occur, and since the thermal conductivity is also lower than that of the comparative example, it can be said that the mortar cured body is excellent in heat insulation. Furthermore, since the water absorption amount and the water permeation amount are lower than those of the comparative examples, the waterproofness is high.
As described above, the premix mortar for filling a window frame gap of the present invention and the mortar are lighter in weight, have a lower plastic viscosity, have a higher yield value, and have better workability, workability, and fillability than conventional mortars. Thus, it can be seen that there are few occurrences of cracks and poor adhesion to the housing, and further excellent heat insulation and waterproof properties.
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| JP2008297140A (en) * | 2007-05-30 | 2008-12-11 | Taiheiyo Material Kk | High fluidity lightweight mortar |
| EP2007696A1 (en) * | 2006-03-22 | 2008-12-31 | Leon Kruss | Construction product |
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| JP2010143807A (en) * | 2008-12-22 | 2010-07-01 | Showa Denko Kenzai Kk | Mortar, preparation method thereof, and gap-filling work using the same |
| US20100314111A1 (en) * | 2009-06-15 | 2010-12-16 | Karcher Jeffery D | Cement Compositions Comprising Particulate Foamed Elastomers and Associated Methods |
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