JP2005081824A - Partially hydrated shaped body of hydraulic composition, its manufacturing process, its usage - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a partially hydrated shaped body of a hydraulic composition which is prevented from producing dust of hydraulic composition powder in circulation and usage, can be stored for a long time and can be used in a simplified mode, its manufacturing method and its usage. <P>SOLUTION: The partially hydrated shaped body of the hydraulic composition is made by partially hydrating and curing the hydraulic composition to an extent capable of retaining its shape and allowing unhydrated part to remain in itself. The partially hydrated shaped body keeping its hydration activity and retaining its shape can be cured completely by "adding water afterwards" as described in the specification to complete hydration reaction to attain a performance equivalent to that of a conventional hydraulic body, and can be utilized in various applications. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a partially hydrated molded body of a hydraulic composition, a method for producing the same, and a method for using the same. In particular, various uses in which the hydraulic composition is used, such as crack fillers, static crushing materials, Partially hydrated molded body of hydraulic composition that can be distributed and used in a simple form as mortar premix products, various concrete premix products, various hole filling materials, backfill materials, etc., its production method and use thereof Regarding the method.

Conventionally, hydraulic compositions have been distributed in the form of their own powders or as mixed powders in which aggregates, various additives, etc. are premixed and packed in moisture-proof paper bags, plastic bags or the like.
In particular, most cement-based materials are currently distributed in bags of 20 to 25 kg.

Such a hydraulic composition packed in a bag is generally used by opening the bag, putting it in a stirring container or a stirring mixer, and kneading it with a predetermined amount of water.
The kneaded mortar or concrete is poured or poured into a pre-prepared mold, and after moderate compaction, for example, adjusting material separation with a vibratory vibrator or the like, it is allowed to cure.

In recent years, downsizing of the distribution form of hydraulic compositions has progressed, but the bag container which is the mainstream of the distribution form is heavy, difficult to carry, and inconvenient to handle.
The hydraulic composition has a true specific gravity of 2 to 3, but the bulk specific gravity is about 1 and requires a volume that is twice the actual weight. It is heavy labor.

Further, when the hydraulic powder is put into a kneading container or apparatus, a large amount of dust is generated, which is not environmentally preferable.
Furthermore, even if the hydraulic composition is contained in a bag having moisture resistance, the bag has high reactivity with respect to moisture and moisture in the air. Therefore, the storage period is about 6 months at the maximum. Currently.

  After using such a hydraulic composition, a large number of empty bags containing the hydraulic composition are generated, which is a waste of resources and waste. In particular, a bag enclosing a hydraulic composition such as cement is difficult to burn and incineration is difficult.

  Conventionally, as a method for repairing and reinforcing cracks in concrete, generally, the periphery of the cracks is first cleaned to remove foreign substances, and depending on the width of the cracks, it is cut into a V shape with a cutter or other equipment, and then resin-based. A method is used in which a cracking material mainly composed of a hydraulic composition is injected after sealing with a sealing agent or the like.

However, in this case, specialized tools such as a concrete cutter, a sealing agent, an injection device and an injection pump are required, and the apparatus becomes large, so that expertise is required.
In addition, the conventional method is excellent in terms of repairing cracks, but the repaired portion often has a different color from the original frame, and is not satisfactory from the point of view of the structure.

  Further, for example, in a water-stopping material, the hydraulic composition is quickly kneaded with water in a rubber container or the like, and the water-stopping effect is obtained by manually rubbing the kneaded material against a predetermined water leak location. However, this method is extremely inefficient.

In static crushed materials, the hydraulic composition is kneaded with water, poured into pre-drilled rocks and concrete holes, and the crushing effect is obtained by the strong expansion force accompanying hydration. It is.
In general, with regard to crushing in water, a paste obtained by mixing and mixing a static crushing agent and water has a specific gravity of 2 or more and is heavier than water. Therefore, when the paste is poured into a perforation in water, Is used, and the paste can be filled in the perforations.

However, even if the specific gravity of the paste is 2 or more, the operation of pouring a liquid in water into the hole is an extremely difficult operation.
In addition, when working underwater, the paste spreads due to the flow of water and tide, and the paste exhibits a strong alkalinity, which is environmentally unfavorable considering the effect on the surrounding ecosystem. .

Another method is to fill the sachet with a static crushing agent and push it directly into the perforations. In this method, water necessary for hydration and expansion of the static crushing agent is supplied through a filled cloth bag.
Although this method can prevent the static crushing agent from diffusing, it is extremely difficult and inefficient to pack the bag densely in the hole in the water, and the bag is not necessarily dense along the shape in the hole. As a result, unnecessary voids are formed in the holes.

  In addition, the hole-in anchor is a general-purpose tool that is used in many daily applications for concrete work, such as holding the formwork during construction of concrete, but it is often removed when construction is complete. After removal, a large number of holes with a diameter of about 6 to 20 mm and a depth of about 100 mm remain as traces on the concrete surface or the like.

If the traces are left as they are, the aesthetic appearance will be lost, so they are backfilled. However, for example, in bridge construction, the number of traces is large, and the backfilling work is very troublesome.
In addition, for such post-filling, cement, sand, an appropriate amount of water, and repairing premixed mortar materials are manually filled and post-filled.

  In view of such problems, as a method of molding and solidifying the hydraulic composition powder, Japanese Patent No. 2514668 includes 5 to 95 parts by weight of a hydraulic composition composed of at least one of cement, slag, and gypsum, quicklime or bitter earth. Disclosed is a molded body in which 5 to 95 parts by weight of lime or a mixture thereof and 0.5 to 1.5% by weight of a disintegration aid are mixed with the hydraulic composition and pressed to form a briquette. Yes.

However, although such a molded body contains a hydraulic composition, the molded body is produced by simply pressurizing and compacting raw material powder, and is brittle, both as a distribution form and as a use form. It is not enough to solve the above problem.
Japanese Patent No. 2514668

  The purpose of the present invention is to solve the above-mentioned problems, reliably prevent the generation of dust in the hydraulic composition powder during distribution and use, enable long-term storage, and simplify the usage form. It is to provide a partially hydrated molded body of a hydraulic composition.

  Another object of the present invention is to provide a method for producing a partially hydrated molded body of a hydraulic composition, which can efficiently, conveniently and economically mold the partially hydrated molded body. is there.

  Furthermore, another object of the present invention is to provide a method for using a partially hydrated molded body of a hydraulic composition, which allows the above partially hydrated molded body to be easily and effectively used for various applications. is there.

  The present inventors can solidify the hydraulic composition to such an extent that it maintains its own shape even when the amount of water is less than the theoretical amount of water, and further allows the hydration activity to remain in the partially hydrated molded body, which is later desired. By supplying water at the timing, it was found that a fully hydrated cured product can be obtained using the remaining hydration activity, and the present invention has been achieved.

That is, in general, the hydrated body of the hydraulic composition is poured into a mold and cured to obtain a molded body. Therefore, the molded body and the hydration reaction are inseparable. It was thought that it could not be obtained.
In contrast, the present invention separates the hydration reaction into two parts, “parts necessary for maintaining the shape” and “physical performance values such as strength and durability”, and is necessary for maintaining the shape of the self-form. Forming a molded body using a hydration reaction, and "water is supplied later" to use the hydration activity remaining in the molded body at any time, thereby curing the conventional hydrate It is based on the knowledge that the same performance as the body can be obtained.

The partially hydrated molded body of the hydraulic composition of the present invention is characterized in that the hydraulic composition is partially hydrated and cured to such an extent that the shape can be maintained.
To give a specific example, the hydraulic composition and water are mixed at a weight ratio of 99: 1 to 50:50 parts by weight, and the weight ratio of the added water is the hydraulic composition. When the water content exceeds the theoretical hydration amount, that is, when the water ratio with respect to 100 parts by weight of the hydraulic composition exceeds about 27 to 28 parts by weight, the theory is increased by heating or reduced pressure during the ongoing hydration reaction. The water is forcibly removed by evaporation so that the water content is not more than the amount of hydration, that is, the water ratio is not more than 28 parts by weight, the shape is maintained and the unhydrated part remains.
The partially hydrated molded body of the hydraulic composition of the present invention preferably further comprises a polymer compound.

  The method for producing a partially hydrated molded body of the hydraulic composition of the present invention comprises mixing the hydraulic composition of the present invention with water in an amount greater than the theoretical amount at which the hydraulic composition exhibits a complete hydration reaction. It is characterized in that it is forcibly dried when hydration proceeds to a stage where it can maintain its own shape, and the hydration activity partially remains.

  Further, another method for producing a partially hydrated molded body of the hydraulic composition of the present invention includes the production of the hydraulic composition and the hydraulic composition in producing the partially hydrated molded body of the hydraulic composition of the present invention. The product is characterized by mixing with an amount of water less than the theoretical amount that exhibits a complete hydration reaction, and proceeding with the hydration reaction of the resulting mixture to form and partially leave the hydration activity. .

Preferably, in the method for producing a partially hydrated molded body of the hydraulic composition, the molding is press molding, extrusion molding or injection molding.
More preferably, in the method for producing a partially hydrated molded article of the hydraulic composition, a polymer compound is further contained in place of the water.

  The method for utilizing the partially hydrated molded body of the hydraulic composition of the present invention is to add water to the partially hydrated molded body of the hydraulic composition of the present invention to complete and cure the remaining hydration activity, thereby cracking. It is used for various purposes such as repair materials.

  Preferably, in the method of using the partially hydrated molded body of the hydraulic composition, the partially hydrated molded body of the hydraulic composition is filled and applied to the crack surface of the structure, and then the crack injection material is It is characterized by being used as a crack filler for filling the inside of a crack and repairing the crack.

The partially hydrated molded body of the hydraulic composition of the present invention can maintain its shape as a molded body, can be easily disintegrated during use, and can improve its working efficiency. In addition, since the hydraulic composition can be easily molded and solidified into a desired shape, it can be used for various applications and generates dust even in its distribution state and working environment. The environment can be maintained very well.
Furthermore, the partially hydrated molded body of the hydraulic composition of the present invention can prevent weathering and enable long-term storage.

  Moreover, the method for producing a partially hydrated molded body of the hydraulic composition of the present invention enables the above partially hydrated molded body to be molded efficiently, simply and economically.

  Furthermore, the utilization method of the partially hydrated molded body of the hydraulic composition of the present invention can achieve the curing of the hydraulic composition by replenishing moisture when used, and opens a wide range of applications. At the same time, the handling can be simplified.

  Furthermore, the partially hydrated molded body of the hydraulic composition of the present invention can be easily and reliably filled and repaired by cracks and the like without requiring special tools or techniques. It is possible to prevent moisture from entering and prevent rusting of the internal reinforcing bars, thereby preventing deterioration or breakage of concrete or the like.

The present invention is illustrated by the following preferred examples, but is not limited thereto.
The partially hydrated molded body of the hydraulic composition of the present invention is obtained by partially hydrating and hardening the hydraulic composition to such an extent that the shape can be maintained. It is hydrated and cured and contains an unhydrated part.
Such a partially hydrated molded product that retains its own shape while maintaining the hydration activity of the present invention is almost the same as a conventional hydrated cured product when used, that is, by “adding water later”, as described later. By completing the hydration reaction to an equivalent performance and curing it, it can be used for various applications.

Here, the “partially hydrated molded product” in the present specification has an ignition loss value (ignition loss) defined by “ignition loss of cement” of JIS R 5202 of 25% by weight or less, preferably It represents a material of 15% by weight or less, and means one that is molded into a state that can be used for the method of use described in the examples described later.
For example, when the ignition loss is 15% by weight, the theoretical water amount of the molded body of the present invention is usually 28% by weight. Therefore, the remaining 13% by weight is retained and retained in the molded body while maintaining the hydration activity. Thus, a partially hydrated molded body is obtained.

The hydraulic composition used in the partially hydrated molded article of the present invention can consist of only hydraulic powder as a powder raw material.
Here, the hydraulic powder means a powder that is hardened by water, preferably ordinary Portland cement, jet cement, alumina cement, super-hard cement, calcium silicate, calcium aluminate, calcium fluoroaluminate, calcium salp. At least one powder selected from the group consisting of foaluminate, calcium aluminoferrite, calcium phosphate, slag, semi-water or anhydrous gypsum and self-hardening powder of quicklime is used.

The particle size and the like of the hydraulic powder are not particularly limited, but those having an average particle size of about 10 to 40 μm are preferable from the viewpoint of the pot life at the time of molding and the strength of the molded product to be obtained. From the standpoint of securing strength, it is preferable that the specific surface area of the brane is 2500 cm ² / g or more.

Further, the hydraulic composition used in the present invention may contain a non-hydraulic powder in addition to the hydraulic powder.
The non-hydraulic powder means a powder that does not harden when contacted with water alone, but its components are eluted in an alkaline or acidic state, or in a high-pressure steam atmosphere, and other already-eluting components. It also includes powders that react to form products.

The non-hydraulic powder includes at least one powder selected from the group consisting of calcium hydroxide powder, dihydrate gypsum powder, calcium carbonate powder, slag powder, fly ash powder, silica stone powder, clay powder and silica fume powder. The body can be preferably used.
These non-hydraulic powders have a function of increasing strength by a pozzolanic reaction or a microfiller effect.

The average particle diameter of these non-hydraulic powders is preferably one or more orders of magnitude smaller than the average particle diameter of the hydraulic composition powder, more preferably two or more orders of magnitude smaller than that of the hydraulic composition powder. However, the lower limit of the fineness is not particularly limited, and is not particularly limited as long as it does not impair the effects of the present invention. Is preferably about 1/500 of the moldability.
By using the non-hydraulic powder having such a particle size, the shape maintaining property of the molded body can be further improved.

In producing the partially hydrated molded article of the present invention, for example, the hydraulic composition and water are in a weight ratio of 99: 1 to 50:50 parts by weight, preferably 80:20 to 95: 5 parts by weight. Mix in proportions.
When the weight ratio of the added water exceeds the theoretical hydration amount of the hydraulic composition, that is, when the water ratio to 100 parts by weight of the hydraulic composition exceeds about 27 to 28 parts by weight, hydration During the reaction, water is forcibly removed by evaporation so that the water content is less than the theoretical hydration amount, that is, the water content is less than 28 parts by weight.

  Here, the theoretical hydration amount of the hydraulic composition is, for example, in the case of ordinary ordinary Portland cement, the theoretical water amount of ordinary Portland cement, that is, the mineral composition of ordinary Portland cement is all hydrated by the hydration reaction. The amount of water required to become a product is 27 to 28 parts by weight with respect to 100 parts by weight of ordinary Portland cement. Specifically, 100 g of ordinary Portland cement and 28 g of water are mixed and cured well. In this case, the hydration proceeds completely with time, and a fully hydrated cured product is obtained. This represents the amount of water that can be obtained.

On the other hand, for example, when kneading a mixture obtained by adding and mixing about 10 parts by weight of water with 100 parts by weight of ordinary Portland cement, a mixture lacking water to complete the hydration reaction, That is, a mixture in which only 10 parts by weight of water is originally required as a theoretical amount of water of 100 parts by weight of the hydraulic composition to 28 parts by weight is just a wet powder.
This can be formed into a desired shape by, for example, press molding and the like can be retained by a partial hydration reaction to obtain the partially hydrated molded body of the present invention.

  More preferably, the droplet diameter of the added water is equal to or smaller than the powder diameter of the hydraulic composition, so that the mixed wet powder of the obtained hydraulic composition and water is so-called ' This is preferable because a uniform mixture can be obtained without forming a kneading d '.

  In addition, when the partially hydrated molded product is used in various applications, if it is brought into contact with water and the hydration reaction proceeds, for example, in the repair of cracks, there is no trace of the color of the water, and almost the same color as that of the original body Is obtained and can maintain a good aesthetic appearance. Moreover, when used as a static crushing material, appropriate expansion is obtained and crushing efficiency is improved.

Furthermore, in the partially hydrated molded article of the present invention, a polymer compound such as a water-soluble polymer compound can be mixed and dispersed as necessary, and is preferably kneaded with a hydraulic composition. A part of water can be substituted for the polymer compound.
In particular, when casting or extrusion molding is used when producing the partially hydrated molded article of the present invention, in order to ensure fluidity, a part of the water should be replaced with a water-soluble polymer. Can do.
Such a polymer compound has a function that contributes to improving the formability in water, improving the performance in the final use phase, and, for example, enhancing the adhesion strength, in the partially hydrated molded product of the present invention.

  Examples of such water-soluble polymers include polyalkylene glycols typified by polyethylene glycol and polymethylene glycol, polyvinyl alcohols such as poval, celluloses such as carboxymethyl cellulose, hydroxyethyl cellulose, and cationized cellulose, or cellulose ethers. And poly (ethylene oxide) obtained by ring-opening polymerization of ethylene oxide such as methyl vinyl ether such as VEMA (bema) and maleic anhydride copolymer, starches, and alkox. It can be used as a molecular compound itself or as a polymer emulsion.

Next, a method for producing a partially hydrated molded body of the hydraulic composition of the present invention will be described in detail.
In the partially hydrated molded body of the hydraulic composition of the present invention, water and the hydraulic composition are kneaded and mixed at the above mixing ratio, then molded, and hydrated to a level that maintains its own shape after molding. At this stage, it is manufactured by demolding and forced drying.

  Specifically, as a molding method, a molding method such as an injection molding method, an extrusion molding method, a pressure molding method, or a casting method can be used, but the molding method is not limited to these, and a known molding method is used. Can be used.

  In order to prepare the partially hydrated molded article of the present invention, first, the hydraulic composition and water are prepared by mixing at the above mixing ratio, and the mixing method is arbitrary known as long as it can be mixed uniformly. It is possible to mix using this method.

  In particular, when using a hydraulic composition containing a hydraulic powder and a non-hydraulic powder, it is preferable to employ a mixing method capable of applying a strong shearing force, such as a proshear type mixer, etc. Knead using By mixing using such a mixer having a high shearing force, the time required for mixing can be shortened.

In addition, as described above, as a method for adding water, a wet composition is obtained by mixing a hydraulic composition and a smaller amount of water than the theoretical amount at which the hydraulic composition exhibits a complete hydration reaction, The hydration reaction of the powder is advanced to form a molded body capable of maintaining its own shape, so that the hydration activity partially remains. If the hydration reaction proceeds to a stage where the self-formation can be maintained, forced drying can be performed at a stage in the middle of the hydration reaction, if necessary.
In this case, any method can be used as long as the hydraulic composition is uniformly added, but the wet powder obtained by adding the amount of water to the hydraulic composition is stably produced. In order to do so, it is necessary to pay attention not to cause so-called kneading.

In order to prevent the formation of kneading, as described above, it is desirable that the droplet diameter of the water to be added is not more than the particle diameter of the hydraulic composition powder.
As a water addition method for this purpose, for example, a dedicated spray nozzle that can be sprayed with a droplet diameter equal to or smaller than that of powder particles, preferably called a commercially available dry fog nozzle, can be used effectively. .

Specifically, a method is preferably used in which powder of the hydraulic composition is put into a mixer, and dry fog is sprayed continuously while the mixer is rotated or mixed.
By carrying out in this way, it is possible to obtain a completely uniform mixture of hydraulic composition and water without any kneading, that is, a wet powder of the hydraulic composition. A uniform partially hydrated molded product can be obtained.

The forced drying in the hydration process can be performed by means such as heating or pressurization. In the production of a fully hydrated cured body of a conventional hydraulic composition, the forced drying causes a harmful state such as cracking. For example, if the molded body has a very small cross-sectional shape with a diameter of about 10 mm. The desired partially hydrated molded article can be obtained without causing harmful cracks.
Such a method for producing a partially hydrated molded body involving a forced drying step can be used for extrusion molding in addition to casting.
Furthermore, even when using a mixed solution of water and a polymer compound in which a part of water is replaced with a water-soluble polymer compound such as alcohol or low molecular weight polyethylene glycol, it is produced in the same process as above. Is possible.

  In place of the above method, the hydraulic composition and a theoretical amount or more of water sufficient to allow the hydraulic composition to be completely hydrated are mixed, and hydration is performed until the self-form can be maintained. A partially hydrated molded body of the hydraulic composition of the present invention can also be produced by forcibly drying at the time of progress and leaving the hydration activity partially.

Specifically, for example, a mixture in the form of a wet powder obtained by adding about 10 parts by weight of water to 100 parts by weight of the hydraulic composition is not suitable for conventional casting and the like.
Therefore, water is added and mixed to the extent that casting can be performed, that is, about 50 parts by weight with respect to 100 parts by weight of the hydraulic composition, and this is cast into a mold that has a desired shape. Dehydration at a stage sufficient for the hydration reaction to maintain its own shape, for example, preferably in the case of ordinary Portland cement, is demolded at a temperature of about 8 hours at 20 ° C. The water required for the hydration reaction is removed. By doing so, it becomes possible to obtain a partially hydrated molded article that is the object of the present invention.

When pressure molding is used as the molding method, a mixture of the obtained hydraulic composition and water, that is, a wet powder of the hydraulic composition is used as a tool for molding, for example, a material conveying screw of an extrusion molding machine. It is put into a die part or a die of a press machine or the like, and is extruded and compacted by a molding pressure of about 5000 kg / cm ² or less, for example.

  More preferably, the surface of the obtained partially hydrated molded body can be subjected to an extremely thin coating treatment such as paraffin wax or organic paint. By providing such a coating, it is possible to prevent the remaining hydration activity from being lost due to moisture in the air during the storage period of the partially hydrated molded body.

The partially hydrated molded body thus obtained maintains the shape as a molded body and has an appropriate disintegration property when used. Therefore, a water-stopping material, a crack filler, a static crushing material, various mortar presses are used. It can be used as a mix product, various concrete premix products, various hole filling materials and backfill materials, and its work efficiency can be improved.
It is more preferable that the partially hydrated molded article of the present invention has a bulk specific gravity of about 0.5 to 1.7 from the viewpoint of shape maintenance and work efficiency.

The partially hydrated molded body of the hydraulic composition of the present invention is given a shape in a state where water is theoretically insufficient and realizes demolding in a short time.
Therefore, in order to cure the partially hydrated molded body of the hydraulic composition of the present invention, the partially hydrated molded body is made of a water-stopping material, a crack filler, a static crushing material, various mortar premix products, various types After being used as a concrete premix product, various filling materials, backfilling materials, etc., it is necessary to supply moisture and cure.

An example in which the partially hydrated molded body of the hydraulic composition of the present invention is used as a crack filler will be described below.
The partially hydrated molded body of the hydraulic composition of the present invention is produced into a desired shape, for example, a chalk-shaped molded body.
Such a chalk-like molded body is easily collapsed by rubbing it along a crack generated on concrete, tile, painted wall surface or the like, and is effectively filled into the crack.
After filling, if water is supplied to the filling site with, for example, a spray or sponge, the filled material still has partial hydrate, that is, hydration activity still remains, so the hydration reaction starts quickly, This completes the filling of cracks.

  In addition, when the tip of the partially hydrated molded article of the present invention molded into a desired shape, for example, chalk, is immersed in water for about 5 to 30 seconds, only the tip immersed in water becomes a flexible paste. The paste state may be rubbed into a crack.

In any method, the hydration reaction is completed in a short time, and in particular, when a super fast cement is used as the hydraulic composition, the hydration reaction is completed within a few minutes. Easy crack repair is possible, and any number of people can easily repair cracks.
Further, since the partially hydrated molded article of the present invention does not contain a binder, powder that protrudes or adheres to the periphery during repair can be easily removed with, for example, a brush or a brush. It is extremely excellent in aesthetics after being used as a material.
Thus, the repaired part obtained is excellent in waterproofness, the color difference after the repair is almost the same as that of the main body, and the maintenance of aesthetics can be maintained very effectively.

Further, preferably, in order to completely seal the crack, the crack filler of the present invention and a conventional crack injection material can be used in combination.
Specifically, for example, the crack filler of the present invention is rubbed against the target crack, but at this time, as a filling port of a conventional crack injection material to be filled later, the surface portion is about 5 to 10 mm in length. Leave the crack filler of the invention without leaving it rubbed.
Next, the crack filler material portion of the present invention that protrudes from the crack is removed with a brush or brush, and water is provided by pressing a sponge or the like containing water against the filled crack filler material of the present invention to provide partial hydration. Let the body be fully hydrated.

Here, since the crack filler of the present invention uses, for example, super-hard hard cement and the like, the curing is completed quickly, and at this point, the aesthetic appearance of the cracked part and the sealing are completed while leaving a part. .
As described above, a conventional crack injection material (for example, product name: ultrafine cement cement-based crack injection material Refrefill Bond, manufactured by Sumitomo Osaka Cement Co., Ltd.) is kneaded from the remaining filling port. Inject into the crack with an acrylic syringe.

  In this method, when cracks are deeply cut into the interior, the conventional crack injection material is filled deeply into the cracks, and the cracks are reliably repaired, while the crack filler of the present invention is applied to the surface. By using it, it is possible to maintain the aesthetics of the surface portion and to develop a function as a sealing material for preventing the conventional cracking injection material from leaching.

  By sealing the cracks in this way, water penetration from the cracks into the concrete frame can be prevented, and rust and corrosion of the internal reinforcing bars can be prevented. As a result, the durability of the concrete frame is improved.

The example which utilizes the partially hydrated molded object of the hydraulic composition of this invention as a static crushing material is demonstrated below.
The partially hydrated molded body of the hydraulic composition of the present invention is molded into a desired shape, for example, a hollow cylindrical shape.
The rock or concrete to be crushed was drilled with the same diameter as the hollow cylindrical partially hydrated molded body, and the hollow cylindrical partially hydrated molded body of the present invention was inserted into the hole and filled. When a predetermined amount of water is poured into the hollow inner diameter part of the hollow cylindrical partially hydrated molded body, the hydration expansion reaction starts immediately, and the expansion force can cause tensile stress in rocks and concrete, which can be crushed. Is.
Therefore, it is used very effectively especially for crushing in water.
Here, underwater crushing refers to, for example, the case of crushing an existing underwater concrete structure, for example, when expanding or reconstructing a marine concrete structure in a harbor.

Usually, the static crushed product is made into a paste having excellent fluidity by previously mixing water.
Since the specific gravity of such paste is about 2.3, which is heavier than water, it is said that it can be filled in the holes drilled in the underwater structure due to the difference in specific gravity. is there.
In view of this point, a method of loading a powdered static crushing agent product into a cloth bag and inserting it into a hole while pushing it with a stick is also used, but this work in water is inefficient and not always effective. It is not an underwater crushing method.

On the other hand, in the present invention, the static crushed material composed of the partially hydrated molded body of the hydraulic composition of the present invention is molded into a rod shape in the partially hydrated state in advance and inserted into the hole. Since only the rod-shaped molded body is inserted, it can be made extremely simple.
When water gradually permeates into the filled partially hydrated molded body, the reaction of the crushing agent is started and the expansion occurs. Is possible.
Furthermore, if necessary, a hydration reaction can be efficiently performed by forming a small water passage of about 1 to 2 mm in the length direction of the center of the molded body.

An example in which the partially hydrated molded body of the hydraulic composition of the present invention is used as a hole-in-anchor backfill material will be described below.
Pulling out and removing hole-in anchors for concrete and bedrock is a common case, regardless of civil engineering or architecture.

If the anchor mark is left as it is, there will be holes in the concrete, so it will be necessary to backfill, but the anchor mark is usually a small hole with a diameter of about 17mm and a depth of about 120mm. Thousands of anchor mark backfilling operations may occur during construction (hanging bridge girders on piers).
Conventionally, it was a method of filling mortars kneaded in small amounts one by one by hand, using thin sticks and sledges, but such a method is extremely inefficient.

According to the present invention, the partially hydrated cement molded body of the present invention having almost the same dimensions as the anchor marks is formed in advance, for example, to a diameter of about 17 mm and a length of about 120 mm, and this is struck into the hole with a hammer. For example, if water in an amount of about 30% by weight of the compact is supplied, hydration occurs and the backfilling operation can be completed.
Alternatively, when the partially hydrated molded body of the present invention is preliminarily immersed in water for several minutes to several hours and absorbed and softened, it may be struck into the hole with a hammer or the like as described above. Thereby, the backfilling operation can be completed.

An example in which the partially hydrated molded body of the hydraulic composition of the present invention is used as a mortar premix product will be described below.
In the partially hydrated molded article of the hydraulic composition of the present invention, water can be immediately infiltrated by adjusting the amount of water added at the time of initial molding and the molding pressure at the time of pressure molding in order to maintain the self-shape. In other words, it can be a “sparse” shaped body. This sparse molded body has a void enough to allow water to permeate quickly inside itself, and by directly putting the partially hydrated molded body into a mixer containing a predetermined amount of water, Kneading can be performed in exactly the same manner as in the case of charging, and fresh mortar (a mortar that has not yet solidified) can be obtained.

The partially hydrated molded article of the present invention can be quickly mixed with water to produce a uniform fresh mortar, and the obtained mortar has the same level of strength development as a conventional product.
As a partially hydrated molded body for mortar premix, considering the performance such as strength development after curing, the smaller the amount of water initially added necessary for self-form maintenance, the better. When the amount is less than 3% by weight, the moldability and shape maintainability become difficult, and the amount of water is particularly preferably about 3 to 10% by weight.

  The partially hydrated molded body of the hydraulic composition of the present invention can be used in various fields as long as it can exhibit the effects of the present invention described above as well as the above-described uses.

The invention is illustrated by the following examples, comparative examples and test examples.
<Crack filler>
Example 1
10 kg of water-stopping material (trade name: Lion Sisui 101, manufactured by Sumitomo Osaka Cement Co., Ltd.) as a hydraulic composition is put into a tilted concrete mixer, and the inlet of the mixer is vinyl to prevent dust. Covered with a sheet. Make a small hole with a diameter of about 5cm in the center of the vinyl sheet, and insert a dry fog nozzle (trade name; Achimist D type, manufactured by Ikeuchi Co., Ltd.) into the mixer. A total of 1.6 liters of water was sprayed for 32 minutes. In addition, the droplet diameter of the spray mist supplied from the dry fog nozzle is about 10 μm, which is approximately equal to or less than the powder particle diameter of the waterstop material to be sprayed.

This gives a mixture in which the water-stopping material (powder): water is in the ratio of 100: 16 parts by weight, and such a mixture is a completely uniform powder wet mixture in which no so-called “kneading lumps” are observed. It was.
This is because kneading lumps are not physically generated because the droplets are smaller than the powder particles.

Such a wet mixture is put into an extrusion molding machine, formed into an elongated cylindrical shape having a diameter of 17 mm and a length of 90 mm, and the same shape as that of chalk. Partial hydration molding of the hydraulic composition as a crack filler of the present invention The body was manufactured.
An ignition loss value (ignition loss) defined in “Ignition loss” of JIS R 5202 of the obtained partially hydrated molded product was 18% by weight.

Comparative Examples 1-3
Commercially available epoxy-based crack repair material (trade name; flexible epoxy resin E600, manufactured by Konishi Co., Ltd.) was used as Comparative Example 1, and a commercially available elastic sealing material-based crack repair material (trade name; View Seal 6909, manufactured by Konishi Co., Ltd.) ) As a comparative example 2, and a commercially available ultrafine cement crack repair material (trade name; Refrefill Bond, manufactured by Sumitomo Osaka Cement Co., Ltd.) as a comparative example 3 was used as a crack filler.

Comparative Example 4
Water-stopping material (trade name: Lion Sisui 101, manufactured by Sumitomo Osaka Cement Co., Ltd.) and water-soluble polymer (trade name: PEO-1, manufactured by Sumitomo Seika Co., Ltd.) ) Is measured and mixed roughly so that the water-stopping material (powder): water-soluble polymer (powder) has a weight part ratio of 9: 1, and further mixed at 85 ° C. for 15 minutes for uniform flow A mixture was obtained.
This mixture is put into an extrusion molding machine, extruded in a melt flow state while maintaining the temperature of the screw and the extrusion die at 80 ° C., cooled, and elongated in the form of an elongated cylinder having a diameter of 17 mm and a length of 90 mm, just chalk and An unhydrated molded body of a hydraulic composition as a crack filler according to the present invention was produced in the same shape.

Test Example 1-1
1) Waterproofing and rust prevention effect of rebar (Preparation of specimen)
A mock test specimen modeled on a general detached house concrete cloth foundation with a total length of 15m, a height of 45cm, and a thickness of 10cm was placed by concrete mixed with excess expansion material, and the bottom surface was deliberately constrained by reinforcing bars. Cracks were generated.
A total of 38 cracks with a crack width of 0.3 to 1.0 mm occurred at intervals of approximately 30 cm. Most of these cracks were through cracks in both the height direction and the thickness direction.
A specimen in which such a through crack occurred was used as a test object.

(Waterproof = rust prevention effect confirmation test of reinforcing bars)
Of the 38 cracks that occurred in the DUT, 8 were not treated, 5 cracks were repaired in Comparative Example 1, 5 were cracked in Comparative Example 2, and the remaining 5 were compared. Using the crack repair material of Example 3, the crack was filled and repaired as described in each manual.

  On the other hand, the chalk-shaped crack repair material obtained in Example 1 was rubbed along the remaining 15 cracks to fill and repair the cracks.

From the time when 24 hours passed after the repair, salt water having a concentration of 15% by weight was sprayed continuously for 48 hours from the direction of the repaired surface.
Seven days after spraying was stopped, the specimen was disassembled, and the rust condition of the internal reinforcing bars was confirmed.
The results are shown in Table 1.

  From Table 1 above, it can be seen that according to the repair material and the repair method thereof according to the present invention, the repair method can be remarkably simplified, and the same rust prevention effect of reinforcing steel as that of a commercially available ultra-fine cement crack repair material can be provided.

(2) Aesthetic maintenance effect (measurement method)
In carrying out crack repair of the above-mentioned test object, the state before and after using each crack repair material was photographed with a digital camera from the same time and the same position, and the data was transmitted to a personal computer, manufactured by Adobe Systems Co., Ltd. Using the image retouching software ADOBE PHOTOSHOP, the RGB value of each pixel was measured, that is, the color difference (color difference) of the cracked portion was measured.

(Color difference measurement result)
The measurement results are shown in Table 2.

From Table 2, it is clear that the color difference after repair is almost the same as the concrete to be tested, which is the reference base material before repair, and has excellent aesthetic maintenance performance, that is, the effect of making cracks inconspicuous. I understand that.
In addition, since the range of color difference of RGB values that can be judged by human vision is around 10, when repair is performed using the crack filler of the present invention, almost no human visual crack is recognized after repair. become unable.

Test Example 1-2
The filling depth with respect to cracking of the chalk-like molded body of the unhydrated hydraulic composition of Comparative Example 4 and the chalk-like partially hydrated molded body obtained in Example 1 was measured.
The cracks to be tested are concrete cracks, and the crack width is 0.1, 0.3, 0.5, 0.9, 1.3 mm as measured by a crack gauge. With respect to each of these cracks, each chalk-like molded body was rubbed 5 times with rubbing and expressed as an average depth filled by being rubbed 5 times.
Here, the filled depth means that the powder filled with a sprayed or wet cloth after being rubbed is supplied with water and cured, and then the repair completed part can be broken to observe the filled cross section. The filling, that is, the repaired depth was measured with calipers, and the average value was shown.
The results are shown in Table 3.

  From Table 3, it can be seen that the chalk-like molded body of the partially hydrated molded body of the present invention has a larger filling depth and is superior in the repair effect.

Test Example 1-3
The efficiency of crack repair time of the chalk-like molded body of the unhydrated hydraulic composition of Comparative Example 4 and the chalk-like partially hydrated molded body obtained in Example 1 was evaluated.
The cracks to be tested are concrete cracks, and the crack width is measured with a crack gauge, with a thin crack width of 0.1 to 0.3 mm and a thick crack width of 0.5 to 1.2 mm. The time required for repairing 10 cracks with a length of 15 cm and the time required for one crack are shown.
Here, the repair time is a total of 10 times required to perform the work until it is determined that the aesthetic recovery and waterproof performance can be satisfied.
However, this time does not include the time required to provide moisture and to cure each hydraulic composition.
The results are shown in Table 4.

  According to Table 4, when the chalk-like molded body by partial hydration molding of the present invention is used, the work efficiency is overwhelmingly improved because the chalk is “filled into cracks while being appropriately broken”. I understand. The crack repair material of the present invention is 3.5 times as large as the crack width of 0.5 to 1. It can be seen that the work efficiency is improved up to 2.6 times in the repair of a thick crack of 2 mm.

<Static crushed material>
Example 2
A uniform mixture was obtained in the same manner as in Example 1, except that the water-stopping material of Example 1 was replaced with static crushed powder (trade name; S-Mite VB, manufactured by Sumitomo Osaka Cement Co., Ltd.).
The mixture was put into an extrusion molding machine in the same manner as in Example 1, and extruded into a cylindrical shape having a diameter of 40 mm and a length of 500 mm by extrusion molding, and the hydraulic composition as a static crushing material of the present invention was A partially hydrated molded body was produced.
An ignition loss value (ignition loss) defined in “Ignition loss of cement” of JIS R 5202 of the obtained partially hydrated molded article was 17% by weight.

Comparative Example 5
A commercially available static crushed material (trade name: S-Mite B type, for summer, manufactured by Sumitomo Osaka Cement Co., Ltd.) was used for comparison.

Test example 2
(Expansion pressure (crushing force) test)
As the object to be crushed, an underwater concrete object to be tested (water temperature 20 to 25 ° C., outdoors, compressive strength 27.3 N / mm ² ) was used. The concrete test body is provided with a cylindrical hole having a diameter of 40 mm and a length of 500 mm.
Next, the static crushed material obtained in Example 2 was filled into the holes of the concrete test specimen. The filling could be carried out very simply and consistently.

On the other hand, for the static crushed powder of Comparative Example 5, a paste was prepared by mixing water so that the kneading water ratio was 27% by weight, and the paste was put in the hole of the concrete test specimen. Filled.
These static crushed materials are crushed by hydration and expansion. Table 5 shows the measurement results 24 hours after the water injection.

The expansion pressure was measured by the following procedure.
1) A seamless steel pipe SCH40-20A steel pipe (outer diameter 53 mm, inner diameter 50 mm) manufactured by NKK (Nippon Steel Pipe Co., Ltd.) is cut into a length of 40 cm.
2) The static crushed material according to Example 2 or Comparative Example 5 was loaded into this steel pipe, and the method is as follows.
That is, in Example 2, the uniform mixture obtained in the same manner as in Example 1 was formed into a hollow cylindrical shape having an outer diameter of 49.9 mm and an inner diameter of 2 mm by extrusion molding, and this was inserted into the steel pipe. -It was loaded and water was poured into the 2 mm inner diameter hole for hydration reaction.
In Comparative Example 5, the paste used in the concrete crushing test was injected and filled.

3) Next, a general strain gauge FLA-6-11 with lead wire manufactured by Tokyo Sokki Kenkyujo Co., Ltd. was attached according to the manual of the strain gauge along the circumferential direction of the outer diameter of the steel pipe.
4) According to the above procedure 1) to 3), the static crushed material inside the steel pipe undergoes a significant volume expansion due to the hydration reaction, and this expansion force is caused by tensile elongation strain on the outer diameter surface of the steel pipe. Appeared. The expansion pressure can be calculated by measuring the tensile elongation strain with the strain gauge attached in 3) above and multiplying it by the elastic coefficient of the steel pipe.

  From Table 5, it can be seen that crushing with the static crushing material of the present invention can significantly simplify the crushing method and can crush almost the same as conventional products.

<Hole-in-anchor backfill material>
Example 3
Ordinary Portland cement (PC, manufactured by Tochigi Factory, Sumitomo Osaka Cement Co., Ltd.) was used as the hydraulic composition.
The mixing ratio of the hydraulic composition and the initially added water required to maintain the self-shape was 80:20 parts by weight, and the resulting mixture was put into an extrusion molding machine, and the diameter was 17 mm. Extruded into a cylindrical shape and cut into a predetermined length of 120 mm. The partially hydrated molded body was allowed to cure for 7 hours at a humidity of 54% and 23 ° C., and was in a state sufficient to maintain its own shape.

Next, this rod-shaped molded body was stored in a drier maintained at 250 ° C. for 5 hours, and at this point, water that was not consumed in the hydration reaction, that is, free water, was forcibly evaporated and removed. Thereby, hydration hardening was forcibly stopped in the hydration reaction state of about 7 hours of material age, the partially hydrated molded object was obtained, and the hole-in-anchor backfill material was manufactured.
An ignition loss value (ignition loss) defined in “Ignition loss of cement” of JIS R 5202 of the obtained partially hydrated molded product was 22% by weight.

Comparative Example 6
Ordinary Portland cement (PC, manufactured by Sumitomo Osaka Cement Co., Ltd., Tochigi Factory), sand and water are uniformly kneaded at a ratio of 1: 4: 0.3 parts by weight to make a fresh mortar. It was pushed into the hole-in anchor mark with a small hand pump, and the surface was further flattened with a gold iron.

Test example 3
(Efficiency of backfilling anchor marks)
A number of anchors were pulled out of the concrete in which the hole-in anchors were embedded.
The size of one hole after extracting a large number of anchors had a cylindrical shape with a diameter of 17 mm and a depth of 120 mm.
The hole-in-anchor backfill material obtained in Example 3 above is hammered into the anchor mark of the concrete having a large number of anchor marks having such a shape with a hammer, and the filled hole-in-anchor backfill material Was supplied with water in an amount of 30% by weight of the hole-in-anchor backfill material to complete the anchor mark backfilling operation.

On the other hand, the mortar backfill material of Comparative Example 6 was manually backfilled on each of the anchor marks.
Table 6 shows the working efficiency of both cases.

  From Table 6 above, it can be seen that the backfilling material of the present invention has an improvement in work efficiency of about 7.4 times compared to the conventional material.

<Mortar premix products>
Examples 4-6
Using a water-stopping material (trade name: Lion Sisui 101, manufactured by Sumitomo Osaka Cement Co., Ltd.) as a hydraulic composition as a raw material, the mixing ratio shown in Table 7 is the same as in Example 1. Water was mixed to produce a partially hydrated molded body.
The ignition loss values (ignition loss) stipulated in JIS R 5202 “Ignition loss of cement” of the obtained partially hydrated molded products were 6 wt%, 17 wt% and 22 wt%, respectively. .

Comparative Example 7
A water-stopping material (trade name; Lion Sisui 101, manufactured by Sumitomo Osaka Cement Co., Ltd.) itself made from ultrafast cement was used for comparison.

Test example 4
The materials of the above Examples 4 to 6 and Comparative Example 7 were mixed with the amount of kneaded water shown in Table 8, charged into the mixer, and uniformly kneaded to prepare a fresh mortar having a diameter of 50 mm × 100 mm. Test specimens were obtained and trained in air until the predetermined age shown in Table 8, and the compressive strength of each specimen was measured.
The results are shown in Table 8.
However, the compressive strength was measured by a method based on JIS A 1108.

The shape is easy to maintain, it can be easily disintegrated during use, and it is also environmentally friendly.For example, anyone can easily use it as a crack crack filler without the need for special tools or techniques. It can be applied to filling and repairing cracks. In addition, it can also be used as static crushed materials, various mortar premix products, various concrete premix products, various hole filling materials, backfill materials, and the like.

Claims (8)

  A partially hydrated molded article of a hydraulic composition, wherein the hydraulic composition is partially hydrated and cured to such an extent that the shape can be maintained.   The partially hydrated molded body of the hydraulic composition according to claim 2, further comprising a polymer compound.   In producing the partially hydrated molded body of the hydraulic composition according to claim 1 or 2, the hydraulic composition and a water in an amount greater than a theoretical amount at which the hydraulic composition exhibits a complete hydration reaction are mixed. A partially hydrated molded body of a hydraulic composition, which is forcibly dried when hydration has progressed to a stage where the self-shape can be maintained and partially retains hydration activity. Manufacturing method.   In producing the partially hydrated molded body of the hydraulic composition according to claim 1 or 2, the hydraulic composition and a lesser amount of water than the theoretical amount at which the hydraulic composition exhibits a complete hydration reaction are mixed. Then, a method for producing a partially hydrated molded body of a hydraulic composition, wherein the resulting mixture is molded by allowing a hydration reaction to proceed and partially leave hydration activity.   The method for producing a partially hydrated molded body of a hydraulic composition according to claim 3 or 4, wherein the molding is press molding, extrusion molding or injection molding. Body manufacturing method.   The hydraulic composition according to any one of claims 3 to 5, wherein a polymer compound is further substituted with a part of the water to be contained. A method for producing a partially hydrated molded article.   A partially hydrated molded body of a hydraulic composition characterized in that water is added to the partially hydrated molded body of the hydraulic composition according to claim 1 or 2 to complete and cure the remaining hydration activity. How to Use. The method for using a partially hydrated molded body of the hydraulic composition according to claim 7, wherein the partially hydrated molded body of the hydraulic composition is used as a partially hydrated molded body of the hydraulic composition. A method for using a partially hydrated molded body of a hydraulic composition characterized by being applied as a crack filler for filling and applying to a surface portion and then filling the crack injection material into the crack to repair the crack. .