JP2010138055A - Resin mortar hardened body and method of constructing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a resin mortar hardened body having balanced excellent material characteristics of a resin material or cement and having excellent wear resistance, decorativeness and profitability. <P>SOLUTION: The method of manufacturing the resin mortar hardened body formed from a plurality kinds of coating layers comprises: (a) a joint cutting step of preliminarily forming a box joint on a construction surface of a floor surface or wall surface of a building material on which a resin mortar hardened body is to be formed; (b) an under layer material forming step of stirring and mixing a mortar composition containing a resin component, a hardening agent component, a cement component and an aggregate component to form an under layer material having a prescribed thickness on a construction surface; (c) a sheet placing step of placing a net sheet on the surface of the under layer material; (d) an intermediate layer material forming step of applying an intermediate layer material having a grain size and a blending ratio larger than that of the grain component in the under layer material on the net sheet; and (e) an upper layer material forming step of applying an upper layer material having a grain size and a bending ratio equal to that of the aggregate component in the intermediate layer material on the intermediated layer material. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a cured resin mortar that can improve durability such as a floor surface in a building and can effectively prevent peeling and beautification thereof, and a construction method thereof.

  The floor surface, outer wall surface, ceiling surface, and the like of a building bear complex required performances such as a living function, a protective function, and a beautiful appearance. However, as the years progress, the deterioration progresses, and the appearance and protection function as a flooring material and the like decrease, and the surface finish layer is peeled off and the structural function is reduced, so that repair is forced.

  Regarding such a method for repairing the exterior wall surface, for example, in Patent Document 1 (Japanese Patent Laid-Open No. 63-219762), a glass mat or cloth is placed on the entire construction wall and impregnated with an unsaturated polyester resin. A method of forming a transparent FRP resin layer, applying a transparent paint on the surface, drying and curing, and then driving a screw (anchor pin) that reaches the frame structure part from the surface to an appropriate part of the tile joint to integrally strengthen it Is disclosed.

Further, in Patent Document 2 (Japanese Patent Laid-Open No. 11-62267), a coating material based on a fiber-containing cement is applied to a cement-based structure, and then a net is embedded in the coating material, or further, the above coating is applied. A method of reinforcing a cement-based structure is described in which a material is additionally applied and then cured in a state where the surface of the coating material is smoothed and smoothed.
Japanese Patent Laid-Open No. 63-219762 JP-A-11-62267

  However, the conventional repair method is a reinforcement protection method mainly using either a resin material or cement, and it does not balance the material properties such as wear resistance, aesthetics, and economy of both. However, there is a problem that the range of selectivity of material design is limited. Furthermore, in the construction method disclosed in Patent Document 1, there is a case where the adhesion affinity between the polyester resin serving as the coating material and the construction surface is lacking, and there is a problem that the installation of the anchor pin is essential. Furthermore, in the reinforcing method of Patent Document 2, there is a case where deterioration due to a change in the diameter of the net embedded in the covering material may be remarkable, and it is difficult to maintain durability over a long period of time.

The present invention has been made to solve the above-mentioned conventional problems, and balances the excellent material properties of a resin material or cement, and is a resin mortar excellent in durability, wear resistance, aesthetics, and economic efficiency. A cured body is provided.
Furthermore, this invention aims at providing the construction method of the resin mortar hardening body excellent in durability and reliability over a long term by suppressing the age-related deterioration of the net sheet material embedded as a reinforcing material.

(1) The cured resin mortar of the present invention is
It is a resin mortar cured body consisting of a plurality of types of coating layers formed on the floor or wall of a building,
The coating layer includes a resin component, a hardener component, a cement component, and an aggregate component,
A net sheet is interposed between the covering layers.

(2) The cured resin mortar of the present invention is the above (1).
The covering layer is composed of three layers: a lower layer material to be coated on a construction surface of a building, an intermediate layer material laminated on the lower layer material, and an upper layer material to be a surface layer, and the net sheet is the lower layer material And the intermediate layer material.
(3) The resin mortar cured body of the present invention is the above (2),
The particle size and the mixing ratio of the aggregate component in the lower layer material are lower than the particle size and the mixing ratio of the aggregate component in the middle layer material laminated on the lower layer material.

(4) The method for applying the cured resin mortar body of the present invention is a method for producing a cured resin mortar body comprising a plurality of types of coating layers,
(A) a joint cutting step for forming box joints in advance on the construction surface of the floor or wall of the building where the resin mortar cured body is formed;
(B) a lower layer material forming step of stirring and mixing a mortar composition including a resin component, a curing agent component, a cement component, and an aggregate component to form a lower layer material having a predetermined thickness on the construction surface;
(C) a sheet laying step of laying a net sheet on the surface of the lower layer material;
(D) a middle layer material forming step of applying on the net sheet a middle layer material having a particle size and a blending ratio higher than the particle size and blending ratio of the aggregate component in the lower layer material;
(E) an upper layer material forming step of applying an upper layer material having the same particle size and blending ratio as the particle size and blending ratio of the aggregate component in the middle layer material onto the middle layer material;
It is characterized by having.

According to the present invention, a cured resin mortar comprising a plurality of types of coating layers and containing a resin component, a curing agent component, a cement component, and an aggregate component, and for a resin (for example, urethane) that forms the coating layer Since a net sheet having resin affinity and alkali resistance is interposed, the durability of the resin mortar cured body against mechanical impacts and peeling and cracking due to temperature fluctuations can be increased, and the resin and cement materials It is possible to provide a cured resin mortar that balances the characteristics and is excellent in wear resistance, appearance, and economy.
Moreover, according to this invention, the construction method of the resin mortar hardening body excellent in durability and reliability over a long term can be provided by suppressing the age-related deterioration of the net sheet material embedded as a reinforcing material.

  The cured resin mortar body of this embodiment is a cured resin mortar body comprising a plurality of types of coating layers coated on the floor or wall surface of a building, and includes a resin component such as urethane, a cement component, and an aggregate component. A net sheet having excellent affinity for a resin such as urethane is interposed between the coating layers. By interposing the net sheet in this way, it is possible to prevent the occurrence of cracks during the drying shrinkage of the coating layer, and to enhance the durability against mechanical impacts and temperature fluctuations.

The resin component, the curing agent component, the cement component, and the aggregate component constitute the coating layer. As the resin component, curing agent component and cement component constituting the coating layer, polymer cement mortar can be exemplified, and additives such as a thickener, a water reducing agent, a curing accelerator and a curing retarder are added as necessary. Also good.
The polymer cement mortar is a cement mortar mainly composed of an aqueous polymer emulsion.
As the polymer constituting the aqueous polymer emulsion, a polyurethane resin can be applied, and a plurality of layers having different characteristics can be formed by making the types and particle sizes of the aggregate components constituting the coating layer different from each other.
As the additive used here, any additive can be used as long as it is usually added to polymer cement mortar.

  As the aggregate component, for example, a ceramic whose particle size is adjusted to a predetermined range (for example, a range of 0.5 to 0.001 mm) such as silica, alumina, silica stone, and sand can be used. It is preferable to mix and use at a blending ratio (for example, 10 to 50% by mass).

The net sheet is flexible so that it can follow the construction surface, has the strength to withstand a predetermined tensile force, and can be applied if it is embedded in the laminated coating layers and is alkali-resistant. , Organic fibers such as vinylon and aramid (aromatic polyamide) fibers, inorganic fibers such as glass fibers, metal wires such as stainless steel wires and steel wires, and the like. In particular, it is preferable to use vinylon fiber from the viewpoint of ensuring affinity with the matrix material forming the coating layer.
Further, since the net sheet is embedded in the coating layer, the diameter of the wire constituting the net is preferably 0.1 mm or more, and the mesh opening is preferably 1 mm or more. When the mesh opening is 1 mm or more, the coating material easily enters the eyes of the net, and the net sheet can be easily embedded in the coating layer. The shape of the net eye is not particularly specified, but any of triangle, square, hexagon, etc. can be applied.
As a commercial product, “NS Net Super” of Nippon Kasei Co., Ltd. can be applied.

The cured resin mortar body of the present embodiment is composed of three layers: a lower layer material in which the coating layer is directly coated on a construction surface of a building, an intermediate layer material laminated on the lower layer material, and an upper layer material serving as a surface layer. The net sheet can be provided so as to be interposed between the lower layer material and the middle layer material.
In this way, by applying a covering material on the floor of a building and embedding a net sheet in it, it is lightweight and can be easily constructed, and it satisfies the required characteristics for each covering layer of the lower layer material to the upper layer material A cured resin mortar can be formed efficiently and economically.

  Furthermore, the cured resin mortar of the present embodiment can make the particle size and the mixing ratio of the aggregate component in the lower layer material lower than the particle size and the mixing ratio of the aggregate component in the intermediate layer material. This realizes a combination of lower layer materials that require high adhesion to construction surfaces such as buildings, and middle and upper layer materials that require higher durability, impact resistance, and heat resistance. be able to. In addition, a tough and excellent crack-resistant coating layer can be formed by interposing a net sheet made of vinylon fiber having alkali resistance between the lower layer material and the middle layer material.

The method for producing a cured resin mortar according to the present embodiment is a method for producing a cured resin mortar comprising a plurality of types of coating layers,
(A) a joint cutting step for forming box joints in advance on the construction surface of the floor or wall of the building where the resin mortar cured body is formed;
(B) a lower layer material forming step of stirring and mixing a mortar composition including a resin component, a curing agent component, a cement component, and an aggregate component to form a lower layer material having a predetermined thickness on the construction surface;
(C) a sheet laying step of laying a net sheet on the surface of the lower layer material;
(D) a middle layer material forming step of applying a middle layer material having a particle size and a blending ratio higher than the particle size and blending ratio of the aggregate component in the lower layer material on the net sheet;
(E) An upper layer material forming step of applying an upper layer material having the same particle size and blending ratio as the aggregate component in the middle layer material onto the middle layer material.
Accordingly, it is possible to provide a method for constructing a cured resin mortar body that balances the material properties of the resin material or cement and is excellent in wear resistance, appearance, and economy.

Example 1
Embodiments of the present invention will be described below with reference to the drawings.
FIG. 1 is an explanatory view showing a construction cross section of a cured resin mortar according to Example 1 of the present invention, and FIG. 2 is a flowchart of a construction method of the cured resin mortar.
As shown in FIG. 1, in the cured resin mortar 10 of Example 1, a plurality of coating layers formed on a concrete floor surface 11 of a building consists of three layers of a lower layer material 12, an intermediate layer material 13, and an upper layer material 14. In addition, a net sheet 15 having resin affinity is interposed between the lower layer material 12 and the middle layer material 13.
The floor 11 of the building is a ground concrete floor or the like that has been previously ground or blasted, and a predetermined box joint 16 is formed according to the construction area of the cured resin mortar body 10, the thickness of the coating layer, and the like. Yes.
Each coating layer (the lower layer material 12, the middle layer material 13, the upper layer material 14) is a resin mortar composition containing a urethane resin component, a cement component, and an aggregate component in a predetermined particle size and a predetermined mixing ratio, respectively. Are mixed and stirred to allow the composite reaction to proceed and cure. For example, a urethane reaction is generated by a composite of a polyol component and a curing agent component in the main agent adjusted to an emulsion state. This urethane reaction can bring out heat resistance and chemical resistance.
Further, a urea reaction is generated by a combined reaction of moisture in the emulsion and an isocyanate component serving as a curing agent. In addition to this urethane reaction and urea reaction, performances of heat resistance, impact resistance and adhesive strength are brought out by the hydration reaction with the moisture of the main agent and the cement component of the aggregate.
In this way, the progress of the above three complex reactions (urethane reaction, urea reaction, cement hydration reaction) leads to the formation of a tough coating film that combines high durability, load resistance, heat resistance, and chemical resistance. ing.

The main component in the lower layer material 12, the middle layer material 13, and the upper layer material 14 is, for example, a polyol-containing aqueous emulsion, which is an odorless milky white liquid having a specific gravity of 1.02.
The curing agent promotes the curing reaction of the main agent, and is made of, for example, an isocyanate component and is an odorless brown liquid having a specific gravity of 1.23.
The aggregate is, for example, a ceramic powder mainly composed of silicon oxide, aluminum oxide or the like, or a composite powder thereof, and the average particle size of which is adjusted to about 0.01 to 0.1 mm can be applied. .

The mixing ratio of the aggregate containing the main agent, the curing agent, and the cement component is set to be different for each of the lower layer material 12, the middle layer material 13, and the upper layer material 14, and in this embodiment, for example, the following blending is performed. Set by ratio.
(X) Lower layer material (main agent: 4 parts by mass, curing agent: 4 parts by mass, aggregate: 20 parts by mass)
(Y) Middle layer material (main agent: 4 parts by mass, curing agent: 4 parts by mass, aggregate: 40 parts by mass)
(Z) Upper layer material (main agent: 4 parts by mass, curing agent: 4 parts by mass, aggregate: 40 parts by mass)
Note that the type and particle size of the aggregate containing the cement component can also be adjusted according to the required construction conditions such as workability and durability.

Thus, the (y) middle layer material excellent in durability, impact resistance, and heat resistance, and the (x) lower layer material blending ratio in which the blending ratio of the aggregate is made relatively small to ensure high adhesion. And a plurality of types of coating layers are formed by combining the blending ratio of (z) and the blending ratio of the upper layer material.
Furthermore, the net sheet 15 made of vinylon fiber having alkali resistance is embedded and interposed between the lower layer material 12 and the middle layer material 13, thereby increasing the crack resistance associated with the drying shrinkage of the cured resin mortar and improving durability. This makes it possible to form a hardened resin mortar on the floor of a building.

That is, the blending ratio of the (x) lower layer material to be the lower layer material 12 has high adhesiveness to the concrete floor, and is applied to the lower layer material 12 taking advantage of this feature. Here, after applying the predetermined amount which becomes the mixture ratio of said (x) lower layer material to the concrete floor surface 11, and carrying out the sheeting | laying of the net sheet 15 before the hardening, (y) middle layer before the hardening further A predetermined amount corresponding to the mixing ratio of the materials is applied onto the net sheet 15, and the lower layer material 12, the net sheet 15, and the middle layer material 13 are integrated to form a base material.
Then, the strongest and tough resin of the present invention is obtained by repeatedly coating a predetermined amount corresponding to the blending ratio of the (z) upper layer material having heat resistance, durability and impact resistance on the tough base material. A mortar hardened body is formed.

Moreover, even if an impact that causes breakage in such a coating layer is applied by interposing the net sheet 15 made of vinylon fiber or aramid fiber between the lower layer material 12 and the middle layer material 13, The occurrence and expansion of the crack can be suppressed without increasing.
Moreover, even in an environment where hot water and cold water are repeatedly applied as in the case of use on the floor of a food factory, the crack resistance performance against rapid expansion and contraction of the coating layer accompanying this heat shock can be improved. .
In addition, by laminating a predetermined amount corresponding to the blending ratio of the (z) upper layer material on the middle layer material 13, the chemical resistance and anti-slip property are imparted to the outermost surface layer of the resin mortar cured body 10. It is possible to grant.

Hereinafter, the construction method of the resin mortar cured body will be described more specifically with reference to the flowchart of FIG.
First, in the box joint cutting process in step S1, a box joint 16 having a width of about 10 mm and a depth of about 10 mm is formed in advance on a concrete floor surface 11 of a building that is a construction surface of a cured resin mortar body. In addition, the concrete floor surface 11 has been subjected to ground treatment by polishing or blasting in order to remove the latency.
Since the shrinkage of the coating layer increases during drying and curing, the shrinkage of the coating layer is absorbed and relaxed by providing the box joint 16 on the concrete floor surface 11.
The box joint 16 is formed by grooving every edge of the construction range and a span of about 5 m. The box joint 16 is pre-filled at the same blending ratio as the lower layer material 12 so as to enhance adhesion with the floor surface and suppress internal shrinkage.

  In the subsequent lower layer material forming step of step S2, after the vacuum cleaning of the concrete floor surface 11 is performed by a dust collector or the like, the blending ratio of the (x) upper layer material composed of the aggregate containing the main agent, the hardener, and the cement component is set. Mixing and stirring are performed, and a process of forming the lower layer material 12 having a predetermined thickness, for example, 1 to 10 mm, is performed using a gold trowel or the like.

  In the sheet laying process in the next step S3, the net sheet 15 is spread on the lower layer material 12 before it is cured after application formation, and the sheet is laid uniformly so that there is no wrinkle of the net sheet.

  In the middle layer material forming step of step S4, the base material obtained by integrating the lower layer material 12 and the net sheet 15 is mixed with the main agent, the curing agent, and the middle layer dedicated aggregate so as to have the blending ratio of the middle layer material (y). The mixed and adjusted composition is uniformly applied while checking the thickness with a gold trowel, and the intermediate layer material 13 is formed on the lower layer material 12 so as to overlap.

In the upper layer material forming step in the last step S5, the composition obtained by mixing and adjusting the main agent, the curing agent, and the aggregate for exclusive use of the upper layer material so as to have the blending ratio of the (c) upper layer material is formed on the formed middle layer material 13 To form the upper layer material 14.
Immediately after the application of the upper layer material 14, the surface may be immediately rolled with a fine bone roller to make the surface uniform.
In addition, when it is desired to further improve the chemical resistance of the cured resin mortar 10 composed of the lower layer material 12, the net sheet 15, the middle layer material 13, and the upper layer material 14, about 12 hours in winter after the coating layer is constructed. It is preferable to perform curing by setting a curing curing time of about 8 hours in summer.

  Here, Tables 1 and 2 show test results A to B for evaluating the cured resin mortar, and show the measurement results of the respective bending strength, tensile strength, and crack followability.

試験片Ａは、下層材量を２ｋｇ／ｍ²、中層及び上層材量を８ｋｇ／ｍ²として、ネットシートを介在させないで作成した場合における比較例１である。
試験片Ｂは、試験片Ａの下層材及び中層及び上層材間に、アラミド繊維からなるネットシートを介在させた実施例に相当するものである。
なお、各表における曲げ強度はＪＩＳＫ６９１１に準拠して測定したデータであり、引張強度及び亀裂追従性はＪＡＳ８１９９３（下地ひび割れ抵抗性試験）ゼロスパン試験を参考に樹脂モルタル硬化体破断時の強度及び伸びをそれぞれ測定して得られたデータを示している。
試験片Ｂに示されるネットシートを含む実施例では、曲げ強度、引張強度、亀裂追従性がネットシート無しの場合の試験片Ａに比較して飛躍的に向上していることがわかる。
さらに、ゼロスパン試験後の破断状況を確認すると、樹脂モルタル硬化体の亀裂が広がり難く、発生した亀裂はネットシートの強度により拡大しにくいことが確認された。
以上のことから、ネットシートを介在させることがより効果的であることが分かる。

The test piece A is Comparative Example 1 when the lower layer material amount is 2 kg / m ² , the middle layer and upper layer material amounts are 8 kg / m ² , and no net sheet is interposed.
The test piece B corresponds to an example in which a net sheet made of aramid fibers is interposed between the lower layer material, the middle layer, and the upper layer material of the test piece A.
In addition, the bending strength in each table is data measured according to JISK6911, and the tensile strength and the crack followability are the strength and elongation when the resin mortar cured body breaks with reference to the JAS81993 (base crack resistance test) zero span test. The data obtained by measurement are shown.
In the example including the net sheet shown in the test piece B, it can be seen that the bending strength, the tensile strength, and the crack followability are remarkably improved as compared with the test piece A in the case of no net sheet.
Furthermore, when the fracture state after the zero span test was confirmed, it was confirmed that the crack of the cured resin mortar was difficult to spread and the generated crack was difficult to expand due to the strength of the net sheet.
From the above, it can be seen that interposing a net sheet is more effective.

As described above, the gist of the present invention is that the durability is enhanced by interposing a net sheet having excellent alkali resistance between the covering layers including the urethane resin component, the cement component, and the aggregate component. And those falling under this category belong to the scope of rights of the present invention.
For example, in this embodiment, the resin mortar cured body 10 having a three-layer structure including the lower layer material 12, the middle layer material 13, and the upper layer material 14 has been described as an example, but two layers of the lower layer material and the upper layer material (middle layer material is omitted). It can also be applied to a resin mortar cured body having a two-layer structure in which a net sheet is laid between them, or a multilayer resin mortar having a net sheet laid between three or more layers.

It is explanatory drawing which shows the construction cross section of the resin mortar hardening body which concerns on one Example of this invention. It is a flowchart of the construction method of the resin mortar hardening body.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Resin mortar hardening body 11 Concrete floor surface 12 Lower layer material 13 Middle layer material 14 Upper layer material 15 Net sheet 16 Box joint

Claims (4)

It is a resin mortar cured body consisting of a plurality of types of coating layers formed on the floor or wall of a building,
The coating layer includes a resin component, a hardener component, a cement component, and an aggregate component,
A cured resin mortar, wherein a net sheet is interposed between the coating layers.   The covering layer is composed of three layers: a lower layer material to be coated on a construction surface of a building, an intermediate layer material laminated on the lower layer material, and an upper layer material to be a surface layer, and the net sheet is the lower layer material The cured resin mortar according to claim 1, wherein the cured resin mortar is interposed between the intermediate layer material and the intermediate layer material.   The resin mortar according to claim 2, wherein the particle size and the mixing ratio of the aggregate component in the lower layer material are made lower than the particle size and the mixing ratio of the aggregate component in the intermediate layer material laminated on the lower layer material. Cured body. A method for producing a cured resin mortar comprising a plurality of types of coating layers,
(A) a joint cutting step for forming box joints in advance on the construction surface of the floor or wall of the building where the resin mortar cured body is formed;
(B) a lower layer material forming step of stirring and mixing a mortar composition including a resin component, a curing agent component, a cement component, and an aggregate component to form a lower layer material having a predetermined thickness on the construction surface;
(C) a sheet laying step of laying a net sheet on the surface of the lower layer material;
(D) a middle layer material forming step of applying a middle layer material having a particle size and a blending ratio higher than the particle size and blending ratio of the aggregate component in the lower layer material on the net sheet;
(E) an upper layer material forming step of applying an upper layer material having the same particle size and blending ratio as the particle size and blending ratio of the aggregate component in the middle layer material onto the middle layer material;
The construction method of the resin mortar hardening body characterized by having.

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