JP2013189557A - Filler, and method for manufacturing the same and method for filling teh same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a filler, a manufacturing method of the same as well as a filling method in which a curing time at filling of the filler can be controlled arbitrarily and filling into a filling part such as a cavity and gap between a concrete structure and a permanent mold can be surely performed.SOLUTION: A filler is made by mixing a cement milk A liquid having cement as a principal component, a quick hardening slurry B liquid containing calcium aluminate, gypsum, and a setting retarder, and a C liquid containing the setting retarder. Further, the B liquid contains an acidic substance, and the acidic substance is aluminum sulfate. In a manufacturing method of the filler, the A liquid is mixed just before filling, after the B liquid and the C liquid are mixed, or the B liquid is mixed just before filling, after the A liquid and the C liquid are mixed. In a filling method, a transportation distance of the filler manufactured in this manufacturing method shall be 30m or less.

Description

  The present invention relates to filling a gap between a permanent formwork and a concrete structure used for repair and reinforcement of a concrete structure, or filling a backside cavity of a mountain tunnel, filling a cavity of a civil engineering structure, etc., lightweight embankment, landfill TECHNICAL FIELD The present invention relates to a filler used for the like, and a filling method using the same.

To repair and reinforce concrete structures, the existing concrete surface was scraped off, or the concrete was crushed down to the reinforcing bars inside the concrete, and then repaired by spraying mortar, or fiber sheets were stretched and resin coating was applied. (See Patent Document 1).
Also, railway, road, and waterway tunnels constructed by the mountain tunnel method may have a back cavity. This back cavity is more adequate than the back of the lining when the tunnel is subjected to plastic pressure or partial pressure. Since ground reaction force cannot be expected, it may be structurally disadvantageous (see Patent Document 2).

Various repairs and reinforcements for concrete structures have been studied and put into practical use.
In general, concrete or mortar is used as a filler for permanent formwork, and the strength of the permanent formwork is necessary to cope with the lateral pressure. The permanent formwork that required power and used FRP was weak to a pressure such as a side pressure, and its use was limited.
Therefore, in general, a filling method in which no side pressure is applied has been proposed (see Patent Document 3).

Conventionally, various plastic fillers have been studied and put into practical use. Further, it has been proposed to obtain a non-flowable plastic grout material by adding a flowable swelling liquid in which attapulgite is mixed in a flowable mortar (see Patent Document 4).
However, when these plasticizers are used, they cannot completely penetrate into the voids, and when they are press-fitted, the FRP is deformed during filling due to the side pressure applied to the FRP.

JP 2011-190141 A Japanese Patent No. 3435122 JP-A-11-256836 Japanese Patent Laid-Open No. 2003-082653

  The present invention arbitrarily controls the curing time at the time of filling the filler, can be surely filled into the cavity of the concrete structure and the permanent mold and the filling portion of the gap, and further shorten the curing time. Provided are a filler, a manufacturing method thereof, and a filling method capable of reducing a lateral pressure on a permanent mold, particularly an FRP mold, and reducing a reinforcing material and a thickness of the permanent mold of a steel plate or a concrete plate.

  That is, the present invention mixes (1) cement milk A liquid mainly composed of cement, calcium aluminate and gypsum, rapid hardwood slurry B liquid containing a set retarder, and C liquid containing a set retarder. (2) In addition, (2) Further, the B liquid contains an acidic substance (1), (3) The acidic substance is aluminum sulfate (2), (4) B liquid (1) to (3), the method for producing the filler according to any one of (1) to (3) above, and (5) the liquid A and the liquid C are mixed and then the liquid B is filled. Packing in which the transport distance of the filler produced by the production method of any one of (1) to (3), (6), (4) or (5) is 30 m or less. Construction method.

  According to the present invention, it is possible to arbitrarily control the curing time at the time of filling, and it is possible to reliably fill the filling portion of the cavity and gap between the concrete structure and the permanent mold, and the permanent mold by shortening the curing time, In particular, not only can the lateral pressure on the FRP formwork be reduced, but also the reinforcement and thickness of the permanent formwork of the steel plate or concrete plate can be reduced, so that an inexpensive permanent formwork can be provided and it is economical. In addition, filling the cavity of the back of the mountain tunnel, filling the cavity or gap of the civil engineering structure, there is no leakage to the surrounding gap, etc., and the filling material with reduced curing time is diluted into groundwater and running water There are effects such as preventing.

  The parts and% used in the present invention are based on mass unless otherwise specified.

  In the present invention, cement milk A liquid mainly composed of cement, calcium aluminate and gypsum, rapid hardening slurry B liquid composed of a setting retarder, and C liquid of setting retarder are mixed immediately before filling. It is a filler capable of controlling the curing time of the resin, and is intended to be surely injected into a filling portion of a cavity or gap of a civil engineering structure or the like.

As the cement used in the present invention, various portland cements such as normal, early strength, and moderate heat, various mixed cements obtained by mixing blast furnace slag and fly ash with these portland cements, and various commercially available fine particles Examples include cement and eco-cement. Among these, it is preferable to use ordinary Portland cement in terms of economy and workability and low slump loss.
The blending ratio of water (W) to cement (C) is 50 to 120% in W / C, preferably 70 to 100%. If it is 120% or more, the expression of short and long-term strength may be poor, If it is 50% or less, the viscosity of cement milk (liquid A) is high, which causes problems in pumpability and may cause problems in mixing properties with the rapid hardening slurry, which is not economical.

The calcium aluminate (hereinafter referred to as CA) used in the present invention contains CaO, Al ₂ O ₃ , and SiO ₂ , and contributes mainly to the expression of short-term strength when used in combination with gypsum. The composition of CA is preferably in the range of CaO content 20 to 60%, Al ₂ O ₃ content 20 to 70%, CaO content 30 to 55%, Al ₂ O ₃ content 30 to 60%, and in the range of SiO ₂ content of 0-20% are more preferred. Outside this range, the short-term strength may be small.
CA is blended with calcia raw materials such as limestone, alumina raw materials such as alumina, bauxite, feldspar, and clay with silica raw materials such as quartzite, quartz sand, quartz, and diatomaceous earth, and then fired in a rotary kiln. Or it is manufactured by melting in an electric furnace or a high frequency furnace.
The CA, the _{12CaO · 7Al 2 O 3, CaO} · Al 2 O 3, 3CaO · Al 2 O 3, 2CaO · Al 2 O 3 · SiO 2 and crystalline compounds such as _{CaO · Al 2 O 3 · 2SiO} 2 Although it can be used, a vitreous material obtained by quenching the melt is preferred from the viewpoint of high short-term strength.
The vitrification rate of CA is as follows: CA is heated at 1400 ° C. for 2 hours, then slowly cooled at a cooling rate of 5 ° C./min, and the area S0 of the main peak of the crystal mineral is determined by powder X-ray diffraction method. It is obtained from the main peak S as X (%) = 100 × (1−S / S0), and is preferably 50% or more, more preferably 80% or more, and most preferably 90% or more from the viewpoint of short-term strength. If it is less than 50%, the short-term strength may be small.
Fineness of CA to be used, Blaine specific surface area (hereinafter, referred to as Blaine) 3000 cm ² / g or more, preferably 4000~7000cm ² / g, is less than 3000 cm ² / g, the improvement in initial strength development Since it does not show enough, it is not preferable.

Examples of the gypsum used in the present invention include anhydrous gypsum, hemihydrate gypsum, and dihydrate gypsum, and further, natural gypsum, chemical gypsum such as phosphate byproduct gypsum, drainage gypsum, and hydrofluoric acid byproduct gypsum, or The gypsum obtained by heat-treating these is included. Of these, anhydrous gypsum is preferred because of its high strength development.
The fineness of the gypsum used is 3000 cm ² / g or more, preferably 4000 to 7000 m ² / g in terms of a brane value. If it is less than 3000 cm ² / g, the initial strength development is often insufficient.
The amount of CA and gypsum used is preferably 50 to 200 parts, more preferably 70 to 150 parts with respect to 100 parts of CA. If it is less than 50 parts, the short-term strength may be small, and if it exceeds 200 parts, the short-term strength may be small.

  The amount of the mixture of CA and gypsum (hereinafter referred to as “quick hardwood”) is preferably 8 to 30 parts, more preferably 10 to 25 parts, relative to 100 parts of cement. If it is less than 8 parts, the short-term strength may be small, and if it exceeds 30 parts, the strength enhancement effect is small and not economical.

  Examples of the setting modifier include organic acids and alkali metal carbonates. Among these, it is preferable to use an organic acid and an alkali metal carbonate in combination because the curing time can be controlled, the hose is not blocked, and the strength development after curing is good.

Examples of organic acids include oxycarboxylic acids such as citric acid, tartaric acid, malic acid, and gluconic acid, or salts thereof (such as sodium salt and potassium salt). Among these, oxycarboxylic acid and / or a salt thereof are preferable, and sodium citrate is more preferable in that the curing time can be controlled and there is no blockage of a hose or the like.

Examples of the alkali metal carbonates include carbonates such as lithium carbonate, sodium carbonate, and potassium carbonate, and bicarbonates such as sodium hydrogen carbonate and potassium hydrogen carbonate. Among these, alkali metal carbonates are preferable and potassium carbonate is more preferable in terms of good strength development after curing.

When the organic acid and the alkali metal carbonate are used in combination, the mixing ratio of the two is preferably 5 to 200 parts, more preferably 10 to 100 parts, with respect to 100 parts of the alkali metal carbonate. If it is less than 5 parts, the curing time cannot be controlled, and a hose or the like may be blocked, and if it exceeds 200 parts, the initial strength development may be reduced.

Although the usage-amount of a setting regulator is not specifically limited in order to adjust according to temperature and kneading time, 0.1-5 parts are preferable with respect to 100 parts of rapid-hardening materials, and 0.3-3 Part is more preferred. If it is less than 0.1 part, it may be difficult to ensure the kneading time, and if it exceeds 5 parts, the curing time may become abnormally long, resulting in a non-uniform solidified state. Further, since the setting modifier is added as the liquid C, it is preferable that the setting agent in the rapid hardening material slurry is slightly less than the amount of setting agent necessary for maintaining the target curing time.
The liquid C setting regulator may be the same component as the liquid B setting regulator, but it is an organic acid such as citric acid, tartaric acid, and gluconic acid because of the ease of adjusting the curing time. It is preferable to use an acid or a salt thereof (such as sodium salt or potassium salt) alone.

  The mixing ratio of water (W) in the rapid hardening material slurry (liquid B) is 50 to 150%, preferably 70 to 120% in W / quick hardening material, and if it exceeds 150%, the rapid hardening material component in the slurry If the amount is less than 50%, the viscosity of the hardened material slurry is high, causing a problem in the pumpability and a problem in mixing with the cement milk. And causes variations in subsequent strength development.

The acidic substance used in the present invention is used to moderate the change in the curing time due to temperature change, to improve the strength development, and to maintain the characteristics of the rapid hardening material slurry. After preparing the rapid hardening material slurry by mixing the rapid hardening material and water, it is necessary to knead the rapid hardening material slurry until the rapid hardening material slurry and the cement milk are mixed. If the kneading time of the rapid hardening material slurry is long, the initially set curing time is shortened, and the strength development may be reduced. In particular, the tendency becomes remarkable at high temperatures, the hose is blocked, and there is a problem that the rapid hardening cement milk may not be sufficiently filled into the mold. In order to solve this problem, an acidic substance is used.

Examples of the acidic substance include phosphates such as monosodium phosphate and monopotassium phosphate, sulfates such as aluminum sulfate and ammonium sulfate, and bisulfates such as sodium hydrogen sulfate and potassium hydrogen sulfate. Among these, sulfate is preferable and aluminum sulfate is more preferable in terms of good fluidity and safety. In addition, strong acids such as sulfuric acid, hydrochloric acid, and nitric acid, and phosphoric acid can also be used.

The amount of the acidic substance used is preferably 10 parts or less and more preferably 5 parts or less with respect to a total of 100 parts of the rapid hardening component and gypsum. If it exceeds 10 parts, strength development may be reduced.

  The C liquid used in the present invention is obtained by dissolving a setting modifier in water, and if necessary, add the C liquid to either before mixing them into cement milk or quick hard material slurry. Thus, the setting time of the rapid hardening cement milk can be arbitrarily changed during the operation.

  Concentration of the liquid C is 1 to 25 parts, preferably 5 to 15 parts of a coagulation adjusting agent in 100 parts of water, and if it is less than 1 part, it is difficult to control the curing time. When it exceeds, the change of the hardening time by the fluctuation | variation of addition amount will become large, and workability | operativity may worsen.

Mixing C liquid into cement milk (A liquid) or quick hard material slurry (B liquid) is carried out to the cement milk being pumped or the branch pipe (Y-shaped pipe or shower ring) in the quick hard material slurry pumping pipe. Press-fitted with a liquid pump.

The mixture of cement milk (liquid A) and rapid hard material slurry (liquid B) is pressed into the branch pipe (Y-shaped pipe or shower ring) in the pumped cement milk pressure pipe by a rapid hard material slurry pump or the like. A method of mixing and injecting with a non-driving mixer (static mixer) is preferable.

  The hardening time after mixing the cement milk (liquid A) and the rapid hardening material slurry (liquid B) takes into consideration the reduction of the side pressure applied to the permanent mold, and the setting speed of the rapid hardening cement milk (height 0.5 m / 1 to 5 minutes is preferable when the min) is fast, and 3 to 20 minutes is preferable when the casting speed (height is about 0.1 m / min) is slow.

  The length of the hose from the mixing of cement milk and the quick-hardening material slurry to filling is 30 m or less, preferably 1 to 10 m. Curing time may be shortened and the hose may be hardened.

  The fluidity of the filler of the present invention is 8 to 15 seconds in terms of JA funnel value, has excellent filling performance, and is suitable for narrow gap filling.

The filling method of the filler of the present invention is the place where the cement milk (liquid A), the hardened material slurry (liquid B) and the liquid C containing the setting retarder are different at the construction site or at the construction site. Are pre-manufactured and mixed on site. About the manufacturing apparatus of these liquids, it may be the same as that of the past, and the mixer used when producing cement milk and quick-hardening material slurry for usual fillers, such as a grout mixer, a mortar mixer, and a hand mixer, is used. be able to. The kneading time is not particularly limited as long as material separation does not occur. For example, a hand mixer is preferably about 1 minute.
The mixing ratio of the A liquid, the B liquid, and the C liquid varies depending on use conditions, but normally, the B liquid is about 5.5 to 50 parts and the C liquid is about 0.01 to 10 parts with respect to 100 parts of the A liquid. It is.

  Hereinafter, it demonstrates in detail based on an experiment example.

Experimental example 1
The cement milk shown in Table 1 and the quick-hardening material slurry were separately kneaded with a hand mixer. Separately, a coagulation adjusting agent 10% aqueous solution C was prepared and added separately. However, the solution C was added to the rapid hardening material slurry.

The prepared cement milk (A liquid) and C hard liquid slurry (B liquid) are mixed uniformly for 10 seconds with a hand mixer to form a filler (A liquid + B liquid + C liquid), and the curing time and compressive strength are measured. did.
Table 2 shows the blending ratio (parts) of the rapid-hardening material with respect to 100 parts of cement and the blending ratio (parts) of the 10% aqueous solution C solution for the setting modifier to 100 parts of the rapid-hardening material. The measurement results are also shown in Table 2.

<Materials used>
Cement: Ordinary Portland cement, commercially available, density 3.15 g / cm ³
Quick hardening material: CA (12CaO · 7Al ₂ O ₃ composition), vitrification rate of 99% or more, brain value 6050 cm ² / g, commercially available anhydrous gypsum pulverized product, brain value 5900 cm ² / g are mixed in equal amounts.
Setting agent (1): Mixture of citric acid and potassium carbonate in a mass ratio of 1: 3 Setting agent (2): Sodium citrate

<Measurement method>
Curing time measurement method: When the filler (A liquid + B liquid + C liquid) is put in a cup and lies sideways and cannot move.
Fluidity test: measured with a JA funnel. According to JSCE-F531 PC grout fluidity test method.
Compressive strength: According to JIS CE-F56 and JIS R 5201 (4 cm × 4 cm × 16 cm specimen used).

  From Table 2, it can be seen that by using the filler of the present invention, the curing time of the filler can be easily controlled and the strength development is good.

Experimental example 2
The test was performed in the same manner as in Experimental Example 1 except that aluminum sulfate was mixed at a ratio shown in Table 3 with respect to 100 parts of the hardened material, and the test was performed according to the kneading time of the hardened material slurry. Table 3 shows the blending ratio of aluminum sulfate and the results of changing the coagulation modifier 10% aqueous solution C.

<Materials used>
Aluminum sulfate: commercial product, water-containing product (16 hydrate)

From Table 3, it can be seen that by using aluminum sulfate, the curing time does not change much even if the rapid hard material slurry (liquid B) is kneaded. Moreover, it turns out that intensity | strength expression is favorable.

Experimental example 3
Fabricate a mold for filling the cavity with a vinyl chloride plate on the side and a back side of plywood with a height of 2 m, a width of 1 m, and a thickness of 10 cm. (Liquid + liquid C) was poured, and a pressure gauge was attached to the center of the bottom of the PVC plate, and the pressure at which the hardened cement milk applied to the mold and the swelling of the PVC plate were measured. The results are also shown in Table 4.
Cement milk (liquid A) and quick hard material slurry (liquid B) are kneaded with a hand mixer and placed in the hopper of each squeeze pump. Cement milk is 8.25 liters / min, and quick hard material slurry is 1.75 liters / min. The cement milk (liquid A) and the hardened material slurry (liquid B) were mixed in the mixing tube on the way, and filled from the upper part of the mold as the hardened cement milk (liquid A + liquid B). C liquid poured the ratio shown in Table 4 with respect to 100 parts of quick hardening materials in quick hardening material slurry (B liquid) with the bifurcated pipe to the quick hardening material slurry (B liquid) side.

<Measurement method>
Maximum pressure: Measured with a digital pressure gauge (VPC-A5-SA-100.0 kPa-1) manufactured by Valcom.
PVC board swelling: The maximum swelling of the PVC board is measured by the difference between the calipers before and after injection.
Curing time: When the pressure gauge no longer increases in pressure.

  From Table 4, it can be seen that by using the filler of the present invention, the curing time can be taken, the pressure applied to the mold after filling is low, and the swelling of the PVC plate is extremely small.

Experimental Example 4
According to the test method of Experimental Example 3, the ratio C shown in Table 5 was poured into the cement milk (liquid A) side through a bifurcated tube with respect to 100 parts of cement in the cement milk (liquid A). The results are also shown in Table 5.

  Table 5 shows that by putting C liquid into the cement milk (A liquid) side, the curing time is longer than when it is used on the rapid hardwood slurry (B liquid) side (C liquid can be reduced). It can be seen that the pressure applied to the frame, the swelling of the PVC plate, etc. are hardly changed, and the compressive strength is not changed.

  According to the present invention, it is possible to arbitrarily control the curing time at the time of filling, and it is possible to reliably fill the filling portion of the cavity and gap between the concrete structure and the permanent mold, and the permanent mold by shortening the curing time, In particular, not only can the lateral pressure on the FRP formwork be reduced, but also the reinforcement and thickness of the permanent formwork of the steel plate or concrete plate can be reduced, so that an inexpensive permanent formwork can be provided and it is economical. In addition, filling the cavity of the back of the mountain tunnel, filling the cavity or gap of the civil engineering structure, there is no leakage to the surrounding gap, etc., and the filling material with reduced curing time is diluted into groundwater and running water It can be used widely in the civil engineering field.

Claims (6)

Cement milk A liquid mainly composed of cement, calcium aluminate and gypsum, rapid hardening material slurry B liquid containing a setting retarder, and C liquid containing a setting retarder. Furthermore, the filler according to claim 1, wherein the liquid B contains an acidic substance. The filler according to claim 2, wherein the acidic substance is aluminum sulfate. The manufacturing method of the filler of any one of Claims 1-3 formed by mixing B liquid and C liquid and mixing A liquid just before filling. The manufacturing method of the filler of any one of Claims 1-3 formed by mixing A liquid and C liquid, and mixing B liquid just before filling. 6. The filling method according to claim 4, wherein the transport distance of the filler produced by the production method according to claim 4 or 5 is within 30 m.