JP2753794B2 - Mortar composition and method using the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a mortar composition which can be used as a repair material or a repair material for ALC (lightweight cellular concrete) or the like to protect an ALC panel or the like and improve durability, and a mortar composition therefor. Related to the construction method using More specifically, it is applied to the surface layer portion (surface or repair / repair portion) of the ALC panel or the like to prevent water from entering from the surface of the ALC panel or the like, and diffuses and releases moisture in the inorganic cured product to the outside. As a result, moisture does not accumulate inside the ALC panel or the like, thereby preventing rusting of the buried corrosive metal material or the like, preventing freezing damage in a cold region, and preventing the ALC panel for a long time. It is an object of the present invention to provide a mortar composition capable of preventing deterioration of the tile or the like, or of easily adhering a ceramic tile to prevent the tile from floating, and a method using the same.

[0002]

2. Description of the Related Art ALC panels have excellent properties such as light weight, heat insulation, fire resistance (non-combustibility), sound insulation and the like.
At present, about 4 million m ³ / year is produced and widely used as a building material.

However, since the ALC panel is light and low in strength, it breaks during transportation or construction, and after it is constructed on the outer wall, it is porous and has high water absorption and water permeability, so that it is difficult to remove water from the outside. Repeated intrusion and drying can cause panel degradation, or in cold climates, windows, sashes,
The so-called frost damage problem, in which the water in places where water is remarkable such as rain gutters, the moisture in the portion where moisture easily stays such as directly above the foundation, or dew condensation water, etc., freezes in winter to damage the ALC panel (frost damage). Things.

[0004] Therefore, it is necessary to repair the chipped portion of the ALC panel, the portion damaged due to deterioration, or the portion that has suffered frost damage, for example, using repair materials listed below.

Japanese Patent Publication No. 59-32419 discloses that obsidian pearlite having no water absorption is 16 to 18 parts by volume, perlite having water absorption is 48 to 53 parts by volume, ALC
16-18 parts by volume of powder, Portland cement 11-2
A repair material composition for ALC consisting of 0 parts by volume and divalent or trivalent metal fatty acid salt powder is described.

Japanese Patent Application Laid-Open No. 62-59581 discloses that Portland cement 20 to 35% by volume, ALC powder 15
A repair material composition for ALC is described that contains -25% by volume, 40-60% by volume of obsidian pearlite having a particle size of 0.6 mm or less, and 2-6% by volume of obsidian pearlite having a particle size of 1.2-2.5mm. .

JP-A-1-203282 describes a repair material for ALC comprising 200 to 400 vol% of obsidian pearlite having a water absorption of 130% by weight or less with respect to cement, a soluble resin powder, and a thickener.

[0008]

However, although the conventional repair materials have been sufficiently considered in terms of bulk specific gravity, bending strength and compressive strength, they have a large water absorption and a low moisture permeability, so that the repaired portion and the adjacent portion have to be repaired. As a result, the accumulated ALC moisture accumulates,
In cold regions, frost damage has not been resolved and is often a problem. Further, even when the repair material is applied over the entire surface to form a base for tile application, problems such as insufficient adhesion strength of the ceramic tile are caused.

In general, when a material that is too hard as compared with the base material is used as the repair material, cracks and peeling of the repair interface occur. Therefore, a material having physical properties similar to the base material is used. It is known that it is better for materials to behave together. However, since the ALC panel itself has high water absorption and water permeability as described above, it causes frost damage and the like, and repair materials having properties similar to this ALC panel also cause frost damage and the like. In addition, since the surface strength is low, a problem arises even as a tiled base.

[0010] On the other hand, repair materials that sufficiently take into account water absorption and water permeability are also commercially available, but the problem of frost damage has not been solved due to insufficient moisture permeability. Further, the strength of the mortar is high and the Young's modulus is 16 × 10 ⁴ kgf / cm ^2.
Degree (Young's modulus of ALC panel is 1.7 to 2.2 × 1
0 Since ⁴ kgf / cm ²⁾ with a high compressive force or stretching force acts repairing material portion on the panel surface when ALC panels and bent toward the interior side and exterior side, for example, by wind pressure or the like is compressed in the vertical direction or When the repair material is too hard, it is not deformed like the panel, and cracks or peels off. In addition, even if the plastering technician applies this over the entire surface and uses it as a base for pasting ceramic tiles, it cannot absorb the deformation due to hot cooling and the deformation due to wet and dry, and the movement reaches the ALC panel surface, This causes a problem of peeling.

[0011]

SUMMARY OF THE INVENTION The present invention has been proposed in view of the above. In a mortar composition containing cement and silica sand as main components, 1 to 40 wt% of an inorganic waterproofing agent containing SiO ₂ as a main component. And 0.2 to 5 wt% of mica powder, and when cured and cured, the mortar solids have a water absorption of 20 g or less, a water permeability of 0.5 ml or less, and a moisture permeability of 100.
The present invention relates to a mortar composition characterized by being adjusted to at least 0 g / m ² · 24 h.

That is, the present invention uses ordinary Portland cement, white cement, or the like as a cement, and contains SiO ₂ as a main component in a mortar composition in order to increase moisture permeability and reduce water absorption and water permeability. 1 to 40 mineral waterproofing agent
wt%, preferably 2 to 30 wt%. If the amount of the inorganic waterproofing agent is less than 1 wt%, the above effect is not exhibited, and if it is more than 40 wt%, the effect is not further improved and it is useless. The above-mentioned inorganic waterproofing agent is specifically “BBc
oncentrate "is a (Japan van manufactured by index), the SiO ₂ as the main component, is intended to include BaSO _4, ZnS, a small amount of mineral oil.

Further, in order to improve the watertightness of the mortar solid, to reduce the presence of calcium hydroxide in the cured product, and to prevent bleaching due to water wetting during or after curing.
5 to 50 wt% of granulated blast furnace slag powder, preferably 5 to 3 wt% having a specific surface area of about 3000 to 6000 cm ² / g.
It is good to mix 0 wt%.

Further, in consideration of the strength, moisture characteristics, and workability of the mortar, an appropriate particle size is selected from a range of a particle size of about 0.01 to 2 mm, and selected from inorganic aggregates in consideration of durability. 5-60 wt% of silica sand, cold water stone, etc. are blended. Preferably, 10 to 50 wt% is blended.

Further, in order to improve the workability of the mortar, prevent cracks, reduce water permeability and water absorption, mica powder is blended in an amount of 0.2 to 5% by weight. Preferably, in consideration of workability and a finished surface, powder of about 1 mm or less is
It is good to mix about t%.

In addition, in consideration of workability, a thickener such as methylcellulose, hydroxypropylmethylcellulose and hydroxyethylcellulose, and an inorganic admixture such as pulverized pulp, dolomite plaster, and fly ash may be blended. Further, in order to reduce shrinkage, a high-performance water reducing agent such as a sulfonated melamine formalin condensate salt type, a naphthalenesulfonic acid formalin condensate salt type or the like, and a shrinkage reducing agent such as an inorganic swelling shrinkage reducing agent may be blended. good. In consideration of the strength, Young's modulus, etc. of the mortar, commonly used inorganic admixtures such as dolomite plaster, fly ash, slaked lime, bentonite, etc., and EVA-calcium carbonate expanded particles may be blended. In order to reduce water permeability and water absorption, a commonly used metal soap such as calcium stearate, a silicone-based water repellent, a zirconium-based, or a fatty acid-based waterproofing agent may be used in combination. In order to improve and stabilize the adhesiveness of the mortar, acrylic, S
A polymer dispersion for admixing cement such as BR or EVA or a re-emulsifying powder resin such as EVA, vinyl acetate or acrylic may be used within a range where moisture permeability is not reduced.

With the mortar composition having the above composition, a mortar (solid material) having high moisture permeability, low water permeability and low water absorption can be obtained, and there is no intrusion of moisture from the surface, and the moisture inside is released to the outside. Therefore, the durability of panels and the like can be improved, freezing damage in cold regions can be prevented, and rusting of corrosive metal materials can be prevented for a long period of time.

In order to repair or repair a surface that has deteriorated due to frost damage or the like, it is desirable to use a base reinforcing material to reinforce the deteriorated surface and to improve the adhesion to the repair mortar material. Such an underlayer reinforcing material contains isocyanate groups 0.5 to 10 wt% and hydrolyzable silane groups (based on silicon atoms) 0.4 to 7.5 wt% and has an average molecular weight of 3000 to 50,000. A one-component curable resin composition containing a polymer as a main component is desirable. When this one-component curable resin composition is applied, the deteriorated base surface can be reinforced and the adhesion to the repair mortar material can be improved. Moreover, since the moisture permeability is high, the internal moisture can be released to the outside through the one-part curable resin composition and the repair mortar material, and the durability of the repaired and repaired parts is improved.

[0019]

Examples of the present invention will be described below.

Examples 1 to 4 and Comparative Examples 1 to 8 Examples 1 to 4 and Comparative Examples 1 to 8 of the present invention are mortar compositions having the composition shown in Table 1.

[0021]

[Table 1]

[Performance test 1: Flexural strength / compression strength test]
Each mortar composition sufficiently kneaded according to JIS R 5201 (physical test method of cement) and JASS 15M-102 (quality standard of pre-mixed cement mortar) is filled into a 40 × 40 × 160 mm formwork, and wetted. Curing is performed in an empty curing room (temperature 20 ° C., humidity 80% RH or more) for up to 48 hours, and the mold is released. Then, the temperature and humidity chamber (temperature 20)
(° C, humidity 65% RH) Cured up to 28 days of material age to prepare test specimens. The test method conforms to JIS R5201 (n =
3). The results are shown in Table 2.

[Performance Test 2: Length Change Test] The method of preparing and testing a test piece conforms to JASS 15M-102 (quality standard of ready-mixed cement mortar) (n = 3).
The results are shown in Table 2.

[Performance test 3: Water absorption test] JASS 1
Specimens are prepared according to 5M-102, cured in a thermo-hygrostat until the age of 28 days, and the water absorption for 5 hours is determined without drying the specimens (n = 3). The results are shown in Table 2.

[Performance Test 4: Water Permeability Test] Each mortar composition sufficiently kneaded was subjected to an inner dimension of 200 × 200 × 1.
It is filled in a 0 mm formwork, left in a moist air curing room for 24 hours, and then demolded and cured in a constant temperature and humidity room until the age of 28 days. After that, 15 according to JIS R 6252 (abrasive paper)
The lower surface at the time of molding is sufficiently polished using No. 0 abrasive paper to prepare a test body. JIS A6 is placed at the center of the polished surface of this specimen.
910 (multi-layer finish coating material): A female pipette (capacity: 10 ml) of a water permeability test device specified in 910 (multilayer finish coating material) is fixed with a silicone sealing material. Then, after being left for 48 hours, the test body is immersed in a basin so as to be below the surface of the water and water is absorbed for 24 hours. After the water absorption, the test apparatus is set so that the lower surface of the test body coincides with the water surface of the basin. Water of 20 ± 3 ℃ is about 25 height above the water surface.
0 mm, read the scale of the mesipette, read the scale after standing for 1 hour, determine the difference from the initial scale,
Let the amount of water per hour be (n = 3). The results are shown in Table 2.

[Performance Test 5; Moisture Permeability Test] Each mortar composition sufficiently kneaded was subjected to an outer diameter of 106 mm and an inner diameter of 100 m.
m, filled into a PVC pipe mold having a height of 5 mm, pressed down smoothly, and cured in a constant temperature and humidity room until a material age of 28 days to obtain a test specimen. With this test piece attached to the formwork, outer diameter 110m
m, into a container made of styrene having a height of 68 mm and filled with 100 g of water, and sealed with paraffin. And
The sample is placed in a thermostat at 40 ° C., and after 24 hours, 48 hours, and 72 hours have passed, the weight is measured, and the moisture permeability is determined from the weight change (n = 3). The results are shown in Table 2.

[Performance Test 6; Measurement of Dynamic Elastic Modulus] Using the test specimen for measuring the bending strength of the performance test 1, the dynamic elastic modulus is obtained by measuring using an autoscan dynamic Young's modulus measuring tester ( n = 3). The results are shown in Table 2.

[0028]

[Table 2]

[Performance Test 7; Adhesion strength test] The test is performed in accordance with the quality standards (draft) of the water absorption adjusting material for cement mortar application by the Japan Society for Finishings. Standard condition; however, the base plate is 250 x 200 x 50 mm
The ALC board was used, and a small tile was stuck using each mortar composition of Example 3 and Comparative Example 6 in the material age of 2 weeks.
Cured up to a week to make a test specimen. Then, the mortar surface of this specimen is 10 m deep until it reaches the substrate in the size of the tile.
An incision of m is made, and the adhesive strength is measured according to the test method specified in JIS A 6916 (Cement-based base adjustment coating material) (n = 3). The results are shown in Table 3. Adhesion performance when wet; concrete base plate (300 × 3
(00 × 50 mm) is polished on the lower surface with No. 150 abrasive paper, and water-impregnated (150 g / m ² ). After draining, apply a prescribed amount of each mortar composition of Example 3 and Comparative Example 6 sufficiently kneaded, apply a comb, apply a mosaic tile, cure in a constant temperature and humidity room until the age of 1 week, and test. Body. After that, JIS A. When dry according to 6916 (standard condition)
Is measured for the adhesive strength. Further, the adhesion strength after immersing the test piece in water at 20 ° C. for 3 hours is measured (n =
3). The results are shown in Table 3.

[0030]

[Table 3]

[Performance Test 8; Hot-Cooling Repeat Test] The test is performed in accordance with the quality standard (draft) of the water absorption adjusting material for cement mortar application by the Japan Society for Finishings. However, the conditions of the test piece are the same as those in the adhesion strength test in the standard condition of the performance test 7. After 3 weeks of age, the back and four sides are painted with silicone sealing material and sealed. The heat-cooling repetition test is performed by irradiating an infrared lamp for 105 minutes so that the surface temperature of the specimen becomes 70 ° C., and then spraying water of 20 ± 5 ° C. for 15 minutes.
This is continued for 300 cycles as a cycle. 300
After the end of the cycle, the specimen is left in a thermo-hygrostat for 24 hours, and then the adhesion strength is measured (n = 3). The results are shown in Table 4.

[0032]

[Table 4]

[Exposure Test in Cold Regions] In Monbetsu, Hokkaido, an exposure test was conducted on a full-scale model building using ALC panels from November 1992 to the end of March 1993. The temperature and humidity conditions in the room were constant at 20 ° C. and 60% RH. The wall structure is shown in FIG. The mortar used for the test was a mortar composition of Example 2 on the entire surface, and a mosaic tile was stuck on the ALC panel substrate using the mortar composition of Example 3 on the entire surface.
The mortar composition of Example 4 was filled with joints. For comparison, the mortar composition of Comparative Example 6 was used, a mosaic tile was attached to an ALC panel, and the mortar composition of Comparative Example 7 was filled.

<Results> In any of the above-described combinations of the second, third, and fourth embodiments and the combination of the third and fourth embodiments, the floating of the tile was confirmed by exposure. In good condition. Moreover, the joint mortar and the adhesive mortar on the back surface were dry, and the release of moisture was confirmed. On the other hand, when the tiles were applied in a combination of Comparative Example 6 and Comparative Example 7, floating of the tiles was partially observed by exposure. Also, it was getting wet and dark.

[Workability test] At the new construction site of an office building using ALC panels, after the completion of the sealing work,
Using the mortar composition of Example 1, the joints were divided into three
The mortar of Example 2 was applied over the entire surface by squeezing, and a base of about 1000 m ² tile and a base of spray coating were prepared.

<Results> When the tiles were adhered to the mortar base of Example 2, the drainage was moderate, the tiles did not shift, and the workability was good. In addition, the bond strength test at 2 weeks of material age was 6.9 kgf / cm ² (ALC panel internal fracture 1
00%), which was no problem.

[Performance test 1 for repair / repair; Adhesion strength test] The base reinforcing materials of Example 5 and Comparative Example 9 shown in Table 5 were applied to an ALC panel, and the mortar composition of Example 1 was applied. The specimens were cured in a constant temperature and humidity chamber until the age of 2 weeks, and the adhesion strength was measured (n = 3). In addition, what applied the base reinforcing material of Example 5 and applied the mortar composition of Example 1 corresponds to the method of claim 5. The results are shown in Table 5.

[Performance Test 2 for Repair / Repair; Moisture Permeability Test] A JIS P 3801 was placed on a 10.8 cm diameter cup.
1 type (thickness 0.2mm, weight 90g / m ² )
And the base reinforcing materials of Example 5 and Comparative Example 9 are applied twice (total applied amount: 350 g / m ² ) and cured in a constant temperature and humidity chamber for 24 hours. Then add 100g of water,
After sealing with paraffin, the weight is measured, put in a thermostat at 40 ° C., and the weight is measured every 24 hours, 48 hours, and 72 hours. The moisture permeability is determined from the change in weight from 48 to 72 hours (n = 3). The results are shown in Table 5.

[0039]

[Table 5]

Although the embodiment of the present invention has been described above, the present invention is not limited to the above-described embodiment, and can be implemented in any manner without changing the configuration described in the claims.

[0041]

As described above, the mortar composition of the present invention has a high moisture permeability and a low water absorption and low water permeability, so that the surface of an ALC panel or the like is repaired or repaired. When applied to parts, etc., it prevents water from entering the inside from the outside and diffuses moisture from the inside to the outside,
The release does not cause moisture to accumulate inside the ALC panel or the like, and rusting of the buried corrosive metal material or the like can be prevented. Further, since no water is accumulated inside, it is possible to prevent frost damage in cold regions. Further, since the intrusion of moisture and the repetition of drying are prevented, the deterioration of the ALC panel or the like can be prevented for a long period of time. In addition, it can absorb deformation due to heat cooling and deformation due to wet and dry, and has high surface strength.
Ceramic tiles can be easily adhered, and floating of the tiles can be prevented.

Further, isocyanate groups of 0.5 to 10 wt.
% And hydrolyzable silane group (based on silicon atom)
Containing 0.4 to 7.5 wt% and having an average molecular weight of 3000
After applying a one-part curable resin composition having a polymer as a main component of up to 50,000 and then applying the mortar composition, the one-part curable resin composition repairs and repairs a surface layer portion of a repaired part. Since it is reinforced and has high moisture permeability, the moisture inside can be released to the outside through the one-part curable resin composition and the repair mortar material, and the durability of the repaired and repaired parts is improved.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing a configuration of a wall in an exposure test.

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification symbol FI E04G 23/02 E04G 23/02 A // (C04B 28/02 14:06 14:20) (72) Inventor Yuzo Shiode Tokyo 4-7-10 Izumicho, Tohoya-shi (56) References JP-A-59-62685 (JP, A) JP-A-51-145525 (JP, A) JP-A-53-109525 (JP, A) JP-A Sho 51-150525 (JP, A) JP-A-55-140780 (JP, A) JP-B-5-12295 (JP, B2)

Claims (4)

(57) [Claims] 1. A mortar composition mainly composed of cement and silica sand, containing 1 to 40% by weight of an inorganic waterproofing agent mainly composed of SiO ₂ and 0.2 to 5% by weight of mica powder, and cured and cured. Water absorption of mortar solids at the time of
0 g or less, water permeability 0.5 ml or less, moisture permeability 1000
A mortar composition characterized in that the mortar composition is adjusted to be at least g / m ² · 24 h. 2. A method comprising applying the mortar composition according to claim 1 to a surface layer portion of an ALC panel or a cured inorganic material in which a corrosive metal material is embedded. 3. An isocyanate group of 0.5 to 10% by weight and a hydrolyzable silane group (based on silicon atom) of 0.4 to 7 are provided on the surface layer of the ALC panel or the cured inorganic material in which the corrosive metal material is embedded. 2. applying a mortar composition according to claim 1 after undercoating a one-part curable resin composition containing 0.5 wt% and having a polymer having an average molecular weight of 3,000 to 50,000 as a main component. Characteristic construction method. 4. The method according to claim 1, wherein the mortar composition according to claim 1 is overcoated on a surface layer portion of an ALC panel or a cured inorganic material in which a corrosive metal material is embedded. A method of applying a porcelain tile using the mortar composition, and further filling the mortar composition according to claim 1.