JP3438101B2 - Construction method of corrosion resistant floor - Google Patents

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention relates to a method for constructing a corrosion resistant floor.

[0002]

2. Description of the Related Art Corrosion-resistant floors are manufactured by placing a glass fiber base material such as glass mat or glass cloth on a cement concrete base material, impregnating and applying a vinyl ester resin on it, and curing it at room temperature by FRP lining. The floor has excellent corrosion resistance.

[0003]

However, the above-mentioned method for constructing a corrosion-resistant floor requires many steps such as substrate preparation, primer application, undercoating, laminating of glass fiber base material, intermediate coating, topcoating, curing, etc. The construction period before use is very long. Also, the time required for curing varies depending on the moisture content of the substrate and the temperature of the outside air.If the substrate substrate has a large amount of moisture or at a low temperature, the curing will be very slow and the construction period will be long, or a curing failure will occur and a film with excellent corrosion resistance will be obtained. I can't do it.

Moreover, there is a drawback in that the workability of floor construction is extremely poor because skill is required for the preparation of the base material, the application of the primer, the undercoating, the lamination work of the glass fiber base material and the like.

[0005]

DISCLOSURE OF THE INVENTION The inventors of the present invention have made earnest studies in view of the above situation, and as a result, a panel made of fiber reinforced plastic [hereinafter referred to as panel. ], A plurality of them are joined together by a joint material and / or a molding joint, and the corrosion-resistant floor is constructed by fixing the panel to the floor, the floor having the same corrosion resistance as the conventional corrosion-resistant floor. However, as compared with the conventional FRP lining method, it was found that the work can be carried out in a short period of time and with good workability without requiring skill, and the present invention has been completed.

That is, the present invention relates to a floor construction method using a plurality of fiber reinforced plastic panels on a concrete floor, wherein the fiber reinforced plastic panels are used to join the panels to each other with joint materials and / or molding joints. An anchor bolt or a cross-shaped or H-shaped plate spring made of stainless steel is fitted into the groove of the panel edge to fix the fiber-reinforced plastic panel to the concrete floor. Fixed,
Provided is a method for constructing a corrosion resistant floor, characterized in that the two panels are bonded to each other with joint material and / or synthetic rubber molding joint and the panel is fixed to the floor.

Next, the construction method of the present invention will be described along the construction procedure. In the present invention, first, the panel is fixed to a base material (floor) such as cement concrete. As a method for fixing the panel, for example, a hole may be opened in the panel and directly fixed with an anchor bolt, or a method may be used in which the panel is not opened and an anchor bolt is used via a metal spring.

The panel used in the present invention may be, for example, a product obtained by impregnating a fiber-reinforced material with a thermosetting resin in advance and curing and molding it into a plate shape. The shape of the panel is not limited to a square and may be any shape, and the size is not particularly limited.

Examples of the thermosetting resin include epoxy resin, unsaturated polyester resin, vinyl ester resin, polyurethane resin, phenol resin, and the like, and it is particularly preferable to use vinyl ester resin having excellent corrosion resistance. Examples of the fiber reinforcement include glass fiber, carbon fiber, aramid fiber and the like, and the shape thereof may be any of long fiber, short fiber, mat and cloth.

As a method of molding the panel, for example, hand lay-up, spray-up, press molding, resin transfer molding and the like can be used. Among them, the press molding having good workability and obtaining the panel in a short time, Resin transfer molding is preferred.

When such a preferable panel forming method is adopted, the construction period of the corrosion-resistant floor of the present invention is remarkably shortened as compared with the conventional case even if the panel forming time is taken into consideration. become.

As described above, in the construction method of the present invention, since a panel is prepared in advance and used, many of the conventional techniques such as substrate preparation, primer application, undercoating, glass mat lamination, intermediate coating, topcoating and curing are required. The process can be omitted, and the construction period can be very short. In addition, problems such as poor curing at low temperatures during on-site construction can be eliminated, and construction can be performed even in low temperatures such as in the winter or in the freezer. Furthermore, since the use of a large amount of solvent and styrene monomer at the construction site is reduced, the problem of bad odor and health and safety can be solved.

Further, since the panel is fixed to the base material such as concrete with anchor bolts, the base material adjustment, which was indispensable in the conventional FRP lining method, becomes unnecessary. If the base material adjustment is not appropriate, the adhesion to the base material is deteriorated. Then
It is also possible to solve the drawback of the conventional technique that the corrosion resistance is extremely lowered. Therefore, it is not necessary to control the water content or remove the oil content in the concrete body, and the construction process can be simplified.

Further, in the panel according to the present invention, the foam synthetic resin sheet is attached to the back surface of the panel, whereby irregularities (unevenness) of the concrete substrate can be absorbed. Examples of the foamed synthetic resin sheet include foamed sheets of thermoplastic resin such as polyethylene, polypropylene, polyvinyl chloride, ABS, and nylon. Alternatively, a liquid resin such as polyurethane may be injected and foamed between the panel and the concrete base material to adjust the unevenness of the concrete base material.

By sticking the foamed sheet to the back surface of the panel in this manner, it is not necessary to additionally use a sander for adjusting the base material, so that environmental problems such as dust generation and noise can be solved.

By embedding a core material in the panel of the present invention, it is possible to prevent the panel from warping and to reduce the weight during handling during transportation or construction. Examples of the core material include lightweight foam such as plywood and polyurethane.

The material of the metal spring used in the present invention is
Made of stainless steel, a metal that is not easily corroded by water, acid or alkali . The shape may be such that the panels can be fixed to each other, and a cross-shaped metal spring is used to fix the intersections of the four panels .

Further, for example, when a height difference occurs between the two panels or when a warp occurs, the panels are fixed by an H-shaped metal spring . If an H-shaped metal spring is used, it is possible to suppress the height difference and warp of the panel.

Further, the metal spring is preferably shaped and dimensioned so as to engage with the groove around the panel to be fixed, in order to fix the panel and suppress height difference and warp. Then, a gap (hereinafter referred to as a joint) between the fixed panels is filled and connected by using a joint material and / or a molding joint.

The panel used in the present invention preferably has a groove at the edge for the purpose of improving the adhesion to the joint material and the molding joint and preventing the permeation of chemicals and water.

The joint material is injected in an amount necessary to fill the groove between the panels and the gap between the panels. As the joint material, for example, silicone resin, modified silicone resin, polysulfide, polyurethane resin, epoxy resin, unsaturated polyester resin, vinyl ester resin, acrylic rubber, butyl rubber, oil-based caulking or the like is used. It is also possible to add a filler, a plasticizer, a short fiber, a thixotropic agent, a colorant, etc. to these resins in order to improve impact resistance and adhesion.

When a joint material is used, it is preferable to lay a sheet of polyethylene, vinyl chloride, etc. under the panel in order to prevent troubles such as inhibition of curing due to moisture and dirt of the base material such as concrete.

The above-mentioned molding joint is used to join a plurality of panels together, and refers to a joint material which is previously molded into a shape required to fill the groove between the panels and the gap between the panels.

As the synthetic rubber used for the synthetic rubber molding joint, styrene-butadiene rubber, butadiene rubber,
Examples thereof include isoprene rubber, nitrile rubber, ethylene propylene diene terpolymer, chloroprene rubber, butyl rubber, chlorosulfonated polyethylene, acrylic rubber, polyurethane rubber, fluorine rubber and silicone rubber.

The molding joint may be used alone, or the molding joint and the joint material may be used in combination to improve the adhesiveness between the molding joint and the panel, and an adhesive may be used to form the panel and the molding joint. You may adhere with.

The panel is preferably embossed on its surface to prevent slippage when oil or water is spilled.

Thus, the construction of the corrosion resistant floor obtained by laminating the reinforced plastic panel of the present invention to the floor using the joint material and / or the molding joint is completed.

As for the method of constructing the corrosion resistant floor, only the method of fixing a plurality of panels to the floor and then joining the panels together has been described in detail as described above, but conversely, after joining the panels together, Of course, the construction method of fixing it to the floor may be used.

The details of the present invention will be described below with reference to examples.

[0030]

EXAMPLES The present invention will be described in detail below with reference to examples and comparative examples. The present invention is not limited to the examples below. Unless otherwise specified, parts are parts by weight and% is% by weight.
Shall be indicated.

Production Example 1 (Production of Panel) A panel was produced by a resin transfer molding method as shown below.

As a gel coat, Polyton Green G-
Using a mixture of 100 parts of 17907 (a vinyl ester resin gel coat manufactured by Dainippon Ink and Chemicals, Inc.) and 1 part of methyl ethyl ketone peroxide, a lower mold having an embossed pattern preheated to 50 ° C. has a film thickness of 500.
It was applied to have a thickness of μm and cured for 20 minutes.

Then, a surface mat (manufactured by Nitto Boseki Co., Ltd. under the trade name MF3) was formed on the cured gel coat layer of the lower mold.
0P), place a glass preform mat preformed in the shape of the panel in advance on the mold, then insert a water resistant plywood with a thickness of 5 mm, and charge another glass preform mat. , The upper mold and the lower mold were combined and clamped.

Next, Dick Light UE-3505
(Vinyl ester resin manufactured by the same company) 100 parts, acetylacetone peroxide 1 part, 6% cobalt naphthenate 0.
Injecting a mixture of 5 parts into the mold so that the resin content of the molded product (panel) is 20 to 30% by weight, 2 to 3 kg.
/ Cm ² and then cured at 50 ° C. for 20 minutes and then released from the mold.

Next, the burrs protruding around the panel were trimmed, and the back surface of the panel had a foaming ratio of 30 times and a thickness of 4 mm.
Torre Pef of No. (a foamed polyethylene sheet manufactured by Toray Industries, Inc.) was laminated with a double-sided tape to obtain a panel A.
A sectional view of panel A is shown in FIG. In FIG. 1, reference numeral 1 is a water resistant plywood, and the water resistant plywood 1 is sandwiched between glass fiber reinforced polyester resins 2 and 2,
The surface is embossed 3. A foam synthetic resin sheet 4 is attached to the back surface. Further, in the peripheral portion of the panel A, a groove 5 having a substantially U-shaped cross section is formed.
Are formed. The time required to manufacture the panel was 1 hour.

Preparation Example 1 (Preparation of joint material) 100 parts of Dick Light UE-2083 (vinyl ester resin manufactured by Doujinsha Co., Ltd.), 4 parts of Aerosil 200 (anhydrous silica of ultrafine particles manufactured by Nippon Aerosil Co., Ltd.), 6% cobalt naphthenate A mixture consisting of 0.5 parts was uniformly dispersed using a high speed stirrer to obtain a joint material A.

Example 1 A plurality of panels A were placed on a concrete floor surface at a distance of 5 mm from each other.
Align the four corners of the panel as shown in Figure-2.
It was held down by the stainless steel leaf spring 6 shown in (4) and the central hole of the spring was fixed by the anchor bolt 7.

Then, a masking tape was applied to the edge of panel A so that the joint material did not squeeze, and the vinyl ester obtained in Preparation Example 1 above was applied to the groove between the edge of panel A and the joint between the panels. A mixture of 100 parts of resin joint material A and 2 parts of methyl ethyl ketone peroxide was injected. When the joint material A began to gel, the masking tape was peeled off and cured for 1 day to finish.

A cross-sectional view of the joint portion is shown in FIG. In FIG. 3, reference numeral 9 is a concrete floor. The corrosion resistance and load resistance of the obtained floor showed the same performance as that obtained by the conventional FRP lining method. The construction period required two days including the curing period for the joint material.

Example 2 As in Example 1, panel A was laid on the floor, holes were made in the four corners of the panel, and the panels were fixed with anchor bolts.

Next, as a joint material, Thiocork (polysulfite manufactured by ABC Trading Co., Ltd.) as a main agent 100.
Parts and 10 parts of the curing agent were used in the same manner as in Example 1 to cure and finish for 1 day. The corrosion resistance and load resistance of the obtained floor showed the same performance as that obtained by the conventional FRP lining method. The construction period required two days including the curing period for the joint material.

Example 3 Panel A was fixed to the floor surface in the same manner as in Example 1, and silicone rubber molding joints preliminarily molded in the shape shown in FIG. Finished inset. The corrosion resistance and load resistance of the obtained floor showed the same performance as that obtained by the conventional FRP lining method. The construction period was one day.

Example 4 Panel A was fixed to the floor using a cross-shaped stainless leaf spring, and then, in order to suppress the height difference between adjacent panels, the H-shaped stainless steel shown in FIG. Leaf spring 10
And the center hole of the spring was fixed with the anchor bolt 7, and the curing was carried out for 1 day in the same manner as in Example 1 to finish.
The corrosion resistance and load resistance of the obtained floor showed the same performance as that obtained by the conventional FRP lining method. The construction period required two days including the curing period for the joint material.

Comparative Example 1 In order to prepare the foundation, the floor surface of well-dried concrete was put on an electric sander to completely remove leitance, oil and dirt, and dust was removed by electric cleaning.

Dick Light UE-1 as a primer
150 (Dainippon Ink and Chemicals, Inc. vinyl ester resin) 100 parts, methyl ethyl ketone peroxide 1.5
Parts, and a mixture of 0.5 parts of 6% cobalt naphthenate were applied to a film thickness of 200 μm, and the mixture was cured at room temperature for 1 day.

Dicklight UE-350 as undercoat
A mixture of 100 parts of No. 5 (vinyl ester resin manufactured by the same company), 1 part of methyl ethyl ketone peroxide, and 0.5 parts of 6% cobalt naphthenate was applied to a film thickness of 150 μm.

Immediately after the undercoating, one layer of chopped strand mat (product name MC450A manufactured by Nitto Boseki Co., Ltd.) was laminated so as not to wrinkle. After lamination, a chopped strand mat was impregnated with the same formulation as the basecoat with a roller brush and then the defoaming roller was used to degas the air bubbles remaining on the mat. Layer another chopped strand mat,
The same formulation was impregnated and defoamed. Then, one layer of surface mat was laminated, and the same composition as above was impregnated and defoamed and cured at room temperature for 1 day.

The same formulation as the undercoat was used as an intermediate coat, and the mixture was applied on the laminate of the mat so as to have a film thickness of 300 μ and cured at room temperature for one day.

As a top coat, Dick Light UE-35
05, 100 parts, melting point 135 ° F paraffin wax 0.5 part, methyl ethyl ketone peroxide 1.0 part,
A mixture of 0.5 parts of 6% cobalt naphthenate was used to apply a coating having a film thickness of 400 μm, and the mixture was cured at room temperature for 2 days to finish. The entire construction period required 6 days.

[0050]

EFFECT OF THE INVENTION Since the method for constructing the corrosion resistant flooring material of the present invention uses a panel made of fiber reinforced plastic, and joining them with joint material and / or molding joint, and fixing the panel to the floor, Compared with the conventional FRP lining method, the construction period can be significantly shortened, and construction is simple and does not require skill, and the working environment can be improved.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing an example of a reinforced plastic panel used in the present invention.

FIG. 2 is a plan view showing a laid state of a fiber-reinforced plastic panel.

FIG. 3 is a sectional view showing an example of a joint portion of the present invention.

FIG. 4 is a sectional view showing an example of a molding joint in the present invention.

FIG. 5 is a plan view showing a laid state using an H-shaped plate spring made of stainless steel according to the present invention.

[Explanation of symbols]

A Fiber reinforced plastic panel 1 plywood 2 Glass fiber reinforced polyester resin 3 embossing 4 Foam synthetic resin sheet 5 grooves 6 Cross-shaped stainless steel leaf spring 7 Anchor bolt 8 joints 9 concrete floor 10 H-shaped leaf spring made of stainless steel B joint material C molding joint

Front page continued (72) Inventor Tadao Saito 16-10-10 Kurawadai, Sodegaura-shi, Chiba (72) Inventor Toshiro Kayano 4-29-12 Kitakoyasu, Kimitsu-shi, Chiba (72) Inventor Kiyoshi Takezuka Chiba 1299-11 Yamazaki, Noda City, Japan (56) Reference JP 62-187031 (JP, A) JP 60-5937 (JP, A) JP 5-59827 (JP, A) JP 4- 158032 (JP, A) Actually opened Sho 63-33846 (JP, U) Actually opened 62-56644 (JP, U) Actually opened 61-163843 (JP, U) Actually opened 60-164509 (JP, U) Furukai Sho 54-35522 (JP, U) Furukaihei 1-162529 (JP, U) (58) Fields investigated (Int.Cl. ⁷ , DB name) E04F 15/00-15/18

Claims (5)

(57) [Claims] 1. A floor construction method using a plurality of fiber-reinforced plastic panels on a concrete floor, wherein the fiber-reinforced plastic panel has a groove for connecting the panels with joint materials and / or molding joints. In order to fix the fiber reinforced plastic panel to the concrete floor, an anchor bolt or a cross-shaped or H-shaped stainless plate spring is attached to the panel edge.
A method for constructing a corrosion-resistant floor, characterized in that the panel is fixed to the groove with anchor bolts, the joints are connected with a joint material and / or a synthetic rubber molding joint, and the panel is fixed to the floor. 2. The construction method according to claim 1, wherein the fiber reinforced plastic panel is an embossed surface-treated fiber reinforced plastic panel. 3. The construction method according to claim 1, wherein the fiber-reinforced plastic panel is a fiber-reinforced plastic panel in which plywood is embedded. 4. The construction method according to claim 1, wherein the fiber reinforced plastic panel is a fiber reinforced plastic panel obtained by impregnating a vinyl ester resin into a fiber reinforced material and curing the resin. 5. The construction method according to claim 1, wherein the fiber-reinforced plastic panel is a laminate of a foamed synthetic resin sheet and a fiber-reinforced plastic panel, and the foamed synthetic sheet side is fixed to the floor. .