JPH0711178B2 - Method for fixing beautiful aggregate on a substrate - Google Patents

Description

The present invention relates to a method for fixing a beautiful aggregate on a substrate such as concrete. In general, on the outer wall of a building such as a boardwalk, a park, a garden, a front door of a restaurant, a road at the front door, a museum, a gymnasium, a museum, etc., on the surface of a base material such as concrete as shown in FIG. Decorative concrete has been used in which a part of the beautiful aggregate is embedded in the concrete. In this specification, the structure shown in FIG. 1 is simply referred to as decorative concrete.

Conventionally, decorative concrete has been manufactured by the so-called washing-out method.

The washout method consists of the following steps. Crusher run 1
The foundation concrete layer 2 is provided on top of the. Crusher run 1 and foundation concrete layer are called foundation. A mortar layer 3 is provided thereon, and a pre-grout mortar 5 containing a beautiful aggregate 4 is applied thereon. This state is shown in FIG.
Then, a set retarder is sprinkled on the pregrout mortar 5, and a curing plastic sheet 6 is put thereon. This state is shown in FIG. Next, the pregrout mortar 5 is left to stand for 2 to 3 hours in summer and 4 to 6 hours in winter to cure the portion of the pre-grout mortar 5 other than the surface. The surface of layer 5 will not cure because of the presence of the cure retarder. Remove the curing sheet,
The mortar component existing on the mortar 5 without hardening is washed out with water to form decorative concrete. This state is shown in FIG.

However, the conventional washing-out method has the following drawbacks.

(1) It is necessary to uniformly apply the curing retardant, and the time for washing out with water from the application of the curing agent depends on the temperature. Therefore, this method must be performed by a skilled person.

(2) In the washing process with water, a large amount of cement sludge flows out, and it is impossible to let this flow out to the sewer system. The reason for this is that the washed-out cement will clog the drainage pipe and become important. Therefore, the places where work is possible are very limited.

(3) Since cement flows out to the bonded portion between the decorative aggregate and the mortar by washing with water, the important adhesive strength is lowered and the decorative aggregate is removed at an early stage.

(4) In the outermost mortar layer, expensive decorative aggregate 4
Must be used in relatively large quantities.

(5) The curing sheet can be used only once, which is a waste of resources.

The present inventor has conducted extensive research to overcome the drawbacks of the prior art for producing decorative concrete, and completed the present invention.

In the present invention, (a) a beautiful aggregate having a major axis of particles of 2 to 10 mm is bonded onto a substrate with a synthetic resin binder, (b) a space between the beautiful aggregates is filled with a cement paste, and (c) The present invention relates to a method of fixing a beautiful aggregate on a substrate, which comprises each step of removing the cement paste on the surface of the beautiful aggregate so that the surface of the beautiful aggregate is exposed when the cement paste layer is initially set.

The present invention will be described in more detail with reference to the drawings. In FIG. 5, a beautiful aggregate 14 having a major axis of 2 to 10 mm is placed on the base 11,
The beautiful aggregate 14 is joined with a synthetic resin joining material (not shown). Then, the gap between the aggregates is filled with cement paste 15 (see FIG. 6). When the layer of the cement paste becomes the initial setting (for example, after about 1 hour), the cement paste on the surface of the beautiful aggregate 14 is removed so that the surface of the beautiful aggregate 14 is exposed, for example, by a polisher with a brush.
See figure). The cement paste on the surface can be removed by a known means other than a polisher with scrubbing brush. That is, the cement paste after the initial setting is relatively soft and can be removed with, for example, a sponge, an ordinary bundle, a rag or the like.

As the beautiful aggregate, beautiful natural boulders or crushed natural stones having excellent design are preferable. Although artificially colored aggregate can be used, it is not so preferable in terms of design. As described above, it is desirable that the aggregate has a major axis in the range of 2 to 10 mm. When it is smaller than this range, the essential design value is rapidly reduced, and when it is larger than this range, the workability of spreading and spreading on the makeup object becomes difficult. In particular, when applied to wall surfaces, the larger the aggregate, the easier the spread coating composition will fall, and if it exceeds this range, the construction will be difficult or even impossible at all.

As the synthetic resin binder, any binder capable of forming a transparent film that is curable at room temperature can be applied. Epoxy resin composition comprising bisphenol A or F type epoxy resin and polyamine or polythiol, unsaturated polyester resin, unsaturated polyester resin composition comprising vinyl monomer such as ethylene and polymerization initiator, synthesized from polyisocyanate and polyol or polyester A urethane resin composition composed of the urethane prepolymer and a polyamine or a polyol as a curing agent, or a urethane resin composition composed of an acrylic polyol and a polyisocyanate are all applicable. The viscosity of these synthetic resin binders is preferably in the range of 500 to 100,000 centipoise. Here, the floor surface is preferably 50 to 20,000 centipoise and the wall surface is preferably 20,000 to 100,000 centipoise.

If the viscosity is lower than this, it becomes difficult to keep the aggregate on the wall surface when it is applied to the wall surface, and the binder flows down to the underground surface when it is applied to the floor surface, and the adhesive strength is reduced. Also, as the viscosity increases, both workability deteriorates,
It will not be practical. The proper viscosity also depends on the size of the natural aggregate used. Larger aggregates generally require higher viscosity binders. The amount of the synthetic resin binder added to 100 parts by weight of the aggregate is preferably 3 to 10 parts by weight based on the solid content. However, this requires less floors and more walls. If the addition amount is less than this, the binding force of the aggregate will be too weak and it will be a problem in practical use, and the addition amount larger than this is not only economically inappropriate, but also increases the degree of discoloration due to natural exposure, so it is practical It is not good.

In the first step, the coating composition consisting of the beautiful aggregate and the synthetic resin binder was applied as a porous beautiful natural aggregate layer by the conventional method, and after it was cured, the second step Fill the cement paste with. The type of cement used depends on taste. In general, it is preferable to use a mixture of white cement as a base and a mixture of cement 1: silica sand 1 and color it with a pigment as needed.

Cement paste is cast on the floor surface and then ironed with a trowel. The wall surface is painted with a trowel and then ironed. The trowel used here is preferably made of rubber or soft plastic. Since such a trowel deforms along the aggregate on the surface of the beautiful aggregate when the cement paste is spread, the surface of the paste layer becomes lower than the aggregate layer, and the beautiful aggregate is exposed more. On the other hand, if you use a trowel that does not easily deform, such as a gold trowel, the cement paste will cover a large part of the aggregate surface, resulting in a waste of cement paste, and it will not be efficient even in the process of exposing the beautiful aggregate, which is not preferable. .

The point here is that the natural beautiful aggregate layer of the first step is a hardened body with appropriate voids, so even if you apply ironing, the flax from the cement paste does not float It produces a stable amount with minimal generation even if it is generated. Next, when ironing only with a rubber iron, since the exposed ratio of the beautiful aggregate is insufficient and the washout design is lacking, brushing with a scrubbing brush is performed at the time when the initial setting of the cement paste begins after ironing. After the degree of stopping is adjusted to the desired degree of exposure of the beautiful aggregate, the surplus cement paste is collected by a dust collector and further polished by a polisher with a waste to complete.

This is a coating and finishing structure which is a construction method which is obtained without the need for a water washing step when the wash-out wind is performed in which the exposure ratio of the beautiful aggregate is increased in the second step, which will be described in detail in the following examples.

Example 1 Bisphenol A type liquid epoxy resin (Epicoat 82
(8, oiled shell) 60 parts by weight of a modified polyamine (Sanmide IM-544, Sanwa Chemical Co., Ltd.) as a curing agent, 16 parts by weight of butyl glycidyl ether as a reactive diluent, and uniformly mixed. To obtain a binder having a viscosity of about 1,000 centipoise. For 1 part by weight of the binder prepared here
20 parts by weight of natural cobblestone having a major axis of 10 mm was added, and the binder was uniformly sprinkled on the surface of the aggregate to obtain a coating composition. The coating composition is a gold trowel and is applied to the indoor floor surface to a thickness of about 10 mm.
It was left to stand for 12 hours to be cured to form a porous aggregate layer.

Next, cement paste prepared by adding 35 parts by weight of water to 100 parts by weight of powder prepared by mixing white cement and silica sand No. 8 in a ratio of 1: 1 is poured into the hardener layer at about 3.5 kg / m ² and then dried with a rubber trowel. I filled the void very much.

When the cement paste layer becomes the initial setting (after about 1 hour), brush with a scrubber with a brush to reach the desired degree of aggregate exposure, and then collect this excess cement paste with a dust collector. Polished and finished with a polisher with a waste cloth. The strength increased as the cement paste hardened, and after 6 hours, it became possible to walk. Almost no fall of the aggregate and discoloration of the aggregate were observed even after about 2 years of use, suggesting a very high possibility for further long-term use.

Example 2 Bisphenol A type liquid epoxy resin (Epicoat 82
8. Oily shell) 60 parts by weight of modified polyamine (Sunamide IM-544, Sanwa Chemical Co., Ltd.) as a curing agent, 12 parts by weight of butyl glycidyl ether as a reactive diluent and 9 parts by weight of colloidal silica. Was added and mixed uniformly to obtain a binder having a viscosity of 100,000 centipoise. 10 parts by weight of major axis 3 mm for 1 part by weight of the binder prepared here
The natural cobblestone was added and the binder was evenly sprinkled on the surface of the aggregate to obtain a coating composition.

The coating composition was applied to an outdoor wall surface with a thickness of about 5 mm using a metal iron and left standing for about 12 hours to be cured to form a porous aggregate layer. Next, cement paste prepared by adding 35 parts by weight of water to 100 parts by weight of powder in which white cement and silica sand No. 8 were mixed at a ratio of 1: 1 was squeezed with a rubber trowel of about 2 kg / m ² to the curing agent layer. The voids were filled.

When the cement paste layer was initially set (after about 1 hour), it was brushed with a polisher with a scrubber until the desired degree of aggregate exposure was reached, and then ground with a polisher with a waste.

The strength increases as the cement paste hardens, and almost no fall of the aggregate or discoloration of the aggregate is seen even after about 4 years of use, suggesting a very high possibility for long-term use. did.

Example 3 Unsaturated polyester resin having a concentration of 55% (Polylite TP-10
0, Dainippon Ink) and 2.0 parts by weight of methyl ethyl ketone peroxide and 0.5 parts by weight of cobalt naphthenate were added to 100 parts by weight of unsaturated polyester resin to prepare a binder having a viscosity of about 500 centipoise. 15 parts by weight of major axis is 10 parts by weight of the binder prepared here.
A natural stone crushed stone aggregate with rounded corners of mm was added, and the binder was uniformly sprinkled on the surface of the aggregate to obtain a coating composition. The coating composition was spread on the roof floor using a metal trowel to a thickness of about 10 mm, about 12
It was left to stand for a period of time to be cured to form a porous aggregate layer.

Then, the cement paste prepared by adding 35 parts by weight of water to 100 parts by weight of powder prepared by mixing white cement and silica sand No. 8 in a ratio of 1: 1 is poured into the hardening material layer at about 3 kg / m ² and squeezed with a rubber trowel. The void was filled.

When the cement paste layer becomes the initial setting (after about 1 hour), brush with a scrubber with a brush to reach the desired degree of aggregate exposure, and then collect this excess cement paste with a dust collector. Polished and finished with a polisher with a waste cloth. The strength increased as the cement paste hardened, and after 6 hours, it became possible to walk. Approximately 4 years after use, the cured unsaturated polyester resin that covered the surface of the aggregate completely peeled off at the exposed part and the background of the aggregate appeared, but the aggregate did not fall off, It also showed sufficient adhesive strength, suggesting a very high potential for long-term use.

(Effect of the Invention) In the structure of the present invention, the porous structure of the beautiful aggregate, which is the main constituent of the design, is formed by the synthetic resin-based bonding agent, and then the voids are filled with the cement paste. Then, when the cement paste layer is initially set, the cement paste on the surface of the beautiful aggregate is removed so that the surface of the beautiful aggregate is exposed. Therefore, its formation is much simpler than the conventional cement-based wash-out finish, and the stability of the finished state is high, so the advantages of beautiful natural aggregate can be fully exerted, and the joint point is completely cement hardened. Since it is covered up with, the workability is superior, but it is much more durable than the washout method, which is inferior in durability. Therefore, the drawbacks of the conventional method have been overcome by the present invention.

Embodiments of the present invention are as follows: (1) (a) A beautiful aggregate having a major axis of particles of 2 to 10 mm is bonded onto a substrate with a synthetic resin binder, and (b) the beautiful bone. Fill the space between the materials with cement paste, and (c) when the cement paste layer is initially set,
A method for fixing a beautiful aggregate on a substrate, which comprises the steps of removing cement paste on the surface of the beautiful aggregate so that the surface of the beautiful aggregate is exposed.

(2) The above-mentioned (1), which is obtained without the need for a water washing step when the wash-out air is made with a high exposed ratio of the beautiful aggregate.
The method described.

(3) The method according to (1) above, wherein the aggregate is a beautiful natural cobblestone or crushed natural stone.

(4) The method according to (1) above, wherein the synthetic resin binder has a viscosity of 500 to 100,000 centipoise.

(5) The method according to (1) above, wherein the synthetic resin binder is a room temperature curable epoxy resin composition comprising a polyepoxide compound and a polyamine or polythiol compound.

(6) The method according to (1) above, wherein the synthetic resin binder is an unsaturated polyester resin composition comprising a polyester resin, a vinyl monomer and a polymerization initiator.

(7) The method according to (1) above, wherein the synthetic resin binder is a urethane resin composition comprising a urethane prepolymer synthesized from polyisocyanate and a polyol or polyester, and a polyamine or polyol as a curing agent.

(8) The method according to (1) above, wherein the synthetic resin binder is a urethane resin composition comprising acrylic polyol and polyisocyanate.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of so-called decorative concrete; FIG. 2 is an explanatory view of a conventional washing-out construction method; FIG. 3 is an explanatory view of a conventional washing-out construction method; 5 is a cross-sectional view of a state in which the beautiful aggregate of the method of the present invention is bonded with a synthetic resin binder (first step); FIG. 6 is the state of FIG. FIG. 7 is a cross-sectional view of a state of being filled with cement paste (second step); and FIG. 7 is a cross-sectional view of a state in which the surface of the beautiful aggregate is exposed (finished product).

Claims (1)

[Claims] (1) A beautiful aggregate having a major axis of particles of 2 to 10 mm is bonded onto a substrate with a synthetic resin binder, (b) a space between the beautiful aggregates is filled with a cement paste, and (b) c) When the cement paste layer is initially set,
A method of fixing a beautiful aggregate on a substrate, which comprises the steps of removing cement paste on the surface of the beautiful aggregate so that the surface of the beautiful aggregate is exposed.