JPH07164414A - Formation of waterproof elastic film on surface of segment - Google Patents

Abstract

PURPOSE:To produce a segment having a resin layer which has a pinhole free smooth and waterproof surface and followability to cracking. CONSTITUTION:A first process forming a release layer 2 to the arbitrary region of the inside surface of a mold 1, a second process forming a waterproof elastic resin layer 3 on the surface of the release layer, a third process forming an adhesive layer on the surface of the waterproof elastic resin layer 3 after curing and a fourth process injecting concrete or mortar before the adhesive layer is cured are provided.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a segment used in a shield construction method.

[0002]

2. Description of the Related Art Conventionally, a segment has been manufactured by injecting concrete into a mold or the like, solidifying it, and then removing it from the mold. By the way, these manufactured segments have a surface coated with a coating agent such as an epoxy resin after the mold is removed from the mold for the purpose of preventing cracks on the surface or waterproofing.

The performance required for the coating agent on the surface of the segment is summarized as follows.・ Excellent high-pressure permeability.・ Excellent followability against cracks (having elasticity).・ Excellent wear resistance.・ Excellent adhesion to concrete.・ Excellent alkali resistance. Therefore, in order to achieve the above-mentioned object, and in order to fill the pinholes and unevenness on the surface of the segment generated at the time of manufacturing, the coating agent is divided into several times and repeatedly applied to increase the film thickness to some extent. There was a need.

However, the coating with the coating agent applied repeatedly has problems that unevenness is apt to occur and the appearance is deteriorated, and that the application of the coating agent requires a lot of work. Also, the pinholes and irregularities that have occurred on the surface of the segment cannot be completely filled with several coats depending on the size, so repair them beforehand by filling the pinholes and irregularities with putty etc. It is necessary to paint from
It was very time consuming.

Therefore, in recent years, Japanese Unexamined Patent Publication No. 5-222780.
No., and JP-A-5-222781,
When a concrete structure is manufactured, a surface layer and another layer are integrally composite-molded by using different materials in a mold or a mold, so that the surface has a performance equivalent to that of the coating agent. Is proposed.

However, these methods have a problem in the adhesion between the surface layer and the concrete layer, and further, the required elastic coating film cannot be applied to the segment surface.

[0007]

Therefore, the present invention relates to a concrete segment used when constructing a tunnel by using a shield construction method, and (a) a release layer is previously formed inside a mold for molding the segment. Forming, (b) then forming a resin layer inside the release layer, (c) then curing or solidifying the resin layer, and then applying an adhesive to the surface thereof, and (d) the adhesion. Concrete or mortar is cast before the layer hardens or solidifies, and (e) the adhesive layer and concrete or mortar are hardened or solidified and then demolded to form a waterproof elastic coating film on the surface of the segment. Solved the problem.

[0008]

DETAILED DESCRIPTION OF THE INVENTION FIGS. 1 (A) and 1 (B) are overall views of a mold used in manufacturing a segment.
Indicates an upper die and a lower die, respectively. In addition, FIG.
(F) is a partial cross-sectional view of the lower mold showing each step of the present invention.

First, a release layer such as a polyethylene resin sheet having an appropriate thickness is attached to the inside of a lower mold as shown in FIG. 2 (B). The release layer may be formed by adhering a polyolefin resin such as polyethylene or polypropylene, or a sheet of a non-adhesive resin such as polytetrafluoroethylene, nylon, vinyl chloride or silicone, which is formed into a sheet. You may apply the liquid material which melt | dissolved resin, such as a solvent, with a brush, a roller, or a spray. Since these release layers affect the surface condition of the waterproof elastic resin layer to be formed later, it is preferable that they are smooth and have a high release property. However, when a pattern is formed on the surface of the waterproof elastic layer, the release layer is limited to this. Not.

Next, as shown in FIG. 2C, a waterproof elastic resin layer is provided on the surface of the release layer. The waterproof elastic resin used in the present invention specifically has the following composition. (A) Reactive epoxy resin 100 parts by weight (b) Curing agent in an amount sufficient to react and cure the reactive epoxy resin of (a). (C) Silyl-terminated polyether 10 to 200 parts by weight (d) Catalyst 0.1-20 parts by weight (e) Silane coupling agent 0.1-20 parts by weight

As the reactive epoxy resin (a), a modified or unmodified conventionally known epoxy resin can be used. For example, various materials such as bisphenol type epoxy resin and rubber modified epoxy resin can be used. Further, if necessary, a reactive diluent or a filler may be added to adjust the viscosity or the like, and a dye, a pigment or the like may be added for the purpose of coloring. Further, the use of a rubber-modified epoxy resin is effective for imparting flexibility to the cured resin.

(B) The sufficient amount of the curing agent for reacting and curing the reactive epoxy resin is a conventionally known curing agent for epoxy resin such as amine curing agent. There is no particular limitation. These curing agents may be added in an amount sufficient to cure the reactive epoxy resin (a), and the mixing ratio is arbitrarily determined by the epoxy equivalent of the epoxy resin. Further, these curing agents are preferably room temperature curing type, but latent curing agents such as heat curing type or moisture curing type can also be used.

The (c) silyl group terminated polyether is a polyether having a methyldimethoxysilyl group at both ends as disclosed in JP-A-53-129347 and the like, which is crosslinked by the action of water in the air and the action of a catalyst. The reaction proceeds and the cured product has rubber elasticity. This silyl group terminated polyether is the reactive epoxy resin 100 of the above (a).
10 to 200 parts by weight, preferably 40
~ 100 parts by weight are mixed. If it is less than 10 parts by weight, the cured product will be hard, and if it exceeds 200 parts by weight, it will be too soft.

The catalyst (d) is used as a reaction accelerator for the silyl group-terminated polyether (c), and is an organic tin compound, an oxidized phosphoric acid ester, a saturated or unsaturated polyvalent carboxylic acid or an anhydride thereof. And organic titanate compounds, and preferably organic tin compounds and organic titanate compounds. Specific examples of the organotin compound include, for example, dibutyltin laurate, dioctyltin malate, dibutyltin phthalate, dibutyltin diversate, dibutyltin diacetate, and the like.Examples of the organic titanate compound include tetrabutyl titanate, tetraisopropyl titanate and trititanate. Examples thereof include ethanolamine titanate. These catalysts are added in an amount of 0.1 to 20 parts by weight, preferably 1 to 3 parts by weight, corresponding to the amount of the (c) silyl group-terminated polyether added.

The (e) silane coupling agent is added for the purpose of improving the adhesive strength, and specifically, N-β (aminoethyl) γ-aminopropyltrimethoxysilane,
Examples thereof include γ-aminopropyltrimethoxysilane, γ-glycidoxypropyltrimethoxysilane, and other known silane coupling agents can be used.
These silane coupling agents can be added in an amount of 0.1 to 20 parts by weight, preferably 4 to 8 parts by weight, based on 100 parts by weight of the reactive epoxy resin (a).

The compositions consisting of (a) to (e) are mixed and applied when applied to the surface of the release layer. The application method is not particularly limited, but since the viscosity of the composition is considerably high, application with a roller, a brush, a spatula or the like is preferable.

In the waterproof elastic resin layer thus applied, the aggregate or the like contained in the concrete or mortar which is subsequently poured into the lower mold does not penetrate the waterproof elastic resin layer to the surface. Thus, the waterproof elastic resin layer is once cured here.

The composition comprising (a) to (e), which constitutes the waterproof elastic resin layer, is a filler such as heavy calcium carbonate and bentonite for the purpose of improving the strength of the coating film, if necessary. Can be added. Further, for the same purpose, a metal or other fibrous reinforcing material may be formed into a sheet and interposed in the waterproof elastic resin layer.

Next, an adhesive is applied to the surface of the cured waterproof elastic resin layer. The adhesive used here is used for the purpose of firmly adhering the waterproof elastic adhesive layer and concrete or mortar to be injected into the lower mold in the next step, as long as it achieves this purpose. Any type of adhesive can be used. Specific examples thereof include epoxy resin adhesives, urethane adhesives, silicone adhesives, and acrylic adhesives, but epoxy resin adhesives are more preferable. Since this adhesive layer is used to bond the waterproof elastic resin layer and the concrete or mortar as described above, it is in an uncured state when the concrete or mortar is poured into the lower mold. It is preferable.

Next, the upper mold is assembled to the lower mold in a state where the adhesive is applied to the surface of the waterproof elastic resin layer, and the concrete is passed through a concrete or mortar pouring hole provided in a part of the upper mold. Or inject mortar. At this time, since the adhesive layer is uncured, when pouring concrete or mortar, it is preferable to do it gently.

[0021]

[Examples] Examples of formulations of the waterproof elastic resin layer of the present invention are shown below. Formulation 1 Agent A Epoxy resin Epomic R-1304 ... 50 (parts by weight) (Mitsui Petrochemical Co., Ltd.) Rubber modified epoxy resin R-1437-3 ... 50 (AC R (stock) ) Silyl group-terminated polyether Cyryl SAT200 60 (manufactured by Kanegafuchi Chemical Co., Ltd.) B agent epoxy resin curing agent X-900S 50 (manufactured by Sanwa Chemical Co., Ltd.) Tin-based Catalyst Neostan U-220 ... 1 (manufactured by Nitto Kasei Co., Ltd.) Silane coupling agent KBM-603 ... 2 (manufactured by Shin-Etsu Chemical Co., Ltd.) Heavy calcium carbonate ... 17 Titanium oxide ... 10 Mixing ratio is Agent A: Agent B = 100/50 Blend 2 Agent A Epoxy resin Epomic R-1304 50 (parts by weight) Rubber modified epoxy resin R-1437-3 ... 5 0 Silyl group-terminated polyether Cyryl SAT030 ... 40 (manufactured by Kaneka Chemical Co., Ltd.) Methyl ethyl ketone ... 4 Agent B Epoxy resin curing agent X-900T ... 50 (manufactured by Sanwa Chemical Co., Ltd.) Tin-based catalyst Neostan U-220 ... 1 Silane coupling agent KBM-603 ... 2 Heavy calcium carbonate ... 14 Titanium oxide ... 10 Mixing ratio is Agent A: Agent B = 100/50 Blend 3 Agent A Epoxy resin Epomic R-1304 ... 30 (parts by weight) Rubber modified epoxy resin R-1437-3 ... 70 Silyl group-terminated polyether Cyryl SAT030 ... 60 Agent B Epoxy resin curing agent X-900S ... 50 Tin-based catalyst KC-1A-3 ... 2 (manufactured by Kyodo Chemical Co., Ltd.) Silane coupling agent KBM-603 ... ‥ 2 Heavy calcium carbonate ‥‥‥ 10 titanium oxide ‥‥‥ 11 mixing ratio A agent: A agent B agent = 100/50 above formulation, it was used by mixing B agent immediately prior to use.

Example 1 Length 1 as shown in FIG.
A release sheet of polyolefin resin (trade name: Millol Touch, manufactured by Kobunka Giken Co., Ltd.) was attached to the inside of a steel lower mold of m × width 30 cm × depth 20 cm with an adhesive. Next, as the waterproof elastic resin layer, the agent A shown in Formulation 1,
Before using the agent B, it was mixed on the surface of the release sheet with a rubber spatula so as to have a film thickness of about 1 mm. This is left for one day, and after confirming that the waterproof elastic resin layer has been cured, a two-component epoxy resin (Three Longie F
-130 Three Bond Unicom Co., Ltd.) was applied to the surface of the waterproof elastic resin layer with a brush so that the film thickness was about 1 mm. Next, about 10 minutes (uncured state) after forming the adhesive layer, 200 parts by weight of a mixture of silica sand No. 4: 5: 6 (= 1: 1: 1) with respect to 100 parts by weight of Portland cement. And 50 parts by weight of water were gently poured, and the mixture was left for 2 days and then demolded.

Example 2 As in Example 1, a release sheet of polyolefin resin (trade name: Millol Touch, manufactured by Kobunshi Giken Co., Ltd.) was attached to the inside of a steel lower mold with an adhesive. Next, A shown in Formulation 1 as a waterproof elastic resin layer
The agent and the agent B were mixed before use and coated on the surface of the release sheet with a rubber spatula so as to have a film thickness of about 1 mm. After leaving this for one day and confirming that the waterproof elastic resin layer has been cured, a two-component epoxy resin (manufactured by Three Longie F-130 ThreeBond Unicom Co., Ltd.) as an adhesive layer is applied to the waterproof elastic adhesive. Apply with a brush to a film thickness of about 1 mm on the surface, and immediately press a glass cloth (trade name CC-7 0.27 mm thickness Nitto Boseki Co., Ltd.) on the surface to temporarily press-bond it, and then About 10 minutes after forming the adhesive layer, 200 parts by weight of silica sand No. 4: 5: 6 (= 1: 1: 1) mixture and 50 parts by weight of water were mixed with 100 parts by weight of Portland cement. The mortar was poured gently, left for 2 days, and then demolded.

Example 3 A segment was produced in the same manner as in Example 1 except that the waterproof elastic adhesive layer of Example 1 was changed to the formulation 2.

Example 4 A segment was produced in the same manner as in Example 1 except that the waterproof elastic adhesive layer of Example 1 was changed to the formulation 3.

Example 5 A segment was produced in the same manner as in Example 1 except that the adhesive layer of Example 1 was formed according to Formulation 1.

Each of the segments manufactured in Examples 1 to 5 was further steam-cured at 120 ° C. for 3 hours, left to stand for 1 day and returned to room temperature, and the smoothness of the waterproof elastic resin layer and the presence or absence of pinholes were confirmed. did. The results are shown in Table 1.

[0028]

[Table 1]

Examples 6 to 8 In addition, as a test on the coating film using the waterproof elastic resins of the formulations 1 to 3 (Examples 6 to 8), the crack compliance of the coating film, the high-pressure water resistance, and the adhesion of concrete were evaluated. confirmed. The results are shown in Table 2.

[0030]

[Table 2]

Regarding the crack followability test of the coating film, concrete pieces (40 mm × 40 mm) were used as shown in FIG.
(mm × 20 mm), two waterproof elastic resin layers were applied and coated thereon, and after curing at 23 ° C. for 7 days, a tensile test was performed to measure the distance between concrete pieces.

The high-pressure permeability test is conducted according to JIS A 140
According to the water permeability test of No. 4, after applying the waterproof elastic resin layer on the pressing surface and curing the waterproof elastic resin layer, the water pressure is 15 kgf / cm.
² was held for 6 hours and the amount of water permeation was measured. The water permeability was calculated by the following formula. Water permeation rate _{(g) = W 2 -W 3} W 2: the specimen before Permeability Test Weight _{(g) W} 3: specimen mass after Permeability Test (g)

Concrete Adhesion Test JIS A 6
The test was performed according to 909.

[0034]

As described above, the release layer formed on the mold at the time of segment molding and the waterproof elastic resin layer formed on the surface of the segment form a segment having a smooth surface without irregularities or pinholes. Can be manufactured. Further, since the waterproof elastic resin layer can be provided on any part of the mold, it can be easily applied selectively only to the joint part such as the bolt box. Further, when the waterproof elastic resin layer or the adhesive layer is reinforced with fibers such as glass cloth and vinylon cloth, it becomes a strong layer having elasticity to further prevent cracks and improve followability.

[Brief description of drawings]

1A and 1B are overall views of a mold used for manufacturing a segment, and FIGS. 1A and 1B show an upper mold and a lower mold, respectively.

2 (A) to 2 (E) are cross-sectional explanatory views showing a construction process of the present invention, in which (A) is a state of a lower mold and (B) is
A state in which a release layer is formed, (C) is a state in which a waterproof elastic resin layer is formed on the release layer, (D) is a state in which an adhesive layer is formed on the waterproof elastic resin layer, (E) Is a state in which concrete or mortar is poured onto the adhesive layer.

FIG. 3 is an overall view of the product of the present invention.

FIG. 4 is an explanatory view showing a test piece created when performing a crack follow-up test and a state of the test.

[Explanation of sign]

 1 Lower mold 2 Release layer 3 Waterproof elastic resin layer 4 Adhesive layer 5 Concrete or mortar layer

Claims (3)

[Claims] 1. A concrete segment used when constructing a tunnel using a shield construction method, comprising: (a)
After forming a release layer inside the mold for molding the segment in advance, (b) then forming a resin layer inside the release layer, and (c) after curing or solidifying the resin layer. , Applying an adhesive on its surface, (d) casting concrete or mortar before the adhesive layer hardens or solidifies, (e)
A method for forming a waterproof elastic coating film on a segment surface, which is characterized in that the adhesive layer and concrete or mortar are hardened or solidified and then released from the mold. 2. The method for forming a waterproof elastic coating film on a segment surface according to claim 1, wherein the resin layer is composed of the following composition. (A) Reactive epoxy resin 100 parts by weight (b) Curing agent in an amount sufficient to react and cure the reactive epoxy resin of (a). (C) Silyl-terminated polyether 10 to 200 parts by weight (d) System 0.1 to 20 parts by weight of catalyst (e) 0.1 to 20 parts by weight of silane coupling agent 3. The method for forming a waterproof elastic coating film on a surface of a segment according to claim 1, wherein the resin layer has a fibrous reinforcing material.