JPH10226554A - Resin mortal composition - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a resin mortal capable of easily blending and applying, hardening a mortal at an early time even at a low temp. and exhibiting high strength. SOLUTION: This resin mortal composition contains cement, a filler, a latex and an alkali silicate, the volume ratio of the filler per 100 pts.wt. cement is 30-250, the content of the latex is 2-150 pts.wt. expressed in terms of solid matter, the alkali silicate is water-soluble or alkali-soluble and the content of the alkali silicate per 100 pts.wt. solid portion of the latex is 1-25 pts.wt. expressed in terms of solid matter.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

TECHNICAL FIELD The present invention relates to a resin mortar composition in which latex is added to cement mortar.
The resin mortar composition of the present invention has excellent early curing properties and exhibits high strength, and is used in general resin mortar construction.

[0002]

2. Description of the Related Art When cement mortar is applied to a concrete structure, the required performance is that it cures quickly, has high adhesion to the underlying concrete, has high resistance to alkali in concrete, and has good durability. It is. Further, workability during construction is good, and low cost is desired.

A number of materials have been developed to satisfy these required performances. However, in terms of performance and cost, the frequency of use of resin mortars obtained by adding latex polymers to ordinary mortars has tended to increase in recent years. Resin mortar has higher adhesive strength than ordinary mortar,
Improvement points such as high bending tensile strength, improvement of deformability, reduction of water permeability and water absorption, improvement of waterproof performance, reduction of drying shrinkage, improvement of impact resistance and abrasion resistance, etc. There are many.

[0004] Resin mortars having many of these features are:
For example, mortar for adjusting the ground such as unevenness of the ground, PC
Mortar for repairing defective parts such as boards, mortar for filling around sashes, mortar for floors where chemical resistance and abrasion resistance are required, mortar for waterproofing where waterproof performance is required, protection mortar for waterproof layer, etc. Mortar for bonding tiles, marble, etc.
It is widely used for lightweight mortar, finishing mortar, spray mortar, etc. using lightweight aggregate.

However, the addition of latex has a serious drawback in that the rate of hydration of the cement is delayed, and the strength of the mortar at the early stage is poor. It is said that the cause is that the contact between the cement particles and water is hindered by the presence of a surfactant or a water-soluble oligomer used in the production of the latex, and further by the presence of the polymer particles.
As a result, the rate of hydration of the cement is further delayed, and in some cases, particularly in winter construction, a problem can be seen.

[0006] For this reason, in the construction in winter, the construction is carried out in combination with a cement quick setting agent or a setting accelerator, but this causes a decrease in strength. On the other hand, a method of imparting high fluidity to the resin mortar itself, casting it, and performing construction is also performed. For example, self-leveling floor materials, grout materials, coating film waterproof materials, architectural finishing materials, and the like. However, as a means for imparting high fluidity to the resin mortar itself, the amount of water is being increased, and as a result, the early curability is inferior. Further, when elasticity is imparted to the mortar, the amount of the resin is large, and the result is that the early curability is further inferior.

For this reason, when mortar with a large amount of resin and high fluidity is applied, the mortar is applied by applying it several times, or by using a cement that hardens quickly, such as alumina cement or ultra-rapid hardening cement. However, there are problems such as a long construction period and a high cost, but a predetermined curability cannot be obtained. As a resin mortar that cures early, the glass transition point is 7
The invention of mixing latex at 0 ° C. or higher is disclosed in
Although this method is disclosed in Japanese Patent No. 183642, the curability of the mortar itself can be improved, but the adhesion to the base at a low temperature is reduced.

Further, a resin mortar composition containing CaSO ₄ and granulated slag is disclosed in JP-A-8-183644, but the initial curability is not always satisfactory.

[0009]

SUMMARY OF THE INVENTION The present invention relates to a resin mortar which can be easily blended and applied at a general construction site, and which can quickly cure cement mortar even at a low temperature and provide high strength. The purpose is to provide. Furthermore, even in a resin mortar in which the resin content is remarkably large and cement particles are floating in the sea of resin, it is possible to provide a resin mortar which can be cured at an early stage and has high strength. Make it an issue.

[0010]

Means for Solving the Problems The inventors of the present invention have conducted intensive studies to solve the above-mentioned problems. As a result, in a mortar having a large amount of latex, a resin was added by adding an appropriate amount of alkali silicate corresponding to the amount of latex. We found that mortar hardened early and exhibited high strength,
The present invention has been reached.

That is, the present invention is as follows. 1. A resin mortar composition containing cement, filler, latex and alkali silicate, wherein the cement 1
The filler is 30 to 250 in volume ratio with respect to 00 parts by weight, the latex is 2 to 150 parts by weight in terms of solid content with respect to 100 parts by weight of the cement, and the alkali silicate is water-soluble or alkali-soluble. Solid content of the latex 10
A resin mortar composition having a solid content of 1 to 25 parts by weight based on 0 part by weight.

2. Latex particle size 180-150
0 nm The resin mortar composition according to the above. 3. 1. The particle size of the alkali silicate is 100 nm or less.
The resin mortar composition according to the above. The resin mortar composition of the present invention contains cement, a filler, a latex, and an alkali silicate as essential components.

Of the above components, cement is JI
S R5210 (Portland cement), R5211
(Blast furnace cement), R5212 (silica cement), R
5213 (Fly ash cement), ordinary Portland cement, early-strength Portland cement, ultra-high-strength Portland cement, moderate heat Portland cement, sulfate-resistant Portland cement, blast furnace cement, silica cement, fly ash cement can be used. In addition, the Japan Cement Association describes in the common sense of cement (issued in March 1994) special cement, white Portland cement, cement-based solidifying material, alumina cement, ultra-rapid hardening cement, colloid cement,
Oil well cement, geothermal well cement, expanded cement, and other special cements can be used.

As the filler, sand, silica sand, cold water sand, calcium carbonate, natural and artificial lightweight aggregates and the like generally used in cement mortar can be used alone or in combination of two or more. The amount used is 30 to 250 volume ratio. If the amount is less than this range, the strength is increased, but cracks due to drying are likely to occur. Preferably it is in the range of 50 to 200 volume ratio.

The volume ratio referred to in the present invention is the ratio of the volume of the filler to the volume of 100 parts by weight of cement,
Since the specific gravity varies greatly depending on the type of filler, the volume ratio is indicated. The latex used in the resin mortar composition of the present invention is not particularly limited as long as it is mixed with various hydraulic compositions and satisfies the performance required for the resin mortar composition. Generally, it is necessary to form a film at room temperature,
For example, (meth) acrylic acid ester, styrene, vinyl acetate, veoba, ethylene, vinyl chloride, latex homopolymerized or copolymerized with each diene monomer can be used. Preferred are acrylic latex,
A styrene-butadiene latex and an ethylene-vinyl acetate latex.

The amount of the latex used is 2 to 150 parts by weight in terms of the solid content of the latex based on 100 parts by weight of the cement. Preferably it is in the range of 3 to 130 parts by weight. Above the lower limit, the adhesion to the base is sufficient and the mortar properties after curing are improved. Below the upper limit, the workability of the construction is improved, and it is also preferable in terms of economy. When the latex content is close to this upper limit, the solids content of the latex will be greater than the amount of cement, and the cement particles will float in the sea of latex rather than the latex in the cement. It is believed that there is. However, according to the present invention, it is quite surprising that even the resin mortar composition in such a state can be cured at an early stage.

The latex has a Tg of -60 to 10 ° C.
Is preferable. Tg may be selected according to the application.
The particle size of the latex is preferably in the range of 180 to 1500 nm. More preferably, 250 to 100
The range is 0 nm. When the amount is equal to or more than the lower limit, the mortar can develop strength at an early stage, and when the amount is equal to or less than the upper limit, the fluidity of the mortar becomes good. Such a latex having a relatively large particle diameter is, for example, a latex obtained by ordinary seed emulsion polymerization is used as a seed for seed emulsion polymerization, and polymerization is performed again.Hereafter, this is repeated as necessary. Method.

As the alkali silicate, Li, Na, K,
Commercially available silicates having Cs, NH _{4 and the} like can be used without any particular limitation. The alkali silicate may be used alone or in combination of two or more. As the alkali silicate, it is preferable to use a water-soluble or colloidal alkali silicate to improve the early strength development of the mortar. As the colloidal alkali silicate, an alkali and soluble alkali silicate is preferable.

When adding the alkali silicate, any of a solution form and a colloidal form may be used, but the colloidal alkali silicate may be used in the form of a powder. In the case of powder or colloid, the particle size is 100 n
m or less. When the particle size is 100 nm or less, it takes no time to dissolve, and the mortar can quickly develop strength.

The amount of the alkali silicate used is 1 to 25 parts by weight in terms of solids based on 100 parts by weight of latex solids. Preferably, the amount is 2 to 10 parts by weight with respect to 100 parts by weight of the solid content of the latex. On the other hand, below the upper limit, mortar hardly causes abnormal setting. The mixing amount of water when adjusting the resin mortar composition of the present invention varies depending on the application method, but in the case of ironing application, JIS R5201 (physical test method for cement), 10.7, and the method of measuring the flow value. 16
An amount corresponding to 0 to 190 mm is desirable. Within this range, the mortar has an appropriate fluidity and the workability of troweling is good, and the water ratio is appropriate and the early strength of the mortar can be easily achieved.

On the other hand, in the case of a resin mortar which requires high fluidity, the amount of water is determined, for example, according to a specification issued by the Housing and Urban Development Corporation, “Standard value for quality testing of self-leveling flooring”.
The flow value is preferably 240 mm or less. If it exceeds 240 mm, the material tends to be separated, and the mortar tends to have a slightly deteriorated early curing property. More preferably,
It is 230 mm or less.

The amount of water in the resin mortar composition of the present invention is not particularly limited, and is determined by the material application method and workability. In the resin mortar composition of the present invention, a cement water reducing agent or a fluidizing agent can be used. As a water reducing agent or a fluidizing agent for cement, one or more commonly used lignin-based, naphthalene-based, melamine-based, carboxylic acid-based and the like can be used, and naphthalene-based and melamine-based Water reducing agents or fluidizing agents are more preferred.

The resin mortar composition of the present invention may contain components other than those described above. For example, a shrinkage reducing agent (glycol ether type, polyether type, etc.), a cold resistant agent (calcium chloride, etc.), a waterproofing agent (stearic acid, etc.), a rust preventive (phosphate, etc.), a viscosity modifier (methyl cellulose,
Hydroxyethyl cellulose, polyvinyl alcohol, etc.), setting regulator (phosphate, etc.), swelling agent (ettringite, lime, etc.), coloring agent (iron oxide, chromium oxide, etc.), defoaming agent (silicone, mineral oil, etc.) ), Reinforcing materials (steel fiber, glass fiber, synthetic fiber, etc.).

In order to further accelerate the curing of the resin mortar composition of the present invention, a cement accelerator such as nitrite may be used in combination. The resin mortar of the present invention is useful as a material for general resin mortar construction work.

[0025]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below with reference to examples and comparative examples. The methods for measuring various physical properties used in Examples and Comparative Examples of the present invention are as follows. Flow test JIS R5201 (physical test method for cement), 1
0.7, the test was conducted according to the method of measuring the flow value. The mortar used in the examples and comparative examples has a flow value of 160 to 190.
mm. Workability test The following criteria were evaluated based on the separation of the iron during mortar construction, elongation of the iron, and the like.

5: Good 3: Slightly poor 1: Not good Flexural strength test A 10 × 25 × 150 mm specimen was prepared and JIS R
The bending strength was measured by a three-point bending test according to 5201 (physical test method for cement) and 10.6.2 bending strength. Fluidity test The fluidity test was carried out in accordance with the Housing and Urban Development Corporation's standard specification "Self-leveling flooring quality test standards". Note that the embodiment,
The mortar used in the comparative example has a flow value of 190 to 230 mm.
Adjusted to use. 7. Curability test JIS R5201 (physical test method for cement);
The starting time was measured according to the setting test, and the curability was determined.

[0027]

[Production Example 1] A production example of an acrylic prototype latex A used for performance evaluation is shown below. The prototype latex is a 2-ethylhexyl acrylate-styrene copolymerized acrylic latex (solid content 45%, calculated Tg about -10 ° C). This was created as follows.

45 parts by weight of styrene, 50 parts by weight of 2-ethylhexyl acrylate, 5 parts by weight of methacrylic acid, 0.2 parts by weight of sodium alkylbenzenesulfonate, polyoxyethylene nonylphenyl ether (HLB = 16.2)
3 parts by weight, 0.5 parts by weight of ammonium persulfate, water 10
An acrylic prototype latex A was obtained by polymerizing 8.3 parts by weight of the mixture by an emulsion polymerization method according to a conventional method. The particle diameter of the latex measured by an electron microscope was 165 nm.

[0029]

[Production Example 2] A production example of an acrylic prototype latex B used for performance evaluation is shown. The prototype latex is a 2-ethylhexyl acrylate-styrene copolymerized acrylic latex (solid content 45%, calculated Tg about -10 ° C). This was created as follows.

Using 100 parts by weight of the prototype latex A (in terms of solid content) as a seed, 45 parts by weight of styrene, 50 parts by weight of 2-ethylhexyl acrylate, 5 parts by weight of methacrylic acid, polyoxyethylene nonyl phenyl ether (H
LB = 16.2) 3 parts by weight, ammonium persulfate 0.5
A mixture of 12 parts by weight of water and 122.2 parts by weight of water was emulsion-polymerized to obtain a prototype latex B. Latex particle size is 200
nm.

[0031]

[Production Example 3] A production example of an acrylic prototype latex C used for performance evaluation is shown. The prototype latex is a 2-ethylhexyl acrylate-styrene copolymerized acrylic latex (solid content 45%, calculated Tg about -10 ° C). This was created as follows.

Using 6 parts by weight (in terms of solid content) of the prototype latex A as a seed, 45 parts by weight of styrene, 50 parts by weight of 2-ethylhexyl acrylate, 5 parts by weight of methacrylic acid, polyoxyethylene nonylphenyl ether (HL)
B = 16.2) A mixture of 3 parts by weight, 0.5 part by weight of ammonium persulfate, and 122.2 parts by weight of water was emulsion-polymerized to obtain a latex C of a prototype. Latex particle size is 425n
m.

[0033]

[Production Example 4] A production example of an acrylic prototype latex D used for performance evaluation is shown. The prototype latex is a 2-ethylhexyl acrylate-styrene copolymerized acrylic latex (solid content 45%, calculated Tg about -10 ° C). This was created as follows.

Using 6 parts by weight of the prototype latex A (in terms of solid content) as a seed, 45 parts by weight of styrene, 50 parts by weight of 2-ethylhexyl acrylate, 5 parts by weight of methacrylic acid, polyoxyethylene nonylphenyl ether (HL)
B = 16.2) A mixture of 3 parts by weight, 0.5 part by weight of ammonium persulfate, and 122.2 parts by weight of water was emulsion-polymerized to obtain a latex C of a prototype. Latex particle size is 1200
nm.

[0035]

[Production Example 5] A production example of an acrylic prototype latex E used for performance evaluation is shown below. The prototype latex is a 2-ethylhexyl acrylate-styrene copolymerized acrylic latex (solid content 50%, calculated Tg about -45 ° C). This was created as follows.

Using 6 parts by weight of the prototype latex A (in terms of solid content) as a seed, 18 parts by weight of methyl methacrylate, 80 parts by weight of 2-ethylhexyl acrylate, 2 parts by weight of methacrylic acid, polyoxyethylene nonylphenyl ether (HLB = 16.2) A mixture of 3 parts by weight, 0.5 part by weight of ammonium persulfate, and 102.9 parts by weight of water was subjected to emulsion polymerization to obtain a prototype latex C. The particle size of the latex was 444 nm.

[0037]

Examples 1 to 8 Resin mortar compositions were prepared in the proportions shown in Table 1 with respect to 100 parts by weight of cement, and flow tests, workability tests and flexural strength tests were performed. In the following Examples and Comparative Examples, the blending amounts of latex and alkali silicate are shown in amounts including water. Table 2 shows the evaluation results.
Shown in

The details of the raw materials used are as follows. Ordinary cement: Ordinary Portland cement (made by Chichibu Onoda Cement Co., Ltd.) Early strength cement: Early strength Portland cement (made by Chichibu Onoda Cement Co., Ltd.) Latex: Acrylic latex (prototypes A to D): Styrene-butadiene latex (DL-460, manufactured by Asahi Kasei Kogyo Co., Ltd., adjusted to 45%) Li silicate: trade name LSS-45, solid content: 26% (particle size of 10 nm or less, manufactured by Nissan Chemical Industry Co., Ltd.) Na silicate: product Name Snowtex 30, solid content 30% (particle type 15 nm, manufactured by Nissan Chemical Industries, Ltd.) Na silicate: Trade name Snowtex ZL, solid content 40% (particle type 85 nm, Nissan Chemical Industry Co., Ltd.) Na: Silicate: trade name PC-500, solid content: 21% (aqueous solution, manufactured by Nissan Chemical Industries, Ltd.) Silicate K: trade name Snowtec K, solid content 20% (aqueous solution, manufactured by Nissan Chemical Industries, Ltd.) Silicate Ca: CAS registration number 10101-39-0, water-insoluble powder, solid content 100% silica sand No. 6: general commercial product Water: tap water

[0039]

Comparative Examples 1-4 A mortar composition was prepared with the composition shown in Table 3 for 100 parts by weight of cement, and a flow test, a workability test and a bending strength test were conducted. Table 4 shows the results. The used raw materials are the same as those used in Examples 1 to 8.

[0040]

Example 9 20 parts by weight of Li: LSS-45 silicate, 50 parts by weight of ordinary cement, 29.4 volume ratio of calcium carbonate, silica sand No. 7 in 100 parts by weight of the prototype latex E
The mixture was mixed at a volume ratio of 7 and water was added to adjust the fluidity to 200 mm to obtain a resin mortar composition. As a result of measuring the curability of this resin mortar composition, the starting time was 8 hours.

The newly used raw materials are as follows. Calcium carbonate: trade name SS30 (manufactured by Shiraishi Calcium Co., Ltd.) Silica sand No. 7: general commercial product Other raw materials used are the same as those used in Examples 1 to 8.

[0042]

Comparative Example 5 To 100 parts by weight of the latex E, 50 parts by weight of ordinary cement, 29.4 parts by volume of calcium carbonate, and 16.7 parts by volume of silica sand No. 7 were mixed, and water was added to make the fluidity 2.
It was adjusted to 10 mm to obtain a resin mortar composition. As a result of measuring the curability of this resin mortar composition, the starting time was 24 hours or more.

The raw materials used are the same as those used in Example 9.

[0044]

Example 10 To 120 parts by weight of the prototype latex E, 25 parts by weight of Snowtex K, 50 parts by weight of ultra-rapid hardening cement, 29.4 volume ratio of calcium carbonate, silica sand No. 7 16.7
The volume ratio was mixed, water was added to adjust the fluidity to 218 mm, and a resin mortar composition was obtained. As a result of measuring the curability of this resin mortar composition, the starting time was 1 hour.

The newly used raw materials are as follows. Ultra-high-hardening cement: Trade name Dr. Q (manufactured by Manol Co.) The other raw materials used are the same as those used in Example 9.

[0046]

COMPARATIVE EXAMPLE 6 120 parts by weight of a prototype latex E, 50 parts by weight of ultra-hard cement, 29.4 volume ratio of calcium carbonate,
A 16.7 volume ratio of silica sand No. 7 was mixed, and water was added to adjust the fluidity to 225 mm to obtain a resin mortar composition. As a result of measuring the curability of this resin mortar composition, the starting time was 12 hours or more.

The raw materials used are the same as those used in Example 10.

[0048]

Example 11 30 parts by weight of Snowtex 30, 50 parts by weight of ordinary cement, 47.1 volume ratio of calcium carbonate, and 6.7 volume ratio of silica sand No. 7 were mixed with 120 parts by weight of a prototype latex E, and water was added. The fluidity was adjusted to 200 mm to obtain a resin mortar composition. This resin mortar composition is cast on a flat polyethylene sheet at a thickness of 3 mm,
Cured under the condition of 20 ° C and 65% RH for 48 hours, JIS
The tensile strength and elongation were measured according to K6301 (physical test method for vulcanized rubber). As a result, the tensile strength was 10.6 kg / cm ² and the elongation was 127%.

[0049]

Comparative Example 7 A resin mortar composition was prepared and evaluated in the same manner as in Example 11 except that no alkali silicate was used. However, the curing was insufficient and an evaluation test could not be performed.

[0050]

[Table 1]

[0051]

[Table 2]

[0052]

[Table 3]

[0053]

[Table 4]

[0054]

According to the present invention, a resin mortar having excellent early curing properties and exhibiting high strength can be obtained. In particular, a resin mortar excellent in early curability and the like can be obtained even if the resin content is large. It also has excellent adhesion to the substrate, and can be used at low temperatures or in thick coating.

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁶ Identification code FI C04B 111: 72

Claims (3)

[Claims] 1. A resin mortar composition containing a cement, a filler, a latex and an alkali silicate, wherein the filler has a volume ratio of 30 to 100 parts by weight of the cement.
250, and the latex is 2 to 150 parts by weight in terms of solids with respect to 100 parts by weight of the cement, and the alkali silicate is water-soluble or alkali-soluble and is 100 parts by weight in terms of solids of the latex. 1 to 25 parts by weight of the resin mortar composition. 2. The latex has a particle size of 180 to 1500.
The resin mortar composition according to claim 1, which has a particle diameter of nm. 3. The resin mortar composition according to claim 1, wherein the particle diameter of the alkali silicate is 100 nm or less.