KR100910129B1 - Inorganic polymer acid resistant mortar for concrete repair included liquid amorphous silicate hydrolysis agent and concrete repair method using the mortar - Google Patents

Inorganic polymer acid resistant mortar for concrete repair included liquid amorphous silicate hydrolysis agent and concrete repair method using the mortar Download PDF

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KR100910129B1
KR100910129B1 KR1020080075824A KR20080075824A KR100910129B1 KR 100910129 B1 KR100910129 B1 KR 100910129B1 KR 1020080075824 A KR1020080075824 A KR 1020080075824A KR 20080075824 A KR20080075824 A KR 20080075824A KR 100910129 B1 KR100910129 B1 KR 100910129B1
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silicate
inorganic polymer
concrete
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amorphous silicate
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안상욱
박동철
이정우
최해영
박재범
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주식회사 인트켐
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    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/006Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing mineral polymers, e.g. geopolymers of the Davidovits type
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    • C04B14/00Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02Granular materials, e.g. microballoons
    • C04B14/04Silica-rich materials; Silicates
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    • C04B18/00Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04Waste materials; Refuse
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    • C04B18/00Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
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    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2103/00Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/0004Compounds chosen for the nature of their cations
    • C04B2103/0006Alkali metal or inorganic ammonium compounds
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    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2103/00Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/0004Compounds chosen for the nature of their cations
    • C04B2103/0006Alkali metal or inorganic ammonium compounds
    • C04B2103/0007K
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    • C04B2103/00Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/0004Compounds chosen for the nature of their cations
    • C04B2103/0006Alkali metal or inorganic ammonium compounds
    • C04B2103/0008Li
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    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20Resistance against chemical, physical or biological attack
    • C04B2111/2038Resistance against physical degradation
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    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
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    • C04B2111/26Corrosion of reinforcement resistance
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    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/72Repairing or restoring existing buildings or building materials
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract

An inorganic polymer acid-resistant mortar composition including a liquid amorphous silicate hydrolyzing agent for concrete repair is provided to reduce a construction cost. An inorganic polymer acid-resistant mortar composition including a liquid amorphous silicate hydrolyzing agent for concrete repair consists of dimethyldimethoxysilane; methacryloxypropylmethyldiethoxysilane; sodium hydroxide; silica sol; 5.4-11wt% of liquid amorphous silicate hydrolyzing agent with a solid content of 40-60% and two or more functional groups; one or more materials selected from the group consisting of sodium silicate, potassium silicate, lithium silicate, potassium-based carbonate, sodium hydroxide and potassium hydroxide; 12.5-24wt% of alkali silicate curing agent whose molar ratio of Si:K:Na is 1:0.01~0.25:0.05~0.80; 22-38wt% of aluminosilicate binding material; 19-60wt% of filler; and 0.1-8wt% of additive.

Description

액상형 비정질 실리케이트계 가수분해제가 포함된 콘크리트 단면보수용 무기폴리머계 내산모르타르 조성물 및 이를 이용한 콘크리트 단면보수 공법{Inorganic Polymer Acid Resistant Mortar for Concrete Repair Included Liquid Amorphous Silicate Hydrolysis Agent and Concrete Repair Method Using the Mortar}Inorganic Polymer Acid Resistant Mortar for Concrete Repair Included Liquid Amorphous Silicate Hydrolysis Agent and Concrete Repair Method Using the Mortar}

본 발명은 액상형 비정질 실리케이트계 가수분해제가 포함된 콘크리트 단면보수용 무기폴리머계 내산모르타르와 이를 이용한 콘크리트 단면보수 공법[ASIR공법]에 관한 것으로서, 더욱 상세하게는 액상형 비정질 실리케이트계 가수분해제를 첨가하여 물과의 1차 반응을 거치지 않고 직접 알칼리 실리케이트계 경화제와의 반응으로 인하여 -Si-O-, -Al-O- 무기폴리머 결합구조를 형성함으로써 콘크리트구조물 보수시 구조물의 내구성 , 내산성 및 내열특성이 향상되어 화학시설물, 하수처리장 및 하수관거 등에 적용 가능한 액상형 비정질 실리케이트계 가수분해제가 포함된 콘크리트 단면 보수용 무기폴리머계 내산모르타르와 이를 바람직하게 이용한 콘크리트 단면보수 공법에 관한 것이다.The present invention relates to an inorganic polymer-resistant acid-resistant mortar for concrete cross-section repair containing liquid amorphous silicate-based hydrolysing agent and a concrete cross-sectional repair method [ASIR method] using the same, and more particularly, by adding a liquid-type amorphous silicate-based hydrolysing agent. Due to the reaction with alkali silicate-based curing agent directly without undergoing the first reaction with water, -Si-O-, -Al-O- inorganic polymer bonding structure is formed, so that the durability, acid resistance and heat resistance of the structure can be improved The present invention relates to an inorganic polymer-resistant acid-resistant mortar for improving concrete sections containing liquid amorphous silicate-based hydrolysants, which can be applied to chemical facilities, sewage treatment plants, sewage pipes, and the like.

일반적인 콘크리트 구조물 보수모르타르는 시멘트 내지 석고와, 고로슬래그 분말, 슬라이애쉬, 메타카올린, 실리카흄 및 카올린계 광물 등의 결합재와, 우레탄수지, 아크릴수지 및 폴리에스테르수지 등의 분말형 폴리머수지와, 규사, 유리분말 및 실리카 등의 충진재와, 경화제와, 분산제, 유동화제 및 증점제 등의 첨가제로 구성되고 있다.
산성 환경에 시설물이 노출될 경우 시설물 표면에서 산성에 의한 중성화가 시작되면서 장기적으로 산성화 및 시설물 내부까지 산성화가 진행되어 모르타르의 열화현상 발생과 함께 내부로 공기가 침투하여 철근표면이 산화되면서 팽창하여 시설물의 박리, 팽창크랙 및 붕괴현상까지 발생하게 되는 것이다. 일반적으로 발전소, 실험실 및 하수관거 등의 시설물 등은 배출되는 산성가스를 흡수, 산화 등의 반응으로 인해서 표면에서 산에 의한 부식이 발생하거나 산성폐수환경에 노출되게 된다. 이러한 산성환경 노출에 의한 부식을 방지하기 위해서 현재까지 지속적으로 모르타르에 여러 가지 방법이 이용되어 왔으나 재료 자체의 문제점을 개선하지는 못하였다. 또한 산성화에 의한 시설물의 피해는 외적으로 드러나는 것뿐만 아니라 표면적으로 드러나 있지 않은 지하매설 시설물이나 수중시설물에 대해서도 발생하고 있으며 심각한 문제로 나타나고 있다.
따라서 이러한 문제해결을 위해 현재 국내에서는 포틀랜드시멘트에 아크릴계 내지 에폭시계 폴리머수지를 혼합한 폴리머시멘트계 보수모르타르를 적용하여 시공하고 있으며 부착성능, 휨·압축강도 등의 개선으로 물리적 성능은 우수하나 유기폴리머 수지를 적용함으로써 장기적으로 산성이나 고온 환경하에 노출시에 부식으로 인한 침식과 열화현상으로 인한 구조물의 문제점이 발생하고 있어 개선이 필요한 상황이다.
또한 부착력을 향상시킨 유무기복합형 코팅제 또는 Si성분을 주성분하거나 플로오르화 비닐화합물로 구성된 단량체를 가지게 함으로써 발수성능을 가지는 코팅제를 도포해 모르타르면의 내산특성을 부여하고자 하였다. 그러나 코팅제 고유특성상 발수성능은 우수하나 주변온도 및 열 변화에 따른 코팅제와 모르타르와의 열팽창특성이 다르기 때문에 온도변화로 인한 코팅제 박리 현상이 나타나 장기적인 내산특성에 한계가 있다.
한편, 대한민국 특허 736884호의 하이브리드 보수 모르타르를 이용한 보수공법은 기존의 시멘트계 보수제와 차별하여 규소계 결합제에 반응성 무기충진제, CSA 및 유기폴리머를 첨가하여 시멘트계 결합과 유기결합을 적용한다고 특성화하여 콘크리트 구조물 보수시 높은 강도와 내구성을 부여할 수 있다고 하였다. 그러나 내구성면에서는 우수하나 기존 열화면에 대한 부착성능 부족과 함께 재료비중이 높아 천정보수시 보수면 중량증가에 따른 탈락현상이 발생하게 되며 또한 유기, 시멘트계 조성물로서 내산성 부분에 있어서는 취약한 것이 단점이다.
그리고, 대한민국 특허 제405022호 역시 콘크리트 보수용 모르타르 조성물로 고분자 수지를 적용 신보수면 및 열화면에 대한 부착성능은 우수하나 시멘트를 기본으로 하기 때문에 시멘트 자체의 내산특성 부족으로 인해 산성환경하의 시설물보수에 부적합하다.
또한, 본 출원인이 발명한 대한민국 특허 제0833871호는 건조 제조한 가수분해제를 사용하고 있어 무기폴리머 반응을 위해 고형분 50중량% 이상의 알칼리 실리케이트계 경화제를 사용하고 있고 이에 따라 추가적인 물의 사용이 필수적이며 혼합시 미용융된 고형물이 잔존하여 무기폴리머 반응이 완전하지 못해 내산성능을 완벽하게 발휘하지 못하는 단점이 있다.
General concrete structure repair mortar includes cement or gypsum, blast furnace slag powder, slice ash, metakaolin, silica fume and kaolin minerals, powdered polymer resin such as urethane resin, acrylic resin and polyester resin, silica sand, It consists of fillers, such as glass powder and a silica, a hardening | curing agent, and additives, such as a dispersing agent, a fluidizing agent, and a thickener.
When the facility is exposed to acidic environment, acid neutralization begins on the surface of the facility, and acidification proceeds to the inside of the facility in the long term. To peel, expansion crack and collapse phenomenon will occur. In general, facilities such as power plants, laboratories, and sewer pipes may be exposed to acidic wastewater or corrosion due to acid on the surface due to absorption, oxidation, and the like. In order to prevent corrosion caused by exposure to acidic environment, various methods have been continuously used to mortar, but the problem of the material itself has not been improved. In addition, damage to facilities due to acidification occurs not only externally, but also on underground underground facilities and underwater facilities, which are not visible on the surface, and are a serious problem.
Therefore, in order to solve this problem, in Korea, the construction is applied by applying a cement cement-based repair mortar in which acryl-based or epoxy-based polymer resins are mixed with the Portland cement. The organic polymer resin is excellent due to the improvement of adhesion performance, bending and compression strength. In the long term, when exposed to acid or high temperature environment, problems with structure due to erosion and deterioration caused by corrosion are needed.
In addition, the organic-inorganic composite coating agent or Si component having improved adhesion to the monomer or composed of a vinyl fluoride compound to have a coating agent having a water-repellent performance to give the acid resistance characteristics of the mortar surface. However, due to the inherent properties of the coating, the water-repellent performance is excellent, but the thermal expansion characteristics of the coating agent and mortar are different according to the ambient temperature and heat change, so that the coating agent peeling phenomenon occurs due to the temperature change, which limits the acid resistance in the long term.
Meanwhile, the repair method using the hybrid repair mortar of Korean Patent 736884 is characterized by applying cement-based bonds and organic bonds by adding reactive inorganic fillers, CSA, and organic polymers to silicon-based binders to differentiate them from conventional cement-based repair agents. It is said to provide high strength and durability. However, it is excellent in terms of durability, but the lack of adhesion to the existing heat screen and the material weight is high due to the dropping phenomenon occurs due to the increase in the weight of the repair surface at any time, and also the weak point in the acid-resistant part as an organic, cement-based composition.
In addition, the Republic of Korea Patent No. 405022 also applies a polymer resin as a mortar composition for repairing concrete, it has excellent adhesion performance to new repair surface and heat screen, but because it is based on cement, it is necessary to repair facilities under acidic environment due to lack of acid resistance of cement itself. Inadequate
In addition, Korean Patent No. 0833871, which was invented by the present applicant, uses a hydrolyzate prepared in dry form, and therefore, an inorganic silicate-based curing agent having a solid content of 50% by weight or more is used for the inorganic polymer reaction. Unresolved solids remain when the inorganic polymer reaction is not complete, there is a disadvantage that does not fully exhibit acid resistance.

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따라서 본 발명의 목적은 액상 형태의 비정질 실리케이트계 가수분해제를 제조 혼합 적용하여 미용융 고형물의 발생을 억제하고 고형분 30중량% 이하의 알칼리 실리케이트계 경화제를 사용하여 경제적이면서도 추가적인 물의 사용이 없이 사용이 용이하며, -Si-O-, -Al-O- 무기폴리머 결합구조를 형성함으로써 산성환경하에 있는 구조물 보수에 적용시 부착력, 내구성 향상뿐만 아니라 내산성이 우수하다는 것을 특징으로 하는 액상형 비정질 실리케이트계 가수분해제가 포함된 콘크리트 단면보수용 무기폴리머계 내산모르타르 조성물 및 이를 이용한 콘크리트 단면보수 공법을 제공하는 것이다.Therefore, an object of the present invention is to use the amorphous silicate-based hydrolyzate in liquid form to produce and apply undissolved solids, and to use the alkali silicate-based curing agent of 30% by weight or less of solids, which is economical and does not require additional water. Easy to form, -Si-O-, -Al-O- inorganic polymer bonding structure, liquid amorphous silicate-based hydrolysis, characterized in that it is excellent in adhesion and durability as well as acid resistance when applied to repair the structure under acidic environment The present invention provides an inorganic polymer-based acid-resistant mortar composition for concrete section repair and the concrete section repair method using the same.

상기 목적은 본 발명에 따라, 액상형 비정질 실리케이트계 가수분해제가 포함된 무기폴리머계 내산모르타르를 이용한 콘크리트 단면보수 공법에 있어서, 디메틸디메톡시실란, 메타크릴록시프로필메틸디에톡시실란, 수산화나트륨 및 실리카졸로 이루어져 있는 액상 형태로서 고형분 40~60중량%, 반응기 2 이상인 것을 특징으로 하는 비정질 실리케이트계 가수분해제 5.4~11중량%와; 소듐실리케이트, 포타슘실리케이트, 리튬실리케이트, 칼륨계 탄산염, 소듐하이드록사이드 및 포타슘하이드록사이드 중 하나 이상으로 이루어져 있으며, Si:K:Na=1:0.01~0.25:0.05~0.80mol ratio를 특징으로 하는 알칼리 실리케이트계 경화제 12.5~24중량%, 알루미노 실리케이트계 결합재 22~38중량%와; 충진재 19~60중량% 및 첨가제 0.1~8중량%로 구성되는 것을 특징으로 하는 액상형 비정질 실리케이트계 가수분해제가 포함된 무기폴리머계 내산모르타르 조성물에 의해 달성된다. 즉, 상기한 액상형 비정질 실리케이트계 가수분해제가 포함된 무기폴리머계 내산모르타르 조성물을 단면보수 대상 콘크리트에 바름으로써 콘크리트 단면보수 공법을 구현하는 것이다. 여기서 콘크리트 단면보수 공법을 통한 보수시에 전처리로 행해지는 열화부분 제거, 철근부식방지용 방청 도포, 표면강화제 도포, 하도 도포 등의 공정은 통상적으로 콘크리트 단면보수 공정에서 사용되는 공정으로서 보수하고자 하는 현장 부위에 따라 전체단계 또는 일부단계를 적용하는 것이 바람직하다.
상기 액상형 비정질 실리케이트계 가수분해제는 상온의 이소프로필알코올 용매를 150~300rpm/min 교반하면서 디메틸디메톡시실란, 메타크릴록시프로필메틸디에톡시실란과 수산화나트륨을 1:1:2 비율로 혼합한 용액과 실리카졸 용액을 각각 동시에 투입하여 일정시간 혼합하여 제조되는 것이 바람직하다.
그리고, 상기 혼합시간은 15~60분이 적당하며 혼합시간이 벗어날 경우 반응된 선형입자들의 분산성이 낮아지거나 엉김현상이 발생하게 된다.
또한, 상기 알루미노 실리케이트계 결합재는 고로슬래그 분말, 슬라이애쉬, 메타카올린, 실리카흄 및 카올린계 광물 중 하나 이상이며 분말도 4,000~15,000㎠/g 이고 Al:Si=1:0.5~2.5mol ratio로 구성되는 것이 효과적이다.
여기서, 상기 충진재는 규사, 유리분말 및 실리카 중 1종 이상 사용하며 바람직하게는 2종 이상 혼합한 입도 d50 0.4~1.2mm 사이인 것이 바람직하다.
그리고, 상기 첨가제는 분산제, 유동화제, 증점제 및 섬유 등으로 구성되며 섬유는 PP(폴리프로필렌)섬유, PE(폴리에틸렌)섬유, 탄소섬유 및 유리섬유 중 하나 이상이며 길이 1mm~30mm 인 것이 효과적이다.
The above object is, according to the present invention, in the concrete cross-section repair method using an inorganic polymer acid-resistant mortar containing a liquid amorphous silicate-based hydrolysing agent, dimethyldimethoxysilane, methacryloxypropylmethyl diethoxysilane, sodium hydroxide and silica 40 to 60% by weight of the solid form, consisting of 5.4 to 11% by weight of the amorphous silicate-based hydrolyzate, characterized in that the reactor 2 or more; Consists of at least one of sodium silicate, potassium silicate, lithium silicate, potassium carbonate, sodium hydroxide and potassium hydroxide, characterized by Si: K: Na = 1: 0.01 to 0.25: 0.05 to 0.80mol ratio 12.5 to 24% by weight of an alkali silicate curing agent and 22 to 38% by weight of an aluminosilicate binder; It is achieved by the inorganic polymer acid-resistant mortar composition containing a liquid amorphous silicate-based hydrolysing agent, characterized in that consisting of 19 to 60% by weight of the filler and 0.1 to 8% by weight of the additive. That is, the concrete cross-sectional repair method is implemented by applying the inorganic polymer acid-resistant mortar composition containing the liquid amorphous silicate-based hydrolyzate to the concrete to be repaired. Here, the processes such as removing the deteriorated part, preserving anticorrosive coating, reinforcing corrosion prevention, surface reinforcing agent, and undercoating, which are performed by pretreatment when repairing through the concrete section repair method, are usually used in the concrete section repair process. It is desirable to apply all or part of the step.
The liquid amorphous silicate-based hydrolyzate is a solution in which dimethyldimethoxysilane, methacryloxypropylmethyldiethoxysilane and sodium hydroxide are mixed at a ratio of 1: 1: 2 while stirring isopropyl alcohol solvent at room temperature for 150 to 300 rpm / min. And silica sol solution are added at the same time and preferably mixed for a predetermined time.
In addition, the mixing time is 15 ~ 60 minutes is suitable, if the mixing time is out of the dispersibility of the reacted linear particles is lowered or entangled phenomenon occurs.
In addition, the aluminosilicate-based binder is at least one of blast furnace slag powder, slice ash, metakaolin, silica fume and kaolin-based minerals, the powder is also 4,000 ~ 15,000 ㎠ / g and Al: Si = 1: 0.5 ~ 2.5 mol ratio It is effective.
Here, the filler is used at least one of silica sand, glass powder and silica, preferably two or more of the particle size d50 0.4 ~ 1.2mm is preferably mixed.
In addition, the additive is composed of a dispersing agent, a fluidizing agent, a thickener and a fiber, and the fiber is at least one of PP (polypropylene) fiber, PE (polyethylene) fiber, carbon fiber and glass fiber, it is effective that the length is 1mm ~ 30mm.

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이와 같은 본 발명은 보수모르타르의 내구성 및 내화학성을 향상시키기 위해서 상온의 이소프로필알코올 용매를 150~300rpm/min 교반하면서 디메틸디메톡시실란, 메타크릴록시프로필메틸디에톡시실란과 수산화나트륨을 1:1:2 비율로 혼합한 용액과 실리카졸 용액을 각각 동시에 투입하여 일정시간 혼합하여 제조된 비정질 실리케이트계 가수분해제, 알루미노 실리케이트계 결합재, 알칼리 실리케이트계 경화제, 충진재 및 첨가제를 혼합하여 구성된 무기폴리머계 내산모르타르 조성물을 제공하며 이를 이용한 콘크리트구조물 단면보수 공법을 제공함으로써 추가적인 물의 사용이 없이 사용이 용이하며, -Si-O-, -Al-O- 무기폴리머 결합구조 형성을 통해 우수한 부착력과 강도성능으로 인해 구조물의 수명연장과 함께 내산성 향상에 우수한 효과가 있다.In order to improve the durability and chemical resistance of the repair mortar, the present invention is a mixture of dimethyldimethoxysilane, methacryloxypropylmethyldiethoxysilane, and sodium hydroxide with stirring at 150 to 300 rpm / min at room temperature. Inorganic polymer system composed of a mixture of amorphous silicate-based hydrolysing agent, aluminosilicate-based binder, alkali silicate-based curing agent, filler and additives prepared by mixing the mixture at a ratio of 2 and the silica sol solution simultaneously for a predetermined time It provides easy-to-use without additional water by providing the acid-resistant mortar composition and the concrete structure cross-section repair method using it. Therefore, it has an excellent effect on improving acid resistance along with extending the life of the structure.

상기 목적 달성을 위해 본 발명은 상온의 이소프로필알코올 용매를 150~300rpm/min 교반하면서 디메틸디메톡시실란, 메타크릴록시프로필메틸디에톡시실란과 수산화나트륨을 1:1:2 비율로 혼합하여 10분 동안 교반한 용액과 실리카졸 용액을 각각 동시에 투입하여 5~10분 동안 혼합 후 혼합된 용액 형태의 비정질 실리케이트계 가수분해제와 소듐실리케이트, 포타슘실리케이트, 리튬실리케이트, 칼륨계 탄산염, 소듐하이드록사이드 및 포타슘하이드록사이드 중 하나 이상으로 이루어진 알칼리 실리케이트계 경화제와 알루미노 실리케이트계 결합재와 충진재 및 첨가제로 이루어진 무기폴리머계 내산모르타르 조성물과 함께 이를 이용한 콘크리트 단면보수 공법을 제공함에 의해 달성된다.
보다 구체적으로 설명하면 다음과 같다.
상기 액상형 비정질 실리케이트계 가수분해제는 이소프로필알코올 용매를 150~300rpm/min 교반하면서 디메틸디메톡시실란, 메타크릴록시프로필메틸디에톡시실란과 수산화나트륨을 1:1:2 비율로 혼합하여 10분 동안 교반한 용액과 실리카졸 용액을 각각 동시에 투입하여 5~10분 동안 혼합 후 혼합된 용액 형태로 전체 중량 대비 3~11중량% 함유되는 것이 바람직하다. 3중량% 미만시 경화제와의 균일한 -Si-O-폴리머 결합반응이 이뤄지지 않아 부착력이 낮아지게 되며 11중량부 초과시 경화제와 미반응된 -Si-O-폴리머가 서로 엉김 현상이 생겨 보수면의 경도저하가 발생하게 된다.
알칼리 실리케이트계 경화제는 소듐실리케이트, 포타슘실리케이트, 리튬실리케이트, 칼륨계 탄산염, 소듐하이드록사이드 및 포타슘하이드록사이드 중 하나 이상으로 이루어지며 전체 중량 대비 12~34중량%를 함유하는 것이 바람직하다. 12중량% 미만시에 결합재와의 반응비가 부족해 완전경화가 안되는 문제가 있으며 34중량% 초과시 과량으로 인해 경화속도가 빨라 작업성 부족현상과 함께 표면급결 후 건조시 내부에서 증발되는 수분에 의한 표면크랙 현상하는 문제점이 있다.
상기 알루미노 실리케이트계 결합재 통상적인 것을 사용할 수 있으며 고로슬래그 분말, 플라이애쉬, 메타카올린, 실리카흄 및 카올린계 광물 중 하나 이상으로 전체 중량 대비 20~48중량%를 함유하며 분말도 4,000~15,000㎠/g 이고 Al:Si=1:0.5~2.5mol ratio로 구성되는 것이 바람직하다. 20중량% 미만시에는 결합재의 Al 함량 부족으로 경화시 불규칙한 -Al-Si-결합구조를 가지게 되어 콘크리트 구조물 보수면의 물리적 성능이 떨어지게 되며 48중량% 초과시 반응에 참여하지 못하는 결합재로 인해 시공면 파손이 발생하는 문제점이 있다.
상기 충진재는 통상적인 것을 사용할 수 있으며 규사, 유리분말 및 실리카 중 1종 내지는 2종 이상 혼합하여 사용하며 바람직하게는 2종 이상 혼합한 입도 d50 0.4~1.2mm 인 것이 적당하며 전체 중량 대비 30~60중량%를 가지는 것이 바람직하다. 30중량% 미만시에 끈적임으로 작업성이 떨어지게 되며 60중량% 초과시에는 과량으로 인해 작업시 도포면에 갈라짐 현상이 발생하며 부착력이 낮아 도포면의 박리나 파손이 발생하게 된다.
상기 첨가제로는 분산제, 유동화제, 증점제 및 섬유 등을 0.1~8중량% 첨가함으로써 보수모르타르 도포시 작업성 향상과 우수한 재료 혼합특성을 얻을 수 있으며 섬유는 PP(폴리프로필렌)섬유, PE(폴리에틸렌)섬유, 탄소섬유 및 유리섬유 중 하나 이상이며 길이는 1mm~30mm 인 것이 적합하고, 0.1미만시에는 작업시 흐름성이 높아 시공두께 증가에 한계가 있게 되며 8중량% 초과시에 혼합 재료의 균일한 분산성 저하로 뭉침 현상과 함께 기포를 다량 함유하게 되어 강도 저하가 나타나게 된다.
이하 본 발명은 액상형 비정질 실리케이트계 가수분해제를 제조 적용을 통한 콘크리트 단면보수용 무기폴리머계 내산모르타르 조성물과 이를 이용한 보수공법을 발명하였으며 실시예를 통해 본 발명을 보다 상세하게 설명하고자 하며 발명이 실시예에 제한되는 것은 아니다.
[실시예 1~3 및 비교예 1~3]
실시예 1~3 및 비교예 1~3의 혼합조성에 대해 하기 <표 1>에 기재하였으며 알루미노 실리케이트계 결합재, 충진재 및 첨가제를 먼저 균일하게 혼합 한 후 혼합조성에 따라 액상형 비정질 실리케이트계 가수분해제, 알칼리 실리케이트계 경화제를 투입 혼합하여 JIS R 5201규정에 따라 혼합하여 시편을 제조하였다. 제조된 시편은 온도 20±1℃, 상대습도 90% 이상인 항온항습기에서 양생 후 24시간이 경과된 시편을 탈형하여 28일 수중양생 후 측정시험을 하였으며 결과를 하기 <표 1>에 기재하였다.
<표 1>실시예1~3 및 비교예1~3 조성물(중량부)
성 분 실시예1 실시예2 실시예3 비교예1 비교예2 비교예3 포틀랜드 시멘트 - - - - - 상용폴리머모르타르 86 석 고 - - - - - 알루미노 실리케이트계 결합재 35 35 35 35 35 분말형 비정질 실리케이트계 가수분해제 - - - 7 5 액상형 비정질 실리케이트계 가수분해제 7 5 4 - - 알칼리 실리케이트계 경화제 21 26 31 21 26 분말형 폴리머수지 - - - - - 충진재 36 33 30 36 33 첨가제 1.0 1.0 1.0 1.0 1.0 - - - - - 14 100 100 100 100 100 100
<표 2>실시예1~3 및 비교예1~3 성능평가
항 목 실시예1 실시예2 실시예3 비교예1 비교예2 비교예3 휨강도(28일,㎏f/㎠) 98 102 109 89 92 62 압축강도(28일,㎏f/㎠) 570 590 620 520 544 430 부착 강도(㎏f/㎠) 33 35 38 30 34 26 flow(cm) 27 26 25 25 23 24 내산성(wt%) -1.8 -1.2 -0.8 -3.6 -3.4 -33
상기 <표 2>에서 내산성 평가는 시편을 20±1℃, 5% 황산용액에 28일 침지 후 꺼내어 세척수로 세척 후 건조하여 시편 무게변화율을 측정하였다. 상기 <표 2>에서 기존 폴리머모르타르 조성물인 비교예 1~3과 비교하여 실시예 1~3같이 액상형 비정질 실리케이트계 가수분해제를 혼합한 보수모르타르 개발기술은 콘크리트 구조물의 내구성능을 향상시킬 수 있으며 내산성 부분에 있어서 비교예보다 우수한 특성을 가질 수 있음을 확인할 수 있다. 이는 액상 형태의 비정질 실리케이트계 가수분해제를 제조 혼합 적용하여 미용융 고형물의 발생을 억제하고 고형분 30중량% 이하의 알칼리 실리케이트계 경화제를 사용한 무기폴리머계 내산모르타르를 이용 추가적인 물의 사용이 없이 -Si-O-, -Al-O- 무기폴리머 결합구조를 형성 경화 후 강한 무기결합력을 가지게 되며 이러한 무기폴리머계 내산모르타르를 적용한 콘크리트 단면보수 공법을 통해 물리적 특성이 개선되는 것을 알 수 있다.
In order to achieve the above object, the present invention is 10 minutes by mixing dimethyldimethoxysilane, methacryloxypropylmethyldiethoxysilane and sodium hydroxide in a 1: 1: 2 ratio while stirring isopropyl alcohol solvent at room temperature for 150 ~ 300rpm / min The solution was stirred at the same time and the silica sol solution was added at the same time and mixed for 5 to 10 minutes, and then mixed with an amorphous silicate-based hydrolyzate, sodium silicate, potassium silicate, lithium silicate, potassium carbonate, sodium hydroxide, It is achieved by providing a concrete cross-sectional repair process using the inorganic silica acid-based mortar composition composed of an alkali silicate-based curing agent and aluminosilicate-based binder and fillers and additives made of at least one of potassium hydroxide.
More specifically described as follows.
The liquid amorphous silicate-based hydrolyzate is mixed with dimethyldimethoxysilane, methacryloxypropylmethyldiethoxysilane and sodium hydroxide in a 1: 1: 2 ratio while stirring isopropyl alcohol solvent at 150 to 300 rpm / min for 10 minutes. The stirred solution and the silica sol solution are added at the same time and mixed for 5 to 10 minutes, and then preferably contained 3 to 11% by weight based on the total weight of the mixed solution. When less than 3% by weight, uniform -Si-O-polymer coupling reaction with the curing agent does not occur, and thus the adhesion is lowered. When more than 11 parts by weight, the curing agent and the unreacted -Si-O-polymer are entangled with each other, so that A decrease in hardness will occur.
The alkali silicate-based curing agent is composed of one or more of sodium silicate, potassium silicate, lithium silicate, potassium carbonate, sodium hydroxide and potassium hydroxide and preferably contains 12 to 34% by weight relative to the total weight. When less than 12% by weight, there is a problem in that it is not fully cured due to lack of reaction ratio with the binder, and when it exceeds 34% by weight, the curing rate is fast due to excess. There is a problem developing.
The alumino silicate-based binder can be used as a conventional, containing at least one of blast furnace slag powder, fly ash, metakaolin, silica fume and kaolin-based minerals 20 to 48% by weight relative to the total weight and also powder 4,000 ~ 15,000㎠ / g And Al: Si = 1: 0.5 to 2.5mol ratio. If less than 20% by weight, the Al content of the binder is insufficient, resulting in irregular -Al-Si-bonding structure when cured, resulting in poor physical performance of the repair surface of the concrete structure. There is a problem that occurs.
The filler may be used a conventional one, one or two or more of the silica sand, glass powder and silica is used, preferably a particle size of d50 0.4 ~ 1.2mm mixed at least two, 30 ~ 60 to the total weight It is preferred to have a weight percent. When less than 30% by weight, the workability is inferior due to stickiness, and when it is more than 60% by weight, cracking occurs on the coated surface due to the excessive amount, and the adhesion is low, resulting in peeling or breakage of the coated surface.
As the additive, dispersant, fluidizing agent, thickener, and fiber may be added in an amount of 0.1 to 8% by weight, thereby improving workability and excellent material mixing characteristics when applying repair mortar. The fibers may be PP (polypropylene) fiber or PE (polyethylene). At least one of fiber, carbon fiber and glass fiber, and length of 1mm ~ 30mm is suitable, and when it is less than 0.1, it has a high flowability during work, which limits the increase in construction thickness. The decrease in acidity causes agglomeration and a large amount of bubbles, resulting in a decrease in strength.
Hereinafter, the present invention has been invented an inorganic polymer acid-resistant mortar composition for concrete cross-section repair through the production and application of a liquid-type amorphous silicate-based hydrolysing agent, and a repairing method using the same. It is not limited to the example.
[Examples 1-3 and Comparative Examples 1-3]
The mixing compositions of Examples 1 to 3 and Comparative Examples 1 to 3 are shown in Table 1 below, and the aluminosilicate binder, filler and additives are uniformly mixed first, and then liquid amorphous silicate-based hydrolyzate according to the mixing composition. A test piece was prepared by mixing the release and alkali silicate curing agent and mixing according to JIS R 5201. The prepared specimens were demolded 24 hours after curing in a thermo-hygrostat with a temperature of 20 ± 1 ° C. and a relative humidity of 90% or more, and then subjected to a measurement test after 28 days of underwater curing, and the results are shown in Table 1 below.
Table 1 Examples 1-3 and Comparative Examples 1-3 Composition (parts by weight)
ingredient Example 1 Example 2 Example 3 Comparative Example 1 Comparative Example 2 Comparative Example 3 Portland cement - - - - - Commercial Polymer Mortar 86 Plaster - - - - - Aluminosilicate Binder 35 35 35 35 35 Powdered Amorphous Silicate Hydrolyzate - - - 7 5 Liquid Amorphous Silicate Hydrolyzate 7 5 4 - - Alkali silicate curing agent 21 26 31 21 26 Powder polymer resin - - - - - Filling 36 33 30 36 33 additive 1.0 1.0 1.0 1.0 1.0 water - - - - - 14 system 100 100 100 100 100 100
Table 2 Examples 1-3 and Comparative Examples 1-3 Evaluation
Item Example 1 Example 2 Example 3 Comparative Example 1 Comparative Example 2 Comparative Example 3 Flexural Strength (28 days, kgf / ㎠) 98 102 109 89 92 62 Compressive strength (28 days, kgf / ㎠) 570 590 620 520 544 430 Adhesive strength (kgf / ㎠) 33 35 38 30 34 26 flow (cm) 27 26 25 25 23 24 Acid resistance (wt%) -1.8 -1.2 -0.8 -3.6 -3.4 -33
In Table 2, the acid resistance evaluation was performed after immersing the specimen in 20 ± 1 ° C. and 5% sulfuric acid solution for 28 days, washing with washing water, and drying to measure the weight change rate of the specimen. Compared with Comparative Examples 1 to 3, which are the existing polymer mortar compositions, in Table 2, the repair mortar development technology in which the liquid amorphous silicate-based hydrolyzate is mixed may improve the durability of the concrete structure. It can be seen that the acid-resistant portion may have superior properties than the comparative example. It is produced by mixing and applying the amorphous silicate hydrolysing agent in liquid form to suppress the occurrence of undissolved solids and using inorganic silica acid-resistant mortar using alkali silicate curing agent with solid content of 30% by weight or less. After forming and curing the O-, -Al-O- inorganic polymer bonding structure, it will have a strong inorganic bonding strength, and it can be seen that the physical properties are improved through the concrete cross-section repair method using the inorganic polymer-resistant mortar.

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Claims (5)

콘크리트 단면보수용 무기폴리머계 내산모르타르 조성물에 있어서,In the inorganic polymer-based mortar composition for concrete cross-sectional repair, 디메틸디메톡시실란, 메타크릴록시프로필메틸디에톡시실란, 수산화나트륨 및 실리카졸로 이루어져 있는 액상 형태로서 고형분 함량 40~60중량%, 반응기 2 이상인 것을 특징으로 하는 액상형 비정질 실리케이트계 가수분해제 5.4~11중량%와;Liquid crystalline amorphous silicate-based hydrolyzate 5.4 to 11, characterized in that the liquid form consisting of dimethyldimethoxysilane, methacryloxypropylmethyl diethoxysilane, sodium hydroxide and silica sol, solid content 40 ~ 60% by weight, reactor 2 or more %Wow; 소듐실리케이트, 포타슘실리케이트, 리튬실리케이트, 칼륨계 탄산염, 소듐하이드록사이드 및 포타슘하이드록사이드 중 하나 이상으로 이루어져 있으며 Si:K:Na=1:0.01~0.25:0.05~0.80mol ratio를 특징으로 하는 알칼리 실리케이트계 경화제 12.5~24중량%와; Alkali, consisting of one or more of sodium silicate, potassium silicate, lithium silicate, potassium carbonate, sodium hydroxide and potassium hydroxide and characterized by Si: K: Na = 1: 0.01 to 0.25: 0.05 to 0.80mol ratio 12.5 to 24% by weight of a silicate curing agent; 알루미노 실리케이트계 결합재 22~38중량%, 충진재 19~60중량% 및 첨가제 0.1~8중량%로 구성되는 것을 특징으로 하는 액상형 비정질 실리케이트계 가수분해제가 포함된 콘크리트 단면보수용 무기폴리머계 내산모르타르 조성물.Inorganic polymer acid-resistant mortar composition for repairing concrete cross sections containing a liquid amorphous silicate-based hydrolyzate, comprising aluminosilicate-based binder 22-38% by weight, filler 19-60% by weight, and additives 0.1-8% by weight . 제 1항에 있어서,The method of claim 1, 상기 액상형 비정질 실리케이트계 가수분해제는, 상온의 이소프로필알코올 용매를 150~300rpm/min 교반하면서 디메틸디메톡시실란, 메타크릴록시프로필메틸디에톡시실란과 수산화나트륨을 1:1:2 비율로 혼합한 용액과 실리카졸 용액을 각각 동시에 투입하여 일정시간 혼합 후 혼합 제조되는 것을 특징으로 하는 액상형 비정질 실리케이트계 가수분해제가 포함된 콘크리트 단면보수용 무기폴리머계 내산모르타르 조성물.The liquid amorphous silicate-based hydrolyzate is a mixture of dimethyldimethoxysilane, methacryloxypropylmethyldiethoxysilane and sodium hydroxide in a 1: 1: 2 ratio while stirring an isopropyl alcohol solvent at room temperature of 150 to 300 rpm / min. Inorganic polymer acid-resistant mortar composition for the concrete cross-sectional repair containing a liquid phase amorphous silicate-based hydrolyzate, characterized in that the solution and the silica sol solution at the same time by mixing at the same time and mixed. 제 1항에 있어서,The method of claim 1, 상기 알루미노 실리케이트계 결합재는 고로슬래그 분말, 슬라이애쉬, 메타카올린, 실리카흄 및 카올린계 광물 중 하나 이상이며 분말도 4,000~15,000㎠/g 이고 Al:Si=1:0.5~2.5mol ratio로 구성되는 것을 특징으로 하는 액상형 비정질 실리케이트계 가수분해제가 포함된 콘크리트 단면보수용 무기폴리머계 내산모르타르 조성물.The aluminosilicate binder is one or more of blast furnace slag powder, slice ash, metakaolin, silica fume and kaolin-based minerals, the powder is also 4,000 ~ 15,000 ㎠ / g and Al: Si = 1: 0.5 ~ 2.5mol ratio An inorganic polymer acid-resistant mortar composition for repairing concrete cross sections containing a liquid amorphous silicate-based hydrolyzate. 콘크리트의 단면 보수공법에 있어서,In the section repair method of concrete, 상기 제 1항 내지 제 3항 중 어느 한 항에 따른 액상형 비정질 실리케이트계 가수분해제가 포함된 콘크리트 단면보수용 무기폴리머계 내산모르타르 조성물을 단면 보수 대상 콘크리트에 바르는 것을 특징으로 하는 콘크리트 단면보수 공법.Concrete cross-sectional repair method characterized in that the inorganic polymer-resistant acid-resistant mortar composition for concrete cross-sectional repair containing the liquid amorphous silicate-based hydrolyzate according to any one of claims 1 to 3 is applied to the concrete to be repaired. 제4항에서,In claim 4, 상기 무기폴리머계 내산모르타르 조성물을 단면보수 대상 콘크리트에 바르기에 앞서 전처리 공정을 진행하되, 상기 전처리 공정은, 열화부분 제거, 철근부식방지용 방청 도포, 표면강화제 도포, 하도 도포 중에서 하나 이상의 단계를 선택하여 이루어지는 것을 특징으로 하는 콘크리트 단면보수 공법.Before applying the inorganic polymer acid-resistant mortar composition to the concrete to be repaired in the section, the pretreatment process may be performed. Concrete section repair method characterized in that made.
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR101310041B1 (en) 2011-03-11 2013-09-17 이석기 Inorganic Binder Composition Hardening at Normal Temperature and Method Treating Surface of Porous Structure Using the Same
CN104129969A (en) * 2014-07-23 2014-11-05 广西启利新材料科技股份有限公司 Geopolymer-based carbon fiber sheet binder
CN104446309A (en) * 2014-11-25 2015-03-25 沈阳建筑大学 Quick repairing material for buildings and preparation method of quick repairing material
KR102513229B1 (en) * 2022-06-15 2023-03-24 대영이엔지씨 주식회사 Finishing composition for suface protection of concrete structure and finishing method for protecting suface of concrete structure using the same

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KR20030074092A (en) 2002-03-14 2003-09-19 한국건설기술연구원 Inorganic composition of concrete repairing agent and concrete surface treatment method using the same
KR20050104156A (en) 2004-04-28 2005-11-02 주식회사 인트켐 Electro-conductive alumino-silicate type mortar composition with high chemical resistance and fire resistance

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR101310041B1 (en) 2011-03-11 2013-09-17 이석기 Inorganic Binder Composition Hardening at Normal Temperature and Method Treating Surface of Porous Structure Using the Same
CN104129969A (en) * 2014-07-23 2014-11-05 广西启利新材料科技股份有限公司 Geopolymer-based carbon fiber sheet binder
CN104446309A (en) * 2014-11-25 2015-03-25 沈阳建筑大学 Quick repairing material for buildings and preparation method of quick repairing material
KR102513229B1 (en) * 2022-06-15 2023-03-24 대영이엔지씨 주식회사 Finishing composition for suface protection of concrete structure and finishing method for protecting suface of concrete structure using the same

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