WO1990007610A1

WO1990007610A1 - Surface-reconditioning system and wear plate for said system

Info

Publication number: WO1990007610A1
Application number: PCT/AT1989/000129
Authority: WO
Inventors: Friedrich Howanietz
Original assignee: Allgemeine Baugesellschaft-A.Porr Aktiengesellschaft
Priority date: 1988-12-23
Filing date: 1989-12-22
Publication date: 1990-07-12
Also published as: ATA315988A; AU4758090A; CA2006492A1

Abstract

A system for reconditioning surfaces, in particular surfaces of roads, roofs and terraces, comprises an insulating layer and a wear layer. The insulating layer is made, in a manner known per se, from a permanently elastoplastic adhesive and is covered by the wear layer, which is composed of prefabricated wear sections. These are made from a wear-resistant material which consists of single-sized particles or from a wear-resistant mixture of different-sized particles which contains no fine particles smaller than 0.3 mm, bonded to a weather-resistant binder impermeable to water vapour. A suitable prefabricated wear section is formed, for example, from a wear-resistant material of single-sized contiguous particles which is only partly embedded in a bed of weather-resistant binder impermeable to water vapour. The binder-free part constitutes the useful surface of the wear section.

Description

Refurbishment system for surfaces and wear plate therefor

The present invention relates to the renovation of surfaces in construction, in particular damaged road surfaces, roof areas and areas in the living area such as terraces.

Various methods are used to restore roadways, especially in the garage area. Milling of the damaged surface areas and reapplication of composite screeds, which due to their mechanical nature must have a minimum thickness of several centimeters, are carried out in practice. As long as there is sufficient load-bearing capacity, poured asphalt is applied without loss of layer thickness due to milling. Its disadvantages are the plastic deformability under constant load and the sensitivity to petroleum derivatives. In the case of damage that does not reach deep into the substance, it can also be coated in the centimeter thick area with reactive resin-bonded mortar. Their disadvantages are gas impermeability and a risk of slipping, especially when wet. Common to all systems is the disadvantage due to the mechanical conditions that cracks cannot be bridged without breaking the coating.

The damage pattern on multi-storey parking areas is particularly characterized by road damage and cracks in the structure, which can damage the paintwork of the set vehicles, because rainwater can release salts from praying, which after evaporation evaporates as water-insoluble residues on the painted surface of the vehicles can stay behind.

Similar problems can be seen in the renovation of areas in the living area, especially when renovating roof areas and terraces. It has been shown time and again in practice that there are leaks in special flat roofs at uncontrollable points. These are caused by aging, mechanical damage or defects in the laying; Plastic and bitumen sheets or galvanized sheet metal sheets are often used as materials. Terrace fastenings, on the other hand, usually consist of horticultural insulation; cement screeds are used as the wear layer, or tiles or concrete blocks laid in the thin-bed mortar on the insulation. To repair such damage, it has always been necessary to remove the old materials, which not only results in a great deal of work, but also the object is exposed to the weather for a long time without protection. Further disadvantages of the known hydraulically bound systems and bitumen-bound building materials are the required minimum layer thicknesses of several centimeters, the associated increased surface loading, the need to raise processes to the new level, etc. All of these measures, especially when restoring the horticultural moisture insulation, require depending on the hardening mechanism, more or less long shutdown periods. When renovating traffic areas, but also in living areas, such as flat roofs and terraces, it would therefore be desirable to have systems that can be used immediately after installation.

To solve these problems, the invention proposes a refurbishment system for surfaces, in particular road surfaces, roof surfaces and terrace surfaces, with an insulating layer and a wear layer, the insulating layer being constructed in a manner known per se from a permanently elastoplastic adhesive and the overlying wear layer from prefabricated Wear plates are formed, which consist of wear-resistant mono-grain or grain mixture bound with a weather-resistant, water-vapor-permeable binder, which is free of fine particles below 0.3 mm.

According to one embodiment of the renovation system of the invention, the wear-resistant monograin is only partly embedded in a bed made of the weather-resistant binder, while the part free of binder forms the useful surface of the wear plate, for example a traffic area.

In practice, the renovation system according to the invention can be used, for example, as follows:

In a first step, after the usual cleaning of the substrate, for example by high-pressure water or sandblasting, after the hardening in the service temperature range of + 80 ° C to -40 ° C and thus under all practical temperature conditions, cracks-overlapping, permanent-elastoplastic insulation layer is applied. As a result of the special structure of the insulating layer, in particular the ratio of plastic to hydraulic binder, the required water vapor permeability is also given. In a second step, prefabricated panels with a specially designed surface are laid in this waterproof and crack-bridging insulating layer. According to one embodiment of the invention, these prefabricated wear plates consist of aggregates, grain to grain, the binding of which takes place only up to a part of the grain diameter, for example up to about 60% of the diameter, with a weather-resistant binder made from reactive synthetic resins or thermoplastics.

After embedding the prefabricated wear plates, the renovated area, for example a traffic area, can be used immediately. Since the surface that can be driven on is made exclusively from grain to grain, without binding agents, the required slip resistance is guaranteed. The water vapor permeability can also be controlled to the desired extent by the structure of the binder and the low thickness of the wear layer.

In contrast to the previously known purely hydraulically hardening systems, which must not be disturbed by compression or vibration during hydration, the renovation system according to the invention is completely insensitive in this regard.

According to a further embodiment of the invention, the prefabricated wear plate is formed from a wear-resistant grain mixture that is free of fine particles below 0.3 mm and is bound with a weather-resistant, water vapor-permeable binder. The grain in these wear plates is encased in the binder system. Wear plates of this type are particularly suitable, for example, for the renovation of terraces and building icons in living areas.

The invention is illustrated by the examples below.

EXAMPLE 1:

The surface is a 15-year-old concrete of grade B 400, which has been trough-shaped removed to a depth of 1 cm due to the action of spikes, additionally palm-sized, shell-shaped spalling due to the effects of frost.

In a first step, the surface is cleaned with a high-pressure water jet without damaging the concrete structure; in a second step, the palm-sized flaking is supplemented with conventional, plastic dispersion-modified filling mortar. After the filling mortar has hardened a mixture of 1 part by weight of cement and 1 part by weight of synthetic material, with a gamma value of 1.6, is applied in a thickness of 2 mm as horizontal moisture insulation. To increase the elongation at break, an alkali-resistant fabric mat with 300 g / m ^{2 is} inserted. The plastic dispersion used has elastoplastic properties, is permanently sticky and has a T _λmax determined according to DIN 53.445 of -40 ° C.

The hardened mixture with a weight ratio of 1: 1 made of cement and dispersion is permanently elastic over a wide temperature range, even at -20 ° C, and is permanently sticky. The high plastic content - the dispersion is 60% in terms of solids content - makes it more dynamic Threshold stress activates the adhesive properties again and again.

In the final step, the prefabricated wear plates (see below) are inserted. The bond is made by adhesion and is so large that the shear test separates the old concrete by shearing off the top layer of concrete. The permanent elastoplasticity of the insulating layer compensates for cracking movements of the substrate, even at low temperatures, depending on the total adhesive thickness at 2mm thickness, still 0.4mm, without the wear plate being damaged.

The prefabricated wear plates used in the example above are manufactured in the following way:

A glass mesh fabric, mesh size 4mm, is sprinkled with a 3 / 5mm grit of diabass. This creates the required surface - grain to grain.

After this preparation, which causes the aggregates to be oriented, the binder, an internally plasticized reactive synthetic resin system based on epoxy resin, is applied in such a way that the aggregates are only embedded in the binder up to about 70% of the grain diameter. In the gel-like state, ie before the binder has hardened, the resin is pierced to the grain with a needle plate; this allows water vapor to pass through. After curing, cutting takes place to a size of 50 x 50 cm.

EXAMPLE 2:

The concrete of a weathered terrace corresponds to a beet quality of B 225, is weathered up to 4mm thick due to frosting effect and is elasto Plastic deformations between the support sockets with cracks over the entire width. The cracks have a width between 0.5 and 0.2 mm.

After a pretreatment as described in Example 1, but without filling the rough structure, the insulating layer is applied. In contrast to Example 1, the mixing ratio of the insulating layer is 1 part by weight of cement, 1 part by weight of pure acrylate dispersion with the same properties as in Example 1, and 1 part by weight of sand with a grain size of 0.1-3 mm. The inert filler is therefore chosen to fill the blowholes; in addition, the mechanical properties, namely a reduced shear strength due to the use of sand, are completely sufficient for the intended use - walking on the terrace.

The insulating layer is much harder than in example 1, but can still be bent over the mandrel at -20 ° C and only breaks at 60 ° at a test temperature of -20 ° C. Including the cavern filling, the thickness over the tips is still 2mm, only in the area of the cracks, with a cover on both sides of 20cm, a fabric mat is inserted.

Before the hydraulic reaction, i.e. within 2 hours, the prefabricated wear plates are pressed in, with a joint width of 3mm; the joints remain unfilled.

The following wear plates are used in this example:

The additions are oriented according to the same method as described in Example 1, but here with a different maximum grain size, namely grit 1 / arrm (mesh size of the fabric 2 mm). The binder consists of cement and water-emulsified synthetic resin based on epoxy resin, in a weight ratio of 1: 1, dried quartz sand with a grain size of 0.1 / 3mm is used as a creaser. Due to the hydraulic component, the binder layer remains permeable to water vapor.

The aggregates are embedded in the binder up to about 70% of the grain diameter.

The panels are finished as in example 1.

EXAMPLE 3

Weathered parking deck on the top floor. Due to the high deformation under load with large spans, the road concrete, especially in the joint area, has been mechanically destroyed, the originally 2 cm wide joint has grown from 45 ° to 4 to 5 cm due to flaking, numerous cracks characterize the surface. When it rains, the water reaches the Itot floor through joints and cracks.

The surface treatment is done by sandblasting. All joints are milled out to a width of 10 cm and a depth of lern. Then the moisture insulation is sprayed on with a thickness of 3mm, into which a reinforcement is inserted. The reinforcement anatte is laid along the milled trough with a loop down into the actual joint, so that there is continuous insulation. Three-dimensional deformations do not lead to the destruction of the joint insulation.

After a hardening time of around 24 hours, the same mixture of cement and plastic dispersion (ratio 1: 1) is mixed with 2% colloidal silica; this is used for thixotropy. The insulating layer is applied with a notched trowel (dimension 4mm) and the prefabricated wear plates are pressed in. By pressing at 4mm notched trowel height, a 2mm thick insulating layer is created after pressing down. The wear plate is laid 4mm up to the milled joint trough, the finished plate height is about 5mm, grain by grain, diabass chippings 3 - 5mm.

The step in the area of the joints, minus the solid insulation layer, is about 1mm high and 9cm wide. A prefabricated wear plate, using the same principle - grain to grain - but with a grain of 8 - 12mm, 8cm wide and around 12mm high, Im long, is pressed into the box. The purpose of this is a high mechanical stability due to the large thickness and the small rageri width to the two connections, as well as a relatively easy removal in the event of damage in the joint insulation area, which germinated when the concrete slabs shifted up to the point of contact due to temperature and deformation under load.

The prefabricated wear plates are produced analogously to the method given in Example 1. With the same compulsory orientation of the aggregates made of diabass chippings, the binder consists of a reaction resin based on polyurethane, with a filler addition of 0 / 1mm in a weight ratio of 1: 1. The wear plate for backfilling the milled trough consists of 8/12 mm diabase grain. In this case, the grain size makes it easy to orient the aggregates on a flat plate. A thixotropic, elastic, but brittle after hardening polyester resin is used in a ratio of 1 part by weight of binder and 2 parts by weight of filler with a grain size of 0.1 / 3 mm.

EXAMPLE 4

Flat roof, the concrete corresponds to quality B 300 and was moisture insulated 10 years ago with welded Bituneri sheets. Concrete walkway slabs lead to the individual skylights, in the edges on rubber bases, about 10 x 10 cm, elastically supported. The bitumen membranes are cracked and partially inelastic due to oxidation, the sidewalk slabs are frozen on the edges, and some are thick. After clearing the finished panels, the destroyed bitumen sheet insulation is left.

To bind the dust, 1 part by weight of cement: 1 part by weight of plastic version is mixed with 3 parts by weight of water and brushed on. Then the moisture insulation layer is applied in two work steps, each time an alkali-resistant reinforcement mat of 450 g / m ² weight was embedded. The total thickness is 5mm on average.

After hardening for about 24 hours at 18 ° C, the walkways are covered with prefabricated wear plates, laid in the same bed of the same material. .

To form the prefabricated wear plate, grit with a grain size of 5 / 8mm is spread out in one layer, the unrolling of the grain being prevented by a 4 x 4m frame.

Thixotropic, elastic reaction resin based on methacrylate serves as a binder. The degree of filling is 1 part by weight of binder, 0.5 part by weight of sand with a grain size of 0.1 mm and 3 parts by weight of colloidal silica. The chippings are embedded in the binder up to about 70% of the grain diameter.

After the binder has hardened, the plates are cut to 50 x 50 cm. EXAMPLE 5

Parking deck of a freely weathered facility, concrete quality B 450, 14 years old.

The access routes to the parking spaces are rough like sandpaper, weathered to a depth of 3mm; the surface itself almost undamaged on the surface. On the other hand, the concrete construction shows continuous cracks, spider-like, in a crack width between 0.5 and 1mm.

After cleaning with high pressure water jets, the insulating layer is applied. It consists of 1 part by weight of cement, 1 part by weight of butadiene styrene, weight ratio 80:20, with a dynamic shear modulus of -60ºC. The consumption is 5 kg / m ² , which corresponds to a layer thickness of approximately 3.2 mm after drying.

The prefabricated wear plates, which are manufactured in the following way, are inserted without reinforcement through fabric insert

Single-grain spreading chippings with a grain size of 3/5 mm are mixed in excess with internally elasticized reaction resin based on epoxy resin. The binder itself is so thixotropic with colloidal silica that the resin flows to the base before it hardens. With an application of 1.75 kg / m ² of binder, embedding of the diabase chips in a thickness of 60% is achieved after hardening. The grain-to-grain wear plate has a synthetic resin film covering of 20-25 μm on the surface, which is rubbed off very quickly by traffic.

EXAMPLE 6

Manufacture of prefabricated wear plates:

Wear-resistant sand with a grain size of 0.3 - 1.7 mm is mixed with thixotropic reaction resin. The binder requirement is 7.5% by weight. This single-core concrete, with a residual content of less than 0.25 mm of a maximum of 6% by weight, is shaken into a steel mold corresponding to a layer thickness of 7 mm, with vertical slats. After stripping and removing the slats from the frame, there are wear plates with 40 x 40 cm, 7mm thickness; a subsequent cutting process is not necessary.

EXAMPLE 7:

Manufacture of prefabricated wear plates:

A grain mixture (40% by weight less than 0.5 mm, 60% by weight greater than 5 mm, missing a grain fraction below 0.25 mm) is mixed with thixotropic reactive resin. The binder requirement is around 9% by weight. As in Example 6, the mixture is shaken into a steel mold with vertical fins.

Due to the lack of a grain fraction below 0.25 mm, a water vapor permeable plate is obtained. The type of production results in smooth plate surfaces; the grain is covered by the adhesive system. This plate is well suited for the fastening of terraces.

Claims

PATENT CLAIMS:

1.Refurbishment system for surfaces, in particular road surfaces, roof surfaces and terrace surfaces, with an insulating layer and a wear layer, characterized in that the insulating layer is constructed in a manner known per se from an adhesive which remains permanently elastoplastic and the overlying wear layer is formed from prefabricated wear plates which consist of wear-resistant mono-grain or grain mixture bound with a weather-resistant, water-vapor-permeable binder, which is free of fine particles under 0.3 mm.

2. Renovation system according to claim 1, characterized in that the wear-resistant monograin is only partially embedded in a bed made of the weather-resistant binder.

3. Rehabilitation system according to claim 2, characterized in that the monograin is embedded up to about 70% of its diameter in a bed made of weather-resistant binder.

4. Rehabilitation system according to one of claims 1 to 3, characterized in that the weather-resistant binder is a reaction resin system based on epoxy resin.

5. Renovation system according to one of claims 1 to 3, characterized in that the weather-resistant binder is a reaction resin system based on polyurethane.

6. Rehabilitation system according to one of claims 1 to 3, characterized in that the weather-resistant binder is a reaction resin system based on methacrylate.

7. Prefabricated wear plate, in particular for a renovation system according to one of claims 1 to 6, characterized in that it is formed from wear-resistant, grain to grain arranged mono-grain, which is only partially embedded in a bed of weather-resistant, water vapor-permeable binder, during the part free of binder forms the useful surface of the wear plate.

8. Wear plate according to claim 7, characterized in that the monograin is embedded up to about 70% of its diameter in the binder bed.

9. Wear plate according to claim 7 or 8, characterized in that it comprises a mesh fabric, in the mesh of which the monograin is oriented.

10. Prefabricated wear plate, in particular for a renovation system according to one of claims 1 to 6, characterized in that it is formed from wear-resistant grain mixture, which is free of fine particles below 0.3 mm, which is bound with a weather-resistant, water vapor-permeable binder.