JP2882734B2 - Resin concrete and resin mortar - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin concrete and a resin mortar containing alumina as a filler.

[0002]

Prior art and its problems Resin concrete is
In general, it is used mainly as a secondary product or repair material for factories, taking advantage of its high strength, excellent water tightness, chemical resistance, and abrasion resistance. Because of the lack of stability,
At present, the application of on-site construction to structures is still at the trial stage. However, focusing on these advantages, it is very unlikely that resin concrete will be applied to important structures such as marine / deep underground structures and structures that require chemical resistance to sulfates. Seems to be expensive.

Conventionally, as fillers for resin concrete or resin mortar, heavy calcium carbonate,
Finely divided silica, fly ash, and the like are known, and heavy calcium carbonate has been frequently used. JP 1
In 197348 and JP-A-3-285853, alumina is also mentioned as an example of one of the fillers to be blended in the resin concrete, but no specific blending example and blending amount are mentioned. It has not been. Therefore, little is known about the properties of resin concrete or resin mortar using alumina as a filler.

[0004] In addition, in the 3rd Annual Conference of Concrete Engineering (1981), pp. 233-236, "Mechanical Properties of Polymethyl Methacrylate Concrete", a resin concrete composition using a methacrylate resin as a binder is described. It has been disclosed. Also, Concrete Engineering Annual Report 9-1 (1987) pp. 271 to 276, "Basic Study on Resin Mortar Using Methyl Methacrylate".
Discloses a resin mortar composition using a methacrylate resin as a binder.

Many studies have been made on methacrylate-based resin concrete so far, but most of the studies are based on basic research on the composition of resin, and the mixing and kneading of resin concrete are supposed to be carried out on site. ,
It is a fact that there is hardly any practical research that is examining implantation.

[0006]

SUMMARY OF THE INVENTION An object of the present invention is to provide a resin concrete and a resin mortar having excellent strength characteristics such as compressive strength and split tensile strength.

[0007]

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of using alumina as a filler.
It is made of a methacrylate-based resin concrete characterized by containing about 20% by weight.

In the present invention, alumina as a filler is used in an amount of 9 to
It is made of a methacrylate resin mortar characterized by containing 34% by weight.

[0009]

DETAILED DESCRIPTION OF THE INVENTION The present invention will be specifically described below. For the resin concrete and resin mortar of the present invention, generally used aggregates such as sand, gravel, crushed stone, and blast furnace slag aggregate can be used. In the case of resin concrete, these aggregates are preferably contained in the composition at 76 to 86% by weight. In the case of resin mortar, 59 to 67% by weight in the composition
It is preferable to be contained. Since mortar lacks coarse aggregate from concrete, resin concrete will be described as a representative thereof in the following description unless otherwise specified.

[0010]

In the present invention, the methacrylate resin serving as the binder is a homopolymer of a methacrylate monomer or a copolymer of a combination of two or more methacrylate monomers, or a methacrylate monomer and the methacrylate monomer. It is mainly composed of a copolymer of a monomer and another copolymerizable monomer. That is, the methacrylate resin in the present invention is a mixture of one methacrylate monomer or a combination of two or more methacrylate monomers, or a methacrylate monomer and a methacrylate monomer. The main component is a mixture with other polymerizable monomers (hereinafter collectively referred to as a liquid resin or a methacrylate-based liquid resin), to which an appropriate polymerization catalyst is added, followed by reaction curing. It was made.

Examples of the methacrylate monomers include methyl methacrylate, ethyl methacrylate, n
-Butyl methacrylate, isobutyl methacrylate,
Examples thereof include t-butyl methacrylate, 2-ethylhexyl methacrylate, cyclohexyl methacrylate, and lauryl methacrylate. In the present invention, those containing methyl methacrylate as a main component are preferable.

Other monomers copolymerizable with the methacrylate monomer include, for example, methyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, t-butyl acrylate, 2-ethylhexyl acrylate, cyclohexyl acrylate, Acrylate monomers such as lauryl acrylate; ethylene glycol di (meth) acrylate, propylene glycol di (meth) acrylate, polyethylene glycol di (meth) acrylate, polypropylene glycol di (meth) acrylate, butylene glycol di (meth) acrylate, Hexylene glycol di (meth) acrylate, 2,2-bis [4- (meth) acryloyloxyphenyl] propane, 2,2-bis [4- (meth) acryloyloxy Cyclohexyl] propane,
2,2-bis [3- (meth) acryloyloxy-2-
[Hydroxypropoxyphenyl] propane, trimethylolpropane tri (meth) acrylate, pentaerythritol tera (meth) acrylate, dipentaerythritol hexa (meth) acrylate, and other polyfunctional (meth) acrylate monomers; dimethyl maleate, diethyl maleate Maleate ester monomers such as catenate, di-n-butyl maleate, di-t-butyl maleate, diisobutyl maleate; dimethyl fumarate, diethyl fumarate, di-n-butyl fumarate;
Fumaric acid ester monomers such as di-t-butyl fumarate and diisobutyl fumarate; and vinyl monomers such as styrene and vinyl toluene. These monomers are used alone or in combination of two or more.

In the present invention, the methacrylate resin may be used in combination with one of the above-mentioned methacrylate monomers, a copolymer comprising a combination of two or more thereof, or a methacrylate monomer. If necessary, other components may be contained in addition to the copolymer with other monomers. Other components include, for example, plasticizers such as di-2-ethylhexyl phthalate, di-n-octyl phthalate, tricresyl phosphate, and di-2-ethylhexyl adipate; oxygen barrier agents such as paraffin wax; Agent; a trace amount of a polymerization inhibitor for stabilizing the monomer; or a polymer or copolymer of the above-mentioned methacrylate-based monomer or acrylate-based monomer. That is, the methacrylate liquid resin in the present invention may be a liquid compound containing the other components as necessary, in addition to the methacrylate liquid resin as a main component.

The above-mentioned binder is generally incorporated in the resin concrete in an amount of 6 to 25% by weight, and particularly preferably 6 to 10% by weight from the economical viewpoint.

The resin concrete and the resin mortar according to the present invention are characterized by using alumina as a filler. As the alumina to be compounded, a granular general commercial product can be used, and the average particle size is 1 to 10
Use is made of granules of μm, preferably 2 to 6 μm.

In the case of resin concrete, it is preferable that alumina is incorporated in the composition in an amount of usually 5 to 20% by weight, particularly 8 to 16% by weight. Further, in the case of resin mortar, it is preferable that alumina is incorporated in the composition in an amount of usually 9 to 34% by weight, particularly 22 to 27% by weight. If the compounding amount is within these ranges, the strength properties of cement concrete and cement mortar are exhibited, but if the compounding amount is less than the lower limit, the liquid resin flows out before curing and material separation is performed. Cause, on the other hand,
If the amount exceeds the upper limit, the workability may deteriorate.

The resin concrete according to the present invention is manufactured by a usual method. That is, after the polymerization catalyst and the like are dissolved in the liquid resin as required, the filler and the aggregate are mixed, and the mixture is reacted and cured to produce the resin.

The resin concrete and the resin mortar of the present invention use alumina as a filler as described above, but contain a filler other than alumina such as heavy calcium carbonate, finely divided silica and fly ash together with alumina. It does not exclude being done. As long as the predetermined amount of alumina is blended, the effects of the invention described below can be exerted.

[0020]

Hereinafter, the present invention will be described in more detail with reference to examples of resin concrete using a methacrylate resin as a binder.

Composition of Resin Concrete [Materials Used] (1) Methacrylate Liquid Resin A commercially available methyl methacrylate liquid resin was used.
This liquid resin is made of methyl methacrylate (hereinafter referred to as MMA).
Sometimes abbreviated. ) As a main component, a polymerization accelerator (tertiary aromatic amine), a crosslinkable monomer (polyfunctional methacrylate), and a small amount of a polymerization inhibitor (Mitsui Petrochemicals ( Co., Ltd., Silical R17D and Silical R17DLV).

In this embodiment, in order to smoothly progress the polymerization reaction of the liquid resin, polymethyl methacrylate (hereinafter, sometimes abbreviated as PMMA) is added to increase the viscosity. Here, a type in which PMMA is separately added as a bead-shaped powder (hereinafter referred to as “resin A”) and a type in which PMMA is dissolved and contained in a liquid resin in advance (manufactured by Mitsui Petrochemicals Co., Ltd., Silal R17K and Silal R17KL)
V, hereinafter referred to as resin B. ) Were used.

As the polymerization initiator, commercially available benzoyl peroxide (manufactured by NOF Corporation, Niiper FF, 50% diluted product) was used (hereinafter sometimes abbreviated as BPO).

(2) Filler Alumina (A-42-3, manufactured by Showa Denko KK, average particle size: about 4 μm, specific gravity: 3.95) and heavy calcium carbonate (average particle size: about 4 μm) for comparison. , Specific gravity 2.70).

(3) Aggregate Crushed stone from Tonohara (Gmax 20 mm, specific gravity of surface dryness 2.71, specific gravity of absolute dryness 2.69, FM 6.90) as coarse aggregate, and mixed silica sand (No. 3 and 6) as fine aggregate No .: Absolute specific gravity 2.60)
And Tenryu-produced land sand (surface dry specific gravity 2.61, absolute dry specific gravity 2.58.
FM 2.45). In addition, these aggregates were used in a substantially dry state.

[Kneading] Table 1 shows the combination of fine aggregate and filler.
And the formulations as shown in Table 2 were performed. Table 2
In the above, the resin / filler ratio indicates a volume ratio of the methacrylate resin to the filler. As a kneading method,
After putting in the aggregate, knead it for 1 minute, and put it in 2-3 minutes after putting in the liquid resin.
Kneaded for minutes.

The amount of the polymerization initiator was 6.5% by weight based on the amount of the unit resin, and was mixed with the resin 30 seconds before the liquid resin was charged.

When resin A was used as the liquid resin, a small amount of PMMA was used as a part of fine aggregate.

[0029]

[Table 1]

[0030]

[Table 2] Composition Table Composition No. Unit Amount (% by weight ) s / a Resin / resin filler Fine aggregate Coarse aggregate ( % ) Filler ratio 1 7.2 12.1 35.5 45.2 46.0 1.67 2-1 6.7 15.2 34.4 43.7 〃 1.80 2-2 7.2 12.6 35.3 44.9 〃 2.35 3 7.2 10.6 36.2 46.0 〃 1.90 4 6.7 15.2 34.4 43.7 〃 1.80 5-1 7.5 13.9 35.5 43.2 〃 2.20 5-2 7.5 13.9 35.5 43.2 〃 2.20

Performance Evaluation [Test Method] Performance evaluation was performed separately for fresh and hardened products.

(1) Fresh JIS A 1101 (test method for concrete slump) and
Slump and air volume were measured in accordance with JIS A 1128 (Test method based on pressure of air volume of concrete not yet solidified (air chamber pressure method)).

[0033] Resin concrete generally has an advantage that the curing time is short, but an appropriate pot life is required when assuming on-site construction. Therefore, the time-dependent change of the slump (5 minutes after mixing the polymerization initiator (immediately after kneading)
And 10 minutes after 10 minutes have elapsed)
We decided to evaluate the pot life. In addition, each time slump was measured, reworking was performed.

(2) At the time of curing In order to examine the relationship between the pot life and the strength characteristics at the time of curing, a diameter of 10 cm ×
After preparing a cylindrical specimen having a height of 20 cm and air-curing for 7 days in a room at 20 ± 2 ° C., JIS A 1182 and JIS
A compression strength test and a split tensile strength test were performed in accordance with A 1185 (compression strength test method and tensile strength test method for polyester resin concrete). Further, at the time of the compressive strength test, the static elastic modulus was also measured.

Further, in order to confirm the strength development due to the material age, immediately after kneading, a cylindrical specimen having a diameter of 10 cm and a height of 20 cm was prepared and mixed with a polymerization initiator two hours after the kneading.
After a lapse of time and at 1, 3, 7, 14, and 28 days of the material age, the compressive strength test was performed. The specimens were air-dried in a room at 20 ± 2 ° C. until a prescribed age. The removal time is
All specimens on which the strength test was performed after 1 day of the material age were all on the 1st day of the material age, and those subjected to the strength test before that were demolded immediately before the test.

[Test Results] Table 3 shows the test results for each of the above formulations. With respect to the performance at the time of freshness, the same consistency as that of the cement concrete was obtained in each of the formulations, and the material separation resistance and other workability were all good.

[0037]

TABLE 3 Test results formulation No. Slump air amount compressive strength tensile strength static modulus (cm) (%) (kgf / cm 2) (kgf / cm 2) (kgf / cm 2) 1 18.5 1.4 371 51 1.34 × 10 ⁵ 2-1 19.0 1.4 496 81 2.07 × 10 ⁵ 2-2 19.5 0.9 504 81 2.15 × 10 ⁵ 3 17.0 1.2 407 60 1.32 × 10 ⁵ 4 16.5 0.9 521 87 2.15 × 10 ⁵ 5-1 18.5 1.1 876 110 2.91 × 10 ⁵ 5-2 19.5 1.1 910 114 2.95 × 10 ⁵

According to the strength test results, the composition using alumina as the filler shows a value about 30% larger in compressive strength and about 50% in split tensile strength than the composition using heavy calcium carbonate. . Further, the ratio of the split tensile strength to the compressive strength is also large, and it can be seen that there is a difference in the strength development depending on the type of the filler. In addition, the composition using land sand as fine aggregate is better than the composition using mixed silica sand.
The strength is somewhat higher.

Table 4 shows the measured values of the slump, the compressive strength, and the change with time of the static elasticity coefficient after mixing the polymerization initiator in the formulation No. 5-1.

[0040]

[Table 4]

FIG. 1 is a graph of the data shown in Table 4. As for the slump, when the elapsed time reaches 40 minutes, a large slump loss occurs, and the initial consistency cannot be obtained clearly. You can see that. In addition, the compression strength shows almost the same value until 20 minutes have elapsed, but the value of the specimen manufactured after 30 minutes has decreased by about 10%. However, the static elasticity coefficient hardly changed regardless of the elapsed time, and poor curing did not occur.

FIG. 2 shows the relationship between the material age and the compressive strength in the above formulation No. 5-2. Although the compressive strength at the age of 7 days showed a slightly small value, almost 100 days at 1 day of age.
% Compression strength is obtained. However, there is a tendency for the strength to increase slightly even after the first day of timber age. In addition, with respect to the compressive strength at the age of 28 days, about 80% (774 kgf / cm ² ) 2 hours after mixing the polymerization initiator and about 90% (879 kg
f / cm ² ), indicating that high strength was obtained at an early stage.

[0043]

The resin concrete and resin mortar using alumina as a filler according to the present invention have superior strength characteristics such as compressive strength and split tensile strength and static elastic modulus as compared with conventional resin concrete and resin mortar. . Furthermore, since alumina as a filler is richer in acid resistance than heavy calcium carbonate, it has extremely high practicality in on-site construction of structures that require strong watertightness, chemical resistance or wear resistance. .

Further, the resin concrete and the resin mortar according to the present invention have not only the above-mentioned excellent strength properties but also the workability equivalent to that of the cement concrete and the cement mortar.

[Brief description of the drawings]

FIG. 1 is a graph showing measured values of slump, compressive strength and static elasticity of a composition No. 5-1 after mixing with a polymerization initiator, with time.

FIG. 2 is a graph showing the relationship between material age and compressive strength in Formulation No. 5-2.

──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Masanori Kuromoto 1043 Shimoyama, Onigakubo, Tsukuba-shi, Ibaraki Pref. 1 Inside Kumagaya Gumi Technical Research Institute (72) Inventor Hideki Koyama Oji-Kiga, Tsukuba-shi, Ibaraki 1043 Shimoyama, Kubota 1 Inside Kumagaya Gumi Technical Research Institute Co., Ltd. (72) Inventor Yasushi Yamada 61-2, Waki, Waki-machi, Kuga-gun, Yamaguchi Prefecture Inside Mitsui Petrochemical Industry Co., Ltd. (72) Inventor Goro Sugaya Tokyo 3-39-10 Yushima, Bunkyo-ku, Mitsui Petrochemical Industry Co., Ltd. (56) References Hiroshima Prefectural Eastern Industrial Technology Center Research Report, 2 (1989) p. 1-5 (58) Field surveyed (Int. Cl. ⁶ , DB name) C04B 26/06 JICST file (JOIS)

Claims (2)

(57) [Claims] 1. A methacrylate resin concrete containing 5 to 20% by weight of alumina as a filler. 2. A methacrylate resin mortar containing 9 to 34% by weight of alumina as a filler.