JPS609188B2 - How to install self-leveling flooring - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a novel method for installing self-leveling flooring.

More specifically, the self-leveling flooring material, which is made by adding water and various additives to a hydration hardening agent such as cement and various types of gypsum, is continuously poured at high speed and in a high capacity directly onto the rough floor surface. This is a construction method for leveling flooring. The purpose of this is to eliminate the construction disadvantages of self-leveling flooring described below, and to improve the overall economic efficiency by making construction more efficient, labor-saving, faster, and shortening the construction period. . In the past, the common method for making rough floor surfaces smooth and horizontal was to apply leveling mortar with a trowel, but in recent years cement and A so-called self-leveling floor formation method has been proposed in which a slurry made by adding water and various additives to a powdered hydrated curing agent such as gypsum is poured onto a rough floor surface to obtain a smooth horizontal surface through natural flow. (For example, Tokubatsu Sho 49-137426)
Compared to the troweling method of leveled mortar, this self-leveling method does not require troweling, so it is easy to apply, has a short curing time, can be completed quickly, and uses natural flow. It is horizontal and smooth, and the finished surface has an excellent appearance. It has the following advantages. Despite these advantages, ``The main reason why self-leveling flooring materials have not necessarily been widely used is that ``the following construction problems, especially the mixing of self-leveling flooring slurry, This is because there are operational constraints or drawbacks in the adjustment process.In other words, in the process of mixing the powdered hydrated hardening material with water and various additives, water is added to a large amount of the powdered hydrated hardening material. The mixing method is prohibited because the powdered hydrated curing material reacts to form a partial coagulum before forming a slurry, and in extreme cases, it causes coagulation of the entire product.

This phenomenon is thought to be because the heat of the reaction between the powdered hydrated curing material and water is not diffused, resulting in a partial temperature rise in the system, and this temperature rise accelerates the hydration reaction. therefore,
Powdered hydrated hardeners must be added to a large volume of water.

In this case, in particular, the powdered hydration curing agent must be carefully and gradually added to the mulched water. Otherwise, the powdered hydration hardening material will form a lump in the water, which will have a significant negative impact on the strength, appearance, and smoothness of the self-leveling flooring. It is not necessarily a good idea to take measures such as prolonging the breakage time or increasing the hawking speed in order to crush the bulge once it has formed. This causes problems such as an increase in the viscosity of the slurry, and even the solidification of the entire slurry during sanding.To prevent such problems, the powdered hydration hardening material must be added gradually to the water over time. However, this means that not only is it time consuming to prepare the self-leveling flooring slurry, but also that its agglomeration time must be extended in advance by the time required for this mixing operation.

That is, in order to prepare a self-leveling flooring slurry of 200k9, powdered hydrated curing agent of 100k9 or more must be gradually added to water. If the hydrated hardener were to begin setting within the time required for mixing, it would be completely impossible to install a self-leveling flooring.

The setting delay of several tens of minutes to several tens of minutes required in this mixing stage is equivalent to several hours to several tens of hours for self-leveling flooring to harden to the point where you can walk on it. This will end up undermining the desire to shorten the construction period for materials. These problems and operational limitations are due to the high reactivity of the powdered hydration hardening material used, which is a key characteristic of self-leveling flooring materials, which is characterized by rapid hardening and short construction times. This is indispensable in order to satisfy the characteristics of quick curing, and it has hitherto been considered extremely difficult to solve the above-mentioned operational problems without impairing early curing properties.

Even if a self-leveling flooring slurry can be obtained by careful manipulation, it still has some problems.

Self-leveling flooring materials are mixed and adjusted near the construction site where they are to be constructed, and then transported to the construction site using a container or pressure-fed using a pump. The reality is that it is difficult in practice to mix the entire amount of self-leveling flooring slurry required at once.

For example, if the floor area to be constructed is 300 mm and the thickness of the flow layer is 1.5 mm, the total amount of self-leveling flooring slurry required is 4.5 mm, and in order to mix and adjust this at once, It would be necessary to prepare approximately 5 hawk containers, and doing so would not be technically or economically advisable.Therefore, one lees trunk container of an appropriate size was
The self-leveling flooring slurry must be mixed in several batches using more than one machine (actually, two machines are used alternately). In this case, of course, it is necessary to repeat a series of operations necessary for slurry mixing adjustment, including measuring and adding water and various additives, carefully adding and mixing the powdered hydrated hardener, and discharging from the mixing container. However, there is a problem that the construction problems will not be resolved at all. As described above, self-leveling flooring materials have many drawbacks in construction, particularly in the process of mixing the powdered hydration hardening agent, water, and various additives, and solutions to these problems have been strongly desired.

As a result of intensive research, the inventors discovered an innovative construction method that solves these drawbacks of self-leveling flooring, which has the characteristics of early hardening and quick construction time, and based on this knowledge, Finally, the present invention was completed.

That is, in the present invention, the powdered hydration curing material and water or an aqueous solution containing additives are mixed at a predetermined ratio, and the viscosity is 100 to 5.
000 (cps) of self-leveling flooring slurry, A. Mixing volume (v) 1.5-100 (
Evening), B. Discharge capacity (V) 0.3 to 10 (evening/sec)
,C. This invention provides a method for constructing a self-leveling flooring material, which is characterized by continuously mixing under conditions of a mixing time (t) of 5 to 300 (sec) and pouring the obtained slurry onto a rough floor surface. .

In this invention, the powdered hydration hardening material refers to various cements, various plasters, various aggregates, and various powdered additives described below, and various types are used according to the required characteristics of self-leveling flooring materials. It consists of the following ingredients and composition.

The cements mentioned in this invention include boltland cement (boltland cement, white cement, early strength cement, jet cement blast furnace cement, silica cement, flyash cement, etc.), alumina cement, and calcium sulfuruminate cement. Examples include expandable cement mixtures.

Examples of the various types of gypsum referred to in this invention include O-type anhydrite Q and B hemihydrate, gypsum plaster, and mixtures thereof.

Examples of aggregates used in this invention include cinnabar sand, cinnabar sand powder, calcium carbonate, clay, talc, dolomite, barium sulfate, etc. Since the viscosity of self-leveling flooring materials is low, powdered or granular aggregates can be used. The coarse aggregate used in general cement concrete (with an average diameter of 5
Willow or larger) are rarely used because they have a high sedimentation property.

The additives used in this invention include a curing modifier to adjust the curing speed of hydration curing components, a viscosity modifier to adjust the viscosity of self-leveling flooring materials, and a viscosity modifier to improve the dispersibility of powdered hydration curing materials. Additionally, it is a dispersant with a water-reducing effect, an antifoaming agent to eliminate foam in self-leveling flooring slurry, an antifreeze agent to prevent self-leveling flooring from freezing before it hardens, and added to hydration hardening materials. Examples include polymer emulsions that give favorable results in terms of strength, adhesion, and the like.

Examples of hardening modifiers include calcium chloride and other metal chlorides, which have a fast-setting effect on Boltland cement; soda carbonate, which has a delayed effect on gypsum hemihydrate;
Examples include citrate, veptone, and glue.

Examples of viscosity modifiers include cellulose ether-based, pinyl-based, acrylic-based water-soluble polymers, and water glass-based viscosity increasers.

Examples of dispersants include metal salts of naphthalene sulfonic acid formalin condensates, lignin-based agents represented by sodium lignin sulfonate, and creosote oil-based agents.

Furthermore, examples of antifoaming agents include silicone-based and nonionic surfactant-based agents, and antifreezing agents include those that have a freezing point lowering effect such as ethylene glycol, propylene glycol, ethylene glycol, glycerin, and salt. can be mentioned.

Examples of polymer emulsions include natural rubber latex, synthetic rubber latex, various synthetic resin emulsions, asphalt emulsions, and wax emulsions. One or more of these additives may be added as necessary.

Among the additives, the method of mixing powdered additives with the powdered hydration hardening material in advance and adding liquid ones to water can eliminate the hassle of measuring operations for self-leveling flooring materials. It is advantageous in this respect. The self-leveling floor material slurry referred to in this invention is made by using the above-mentioned powdered hydration hardening material as a base material, adding aggregate, water, and the various additives mentioned above as necessary, and simply pouring it onto the rough floor surface to phosphorus harden it. A slurry mixed for the purpose of forming a smooth horizontal floor surface.

In this case, the viscosity range of the self-leveling flooring slurry required for natural flow is 5000 centipoise (cps).
The necessary conditions for a self-leveling flooring material are that the specific ps is desirably 100 to 150 and the setting start time is 5 to 300 minutes. In this case, the ratio of powdery ingredients to water varies depending on the type and blending ratio of the powdery hydration hardening material, aggregate, and various additives, but it is generally added to 100 parts by weight of the powdery ingredients. The amount of water used ranges from 30 to 9 parts by weight.

The most important point in this invention is that this self-leveling flooring slurry can be uniformly connected and mixed in a short time. For this purpose, it is necessary to perform continuous mixing under conditions that satisfy each of the following requirements. That is, "A mixing capacity v (evening): 1.5 to 100 (preferably 3 to 50
, more preferably 3 to 20) B Discharge capacity V (sec): 0.3 to 10 (preferably 0.3 to 3, more preferably 0.5 to 144) C Mixing time t (s
ec) 35 to 300 (preferably 5 to 1703, preferably 6 to 40) However, t=v/V Here, the mixing capacity is the amount of time the powder component and liquid component are in contact for tsec (mixing time) It means the total capacity of the chicken, and the discharge capacity means the volume of slurry that can be continuously obtained per unit time.

Next, in order to facilitate understanding of the present invention, explanation will be given based on a conceptual flow sheet of construction shown in the drawings.

Hydrated hardening materials and aggregates such as cements and various types of gypsum, hardening modifiers, viscosity modifiers, defoaming agents, polymer emulsions, and antifreeze agents are mixed in advance and powdered components are mixed in advance and processed into Hopper Tomimoto. Can be stored.

Water and other liquid components are also premixed and stored in tank 3. The powder component and the liquid component are each continuously and quantitatively fed into a continuous mixing device using a powder metering device, for example, a screw feeder 2 and a pump 4. The self-leveling flooring slurry continuously discharged from the mixing machine is pumped to a place where it is to be floated by a pump 8 or the like. In addition to the devices listed above, table feeders are also suitable for continuous quantitative supply of powder, as well as rotary feeders, belt feeders, chain feeders, electromagnetic feeders, plunger feeders, and reciprocating feeders. Alternatively, a bucket feeder or the like may be used, and the desired supply amount and changes in the supply amount are made in a manner appropriate to the device.

A common and simple method is to use the pump 4 to adjust the liquid component to the desired flow rate indicated by the flow rate indicator 6 using the valve 5, but a metering pump or other method may also be used.

If the liquid component is only water, or if there is a device that can mix quantitatively the liquid components of various additives in the water supply piping, it is possible to omit the liquid component tank 3. , can be supplied.Pumps for pumping self-leveling flooring to the site where it will actually be constructed include "squeeze pump, diaphragm pump," plunger pump, whirlpool pump, and other pumps for pumping general slurry. ``Squeeze pumps, which are also used to pump concrete, mortar, etc.''
It is suitable because it is easy to maintain.

A suitable continuous mixing device that satisfies the requirements of this invention requires that it be of such a structure that the self-leveling slurry discharged from it is uniform without any lumps. In order to prevent mako from forming, there is no dead zone in the continuous mixing tank where the powdered ingredients and liquid ingredients are mixed together at the same time as the white shark. It is necessary to have a structure of the fly floating blades that can apply sufficient shearing force necessary for dispersion before being discharged.QOne example of a continuous mixing device suitable for carrying out this invention is ``As shown in the conceptual diagram shown in Figure 7, the overall shape is a hollow disk,
Inside the casing, there is a disk-shaped fly blade whose rotation axis is the center of the circle.It has a supply port for the components to be mixed at or near the center, and a discharge port is part of its outer periphery. It is of the format established in .

This type of continuous mixing device uses centrifugal force to create a suction state around the center of the rotating rope floating blade, so that the supplied powder and liquid components do not stagnate near the supply port. It has the following characteristics: it has a large discharge capacity per mixer volume, and it is possible to provide a high shearing force by changing the structure of the Todesk-type condensing frame blade.

And this type of lily pad usually has a power rating of 30mp. m. ~30
05. P. It is often operated within the range of m4. Continuous mixing devices in the form of hollow discs are useful in implementing the present invention, but the invention is not limited thereto.

That is, the continuous mixing device used in the present invention may be any device that satisfies all of the above-mentioned continuous mixing conditions, and the type and foundation of the device itself are not critical.

If a continuous mixing device with an actual internal volume (substantially the same as the mixing volume) of 100 mm or more is used in the present invention, the entire device will be too large, requiring a great deal of effort to move, and This also increases the price, which is not the intention of the present invention. (Actual internal volume here is the content of the casing minus the actual volume of the lantern blades, etc., and essentially refers to the area where the shearing force due to the rotation of the fly frame blades is applied. (The volume of the discharge port is not included.) Also, depending on the device whose actual internal volume is 1.5 or less, it is virtually impossible to satisfy the discharge capacity and mixing time shown above.

That is, when the cosmetic volume is less than 1.5 sec and the discharge capacity is 0.3 sec, the mixing time is less than ec. Continuously mixing self-leveling flooring requires less repetition of a series of operations consisting of measuring, adding, mixing, and discharging compared to traditional batch mixing methods, but the dispensing capacity is 0.43 m/s. sec (1.08 mm hr) or less, it is too small compared to the amount required for the place where normal self-leveling flooring is to be installed, so even though the flow continues ~ it is already far ahead. The self-leveling flooring material that is poured into the flooring begins to solidify, resulting in the inconvenience that a smooth horizontal surface cannot be obtained as a whole.

In addition, if the discharge capacity exceeds 10 t/sec (10.8 ah/hr), the speed of the drift boat will be too high, making it impossible to actually control the drift boat operation. Increasing the discharge capacity also increases the overall size of the accompanying powder supply device and pump for pressure feeding, which is another purpose of this invention to provide self-leveling flooring to construction sites that require it. It is too large and uneconomical to be used as a movable device for nearby mixing and adjustment. As for the mixing time, if the self-leveling flooring slurry is uniform and does not form lumps, the shorter the mixing time, the better.

However, according to the inventors, ``If the mixing time t=$ec or less,
If the discharge capacity exceeds 043 m/sec,
It was impossible to see clearly any areas of poor dispersion in the self-leveling flooring slurry. Mixing time: 30 ec
In the above cases, continuous mixing and flow separation construction is possible, but one of the purposes of the present invention is to shorten the time required for mixing, shorten the setting time, and self-leveling the powdered hydration hardening material. The purpose of the present invention is to enable the construction of flooring materials, and it is not the intention of the present invention to use a continuous mixing device that takes an unnecessarily long mixing time.

The inventors of the present invention discovered yet another advantage while implementing this invention.

When pouring self-leveling flooring material onto a lees bed surface, it is quite difficult to accurately know in advance the amount required, and the amount is usually determined on a case-by-case basis. In this case, the amount of self-leveling slurry mixed and prepared does not necessarily match the amount required for flowing, and a residue may still be left. Of course, this residual slurry cannot be reused, so it is not only wasteful and uneconomical, but also a problem with finding a place to dispose of it. By stopping the mixed light frame as soon as it is determined, almost no residue is created.
It is now possible to complete the construction. Examples will be shown below to further aid understanding of the present invention.

Example 1 The composition of the self-leveling flooring material used in this example is shown below.

The self-leveling flooring slurry in the above case had a specific gravity of 1.5, a viscosity of 250 ps, and began to set 24 minutes after mixing.

Construction was carried out using a souma as shown in the drawings.

The capabilities of each device are shown below. 1. Powder hopper one
300 and 2. Screw feeder 3000 & Soh length 60
r wind) 3. Water tank 300Z4. Pump (swirl type) 3000Z no hr5. palf
IB stop valve6. Flowmeter
.

The meter powder component was placed in the 300 meter hopper, and water and antifoaming agent were placed in the tank and added as necessary during construction. The constant supply of water was adjusted using a stop valve so that the flow rate was 1500k9/hr while monitoring the water from the pump with a rotameter. A squeeze pump was used to transport the self-leveling flooring material, and was operated to match the discharge capacity of the continuous mixing device. The rough floor surface to be constructed was the 1300th floor of the second floor of a two-story reinforced concrete building, and the construction equipment was installed near the construction site, and the self-leveling flooring material was transported to the second floor using a squeeze pump.

The planned thickness of the self-leveling floor material was 2 shipboards, so it was planned to require 6,000 meters, but it would take 5,200 meters to reach the position of the pin that indicates the desired thickness of the boat installed on the floor. was sufficient. For this reason, we decided to stop the mixed light azusa on the way to the river, and without creating any residue.
The construction was completed and the building was opened. Self-leveling flooring is approximately 2 years old after drift boating.
Condensation and hardening began in 0 minutes, and a smooth and level floor surface on which to walk was formed after 4 hours. The time required for this construction work is
It took a total of three hours, including a little less than two hours for the drift boat, one hour for setting up the pump pressure line, and one hour for preparing the raw materials, such as the mixed oak clothing layer.

In other words, it is common knowledge in the construction industry that it takes 3 hours to finish the rough floor surface smooth and level, and that the next work can be started after about 4 to 6 hours. It's unthinkable and nothing short of dramatic. Example 2 A self-leveling flooring material with the following formulation was prepared in Example 1.
According to almost the same construction procedure as above, 40〆 per house,
A total of 800 20-unit RC housing complexes were constructed.

The above self-leveling flooring slurry has a specific gravity of 1.8 and a viscosity of 4.
Coagulation starts 24 minutes after 0 ratio ps mixing.

The construction was carried out in almost the same manner as in Example 1, but since the formulation and specific gravity of the slurry were different, the supply capacity of the screw feeder was changed to 3780 k9/hr (65 rpm), and the water supply was changed to 1620 k9/hr.

Also, since the only liquid component in this formulation is water, the pump in 4 and the tank in 3 were omitted, and the water supply was directly connected to the valve in 5. Then, using a car equipped with equipment other than this tank and pump, the vehicle was parked near the construction site, and the self-leveling flooring material was pumped from the top of the car to the floor surface to be constructed. The thickness is 3mm, so each house has 1200mm, a total of 24mm, but in reality it varied between 1000 and 1500mm.

Since the discharge flow capacity of the self-leveling flooring material is 3000 hours, the same as in Example 1, the drift time per house is 20 minutes to 3 minutes. The work required to move the tip of the pressure feed hose to start the construction of the next door after completing the construction of one door is 2.
The duration was ~4 minutes, during which time the entire device including the continuous mixing device and pump was stopped, and once the pressure hose was set, it was restarted.

Therefore, the equipment was operated for 20 to 30 minutes and stopped for 2 to 4 minutes, and the time required to construct 20 houses was about 6 hours. The self-leveling flooring slurry began to set about 2 minutes after floating, and a smooth horizontal surface on which to walk was formed after 5 hours.

This example shows that in addition to the effects of Example 1, continuous construction can be performed intermittently. Of course, the equipment down time is not allowed to exceed the setting time of the self-leveling Tokomura slurry. Comparative Example 1 300% of the self-leveling flooring material with the formulation shown in Example 1
Using the mixing vessel, a slurry was prepared by placing the liquid component in advance into the vessel and gradually adding the powder component.

At this time, the amount of powder components added was approximately 200 tons, and it took 18 minutes to add the entire amount.After addition, to mix evenly, the powder was poured for 2 minutes, and then immediately pumped into a flow boat. However, it began to condense before it flowed onto the rough floor surface and formed a smooth horizontal surface due to natural flow, making it impossible to obtain a smooth and horizontal floor surface. Comparative Example 2 The amount of sodium citrate added in Example 1 was changed to 0.1
Using a self-leveling flooring formulation with a setting time of 5 and a setting start time of 6 minutes, the same machine as in Comparative Example 1 and two 300 mixers were used to construct a rough floor surface of 300 to a planned thickness of 20. I did this.

The average time required for the series of operations of measuring the liquid component, gradually adding the powder component, and draining the pump using the pressure pump is 30 minutes, and the two foot frame mixing vessels are operated alternately. As a result, it was possible to flow onto the rough bed surface at a rate of 1200 tons/hr.

The amount of self-leveling float village actually required for the flowboat was 5,800 meters compared to the planned 6,000 meters, and since mixed light and azusa operations had already begun by the time the accurate flow rate could be determined, the remaining 200 meters was required. was forced to. Furthermore, the series of operations was repeated 20 times, which required a great deal of effort. The net amount of time required for construction was 5 hours. The self-leveling flooring material that was poured and naturally flowed began to solidify 60 minutes after being mixed, and about 3 minutes or more after it was poured, forming a smooth surface, but it took two feeding hours to become walkable. It took. Comparative Example 3 The self-leveling floor village with the formulation of Example 2 has a discharge capacity of 0.
．． Using a continuous mixing device of 2 so/sec (?20〆/hr) and other devices similar to those shown in Example 1 that are suitable for this discharge capacity, a rough bed surface of 300㎡ was heated. Constructed.

The planned thickness of the drift boat is 3 yanagi, so the planned amount of self-leveling floor village is 9000 yanagi. The amount required for actual construction was 8,500 tons, and the operating time of the continuous mixing device, that is, the time required for construction, was about 1 hour. In this case, because the flow rate is slow, before the necessary self-leveling material has been supplied to the rough surface,
The self-leveling flooring material that was laid down earlier has progressed to set and harden, and although the finished surface is partially smooth, it is not level as a whole and has a gentle unevenness on the 10-15 side, which is unsightly. The time required for the entire construction including preparation and cleanup was one hour, which is very inefficient compared to Example 1. From the above examples and comparative examples, the present invention The effects are obvious, but they can be summarized below t as follows.

1. The present invention makes it possible to construct self-leveling flooring materials with a short setting time, which is virtually impossible to construct using conventional construction methods, thereby shortening the construction period.

2. Conventional construction methods required a series of repeated operations such as measuring, charging, feeding, and discharging, which required a great deal of labor, but the present invention saves labor (speeds up construction and shortens construction time). What became possible.

3 As an additional effect of the present invention, conventional construction methods inevitably left some residue of self-leveling flooring, but the method of the present invention makes it possible to perform construction without leaving any residue at all. thing.

[Brief explanation of the drawing]

The drawing is an example of a conceptual flow sheet of the construction apparatus of the present invention. 1...Popper, 2...Screw feeder, 3...
Tank, 4...Pump, 5...Valve, 6...
Flowmeter, 7... Continuous mixing device, 8... Pump. drawing

Claims (1)

[Claims] 1 A slurry having a viscosity of 10 cps to 500 cps is produced by continuously mixing a powdered hydrated hardening material and water or an aqueous solution containing an additive at a predetermined ratio under conditions that satisfy the following requirements. A method for constructing self-leveling flooring, which comprises preparing a slurry and pouring this slurry onto a rough floor. A Mixing capacity v(l): 1.5-100B Discharge capacity V(l/sec): 0.3-10C Mixing time
t (sec) 5:~300 However, t=v/V2 The construction method according to claim 1, wherein the powdery hydration hardening material comprises gypsum, cement, aggregate, and powdery additive. 3. The construction method according to claim 1, which comprises a powdered hydrated hardening material, gypsum, cement, and a powdered additive. 4. The construction method according to claim 1, wherein the powdered hydrated hardening material is a mixture of gypsum and aggregate or powdered additives. 5. The construction method according to claim 1, wherein the powdered hydrated hardening material is a mixture of cement and aggregate or powdered additives. 6. The construction method according to claim 1, wherein the powdered hydrated hardening material comprises gypsum and/or cement. 7. The construction method according to claim 1, wherein the ratio of the powdery hydrated hardening material to water or an aqueous solution containing an additive is in the range of 100/30 to 100/90 by weight. 8. The construction method according to claim 1, wherein the slurry has a viscosity of 200 cps to 1500 cps. 9 Under continuous mixing conditions, the mixing capacity is 3 to 50 liters, the discharge capacity is 0.3 to 3 liters/sec, and the mixing time is 5 to 170 liters.
The construction method according to claim 1, which is sec. 10 Under continuous mixing conditions, the mixing volume is 3 to 20 liters,
Discharge capacity is 0.5~1.4l/sec, mixing time is 6~
The construction method according to claim 1, wherein the construction time is 40 seconds.