WO2021177286A1 - 構造物保護シート、コンクリートブロック及び補強された構造物の製造方法 - Google Patents
構造物保護シート、コンクリートブロック及び補強された構造物の製造方法 Download PDFInfo
- Publication number
- WO2021177286A1 WO2021177286A1 PCT/JP2021/007894 JP2021007894W WO2021177286A1 WO 2021177286 A1 WO2021177286 A1 WO 2021177286A1 JP 2021007894 W JP2021007894 W JP 2021007894W WO 2021177286 A1 WO2021177286 A1 WO 2021177286A1
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- WIPO (PCT)
- Prior art keywords
- layer
- protective sheet
- resin
- polymer cement
- concrete
- Prior art date
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Images
Classifications
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/72—Repairing or restoring existing buildings or building materials
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G23/00—Working measures on existing buildings
- E04G23/02—Repairing, e.g. filling cracks; Restoring; Altering; Enlarging
- E04G23/0218—Increasing or restoring the load-bearing capacity of building construction elements
- E04G2023/0251—Increasing or restoring the load-bearing capacity of building construction elements by using fiber reinforced plastic elements
Definitions
- the present invention relates to a method for manufacturing a structure protective sheet, a concrete block and a reinforced structure. More specifically, a structure protective sheet capable of significantly reducing the construction period for providing a protective layer on the surface of a structure such as concrete and protecting the structure for a long period of time, and a structure protective sheet thereof were used. Regarding the manufacturing method of concrete blocks and reinforced structures.
- Civil engineering structures such as road bridges, tunnels, floodgates and other river management facilities, sewer pipes, and bay walls will be repaired and reinforced as they age.
- the repair work is carried out by recoating the coating material multiple times after repairing the defective part and the fragile part.
- the reinforcement work is carried out by repeatedly applying a reinforcing coating material to the entire portion to be reinforced.
- undercoating, intermediate coating, and topcoating are performed in order on concrete, but usually, the intermediate coating and each coating process are continuous in order to dry the coating.
- the undercoat, the first intermediate coat, the second intermediate coat, the first top coat, and the second top coat are applied for a total of five layers, it takes at least five days.
- it since it is painted outdoors, it may not be sufficiently dried in rainy weather, or the painting work itself may not be possible, depending on the weather.
- Patent Document 1 proposes a sheet and a method that are simple, low cost, shorten the construction period, and surely prevent deterioration of concrete.
- a concrete repair sheet having an intermediate layer having a resin film and a surface layer made of a cloth material laminated on both sides thereof via an adhesive resin is attached to a concrete surface to be repaired with a construction adhesive.
- a concrete repair method is performed in which a paint is applied to the surface layer on the side opposite to the concrete surface of the attached concrete repair sheet.
- Patent Document 2 states that it prevents the alkali-aggregate reaction, has excellent followability to cracks in concrete structures, and does not cause swelling of the coating film even when the temperature rises after the coating film is formed.
- a method for protecting a concrete structure using a coating material that makes it possible to prevent the concrete from peeling off has been proposed.
- This technique is a method of forming a base conditioner coating film on the surface of a concrete structure and forming a coating film on the surface of the coating film.
- the base conditioner coating film is formed from a composition containing a cationic (meth) acrylic polymer emulsion and an inorganic hydraulic substance.
- the coating film formed on the surface of the substrate adjusting material coating film is a coating film formed from a composition containing an alkyl (meth) acrylate-based emulsion and an inorganic water-hard substance, and has an elongation rate of 50 to 2000% at 20 ° C.
- the salt-shielding property is 10-2 to 10-4 mg / cm 2 ⁇ day, the water vapor permeability is 5 g / m 2 ⁇ day or more, and the film thickness is 100 to 5000 ⁇ m.
- JP-A-2010-144360 Japanese Unexamined Patent Publication No. 2000-16886
- Conventional concrete repair sheets such as Patent Document 1 have a difference in adhesive strength between a base material and another layer (for example, an adhesive layer or a reinforcing member), a difference in elongation of the base material, the adhesive layer, the reinforcing member, etc., and adhesion.
- a base material and another layer for example, an adhesive layer or a reinforcing member
- adhesion There are problems to be solved, such as the problem of adhesive strength between the agent layer and concrete.
- the base material and the reinforcing member are bonded by an adhesive layer, but when stress is applied to the concrete repair sheet during or after the construction of the concrete repair sheet, the base material, the adhesive layer and the reinforcing member are reinforced.
- the difference in elongation of the members and the like can cause peeling of the layer interface based on the difference between the adhesive force between the base material and the adhesive layer and the adhesive force between the adhesive layer and the reinforcing member.
- the adhesive layer provided on the concrete repair sheet is softened by heating or the like and bonded to the concrete, but if sufficient adhesive strength cannot be obtained, the concrete repair sheet is peeled off from the concrete surface and used as a repair sheet. May not work.
- the concrete after the concrete repair sheet was applied sometimes swelled over time, but this phenomenon was caused by the presence of the repair sheet, which has low water vapor permeability, and the water vapor inside the concrete lost its escape. Is considered to be.
- the method of forming a coating film by coating on site takes one day for each layer coating as described in the above background technology column, and for example, six layers of coating film from the undercoat to the topcoat layer. It takes as long as 6 days to form the above, and there is a problem that the film thickness varies and the quality and characteristics such as surface roughness and water content are difficult to stabilize.
- the present invention has been made to solve the above problems, and an object of the present invention is to significantly reduce the construction period when providing a protective layer on the surface of a structure such as concrete, and to protect the structure for a long period of time.
- a structure protection sheet that can prevent swelling caused by water vapor inside concrete and prevent deterioration of adhesiveness, and a construction method for concrete blocks and reinforced structures using the structure protection sheet. To provide.
- the present inventor has researched a concrete protective sheet that can stably protect concrete for a long period of time without relying on a construction method in which a layer is formed on the surface of concrete by a coating means.
- the concrete protective sheet is provided with performance according to the characteristics of the concrete, specifically, it has a water vapor permeability capable of discharging the water in the concrete as water vapor, and further, cracks and expansions generated in the concrete.
- the present invention has been completed by making it possible to further provide followability that can follow the concrete, waterproofness that does not allow deterioration factors such as water and chloride ions to permeate into concrete, salt shielding property, and neutralization prevention property. I let you. And this technical idea can be applied as a structure protection sheet to other structures not for concrete.
- the structure protective sheet according to the present invention is a structure protective sheet including a polymer cement hardened layer provided on the structure side and a resin layer provided on the polymer cement hardened layer, and is permeable to water vapor. It is characterized in that the rate is 10 to 50 g / m 2 ⁇ day.
- the polymer cement hardened layer provided on the structure side is excellent in adhesion to the structure because it contains a cement component, and the resin layer provided on the polymer cement hardened layer is waterproof. It is possible to impart excellent performance such as salt-shielding property and neutralization-preventing property. Since the polymer cement hardened layer contains a cement component, it can be expected to have a certain degree of water vapor permeability, but it is presumed that the resin layer provided on the polymer cement hardened layer results in inferior water vapor permeability.
- the water vapor transmittance of the entire structure protective sheet is within a predetermined range
- the water vapor inside is preferably permeated after being attached to a structure such as concrete. Since it can be discharged to the outside, the occurrence of swelling can be suitably prevented, and further, the deterioration of adhesiveness can be prevented.
- the merit that the water vapor permeability is within a predetermined range is that the structure allows steam to escape easily, so that the corrosion of metals (for example, reinforcing bars) in the structure tends to be suppressed.
- the structure protection sheet is applied to the structure on a rainy day, the surface of the structure gets wet and the structure itself contains water.
- the structure protective sheet according to the present invention makes it easier for moisture that has permeated the structure to escape to the outside after construction (after the production of the reinforced structure).
- Another advantage of the structure protective sheet according to the present invention is that the water vapor transmittance can be controlled, so that it can be attached to the surface of the structure even when the cement of the structure is not hardened, for example. It is in. That is, if water is rapidly removed when the cement is molded and hardened, the cement tends to become porous and the strength of the structure tends to decrease.
- the structure protective sheet according to the present invention is attached to the cement before hardening.
- the speed of water removal during the hardening of the cement can be controlled, and there is an advantage that it becomes easy to avoid the above-mentioned porous structure. Furthermore, since the structure protection sheet can be mass-produced by the coating process and the drying process on the production line of the factory, it is possible to realize cost reduction, drastic reduction of the work period at the site, and long-term protection of the structure.
- the structure protective sheet according to the present invention preferably has a sulfuric acid penetration depth of 0.1 mm or less after being immersed in a 5% sulfuric acid aqueous solution for 30 days while being wrapped in a basic building concrete block.
- the structure protective sheet since the structure protective sheet has excellent sulfuric acid resistance, it can be used as an extremely suitable repair sheet for structures such as sewer concrete structures where corrosion caused by sulfuric acid occurs.
- the surface of the resin layer opposite to the polymer cement hardened layer side was contaminated with carbon particle-containing oil, and then installed vertically and contaminated from a position about 2 meters away.
- the removal rate of contaminants when cleaned by pouring tap water on the surface vigorously almost horizontally using a hose may be 95% or more.
- the surface of the structure protective sheet according to the present invention has excellent cleanability, and is extremely suitable for structures such as highway walls and tunnel walls to which contaminants easily adhere. It can be used as a repair sheet.
- the polymer cement cured layer is a layer containing a cement component and a resin, and the resin may be contained in an amount of 10% by weight or more and 40% by weight or less.
- the present invention by controlling the ratio of the cement component and the resin component, it becomes easy to form a polymer cement hardened layer, and the polymer cement hardened layer is a layer having excellent followability and good compatibility.
- the adhesion of itself is excellent.
- the cement component contained in the polymer cement hardened layer on the structure side acts to enhance the adhesion to the structure such as concrete.
- the structure protective sheet according to the present invention may be used in a state where two or more layers are stacked.
- the structure protected by the structure protection sheet according to the present invention can be further protected. Therefore, for example, when two structure protection sheets according to the present invention are attached side by side, another structure protection sheet according to the present invention is attached so as to cover the boundary between these structure protection sheets. Can be done.
- the tear load measured by JIS K6781 is preferably 3 to 20N.
- the present invention when a protected structure collapses or collapses, it is appropriately torn and the peeling remains in a small area, so that the collapse or collapse caused by the large area being peeled off in a chained manner is prevented. be able to. Further, even when it becomes necessary to remove only a part of the protected structure, the structure can be torn at an arbitrary place, so that the part of the structure can be removed.
- the structure protective sheet according to the present invention preferably further includes a mesh layer.
- the present invention since it has a mesh layer, it is possible to impart excellent performance such as strength.
- the mesh layer at the interface between the polymer cement cured layer and the resin layer.
- the adhesive strength between the polymer cement hardened layer and the resin layer can be made excellent.
- the mesh layer may be present in the polymer cement hardened layer.
- a structure protective sheet having excellent hardness can be obtained.
- the mesh layer preferably has a line pitch of 50 mm to 1.2 mm (linear density of 0.2 to 8.0 lines / cm).
- the material of the polymer cement hardened layer can be sufficiently impregnated between the mesh layers, and the strength of the structure protective sheet according to the present invention can be easily improved.
- the mesh layer is selected from the group consisting of polypropylene fibers, vinylon fibers, carbon fibers, aramid fibers, glass fibers, polyester fibers, polyethylene fibers, nylon fibers and acrylic fibers. It may be composed of at least one kind.
- the material of the mesh layer can be arbitrarily selected in consideration of the adhesion to the resin material used for the resin layer, and a structure protective sheet having excellent strength can be obtained.
- one surface of the resin layer is imparted with design.
- the resin layer is provided with a design property
- a desired design property can be imparted to the appearance of the structure simply by attaching the structure protection sheet to the structure, which can contribute to shortening the construction period.
- Such a structure protective sheet is useful, for example, when it is desired to give a desired pattern to the foundation of a building such as a house.
- the design property is imparted by providing an uneven shape on the surface of the resin layer or by printing.
- the present invention it is possible to impart excellent designability to the structure protective sheet, and it is also possible to impart functions such as soundproofing performance and antifouling performance in addition to three-dimensional designing property due to the surface uneven shape of the resin layer.
- the design property may be imparted to the surface of the resin layer opposite to the side on which the polymer cement cured layer is provided.
- the surface side of the structure protective sheet according to the present invention is subjected to a design-imparting treatment, which can be made more excellent in design, and is, for example, embossed.
- the design has a concavo-convex shape on the surface, resulting in a design having a more three-dimensional effect.
- the concrete block according to the present invention is a concrete block using the structure protection sheet according to the present invention, and the polymer cement hardened layer of the structure protection sheet is attached to the surface via an adhesive layer. It is characterized by being.
- a structure protective sheet composed of only a layer that does not contain a base material or a reinforcing member since a structure protective sheet composed of only a layer that does not contain a base material or a reinforcing member is used, it can be easily attached to the surface of a concrete block. As a result, a structure protective sheet having a predetermined water vapor permeability can be stably provided on the surface of the concrete block even if the worker is not a skilled worker, the construction period can be significantly reduced, and the concrete block can be used for a long period of time. Can be protected.
- the method for manufacturing a reinforced structure using the structure protective sheet according to the present invention is the method for manufacturing a reinforced structure according to the present invention, and the structure is described after an adhesive is applied on the structure.
- the feature is that the object protection sheet is attached.
- the structure protective sheet composed of only the layer not including the base material and the reinforcing member is used, it can be easily attached to the surface of the structure.
- a structure protective sheet having a predetermined water vapor transmittance can be stably provided on the surface of the structure even if the operator is not a skilled worker, the construction period can be significantly reduced, and the structure can be used for a long period of time. Can be protected.
- an undercoat layer may be provided between the structure and the adhesive.
- the undercoat layer provided between the structure and the adhesive acts to enhance mutual adhesion, so that the structure protective sheet can stably protect the structure for a long period of time. ..
- a structure protection sheet capable of discharging water in a structure such as concrete and protecting the structure for a long period of time, a concrete block using the structure protection sheet, and a construction method are provided.
- the structure protective sheet is given performance according to the characteristics of the structure so that it can follow the cracks and expansions that occur in the structure and prevent deterioration factors such as water and chloride ions from penetrating the structure. It is possible to provide a structure protective sheet that can realize that the deterioration factor in the structure can be discharged and that the structure has transparency. In addition, it has the advantage of improving quality stability and uniformity as compared with layers that have been formed by hand coating.
- (A) is a photograph of the structure protection sheet according to Example 6,
- (b) is a photograph of the structure protection sheet according to Example 7, and
- (c) is a photograph of the structure protection sheet according to Comparative Example 4. It is a photograph.
- It is sectional drawing which shows another example of the structure protection sheet which concerns on this invention.
- It is explanatory drawing which shows another example which applied the structure protection sheet to the cast-in-place construction method.
- the structure protective sheet 1 As shown in FIG. 1 or FIG. 3C, the structure protective sheet 1 according to the present invention has a polymer cement hardened layer 2 provided on the structure 21 side and a resin provided on the polymer cement hardened layer 2. It has a layer 3. Both the polymer cement hardened layer 2 and the resin layer 3 may be formed as a single layer or as a laminated layer, respectively. Further, depending on the required performance, another layer may be provided between the polymer cement cured layer 2 and the resin layer 3.
- the structure protective sheet 1 has a water vapor permeability of 10 to 50 g / m 2 ⁇ day. Since the polymer cement hardened layer 2 contains a cement component, it can be expected to have a certain degree of water vapor permeability, but the resin layer 3 provided on the polymer cement hardened layer 2 results in inferior water vapor permeability. Presumably, such a problem does not occur in the present invention, and since the water vapor transmittance of the entire structure protective sheet 1 is within a predetermined range, the water vapor inside after being attached to a structure such as concrete is suitable.
- the water vapor permeability is within a predetermined range is that the structure allows steam to escape easily, so that the corrosion of metals (for example, reinforcing bars) in the structure tends to be suppressed.
- the structure protective sheet 1 is applied to the structure on a rainy day, the surface of the structure becomes wet and the structure itself contains water. However, the structure protective sheet 1 is applied. However, since it has the above-mentioned water vapor permeability, the moisture that has permeated the structure after construction (after the production of the reinforced structure) is easily released to the outside.
- the concrete immediately after hardening contains a large amount of water inside, and the structure protective sheet 1 according to the present invention can be suitably used for such concrete.
- Another advantage of the structure protective sheet 1 according to the present invention is that the water vapor transmittance can be controlled, so that it can be attached to the surface of the structure even when the cement of the structure is not hardened, for example. At the point. That is, if water is rapidly removed when the cement is molded and hardened, the cement tends to become porous and the strength of the structure tends to decrease.
- the structure protective sheet 1 according to the present invention is attached to the cement before hardening.
- the structure protective sheet 1 according to the present invention cannot sufficiently permeate water vapor and prevents a swelling phenomenon or the like after being attached to the structure. It cannot be done and the adhesiveness becomes insufficient. If it exceeds 50 g / m 2 ⁇ day, the speed of water removal at the time of hardening of the cement becomes excessively high, and there is a possibility that the cured product of the cement becomes porous.
- the preferable range of the water vapor transmittance is 20 to 50 g / m 2 ⁇ day.
- the structure protective sheet 1 according to the present invention having such a water vapor transmittance can be obtained, for example, by using a polymer cement cured layer 2 described later and a resin having a predetermined water vapor transmittance for the resin layer 3. ..
- the water vapor permeability in the present invention can be measured by the method described later.
- the structure protective sheet 1 according to the present invention preferably has a sulfuric acid penetration depth of 0.1 mm or less after being immersed in a 5% sulfuric acid aqueous solution for 30 days while being wrapped in a basic building concrete block. If the sulfuric acid penetration depth exceeds 0.1 mm, the sulfuric acid resistance of the structure protective sheet 1 according to the present invention becomes insufficient, and it is used for structures such as sewer concrete structures that are corroded by sulfuric acid. Sometimes you can't. A more preferable upper limit of the sulfuric acid permeation depth is 0.01 mm. The sulfuric acid permeation depth in the present invention can be measured by the method of Examples described later.
- the structure protective sheet according to the present invention may be used in a state where two or more layers are stacked. Since the structure protected by the structure protection sheet according to the present invention can be further protected, for example, when two structure protection sheets according to the present invention are attached side by side, these structures are attached. Another structure protective sheet according to the present invention can be attached so as to cover the boundary between the object protective sheets. In the structure protective sheet according to the present invention, since the polymer cement hardened layer contains cement and a resin component, the resin layer of the structure protective sheet according to the present invention previously attached to the structure Also shows suitable adhesiveness. Therefore, the structure protective sheet according to the present invention can be preferably used in a stacked state.
- the tear load measured according to the description of the tear load test item in JIS K 6781 is preferably 3 to 20 N.
- the structure can be torn at an arbitrary place, so that the part of the structure can be removed.
- the tear load is less than 3N, it becomes difficult to protect the structure itself, and if it exceeds 20N, tearing at an appropriate timing may not occur.
- a more preferable range of the tear load is 5 to 15 N.
- the tear load in the present invention can be measured by the method of Examples described later.
- the structure protective sheet 1 according to the present invention preferably has a thickness distribution of ⁇ 100 ⁇ m or less. Since the thickness distribution of the structure protective sheet 1 is within the above range, a layer having a small thickness variation can be stably provided on the surface of the structure 21 even if the operator is not a skilled worker. Further, by controlling the thickness distribution within the above range, it becomes easy to uniformly reinforce the structure.
- the polymer cement hardened layer 2 provided on the structure 21 side has excellent adhesion to the structure 21, and the resin layer 3 provided on the polymer cement hardened layer 2 has a predetermined water vapor permeability. It is possible to easily impart excellent properties such as waterproofness, salt shielding property, and neutralization prevention property.
- the structure protection sheet 1 can be mass-produced by the coating process and the drying process on the production line of the factory, it is possible to reduce the cost, significantly reduce the work period at the site, and realize long-term protection of the structure. As a result, the construction period for bonding to the surface of the structure 21 can be significantly reduced, and the structure 21 can be protected for a long period of time.
- the structure 21 is a mating member to which the structure protection sheet 1 according to the present invention is applied.
- Examples of the structure 21 include a structure made of concrete.
- the concrete is generally obtained by casting and curing a cement composition containing at least a cement-based inorganic substance, an aggregate, an admixture and water.
- Such concrete is used for river management facilities such as road bridges, tunnels, and water gates, sewer pipes, harbor quays, bridges, balustrades, side walls of highways, sewage pipes (inner surface, outer surface, joints), sewage facilities (sewage treatment facilities, irrigation canals).
- the structure protective sheet 1 by applying the structure protective sheet 1 to the structure 21 made of concrete, it is possible to follow the cracks and expansions that occur in the concrete, and the deterioration factors such as water and chloride ions do not permeate into the concrete. It has the special advantage that the water in the concrete can be discharged as water vapor.
- the polymer cement hardened layer 2 is a layer arranged on the structure side.
- the polymer cement hardened layer 2 may be, for example, a single layer that is not overcoated as shown in FIG. 1 (A), or may be a laminated layer that is overcoated as shown in FIG. 1 (B). Whether to use a single layer or a laminated layer is arbitrarily set in consideration of the overall thickness, imparting function (followability, adhesiveness to a structure, etc.), factory production line, production cost, etc., for example, a production line. If the thickness is short and the single layer does not have a predetermined thickness, two or more layers can be overcoated to form the film.
- the second layer is formed after the first layer is dried.
- the polymer cement hardened layer 2 may have a structure in which layers having different properties are laminated. For example, by forming a layer having a higher proportion of the resin component on the resin layer 3 side, the layer having a high resin component adheres to the resin layer, and the layer having a high cement component adheres to the concrete structure. The sex is extremely excellent.
- the polymer cement hardened layer 2 is preferably a layer containing a cement component and a resin. More specifically, it is obtained by forming a resin (resin component) containing a cement component into a paint and applying this paint.
- the cement component include various cements, limestones containing a component composed of calcium oxide, and viscosities containing silicon dioxide. Of these, cement is preferable, and examples thereof include Portland cement, alumina cement, early-strength cement, and fly ash cement. Which cement is selected is selected according to the characteristics that the polymer cement hardened layer 2 should have, and is selected in consideration of, for example, the degree of followability to the concrete structure 21. In particular, Portland cement defined in JIS R5210 can be preferably mentioned.
- the resin component examples include acrylic resin, acrylic urethane resin, acrylic silicone resin, fluororesin, flexible epoxy resin, polybutadiene rubber, and acrylic resin exhibiting rubber properties (for example, synthetic rubber containing an acrylic acid ester as a main component). Can be mentioned. It is preferable that such a resin component is the same as the resin component constituting the resin layer 3 described later from the viewpoint of enhancing the adhesion between the polymer cement cured layer 2 and the resin layer 3. Further, as the resin component, any of a thermoplastic resin, a thermosetting resin, and a photocurable resin may be used.
- curing of the polymer cement cured layer 2 does not mean that the resin component is limited to a resin that cures and polymerizes, such as a thermosetting resin or a photocurable resin, but when it becomes the final layer. It is used in the sense that a material that hardens to the surface should be used.
- the content of the resin component is appropriately adjusted according to the material used, etc., but is preferably 10% by mass or more and 40% by weight or less with respect to the total amount of the cement component and the resin component. If it is less than 10% by weight, the adhesiveness to the resin layer 3 may be lowered and it may be difficult to maintain the polymer cement hardened layer 2 as a layer. If it exceeds 40% by weight, it may be difficult to maintain the polymer cement hardened layer 2 as a layer. Adhesion may be inadequate. From the above viewpoint, the more preferable range of the content of the resin component is 15% by weight or more and 35% by weight or less, but more preferably 20% by weight or more and 30% by weight or less.
- the paint for forming the polymer cement hardened layer 2 is a coating liquid in which a cement component and a resin component are mixed with a solvent.
- the resin component is preferably an emulsion.
- an acrylic emulsion is a polymer fine particle obtained by emulsion polymerization of a monomer such as an acrylic acid ester using an emulsifier.
- Acrylic acid-based polymer emulsion obtained by polymerizing the body mixture in water containing a surfactant can be preferably mentioned.
- the content of the acrylic acid ester or the like constituting the acrylic emulsion is not particularly limited, but is selected from the range of 20 to 100% by mass.
- the surfactant is also blended in an amount as required, and the amount is not particularly limited, but a surfactant to the extent that it becomes an emulsion is blended.
- the polymer cement hardened layer 2 is formed by applying the coating liquid on a release sheet and then drying and removing the solvent (preferably water).
- a mixed composition of a cement component and an acrylic emulsion is used as a coating liquid to form a polymer cement hardened layer 2.
- the resin layer 3 may be formed on the release sheet after the polymer cement cured layer 2 is formed, but the polymer cement cured layer 2 is formed after the resin layer 3 is formed on the release sheet.
- the polymer cement hardened layer 2 may be formed after the resin layer 3 is formed on the release sheet.
- the release sheet when designability is imparted, for example, the release sheet is embossed or matted (concavo-convex shape is imparted), and then a resin layer 3 (two layers even if it is a single layer) is provided.
- the above-mentioned multiple layers may be formed), and the polymer cement hardened layer 2 (either a single layer or two or more layers may be formed) is formed in this order, and the resin layer 3 is provided with a design property.
- the structure protection sheet 1 may be manufactured by using the method of imparting.
- the thickness of the polymer cement hardened layer 2 is not particularly limited, but the usage pattern of the structure 21 (river facilities such as road bridges, tunnels, water gates, sewer pipes, harbor quays, bridges, balustrades, side walls of highways, sewer pipes ( Inner surface, outer surface, joints), sewage facilities (sewage treatment facilities, irrigation canals), underwater facilities, tunnels for wiring in areas near the sea, dam drainage channels, civil engineering structures such as manhole inner walls, concrete roofs, totan roofs, concrete It is arbitrarily set according to the roof, building pipes, ALC panels, indoor flooring materials, buildings such as the inner and outer surfaces of tunnels), the degree of aging, and the shape.
- the specific thickness of the polymer cement hardened layer 2 can be, for example, in the range of 0.5 mm to 1.5 mm. As an example, when the thickness is 1 mm, the thickness variation is preferably within ⁇ 100 ⁇ m. Such a thickness of accuracy cannot be achieved by on-site coating, and can be achieved by stable coating on a factory production line. Even if it is thicker than 1 mm, the thickness variation can be within ⁇ 100 ⁇ m. Further, when it is thinner than 1 mm, the thickness variation can be further reduced.
- Water vapor is easily permeated through the polymer cement hardened layer 2 due to the presence of the cement component. Water vapor transmission rate at this time is, for example, 20 ⁇ 60g / m 2 ⁇ about day.
- the cement component has good compatibility with, for example, the cement component constituting concrete, and can be excellent in adhesion to the concrete surface.
- the polymer cement hardened layer 2 containing the cement component has good adhesion to the adhesive 23. Glue.
- the polymer cement hardened layer 2 has stretchability, it can follow the change of concrete even when the structure 21 is cracked or expanded.
- the present invention preferably further includes a mesh layer.
- a mesh layer When repairing large concrete members such as road bridges, tunnels, river management facilities such as water gates, sewer pipes, civil engineering structures such as bay walls, etc. using the structure protection sheet according to the present invention, the structure according to the present invention.
- the material protection sheet itself is required to have sufficient strength (tensile strength, bending strength, hardness, surface strength, punching strength, toughness, etc., the same shall apply hereinafter in the present specification), but the above mesh layer is further provided. Therefore, the structure protective sheet according to the present invention can have sufficient strength to withstand the repair of the large concrete member as described above.
- the structure protective sheet 1 according to the present invention is provided with a mesh layer 5 at the interface between the polymer cement cured layer 2 and the resin layer 3 because the structure protective sheet 1 according to the present invention has excellent adhesion strength. Is preferable.
- the above-mentioned adhesive strength means that the surface of the structure protective sheet 1 according to the present invention on the polymer cement hardened layer 2 side is attached to the concrete surface using an adhesive, and a tension jig is fixed to the surface of the resin layer 3. It is obtained by measuring the strength at which tensile delamination occurs by pulling the tensioning jig to the side opposite to the concrete side at a speed of 1500 n / min.
- the mesh layer 5 may exist inside the polymer cement hardened layer 2 as shown in FIG. 1 (B).
- the mesh layer 5 may be arranged on the surface of the polymer cement cured layer 2 opposite to the surface in contact with the resin layer 3, but the mesh layer 5 may be embedded inside the polymer cement cured layer 2. preferable. Since the mesh layer 5 is embedded inside the polymer cement hardened layer 2, the contact area between the mesh layer 5 and the polymer cement hardened layer 2 is increased, and it becomes easy to improve the adhesive strength between the two, and the polymer cement. It becomes easy to secure the strength of the entire cured layer 2. If the mesh layer 5 is not embedded inside the polymer cement hardened layer 2, peeling is likely to occur at the interface between the mesh layer 5 and the polymer cement hardened layer 2.
- the mesh layer 5 when the mesh layer 5 is present inside the polymer cement hardened layer 2, the mesh layer 5 may be present at a position half the thickness of the polymer cement hardened layer 2, but the resin layer 3 is more present. It is desirable to be on the side.
- the adhesive force is improved by 1.3 times on average.
- the mesh layer 5 is impregnated with a material (for example, a cement component or a resin component) constituting the polymer cement cured layer 2.
- a material for example, a cement component or a resin component constituting the polymer cement cured layer 2.
- the state in which the material constituting the polymer cement cured layer 2 is impregnated in the mesh layer 5 means that the material constituting the polymer cement cured layer 2 is filled between the fibers constituting the mesh layer 5. This means that the impregnation state makes it easy to make the adhesive strength between the mesh layer 5 and the polymer cement hardened layer 2 extremely excellent. Further, the interaction between the mesh layer 5 and the material of the polymer cement hardened layer 2 is likely to be stronger, and the strength of the structure protective sheet 1 is likely to be improved.
- the mesh layer 5 has a structure in which fibers of warp and weft are arranged in a lattice pattern.
- the fiber is composed of at least one fiber selected from the group consisting of, for example, polypropylene fiber, vinylon fiber, carbon fiber, aramid fiber, glass fiber, polyester fiber, polyethylene fiber, nylon fiber and acrylic fiber.
- polypropylene fibers and vinylon fibers can be preferably used.
- the shape thereof is not particularly limited, and in addition to the biaxial braid as shown in FIG. 6, for example, an arbitrary mesh layer 5 such as a triaxial braid can be used.
- the mesh layer preferably has a line pitch of 50 mm to 1.2 mm (linear density of 0.2 to 8.0 lines / cm). If the pitch is 1.2 mm or less, the bonding of the polymer cement layers above and below the mesh may be insufficient, and the surface strength of the structure protective sheet may be insufficient. Further, when the line pitch exceeds 50 mm, the surface strength of the structure protective sheet is not adversely affected, but the tensile strength may be weakened. In the structure protective sheet of the present invention, there is a trade-off relationship between tensile strength and surface strength, and a mesh suitable for application to the present invention has a line pitch in the range of 50 mm to 1.2 mm.
- the mesh layer 5 may have a size that covers the entire surface of the polymer cement hardened layer 2 when viewed from the upper surface side of the polymer cement hardened layer 2, or may be smaller than the polymer cement hardened layer 2. That is, the area of the mesh layer 5 in a plan view may be the same as or smaller than the area of the polymer cement hardened layer 2 in a plan view, but the area of the mesh layer 5 in a plan view is a polymer. It is preferably 60% or more and 95% or less with respect to the plan view area of the cement hardened layer 2. If it is less than 60%, the strength of the structure protective sheet according to the present invention may be insufficient, and the strength may vary.
- the adhesive strength between the polymer cement cured layers 3 may be inferior in the configuration in which the polymer cement cured layers 3 are laminated via the mesh layer 5, and the structure protective sheet according to the present invention is used as a structure. There is an increased risk of peeling of the polymer cement hardened layer 2 portion when it is applied to.
- the plane viewing area of the mesh layer 5 and the like can be measured by a known method.
- the resin layer 3 is a layer that is arranged on the opposite side of the structure 21 and appears on the surface.
- the resin layer 3 may be, for example, a single layer as shown in FIG. 1 (A), or may be a laminate consisting of at least two layers as shown in FIG. 1 (B).
- Whether to use a single layer or a laminated layer takes into consideration the overall thickness, imparting function (waterproofness, salt shielding property, neutralization prevention property, water vapor permeability, etc.), factory production line length, production cost, etc. For example, when the production line is short and a single layer does not have a predetermined thickness, two or more layers can be overcoated to form the film.
- the second layer is applied after the first layer is dried. The second layer is then dried.
- the resin layer 3 is coated with a paint that has flexibility and can follow cracks and cracks generated in concrete and can form a resin layer having excellent waterproofness, salt shielding property, neutralization prevention property and water vapor permeability. And get it.
- the resin constituting the resin layer 3 include an acrylic resin exhibiting rubber properties (for example, a synthetic rubber containing an acrylic acid ester as a main component), an acrylic urethane resin, an acrylic cone resin, a fluororesin, a flexible epoxy resin, and a polybutadiene rubber. Can be mentioned. It is preferable that the resin material is the same as the resin component constituting the polymer cement layer 2 described above. In particular, a resin containing an elastic film-forming component such as rubber is preferable.
- the acrylic resin exhibiting rubber properties is preferably made of an aqueous emulsion of an acrylic rubber copolymer in that it is excellent in safety and coatability.
- the proportion of the acrylic rubber-based copolymer in the emulsion is, for example, 30 to 70% by mass.
- the acrylic rubber-based copolymer emulsion can be obtained, for example, by emulsion polymerization of the monomer in the presence of a surfactant.
- a surfactant any of anionic, nonionic and cationic surfactants can be used.
- the resin layer 3 is preferably composed of a resin exhibiting excellent water vapor permeability.
- the water vapor transmittance of the structure protective sheet according to the present invention can be within the above range.
- the paint for forming the resin layer 3 is a resin by preparing a mixed coating liquid of a resin composition and a solvent, applying the coating liquid on a release sheet, and then drying and removing the solvent.
- Form layer 3. The solvent may be water or an aqueous solvent, or may be an organic solvent such as xylene / mineral spirit. In the examples described later, an aqueous solvent is used, and the resin layer 3 is made of an acrylic rubber composition.
- the order of the layers formed on the release sheet is not limited, and may be, for example, the order of the resin layer 3 and the polymer cement cured layer 2 as described above, or the polymer cement cured layer 2 and the resin layer 3. It may be in the order of.
- the thickness of the resin layer 3 is arbitrarily set according to the usage pattern of the structure 21 (road bridges, tunnels, river management facilities such as water gates, civil engineering structures such as sewer pipes and harbor quays), the degree of aging, and the shape. NS.
- the thickness is preferably any one within the range of 50 to 150 ⁇ m, and the thickness variation is preferably within ⁇ 50 ⁇ m. Such a thickness of accuracy cannot be achieved by on-site coating, and can be stably achieved on a factory production line.
- the resin layer 3 has high waterproofness, salt-shielding property, and neutralization-preventing property, but it is preferable that water vapor permeates.
- the water vapor transmittance is appropriately adjusted so that, for example, the water vapor transmittance of the structure protective sheet 1 according to the present invention is 10 to 50 g / m 2 ⁇ day.
- the structure protective sheet 1 can be provided with high waterproofness, salt-shielding property, neutralization-preventing property, and predetermined water vapor permeability.
- the compatibility with the polymer cement hardened layer 2 is good, and the adhesion can be excellent.
- the water vapor permeability was measured in accordance with JIS Z0208 "Humidity Permeability Test Method for Moisture-Proof Packaging Material".
- the resin layer 3 may contain a pigment from the viewpoint of being able to have abundant color variations of the structure protective sheet 1 according to the present invention.
- the resin layer 3 may contain an inorganic substance. By containing an inorganic substance, scratch resistance can be imparted to the resin layer 3.
- the inorganic substance is not particularly limited, and examples thereof include conventionally known materials such as metal oxide particles such as silica, alumina, and titania.
- the surface of the resin layer 3 opposite to the polymer cement hardened layer 2 side is contaminated with carbon particle-containing oil and then installed vertically, and is contaminated from a position about 2 meters away.
- the removal rate of contaminants is 95% or more when the surface is cleaned by pouring tap water vigorously almost horizontally using a hose.
- the surface of the resin layer 3 has excellent cleanability, and can be used as an extremely suitable repair sheet for structures such as highway walls and tunnel walls to which contaminants easily adhere. If the removal rate of the above-mentioned contaminants is less than 95%, the antifouling property becomes insufficient, and the above-mentioned walls of the expressway and the walls of the tunnel are apt to give the impression that they are "dirty". On the other hand, the higher the removal rate of pollutants, the better, but usually it is 98% or less.
- the resin of the resin layer a material that can easily remove contaminants such as acrylic silicone resin is selected, or a resin is used. It can be obtained by including a material (antifouling agent) that makes it easy to remove contaminants such as silicon resin or silicon fine particles in the layer.
- a material insectifouling agent
- the evaluation of pollutability in the present invention can be carried out by the method of Examples described later.
- the resin layer 3 may contain additives that can impart various functions. Examples of such an additive include cell roll nanofibers and the like.
- designability is imparted to any one surface of the resin layer 3.
- either one surface means the surface on the polymer cement hardened layer 2 side or the opposite surface.
- the design property is provided by providing an uneven shape or is imparted by printing.
- the treatment for imparting the design property is not particularly limited, and for example, an embossing treatment or a matte treatment (matte treatment) applied to the surface of the resin layer, a mirror treatment (gloss treatment), or printing on the surface of the resin layer. Is preferably used.
- the embossing treatment is a treatment for imparting a desired uneven shape to the surface of the resin layer 3, and for example, the embossing roll 10 having irregularities corresponding to the irregularities to be imparted to the roll surface as shown in FIG. 7 has not been formed.
- the cured resin layer 3' is sent out, the surface of the uncured resin layer 3'is pressed against the surface, the unevenness of the emboss roll 10 is transferred to the surface of the uncured resin layer 3', and then the uncured resin layer 3'is cured.
- a method of forming the resin layer 3 by allowing the resin layer 3 to be formed can be mentioned.
- the shape of the unevenness of the embossed roll is not particularly limited, and may be appropriately selected according to the desired design.
- the method of forming the uneven shape on the surface of the resin layer 3 is not limited to the embossing treatment, and other methods may be used, and so-called matte processing can be performed by a method similar to the embossing treatment. Is. For example, as shown in FIG. 8, a dimple-shaped (hemispherical) uneven shape is provided on the release layer 4 to a depth of about 1 micron, and the uncured resin layer 3'is coated on the dimple-shaped (hemispherical) uneven shape, and then uncured.
- the resin in the cured resin layer 3' is cured, the polymer cement layer 2 is further provided, and then the release layer 4 is peeled off, a structure protective sheet having a mat-like design formed on the surface of the resin layer 3 can be obtained. Obtainable.
- the method for printing the surface of the resin layer 3 is not particularly limited, and for example, a solvent, a binder resin (urethane-based, acrylic-based, nitrocellulose-based, rubber-based, etc.), various pigments, extender pigments, and additives (plasticizer) are used. Printing may be performed with an ink obtained by adding an agent, a desiccant, a stabilizer, etc.).
- the pattern to be printed is not particularly limited, and characters, patterns, etc. are appropriately selected according to the design to be given to the structure.
- examples of the above-mentioned ink printing method include known printing methods such as offset printing, gravure printing, flexographic printing, silk screen printing, and inkjet printing.
- the surface of the resin layer 3 may be subjected to a treatment such as corona treatment or ozone treatment before printing the ink.
- a treatment such as corona treatment or ozone treatment
- the structure protective sheet of the present invention is provided with an embossed or matte uneven surface on the surface of the release sheet, a design is formed on the uneven surface by printing, and then a resin layer and a polymer cement layer are provided in this order. Can be formed with.
- a transparent resin layer such as acrylic silicon at the interface between the release sheet and the uneven surface. In that case, since a resin layer such as acrylic silicon is present on the outermost surface after protecting the structure, it greatly contributes to the improvement of weather resistance.
- the design property may be imparted to at least one surface of the resin layer 3, for example, the surface of the resin layer 3 opposite to the one polymer cement cured layer 2 side (the surface of the structure protective sheet 1).
- a more favorable design can be imparted, and particularly when an uneven shape is imparted by embossing or the like, a design having an excellent three-dimensional effect can be imparted. Gender can be given.
- the imparted design does not come into direct contact with the outside air, so that excellent designability can be maintained for a long period of time.
- the resin layer 3 may be formed so as to be transparent or translucent.
- the structure protective sheet according to the present invention there is also a structure in which a printing layer is provided on the surface of the resin layer 3 on the polymer cement cured layer 2 side, and an uneven shape is provided on the surface on the opposite side of the resin layer 3 by embossing or the like. Suitable. It is possible to simultaneously obtain an excellent design property due to the printed layer and a three-dimensional effect due to the embossed uneven shape, and it is also possible to impart functions such as antiglare, soundproofing and antifouling properties due to the uneven shape.
- the produced structure protective sheet 1 may be provided with a release sheet 4 on one surface of the polymer cement cured layer 2 and the resin layer 3.
- the release sheet 4 can protect the surface of the structure protection sheet 1 when going to the construction site, for example, and at the construction site, the undercoat layer 22 or the adhesive layer 23 is placed on the target structure 21.
- the release sheet 4 is preferably a process paper used in the production process of the structure protection sheet 1.
- the material of the process paper used as the release sheet 4 is not particularly limited as long as it is a conventionally known one used in the manufacturing process.
- a laminated paper having an olefin resin layer such as polylopylene or polyethylene or a layer containing silicon can be preferably mentioned.
- the thickness is not particularly limited, but can be any thickness, for example, about 50 to 500 ⁇ m, as long as it is not a thickness that hinders handling in manufacturing and construction.
- the structure protection sheet 1 described above can discharge water in a structure such as concrete, and can protect the concrete structure 21 for a long period of time.
- the structure protective sheet 1 is provided with performance according to the characteristics of the concrete structure 21 to follow the cracks and expansions that occur in the concrete structure 21, and the concrete structure 21 is deteriorated by water, chloride ions, etc. It is possible to prevent the factor from penetrating and to provide the permeability so that the deterioration factor in the concrete structure 21 can be discharged. Since such a structure protective sheet 1 can be manufactured at a factory, it is possible to mass-produce high-quality ones having stable characteristics. As a result, construction can be carried out without relying on the skills of craftsmen, and the construction period can be shortened and labor costs can be reduced.
- the use of the structure protection sheet according to the present invention includes various objects other than the surface reinforcement of civil engineering structures such as road bridges, tunnels, water gates and other river management facilities, sewer pipes, harbor quays, bridges and balustrades. It can be mentioned and various effects can be obtained. Specifically, for example, it is attached to a metal roof such as a totan roof to impart metal corrosion resistance, attached to a building pipe to reinforce the surface, and attached to an ALC panel of a factory building to reduce deterioration or repair.
- a metal roof such as a totan roof to impart metal corrosion resistance
- ALC panel of a factory building to reduce deterioration or repair.
- the concrete block according to the present invention is characterized in that the polymer cement hardened layer of the structure protective sheet according to the present invention is attached to the surface via an adhesive layer.
- the adhesive constituting the adhesive layer is not particularly limited, and examples thereof include the same adhesives described later. Further, an undercoat layer, which will be described later, may be provided on the concrete block before forming the adhesive layer.
- the concrete block to which the structure protective sheet according to the present invention is attached is not particularly limited, and examples thereof include those having an arbitrary shape according to the purpose of use. Specifically, for example, the inner wall of a tunnel, the median strip of a highway, a bridge, a sewer pipe, the foundation of a house, etc., and the target is a wide range of fields of civil engineering and construction.
- Such a concrete block according to the present invention has an excellent water vapor transmittance because the above-mentioned structure protective sheet according to the present invention is attached to the surface, and a swelling phenomenon caused by moisture in the concrete block. And the decrease in adhesive strength can be suppressed.
- the method for manufacturing a reinforced structure using the structure protective sheet according to the present invention is a construction method using the structure protective sheet 1 according to the present invention, and is a construction method using the structure 21. After applying the adhesive 23 on the structure protective sheet 1, the structure protective sheet 1 is attached. In this construction method, the structure protective sheet 1 can be easily attached to the surface of the structure 21. As a result, the structure protection sheet 1 can be provided on the structure 21 even if the worker is not a skilled worker, the construction period can be significantly reduced, and the structure 21 can be protected for a long period of time.
- FIG. 3 is an explanatory view of the construction method (manufacturing method of the reinforced structure) of the structure protection sheet 1.
- the undercoat layer 22 can be formed by applying a coating liquid in which a resin such as an epoxy resin and a solvent are mixed to the structure 21 and then volatilizing and drying the solvent in the coating liquid.
- a resin such as an epoxy resin and a solvent
- the thickness of the undercoat layer 22 is not particularly limited, but can be, for example, in the range of 100 to 150 ⁇ m.
- the structure protective sheet 1 can stably protect the structure 21 for a long period of time. If the structure 21 has cracks or defects, it is preferable to provide the undercoat layer 22 after repairing the cracks or defects.
- the repair is not particularly limited, but usually cement mortar, epoxy resin, or the like is used.
- the adhesive 23 is applied as shown in FIG. 3 (B). As shown in FIG. 3C, the structure protective sheet 1 is attached to the applied adhesive 23 without drying.
- the adhesive 23 include urethane-based adhesives, epoxy-based adhesives, and adhesives using an acrylic resin exhibiting rubber properties (for example, synthetic rubber having an acrylic acid ester as a main component).
- 23, which is composed of the same type of resin component as the resin component constituting the polymer cement hardened layer 2 of the structure protective sheet 1, is more preferable because the adhesive strength with the polymer cement hardened layer 2 is high.
- the thickness of the adhesive 23 is not particularly limited.
- the adhesive 23 is usually applied to concrete by means such as brush coating or spray coating, and then naturally dried and cured over time.
- FIG. 4 is an explanatory view showing an example in which the structure protection sheet 1 is applied to the cast-in-place construction method.
- the cast-in-place construction method is a construction method in which a formwork 24 is formed at a work site, a concrete composition 21'is poured into the formwork 24, and the concrete composition 21'is left to harden to obtain a concrete structure 21.
- the structure protective sheet 1 is attached to the surface of the hardened concrete structure 21, so that the structure 21 is less likely to deteriorate.
- the undercoat layer 22 is applied and dried on the surface of the concrete structure 21, the adhesive 23 is applied on the undercoat layer 22, and then the structure protective sheet 1 is bonded. Then, usually, the adhesive 23 is dried and cured by leaving it to stand naturally to adhere the structure protective sheet 1.
- the structure protection sheet 1 is attached by the same construction method as described above. In this way, the life of the concrete structure 21 can be extended.
- a step of applying a primer layer 7 containing a curable resin material to the surface of the concrete structure 21 (2) a primer.
- each step will be described.
- the concrete structure 21 is a mating member to which the structure protective sheet 1 according to the present invention is applied, and examples thereof include the same members as those described above.
- the primer layer 7 containing the curable resin material is applied to the surface of the concrete structure 21.
- the curable resin material is not particularly limited as long as it has the property of being cured by thermosetting, photocuring or other methods to form a resin, but an epoxy compound can be preferably used.
- the cured primer layer (not shown in FIG. 10) formed by curing the primer layer 7 is an epoxy cured product.
- the epoxy cured product is generally an epoxy compound having two or more epoxy groups cured with a curing agent.
- an epoxy cured product is used as a primer layer will be described as an example.
- Examples of the epoxy compound include bisphenol A type epoxy resin, bisphenol F type epoxy resin, bisphenol S type epoxy resin, orthocresol novolac type epoxy resin, alicyclic epoxy resin, aliphatic epoxy resin, and diglycidyl etherified phenols. Examples thereof include diglycidyl etherified epoxies of alcohols.
- Examples of the curing agent include polyfunctional phenols, amines, polyamines, mercaptans, imidazoles, acid anhydrides, phosphorus-containing compounds and the like.
- the polyfunctional phenols include hydroquinone, which is a monocyclic bifunctional phenol, resorcinol, catechol, bisphenol A, which is a polycyclic bifunctional phenol, bisphenol F, naphthalenediols, biphenols, and halides thereof. , Alkyl group substituents and the like.
- novolak and resole which are polycondensates of these phenols and aldehydes, can be used.
- amines include aliphatic or aromatic primary amines, secondary amines, tertiary amines, quaternary ammonium salts and aliphatic cyclic amines, guanidines, urea derivatives and the like.
- the material of the primer layer 7 is an epoxy resin-based primer, for example, a main agent of bisphenol A type epoxy or bisphenol F type epoxy, and curing of polyamines or mercaptans.
- the epoxy resin-based primer may contain, for example, a coupling agent, a viscosity modifier, a curing accelerator, or the like, in addition to the main agent and the curing agent.
- a primer layer 7 for example, a two-component reaction-curable water-based epoxy resin emulsion "Aromble Coat P-300" manufactured by Toagosei Co., Ltd. (trade name, "Aromble Coat” is a registered trademark of Toagosei Co., Ltd. .) Can be used.
- the primer layer 7 is generally used as an undercoat material for the concrete structure 21.
- a solvent-type epoxy resin solvent solution, an epoxy resin emulsion and other general emulsions, an adhesive or the like may be applied to the surface of the concrete structure 21 as the undercoat material.
- the undercoat material can be applied by a usual method, for example, it is applied to the surface of the concrete structure 21 to be prevented from deterioration by a general method such as applying it with a brush or a roller, or spraying it with a spray gun or the like. And form a coating film.
- the thickness of the primer layer 7 is not particularly limited, but is preferably in the range of 50 ⁇ m or more and 300 ⁇ m or less in a wet state.
- the thickness of the primer layer 7 By setting the thickness to 50 ⁇ m or more, it becomes easy to make the thickness of the primer layer 7 uniform in consideration of the penetration of the material of the primer layer 7 into the concrete, and the adhesiveness between the concrete structure 21 and the structure protective sheet 1 is improved. It will be easier to secure.
- the upper limit of the thickness of the primer layer 7 is not particularly limited, but it is preferably 300 ⁇ m or less in terms of ease of application, the meaning of minimizing the deviation between the two layers at the time of adhesion, and the optimization of the material usage fee. .. Since the primer layer 7 provided as the undercoat layer of the concrete structure 21 and the concrete structure 21 and the structure protective sheet 1 act to enhance mutual adhesion, if the primer layer 7 is made the above thickness, the structure is protected.
- the sheet 1 is stable for a long period of time to reinforce and protect the concrete structure 21 easily.
- the repair method is not particularly limited, but the repair is usually performed using cement mortar, epoxy resin, or the like.
- the structure protective sheet 1 is installed on the primer layer 7 so that the primer layer 7 and the polymer cement hardened layer 2 are in contact with each other.
- the structure protective sheet 1 can be installed, for example, by applying the primer layer 7 on the concrete structure 21 and then laminating the structure protective sheet 1 as shown in FIG.
- the structure protective sheet 1 composed of layers having a small thickness variation can be provided on the concrete structure 21 even if the worker is not a skilled worker, the construction period can be shortened, and the concrete structure 21 can be used for a long period of time. Can be protected over.
- the primer layer 7 can be applied not on the concrete structure 21 but on the surface 2 of the polymer cement hardened layer of the structure protective sheet 1 immediately before bonding.
- the primer layer 5 that functions as an undercoat layer can be used as an adhesive layer without using an adhesive. Therefore, in the present invention, the structure protective sheet 1 can be directly placed on the primer layer 7 (uncured, wet state), and the process can be shortened.
- Step (3) is a step of curing the primer layer 7 to form a cured primer layer (not shown in FIG. 10).
- the curing of the primer layer 7 is performed, for example, by leaving the primer layer 7 and the structure protective sheet 1 in a bonded state for 24 hours.
- Example 1 A release sheet having a thickness of 130 ⁇ m made of PP laminated paper embossed in advance was used.
- a resin layer was formed on the release sheet by the following method. First, an emulsion composition containing 60 parts by mass of acrylic silicone resin, 25 parts by mass of titanium dioxide, 10 parts by mass of ferric oxide, and 5 parts by mass of carbon black was prepared. After applying this emulsion composition on the release sheet, it was heat-treated and cured to form a resin layer. The thickness of the resin layer was set to 0.1 mm. Next, a polymer cement hardened layer was formed on the resin layer.
- an aqueous acrylic emulsion containing 45 parts by mass of the cement mixture was prepared as a composition for forming a hardened polymer cement layer.
- the cement mixture contains at least 70 ⁇ 5 parts by mass of Portoland cement, 10 ⁇ 5 parts by mass of silicon dioxide, 2 ⁇ 1 part by mass of aluminum oxide, and 1 to 2 parts by mass of titanium oxide, and the acrylic emulsion is acrylic. It contains at least 53 ⁇ 2 parts by mass of an acrylic acid-based polymer and 43 ⁇ 2 parts by mass of water that have been emulsified and polymerized using an acid ester monomer as an emulsifier.
- the polymer cement layer 2 obtained by applying and drying a composition for forming a polymer cement hardened layer in which these are mixed is a composite layer containing 50% by mass of Portland cement in an acrylic resin.
- the composition for forming a cured polymer cement layer was applied onto a resin layer and dried to form a 1.29 mm thick polymer cement cured layer composed of a single layer. In this way, a structure protective sheet having a total thickness of 1.39 mm was produced.
- This structure protective sheet was continuously produced in a factory controlled at about 25 ° C., and was wound into a roll in a manner including a release sheet.
- Water vapor permeability The water vapor transmittance of the structure protective sheet according to Example 1 was measured.
- Water vapor transmission rate (WVTR) also called “moisture permeability” which represents the amount of water vapor permeability of 1 m 2 film (structural protection sheet 1) in 24 hours in grams, g / m 2 ⁇ It is represented by day or g / ml / day. It is used as an index showing the water vapor barrier property.
- WVTR Water vapor transmission rate
- the measurement was performed by a method conforming to JIS Z 0208 (B).
- the water vapor transmittance of the structure protective sheet according to the first embodiment is 30 g / m 2 ⁇ day, and when applied to the protection of a concrete structure, the swelling phenomenon caused by the inside of the concrete occurs due to the feature that the above is easily released. There is also a tendency to suppress the corrosion of metal in the structure. In addition, there is no problem of concrete shape due to excessively rapid diffusion of water inside the concrete.
- the sulfuric acid permeation depth after being immersed in a 5% sulfuric acid aqueous solution in a state of being wrapped in a basic building concrete block after 30 days was measured.
- the structural protective sheet of the present invention is wrapped in a rectangular parallelepiped building concrete basic block so as to cover all surfaces, immersed in a 5% sulfuric acid aqueous solution for 30 days, and then the building concrete basic block. Cut out the part that had been immersed in the sulfuric acid aqueous solution in half, and spray a 1% solution of phenolphthaline on the cross section to visually check the vertical distance (shortest distance) from the block end of the colored part at 5 places arbitrarily with a nogisu.
- the measured and average value was taken as the sulfuric acid penetration depth.
- the sulfuric acid penetration depth after 30 days was not visually recognized, and it was confirmed that it could sufficiently withstand applications requiring sulfuric acid resistance such as sewage piping. ..
- the surface of the resin layer according to Example 1 opposite to the polymer cement hardened layer side was contaminated by applying the above carbon particle-containing oil, and the contaminated surface was fixed so as to be vertical. After that, it was observed that the carbon-containing oil was removed by pouring tap water vigorously almost horizontally using a hose from a point about 2 m away toward the contaminated surface. The evaluation was performed visually. Of all the contaminated areas, the area where the contamination has been removed and no contamination is recognized is distinguished from the area where the contamination is found to remain, and the contamination is removed for all the contaminated areas. The percentage of the area where no contamination was found was defined as the removal rate. The removal rate of the structure protective sheet according to Example 1 was 98%, and it was confirmed that the ease of cleaning required for the inner wall of the tunnel and the median strip of the expressway was satisfied.
- the tear load of the structure protection sheet according to Example 1 was measured according to the item of tear load in JIS K 6781.
- the tear load of the structural part protective sheet according to the first embodiment is 13 N, and when the protected structure collapses or collapses, it is appropriately torn and the peeling remains in a small area, so that a large area is formed in a chain reaction. It was confirmed that it is possible to prevent collapse and collapse due to peeling.
- Example 2 The composition for forming a cured polymer cement layer prepared in the same manner as in Example 1 was applied onto the resin layer so that the thickness before drying was 1.0 mm, and then the density was 1.0 lines / cm. A mesh layer having a pitch of 10 mm was arranged. Next, the composition for forming a cured polymer cement layer was further coated on the mesh layer on the resin layer so as to have a thickness of 1.0 mm before drying, and then dried.
- a structure protective sheet was prepared in the same manner as in Example 1 except that a polymer cement hardened layer having a thickness of 1.29 mm was formed, and was wound into a roll in the same manner as in Example 1.
- Example 2 The strength of the structure protective sheet obtained in Example 2 was evaluated by the breaking strength measured by a tensile tester (manufactured by Shimadzu Corporation, AGSJ). As a result of measurement with a width of 50 mm, the strength of Example 2 was 1500 N.
- A4 size 200 mm ⁇ 300 mm was cut out from the structure protective sheet wound in a roll shape, the thickness of each part was measured at 14 points, and the thickness variation was calculated. In Example 2, the thickness variation was 26 ⁇ m.
- Example 2 In Example 2, the total thickness of the structure protective sheet was changed.
- a structure protective sheet having a total thickness of 0.76 mm was prepared by laminating a polymer cement layer having a thickness of 0.66 mm and a resin layer having a thickness of 100 ⁇ m.
- a structure protective sheet having a total thickness of 1.06 mm was prepared by laminating a polymer cement layer having a thickness of 0.96 mm and a resin layer having a thickness of 100 ⁇ m.
- Example 5 a structure protective sheet having a total thickness of 1.57 mm was prepared by laminating a polymer cement layer having a thickness of 1.47 mm and a resin layer having a thickness of 100 ⁇ m. Other than that, it was the same as in Example 2.
- Example 3 As a result of measurement with a width of 50 mm, in Example 3, the strength was 1200 N and the water vapor transmittance was 18.2 g / m 2 ⁇ day. In Example 4, the strength is 1500 N, the water vapor transmission rate was 13.0g / m 2 ⁇ day. In Example 5, the strength is 1600 N, the water vapor transmission rate was 10.2g / m 2 ⁇ day. There was no problem with strength and water vapor permeability at any thickness, and it was usable.
- the coating film which is a laminate of the polymer cement layer and the resin layer, was peeled off from the process paper, and the tensile breaking strength was evaluated with a tensile tester (manufactured by Shimadzu Corporation, AGS-J).
- Comparative Example 2 In Comparative Example 1, the work was carried out in a working environment controlled at about 40 ° C. A polymer cement layer having a thickness of 1.18 mm composed of two spray-coated layers and a resin layer having a thickness of 100 ⁇ m consisting of two spray-coated layers were formed, and the total thickness of the structure protective sheet was set to 1.28 mm. Other than that, it was the same as in Comparative Example 1.
- Comparative Example 3 In Comparative Example 3, the work was carried out in a working environment controlled at about 10 ° C. A polymer cement layer having a thickness of 1.29 mm composed of two spray-coated layers and a resin layer having a thickness of 100 ⁇ m consisting of two spray-coated layers were formed, and the total thickness of the structure protective sheet was set to 1.39 mm. Other than that, it was the same as in Comparative Example 1.
- Example 6 The emulsion composition was applied onto the release sheet in the same manner as in Example 1, and then heat-treated to cure the emulsion composition to form a resin layer. In the process of curing, the matte processing of PP laminated paper transfers it to the resin layer to impart designability. After that, a structure protective sheet was prepared in the same manner as in Example 1, and wound into a roll in the same manner as in Example 1. When a structure protective sheet having a size of 10 cm ⁇ 10 cm was cut out from this roll-shaped structure protective sheet 1 and the release sheet was peeled off, it could be peeled off well, and the surface of the resin layer was well matted (matte). It was confirmed that processing) was performed.
- Example 7 A structure protective sheet was produced in the same manner as in Example 6 except that the PP laminated paper was mirror-treated instead of being embossed in advance. The mirror surface treatment was performed by pressing a drum having a mirror surface on PP laminated paper.
- Example 4 A structure protective sheet was produced in the same manner as in Example 6 except that the PP laminated paper was not embossed in advance.
- the structure protective sheets prepared in Examples 6 and 7 and Comparative Example 4 were each cut into a size of 5 cm ⁇ 5 cm and installed side by side in a mount shape. With all the paper patterns removed, the tabletop lighting stand was used to uniformly illuminate from the direction in which the paper patterns were, and the reflected image of the lighting fixture was visually confirmed. Photographs of Examples 6 and 7 and Comparative Example 4 are shown in FIGS. 9 (a) to 9 (c), respectively.
- the structure protection sheet according to Comparative Example 4 showed a reflection to the extent that the shape of the lighting fixture could be visually recognized. In the structure protective sheet according to Example 7, more than in Comparative Example 1, reflection was observed so that the shape of the luminaire could be clearly recognized.
- Example 6 the light of the luminaire is sufficiently scattered so that the presence of the luminaire cannot be visually recognized and the reflected light is so uniform and uneven that the presence of the light source by the luminaire cannot be recognized from the reflected light. There was no.
- Example 7 A release sheet having a thickness of 130 ⁇ m made of PP laminated paper was used. A composition for forming a resin layer containing an acrylic resin was applied onto the release sheet and dried to form a resin layer having a thickness of 100 ⁇ m composed of a single layer. Then, the composition for forming a polymer cement cured layer was applied onto the resin layer and dried to form a polymer cement cured layer having a thickness of 1.29 mm and having a single layer. In this way, a structure protective sheet having a total thickness of 1.39 mm was prepared. This structure protective sheet was continuously produced in a factory controlled at about 25 ° C., and was wound into a roll with a release sheet included.
- the composition for forming the resin layer is an acrylic silicone-based resin.
- This acrylic silicone resin is an emulsion composition containing 60 parts by weight of acrylic silicone resin, 25 parts by weight of titanium dioxide, 10 parts by weight of ferric oxide, and 5 parts by weight of carbon black.
- the composition for forming a hardened polymer cement layer is an aqueous acrylic emulsion containing 45 parts by weight of a cement mixture.
- the cement mixture contains at least 70 ⁇ 5 parts by mass of Portoland cement, 10 ⁇ 5 parts by mass of silicon dioxide, 2 ⁇ 1 part by mass of aluminum oxide, and 1 to 2 parts by mass of titanium oxide, and the acrylic emulsion is an acrylic acid ester monomer.
- the polymer cement cured layer obtained by applying and drying a composition for forming a polymer cement cured layer in which these are mixed is a composite layer containing Portland cement in an acrylic resin in an amount of 50% by mass.
- the structure protective sheet obtained by the above method was attached to concrete in the following steps.
- a resin composition for forming a primer layer trade name "Aromble Coat (registered trademark) P-300" (Toagosei Co., Ltd.), is applied to a concrete basic block for construction to a thickness of 150 ⁇ m, and the coated surface is coated.
- the surface of the structure protective sheet on the polymer cement hardened layer side was directly pressure-bonded while remaining in a wet state (as a primer layer), and then the release sheet was peeled off.
- the primer layer was cured by leaving it for 24 hours to obtain a cured primer layer.
- the building concrete basic block was laminated in the order of the polymer cement hardened layer and the resin layer only through the primer layer.
- Example 5 The structure protective sheet prepared according to Example 7 was attached to concrete in the following steps.
- a resin composition for forming a primer layer trade name "Aromble Coat (registered trademark) P-300" (Toa Synthetic Co., Ltd.), is applied to a basic block of concrete for construction to a thickness of 150 ⁇ m, dried, and further.
- the product name "Bond (registered trademark) VM Netless Primer” (Konishi Co., Ltd.), which is an adhesive for polyurea urethane resin, is applied to a thickness of 200 ⁇ m, and the coated surface is in a wet state without waiting for drying.
- the structure protective sheet obtained in Comparative Example 5 was attached to the building concrete basic block so that the polymer cement hardened layer was in contact with the adhesive (layer).
- the building concrete basic block was laminated in the order of the polymer cement hardened layer and the resin layer via the primer layer and the adhesive layer.
- the peeling force of the structure protective sheet in Example 7 was 1.40 N / mm 2
- that in Comparative Example 1 was 1.40 N / mm 2 . It was clarified that there was almost no difference in peeling force between Example 7 and Comparative Example 5. That is, the structure protective sheet of the present invention is necessary and sufficient for the concrete structure even if the coating of the adhesive layer, which was conventionally considered to be indispensable to be performed together with the primer coating in the bonding of concrete, is omitted. It was revealed that it shows adhesive strength.
- a resin layer was formed in the same manner as in Example 1 except that the thickness was set to 50 ⁇ m.
- a mesh layer having a density of 1.0 line / cm and a pitch of 10 mm was arranged on the formed resin layer.
- an aqueous acrylic emulsion containing 45 parts by mass of the cement mixture and 4% by mass of calcium silicate hydrate as a curing accelerator was prepared as a composition for forming a cured polymer cement layer.
- the cement mixture contains at least 70 ⁇ 5 parts by mass of Portoland cement, 10 ⁇ 5 parts by mass of silicon dioxide, 2 ⁇ 1 part by mass of aluminum oxide, and 1 to 2 parts by mass of titanium oxide, and the acrylic emulsion is acrylic.
- composition for forming a hardened polymer cement layer contains at least 53 ⁇ 2 parts by mass of an acrylic acid-based polymer and 43 ⁇ 2 parts by mass of water obtained by emulsion polymerization using an acid ester monomer as an emulsifier. These were mixed at the stirring speed under the conditions shown in Table 1 below to prepare a composition for forming a hardened polymer cement layer.
- the composition for forming a cured polymer cement layer is applied onto a resin layer, dried in an air-drying time of 5 minutes, and cured at a curing temperature of 60 ° C. to obtain a 1.29 mm thick polymer cement cured layer composed of a single layer.
- a structural protective sheet having a structure in which a mesh layer was provided at the interface (S / HC interface) between the resin layer (S) and the polymer cement cured layer (HC) was produced.
- Reference Examples 2-9 The same applies to Reference Example 1 except that the thickness of the resin layer, the content of the curing accelerator in the composition for forming the polymer cement cured layer, the setter / base ratio, the air-drying time, the curing temperature and the stirring speed are changed as shown in Table 1 below.
- the structure protection sheet according to Reference Examples 2 to 9 was prepared.
- Reference example 10 The composition for forming a polymer cement hardened layer prepared in the same manner as in Reference Example 1 was applied onto the resin layer so that the thickness before drying was 1.0 mm, and then the density was 1.0 line / cm. A mesh layer having a pitch of 10 mm was arranged. Next, the composition for forming a cured polymer cement layer was further coated on the mesh layer on the resin layer so as to have a thickness of 1.0 mm before drying, and then dried. A structure protective sheet according to Reference Example 10 was produced in the same manner as in Reference Example 1 except that a polymer cement hardened layer having a thickness of 1.29 mm was formed.
- Reference Examples 11 to 18 Same as Reference Example 10 except that the thickness of the resin layer, the content of the curing accelerator in the composition for forming the polymer cement cured layer, the setter / base ratio, the air-drying time, the drying temperature and the stirring speed were changed as shown in Table 1 below.
- the structure protective sheet according to Reference Examples 11 to 18 was produced.
- the structure protective sheet according to Reference Examples 1 to 18 is attached to the concrete surface via an adhesive (Toagosei Co., Ltd., Aron Alpha (registered trademark) professional impact resistance), and a tension jig is attached to the resin layer surface. It was fixed using Aron Alpha (registered trademark) professional impact resistance manufactured by Toagosei Co., Ltd. Next, the strength at which tensile delamination occurs was measured as the adhesion strength using a universal tester on the side opposite to the concrete side of the tension jig.
- a graph showing the adhesion strength of the structure protective sheet according to Reference Examples 1 to 18 is shown in FIG. 12, and as shown in Tables 1 and 12, the mesh layer is located at the interface between the polymer cement hardened layer and the resin layer.
- the structural protective sheet according to Reference Examples 1 to 9 arranged has a clearer adhesion strength than the structure protective sheet according to Reference Examples 10 to 18 in which the mesh layer is arranged in the polymer cement hardened layer. It was excellent.
- Reference Examples 1 to 9 and Reference Examples 10 to 18 are manufactured under the same conditions except that the arrangement positions of the mesh layers are different from each other. When the mesh layer was arranged at the interface between the polymer cement hardened layer and the resin layer, the adhesion strength was superior to that when the mesh layer was arranged in the polymer cement hardened layer.
- Structure protection sheet 2 Polymer cement hardened layer 3 Resin layer 3'Unhardened resin layer 4 Release sheet 5 Mesh layer 7 Primer layer 10 Embossed roll 21 Structure (concrete) 21'Concrete composition (structure forming composition) 22 Undercoat layer 23 Adhesive 24 formwork
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Abstract
Description
本発明に係る構造物保護シートのもう一つの利点は、その水蒸気透過率を制御できるので、例えば構造物のセメントが硬化していないような状態でも当該構造物の表面に貼り付けることができる点にある。すなわち、セメントを成型して硬化させる際に急激に水分が抜けるとセメントがポーラスになって構造物の強度が落ちる傾向となるが、本発明に係る構造物保護シートを硬化前のセメントに貼り付けることで、セメントの硬化時の水分除去のスピード等をコントロールでき、上記ポーラス構造になるのを避けやすくなるメリットもある。
さらに、構造物保護シートは工場の生産ラインでの塗工工程と乾燥工程により量産できるので、低コスト化、現場での作業工期の大幅削減、構造物の長期保護を実現することができる。
このような構造物保護シートは、例えば、住宅等の建造物の基礎に所望の模様を付与したいとき等に有用となる。
また、これまで手塗りで形成されてきた層と比較して品質の安定性、均一性を改善できる利点を有する。
本発明に係る構造物保護シート1は、図1又は図3(C)に示すように、構造物21側に設けられたポリマーセメント硬化層2と、ポリマーセメント硬化層2上に設けられた樹脂層3とを備えている。このポリマーセメント硬化層2と樹脂層3の両層が、それぞれ、単層で形成されてもよいし積層として形成されてもよい。また、求められる性能によっては、ポリマーセメント硬化層2と樹脂層3との間に別の層を設けてもよい。
本発明に係る構造物保護シート1のもう一つの利点は、その水蒸気透過率を制御できるので、例えば構造物のセメントが硬化していないような状態でも当該構造物の表面に貼り付けることができる点にある。すなわち、セメントを成型して硬化させる際に急激に水分が抜けるとセメントがポーラスになって構造物の強度が落ちる傾向となるが、本発明に係る構造物保護シート1を硬化前のセメントに貼り付けることで、セメントの硬化時の水分除去のスピード等をコントロールでき、上記ポーラス構造になるのを避けやすくなるメリットもある。
上記水蒸気透過率が10g/m2・day未満であると、本発明に係る構造物保護シート1が十分に水蒸気を透過させることができず、構造物に貼り付けたあとの膨れ現象等を防止できず接着性が不十分となる。50g/m2・dayを超えると、セメントの硬化時の水分除去のスピードが過剰に早くなり、セメントの硬化物がポーラスになる不具合が生じる可能性がある。上記水蒸気透過率の好ましい範囲は20~50g/m2・dayである。
このような水蒸気透過率を有する本発明に係る構造物保護シート1は、例えば、後述するポリマーセメント硬化層2と、所定の水蒸気透過率を有する樹脂を樹脂層3に用いることにより得ることができる。
本発明における水蒸気透過率は、後述する方法で測定することができる。
本発明における硫酸浸透深さは、後述する実施例の方法で測定することができる。
本発明に係る構造物保護シートは、ポリマーセメント硬化層がセメントと樹脂成分とを含有するものであるため、先に構造物に貼り付けた本発明に係る構造物保護シートの樹脂層に対しても好適な接着性を示す。そのため、重ねた状態で本発明に係る構造物保護シートは好適に使用できる。
本発明における引裂荷重は、後述する実施例の方法で測定することができる。
構造物21側に設けられたポリマーセメント硬化層2は、構造物21との密着性等に優れ、ポリマーセメント硬化層2上に設けられた樹脂層3は、所定の水蒸気透過率を有するが、防水性、遮塩性、中性化阻止性等に優れた性質を容易に付与できる。
また、構造物保護シート1は工場の生産ラインでの塗工工程と乾燥工程により量産できるので低コスト化、現場での作業工期の大幅削減、構造物の長期保護を実現することができる。その結果、構造物21の表面に貼り合わせる際の工期を大幅に削減できるとともに構造物21を長期にわたって保護することができる。
構造物21は、本発明に係る構造物保護シート1が適用される相手部材である。
構造物21としては、コンクリートからなる構造物を挙げることができる。
上記コンクリートは、一般的には、セメント系無機物質と骨材と混和剤と水とを少なくとも含有するセメント組成物を打設し、養生して得られる。こうしたコンクリートは、道路橋、トンネル、水門等河川管理施設、下水道管渠、港湾岸壁、橋、欄干、高速道路の側壁、下水管(内面、外面、接手)、下水施設(下水処理施設、用水路)、水中施設、海に近い地域の配線のトンネル、ダム放水路、マンホール内壁面等の土木構造物、コンクリート屋根、トタン屋根、コンクリート屋上、建築用配管、ALCパネル、屋内の床材、煙突の内面や外面等の建築物等として広く使用される。本発明では、コンクリートからなる構造物21に構造物保護シート1を適用することで、コンクリートに生じたひび割れや膨張に追従でき、コンクリート内に水や塩化物イオン等の劣化因子を浸透させず、コンクリート中の水分を水蒸気として排出できる、という格別の利点がある。
ポリマーセメント硬化層2は、図3(C)に示すように、構造物側に配置される層である。このポリマーセメント硬化層2は、例えば、図1(A)に示すように重ね塗りしない単層であってもよいし、図1(B)に示すように重ね塗りした積層であってもよい。単層とするか積層とするかは、全体厚さ、付与機能(追従性、構造物への接着性等)、工場の製造ライン、生産コスト等を考慮して任意に設定され、例えば製造ラインが短くて単層では所定の厚さにならない場合は、2層以上重ね塗りして形成することができる。なお、例えば2層の重ね塗りは、1層目の層を乾燥した後に2層目の層を形成する。
また、ポリマーセメント硬化層2は、性質の異なるもの同士が積層された構成であってもよい。例えば、樹脂層3側に樹脂成分の割合をより高めた層とすることで、樹脂成分の高い層が樹脂層と接着し、セメント成分の高い層がコンクリート構造物と接着することとなり両者に対する接着性が極めて優れたものとなる。
上記セメント成分としては、各種のセメント、酸化カルシウムからなる成分を含む石灰石類、二酸化ケイ素を含む粘度類等を挙げることができる。なかでもセメントが好ましく、例えば、ポルトランドセメント、アルミナセメント、早強セメント、フライアッシュセメント等を挙げることができる。いずれのセメントを選択するかは、ポリマーセメント硬化層2が備えるべき特性に応じて選択され、例えば、コンクリート構造物21への追従性の程度を考慮して選択される。特に、JIS R5210に規定されるポルトランドセメントを好ましく挙げることができる。
また、上記樹脂成分は熱可塑性樹脂、熱硬化性樹脂、光硬化性樹脂のいずれを使用してもよい。ポリマーセメント硬化層2の「硬化」の文言は、樹脂成分を熱硬化性樹脂又は光硬化性樹脂等、硬化して重合する樹脂に限定されるという意味ではなく、最終的な層となった場合に硬化するような材料を用いればよいという意味で用いている。
上記アクリル系エマルションを構成するアクリル酸エステル等の含有量は特に限定されないが、20~100質量%の範囲内から選択される。また、界面活性剤も必要に応じた量が配合され量も特に限定されないが、エマルジョンとなる程度の界面活性剤が配合される。
本発明は、更にメッシュ層を備えることが好ましい。
本発明に係る構造物保護シートを用いて、道路橋、トンネル、水門等河川管理施設、下水道管渠、湾岸壁等の土木構造物等の大型コンクリート部材の補修を行う場合、本発明に係る構造物保護シート自体にも十分な強度(引張強度、曲げ強度、硬度、表面強度、打ち抜き強度靱性等をいい、本明細書において以下同様とする。)が求められるが、上記メッシュ層を更に備えることで、本発明に係る構造物保護シートは、上述のような大型コンクリート部材の補修に耐え得る十分な強度を備えることができる。
上記付着強度とは、本発明に係る構造物保護シート1のポリマーセメント硬化層2側の面をコンクリート表面に接着剤を用いて貼り付け、樹脂層3の表面に引張治具を固定して該引張治具をコンクリート側と反対側に1500n/minの速度で引っ張ることで引張り層間剥離が生じる強度を測定することで得られる。
また、メッシュ層5がポリマーセメント硬化層2の内部に存在している場合、該メッシュ層5は、ポリマーセメント硬化層2の厚みの半分の位置に存在していればよいが、より樹脂層3側に存在することが望ましい。メッシュ層5がポリマーセメント硬化層2中で樹脂層3側に存在している場合、付着力は平均的に1.3倍向上する。
メッシュ層5にポリマーセメント硬化層2を構成する材料が含侵されている状態とは、メッシュ層5を構成する繊維間にポリマーセメント硬化層2を構成する材料が充填された状態にあることを意味し、このような含侵状態にあることで、メッシュ層5とポリマーセメント硬化層2との接着強度が極めて優れたものとしやすくなる。また、メッシュ層5とポリマーセメント硬化層2の材料との相互作用がより強固となりやすく、構造物保護シート1の強度をより良好にしやすくなる。
上記繊維としては、例えば、ポリプロピレン系繊維、ビニロン系繊維、炭素繊維、アラミド繊維、ガラス繊維、ポリエステル繊維、ポリエチレン繊維、ナイロン繊維及びアクリル繊維からなる群より選択される少なくとも1種の繊維から構成されたものである好ましく、なかでも、ポリプロピレン繊維、ビニロン繊維を好適に使用することができる。
またその形状は、特に限定されず、図6に示したような二軸組布のほか、例えば、三軸組布等任意のメッシュ層5を用いることができる。
本発明の構造物保護シートにおいて、引張強度と表面強度はトレードオフの関係にあり、本発明に適用するに適したメッシュは、線ピッチ50mm~1.2mmの範囲にあるものである。
すなわち、メッシュ層5の平面視したときの面積は、ポリマーセメント硬化層2の平面視したときの面積と同じであってもよく、小さくてもよいが、メッシュ層5の平面視面積は、ポリマーセメント硬化層2の平面視面積に対し60%以上、95%以下であることが好ましい。60%未満であると本発明に係る構造物保護シートの強度が不十分となることがあり、また、強度のバラツキが生じることもある。95%を超えると、メッシュ層5を介してポリマーセメント硬化層3が積層された構成において、ポリマーセメント硬化層3同士の接着強度が劣ることがあり、本発明に係る構造物保護シートを構造物に施工したときに、ポリマーセメント硬化層2部分に剥離が生じる危険性が高まる。なお、上記メッシュ層5等の平面視面積は、公知の方法で測定できる。
樹脂層3は、図3(C)に示すように、構造物21とは反対側に配置されて、表面に現れる層である。この樹脂層3は、例えば、図1(A)に示すように単層であってもよいし、図1(B)に示すように少なくとも2層からなる積層であってもよい。単層とするか積層とするかは、全体厚さ、付与機能(防水性、遮塩性、中性化阻止性、水蒸気透過性等)、工場の製造ラインの長さ、生産コスト等を考慮に設定され、例えば製造ラインが短くて単層では所定の厚さにならない場合は、2層以上重ね塗りして形成することができる。なお、重ね塗りは、1層目の層を乾燥した後に2層目の層を塗工する。2層目の層は、その後乾燥される。
また、樹脂層3は、無機物を含有していてもよい。無機物を含有することで樹脂層3に耐擦傷性を付与することができる。上記無機物としては特に限定されず、例えば、シリカ、アルミナ、チタニア等の金属酸化物粒子等従来公知の材料が挙げられる。
また、本発明に係る構造物保護シートは、樹脂層3のポリマーセメント硬化層2側と反対側の表面をカーボン粒子含有オイルで汚染した後垂直に設置し、2メートル程度離れた位置から汚染された面に水道水を、ホースを用いてほぼ水平に勢いよくかけることで清掃したときの汚染物の除去率が95%以上であることが好ましい。樹脂層3の表面の清掃性が優れたものとなり、例えば、高速道路の壁やトンネルの壁面といった汚染物質が容易に付着する構造物に対し極めて好適な補修シートとして用いることができる。上記汚染物の除去率が95%未満の場合、防汚性が不十分となり上記のような高速道路の壁やトンネルの壁面においては感覚的にも『汚れている』という印象を受けやすくなる。他方、汚染物の除去率は高ければ高い方がよいが、通常は98%以下となる。
なお、このような汚染物の除去率を有する本発明に係る構造物保護シート1は、例えば、樹脂層の樹脂として、アクリルシリコーン樹脂等の汚染物の除去をしやすい材料を選択するか、樹脂層にシリコン樹脂又はシリコン微粒子等の汚染物の除去をしやすい材料(防汚剤)を含有させる等によって得ることができる。
本発明における汚染性の評価は、後述する実施例の方法で実施することができる。
また、樹脂層3は様々な機能を付与できる添加剤を含有していてもよい。このような添加剤としては、例えば、セルロールナノファイバー等が挙げられる。
本発明に係る構造物保護シートは、樹脂層3のいずれか一方の面に意匠性が付与されていることが好ましい。ここで、いずれか一方の面とは、ポリマーセメント硬化層2側の面又はその反対の面をいう。意匠性は凹凸形状を設けるか又は印刷によって付与されていることが好ましい。上記意匠性を付与する処理としては特に限定されず、例えば、上記樹脂層の表面に施されたエンボス処理又はマット処理(つや消し処理)、ミラー処理(光沢処理)、または上記樹脂層の表面に印刷を行う処理が好適に用いられる。
上記エンボスロールの凹凸の形状は特に限定されず、所望する意匠に応じで適宜選択すればよい。
なお、エンボス処理のその他の条件等は樹脂フィルムに対するエンボス処理として従来公知の条件を採用できる。
また、上記樹脂層3の表面に凹凸形状を形成する方法としては、エンボス処理に限定はされず、他の方法を用いてもよく、エンボス加工と類似の方法でいわゆるマット加工を行うことも可能である。
例えば、図8に示したように、離型層4にディンプル形状(半球状)の凹凸形状を深さ1ミクロン程度に設け、その上に上記未硬化の樹脂層3’を塗布し、その後未硬化の樹脂層3’中の樹脂を硬化させ、さらにポリマーセメント層2を設けた後に離型層4を剥離すれば、樹脂層3の表面にマット状の意匠が形成された構造物保護シートを得ることができる。
上記印刷する模様等は特に限定されず、構造物に付与する意匠に応じて適宜、文字、絵柄等が選択される。
また、上記インキの印刷方法としては、例えば、オフセット印刷、グラビア印刷、フレキソ印刷、シルクスクリーン印刷、インクジェット印刷などの公知の印刷方法が挙げられる。
なお、樹脂層3に対する密着性向上のため、上記インキを印刷する前に樹脂層3の表面にコロナ処理やオゾン処理等の処理が施されていてもよい。
本願発明の構造物保護シートは一例として、離型シートの表面にエンボス状もしくはマット状の凹凸面を設け、その凹凸面に印刷により意匠を形成し、さらに樹脂層、ポリマーセメント層の順に設けることで形成することができる。
また、上記離型シートと凹凸面との界面にアクリルシリコンなどの透明樹脂層を介在させることも好適である。
その場合、構造物を保護した後の最表面にアクリルシリコンなどの樹脂層が存在するため、耐候性の向上に大きく寄与する。
また、樹脂層3のポリマーセメント硬化層2側の表面に意匠性の付与が施されている場合、付与された意匠が直接外気に接しないため長期間にわたり優れた意匠性を維持でき、また、エンボス処理を行った場合、立体的な意匠を付与しつつ樹脂層3の表面は平坦な構成が得られる。この場合、樹脂層3を透明又は半透明になるように形成してもよい。
更に、本発明に係る構造物保護シートでは、樹脂層3のポリマーセメント硬化層2側の表面に印刷層を設け、樹脂層3の反対側の表面にエンボス処理等により凹凸形状を設けた構造も好適である。印刷層による優れた意匠性とエンボス処理の凹凸形状による立体感とを同時に得ることができ、更に上記凹凸形状による防眩性、防音性や防汚性といった機能を付与することもできる。
また、本発明に係る構造物保護シートにポリロタキサンを添加することで改質したり、樹脂組成や粒子を添加して表面強度の向上を図ったりすることもできる。
本発明に係るコンクリートブロックは、本発明に係る構造物保護シートのポリマーセメント硬化層が接着剤層を介して表面に貼り付けられていることを特徴とする。
上記接着剤層を構成する接着剤としては特に限定されず、例えば、後述する接着剤と同様の物が挙げられる。
また、上記接着剤層を形成する前のコンクリートブロックに対し、後述する下塗り層を設けてもよい。
本発明に係る構造物保護シートを用いた補強された構造物の製造方法は、図3に示すように、上記本発明に係る構造物保護シート1を使用した施工方法であって、構造物21上に接着剤23を塗布した後に構造物保護シート1を貼り合わせる、ことを特徴とする。この施工方法は、構造物21の表面に構造物保護シート1を容易に貼り合わせることができる。その結果、熟練した作業者でなくとも構造物保護シート1を、構造物21に設けることができ、工期を大幅に削減できるとともに、構造物21を長期にわたって保護することができる。
(1)コンクリート構造物21の表面に、硬化性樹脂材料を含有するプライマー層7を塗布する工程
(2)プライマー層7の上に、このプライマー層7とポリマーセメント硬化層2とが接するように構造物保護シート1を設置する工程
(3)プライマー層7を硬化させて硬化プライマー層とする工程
を有する方法であってもよい。以下、各工程について説明する。
(構造物)
コンクリート構造物21は、本発明に係る構造物保護シート1が適用される相手部材であり、上述したものと同様のものが挙げられる。
工程(1)では、コンクリート構造物21の表面に、硬化性樹脂材料を含有するプライマー層7を塗布する。
硬化性樹脂材料としては、熱硬化、光硬化その他の方法で硬化して樹脂となるような性質を有する材料であれば特に制限はないが、好ましくは、エポキシ化合物を挙げることができる。この場合、プライマー層7が硬化することで形成される硬化プライマー層(図10には不図示)は、エポキシ硬化物となる。エポキシ硬化物は、一般には、2つ以上のエポキシ基を有するエポキシ化合物を硬化剤により硬化させたものである。以下、エポキシ硬化物をプライマー層に用いる場合を例にとって説明する。
また、硬化剤としては、多官能フェノール類、アミン類、ポリアミン類、メルカプタン類、イミダゾール類、酸無水物、含リン化合物等が挙げられる。これらのうち、多官能フェノール類としては、単環二官能フェノールであるヒドロキノン、レゾルシノール、カテコール、多環二官能フェノールであるビスフェノールA、ビスフェノールF、ナフタレンジオール類、ビフェノール類、及び、これらのハロゲン化物、アルキル基置換体等が挙げられる。更に、これらのフェノール類とアルデヒド類との重縮合物であるノボラック、レゾールを用いることができる。アミン類としては、脂肪族又は芳香族の第一級アミン、第二級アミン、第三級アミン、第四級アンモニウム塩及び脂肪族環状アミン類、グアニジン類、尿素誘導体等が挙げられる。
上記例示のうち、プライマー層7の材料(硬化性樹脂材料を含む。)としては、エポキシ樹脂系プライマーとして、例えば、ビスフェノールA型エポキシ又はビスフェノールF型エポキシの主剤と、ポリアミン類又はメルカプタン類の硬化剤とを用いるもの等が挙げられる。また、上記エポキシ樹脂系プライマーは、上記主剤と硬化剤以外に、例えば、カップリング剤、粘度調整剤及び硬化促進剤等を含んでもよい。このようなプライマー層7として、例えば、東亞合成社製2液反応硬化形水系エポキシ樹脂エマルション「アロンブルコートP-300」(商品名・なお「アロンブルコート」は東亞合成社の登録商標である。)を用いることができる。
プライマー層7の厚さは特に限定されないが、好ましくはウエットの状態で50μm以上、300μm以下の範囲内とすることができる。50μm以上とすることでプライマー層7の材料のコンクリートへのしみ込みを考慮した上でプライマー層7の厚さを均一にしやすくなると共に、コンクリート構造物21と構造物保護シート1との接着性を確保しやすくなる。プライマー層7の厚さの上限は特に制限はされないが、塗布のしやすさや接着時の両層のずれを最小化する意味、また材料の使用料の最適化から、300μm以下とすることが好ましい。コンクリート構造物21の下塗り層として設けるプライマー層7、コンクリート構造物21と構造物保護シート1との相互の密着を高めるように作用するので、プライマー層7を上記厚さにすれば、構造物保護シート1は長期間安定してコンクリート構造物21を補強し保護しやすくなる。
なお、コンクリート構造物21にひび割れや欠損が生じている場合には、プライマー層7を塗布する前に、上記ひび割れや欠損を補修した後にプライマー層7を設けることが好ましい。補修の方法は特に限定されないが、通常セメントモルタルやエポキシ樹脂等が使って補修が行われる。
工程(2)では、プライマー層7の上に、このプライマー層7とポリマーセメント硬化層2とが接するように構造物保護シート1を設置する。構造物保護シート1の設置は、例えば、図10に示すように、コンクリート構造物21上にプライマー層7を塗布した後に構造物保護シート1を貼り合わせることで行うことができる。その結果、熟練した作業者でなくとも厚さのバラツキの小さい層で構成された構造物保護シート1を、コンクリート構造物21に設けることができ、工期を削減できるとともに、コンクリート構造物21を長期にわたって保護することができる。なお、プライマー層7はコンクリート構造物21上でなく、貼り合わせ直前に構造物保護シート1のポリマーセメント硬化層表面2に塗布することも可能である。
工程(3)は、プライマー層7を硬化させて硬化プライマー層(図10には不図示)とする工程である。プライマー層7の硬化は、例えば、プライマー層7と構造物保護シート1とを張り合わせた状態で24時間放置することによって行う。通常の環境における施工において硬化させることで、温度、湿度などの管理が不要となる利点がある。
あらかじめエンボス加工をしたPPラミネート紙からなる厚さ130μmの離型シートを用いた。
その離型シート上に樹脂層を以下の方法で形成した。
まず、アクリルシリコーン樹脂60質量部と、二酸化チタン25質量部と、酸化第二鉄10質量部と、カーボンブラック5質量部とを含有するエマルジョン組成物を準備した。このエマルジョン組成物を上記離型シート上に塗布した後、加熱処理をしてこれを硬化させて、樹脂層を形成した。樹脂層の厚さは0.1mmとなるようにした。
次に、樹脂層の上にポリマーセメント硬化層を形成した。
具体的には、セメント混合物を45質量部含む水系のアクリルエマルジョンをポリマーセメント硬化層形成用組成物として準備した。ここで、セメント混合物は、ポルトランドセメント70±5質量部、二酸化ケイ素10±5質量部、酸化アルミニウム2±1質量部、酸化チタン1~2質量部を少なくとも含むものであり、アクリルエマルジョンは、アクリル酸エステルモノマーを乳化剤として使用して乳化重合したアクリル酸系重合物53±2質量部、水43±2質量部を少なくとも含むものである。これらを混合したポリマーセメント硬化層形成用組成物を塗布乾燥して得られたポリマーセメント層2は、ポルトランドセメントをアクリル樹脂中に50質量%含有する複合層である。
上記ポリマーセメント硬化層形成用組成物を、樹脂層の上に塗工し乾燥してから単層からなる厚さ1.29mmのポリマーセメント硬化層を形成した。
こうして合計厚さ1.39mmの構造物保護シートを作製した。なお、この構造物保護シートは、約25℃に管理された工場内で連続生産され、離型シートを含んだ態様でロール状に巻き取った。
実施例1に係る構造物保護シートついて、水蒸気透過率を測定した。水蒸気透過率(WVTR)は、「透湿度」とも呼ばれ、1m2のフィルム(構造物保護シート1)を24時間で透過する水蒸気の量をグラム数で表すものであり、g/m2・day又はg/ml/dayで表す。水蒸気バリア性を示す指標として用いられている。JIS Z 0208(B)に準拠した方法で測定した。
実施例1に係る構造物保護シートの水蒸気透過率は30g/m2・dayであり、コンクリート構造物の保護に適用した際、上記を逃がしやすい特徴のためコンクリート内部に起因した膨れ現象を生じることもなく、また構造物中の金属の腐食を抑制ができる傾向になる。またコンクリート内部の水分が過剰に早く拡散することによるコンクリート形状の不具合も生じることがない。
実施例1に係る構造物保護シートについて、建築用コンクリート基本ブロックに包んだ状態で5%硫酸水溶液に30日後浸漬後の硫酸浸透深さを計測した。
具体的には、本願発明の構造物保護シートで、直方体形状の建築用コンクリート基本ブロックの全ての面を覆うように包んだ状態で5%硫酸水溶液に30日間浸漬後、上記建築用コンクリート基本ブロックの硫酸水溶液に浸漬していた部分を半分に切り出し、断面にフェノールフタレイン1%溶液を噴霧して着色した部分のブロック端部からの垂直距離(最短距離)を任意に5カ所、ノギスにより目視測定し平均した値を硫酸浸透深さとした。
実施例1に係る構造物保護シートの耐硫酸性については、30日後の硫酸浸透深さが目視では認められず、下水の配管など耐硫酸性が求められる用途に十分に耐えることが確認された。
実施例1に係る樹脂層のポリマーセメント硬化層側と反対側の表面をカーボン粒子含有オイルで汚染した後垂直に設置し、2メートル程度離れた位置から汚染された面に水道水を、ホースを用いてほぼ水平に勢いよくかけることで清掃したときの汚染物の除去率を算出した。
具体的には、カストロール エンジンオイル EDGE 0W-20 4L 4輪ガソリン車専用全合成油(カストロール社製)100重量部に、カーボンECP200L(ライオンスペシャリティケミカルズ製)5重量部を添加し、攪拌することでカーボン粒子含有オイルを作成した。
実施例1に係る樹脂層のポリマーセメント硬化層側と反対側の表面を、上記のカーボン粒子含有オイルを塗ることで汚染し、汚染した表面を垂直になるように固定した。
しかるのち汚染した表面に向けて、約2m離れた地点から水道水をホースを用いてほぼ水平に勢いよくかけることで、カーボン含有オイルが取り除かれる様子を観察した。
評価は目視で行った。
汚染させた全ての面積の内、汚染が取り除かれて汚染が認められなくなった面積と、汚染が残存していることが認められる面積とを区別し、汚染させた全ての面積に対する汚染が取り除かれて汚染が認められなくなった面積の割合を、除去率とした。
実施例1に係る構造物保護シートの除去率は98%であり、トンネル内壁や高速道路の中央分離帯などに求められる清掃容易性を満たすことが確認された。
実施例1に係る構造物保護シートの引裂荷重をJIS K 6781にある、引裂荷重の項目に準じて測定した。
実施例1に係る構造部保護シートの引裂荷重は13Nであり、保護をした構造物の崩壊や崩落が生じた際に適切に引き裂かれ、剥がれが小面積に留まるため、連鎖的に大面積が引き剥がれることに伴う崩壊や崩落を防止することができることが確認された。
実施例1と同様にして準備したポリマーセメント硬化層形成用組成物を、樹脂層の上に乾燥前の厚さが1.0mmとなるように塗工した後、密度1.0本/cm、ピッチ10mmであるメッシュ層を配設した。次いで、そのメッシュ層の上にさらに、上記ポリマーセメント硬化層形成用組成物を、樹脂層の上に乾燥前の厚さが1.0mmとなるように塗工した後、これを乾燥させて、厚さ1.29mmのポリマーセメント硬化層を形成した以外は実施例1と同様にして構造物保護シートを作製し、実施例1と同様にロール状に巻き取った。
実施例2で得られた構造物保護シートの強度を引張試験機(株式会社島津製作所製、AGSJ)で測定した破断強度で評価した。
幅50mmで測定した結果、実施例2の強度は1500Nであった。
[厚さバラツキの測定]
実施例2について、ロール状に巻き取った構造物保護シートから、A4サイズ程度(200mm×300mm)を切り出し、各部で14箇所の厚さを測定し、その厚さバラツキを計算した。実施例2では、厚さバラツキが26μmであった。
実施例2において、構造物保護シートの合計厚さを変化させた。実施例3は、厚み0.66mmのポリマーセメント層と、厚さ100μmの樹脂層とを積層した合計厚さ0.76mmの構造物保護シートを作製した。実施例4は、厚さ0.96mmのポリマーセメント層と、厚さ100μmの樹脂層とを積層した合計厚さ1.06mmの構造物保護シートを作製した。実施例5は、厚さ1.47mmのポリマーセメント層と100μmの樹脂層とを積層した合計厚さ1.57mmの構造物保護シートを作製した。それ以外は実施例2と同様とした。
実施例3~5について、強度と水蒸気透過率を測定した。強度は引張試験機(株式会社島津製作所製、AGS-J)で測定した破断強度で評価した。水蒸気透過率(WVTR)は、「透湿度」とも呼ばれ、1m2のフィルム(構造物保護シート1)を24時間で透過する水蒸気の量をグラム数で表すものであり、g/m2・day又はg/ml/dayで表す。水蒸気バリア性を示す指標として用いられている。JIS Z0208(B)法に準拠した方法で測定した。
現場でコンクリート上にスプレー塗工する作業を再現した。約25℃程度に管理した作業環境で、コンクリート板上にスプレー塗りでエポキシ樹脂からなる下塗り層を形成し、工程紙上にスプレー塗り1層からなる厚さ1.47mmのポリマーセメント層2を形成し、その上にスプレー塗り層からなる厚さ100μmの樹脂層を形成した。各層は、塗工後の放置時間(常温、12時間)と乾燥(40℃、24時間)の関係で、2日で1層とした。ポリマーセメント層と樹脂層との合計厚さは1.57mmであった。乾燥後、工程紙上からポリマーセメント層と樹脂層との積層体である塗装膜を剥がし、引張試験機(株式会社島津製作所製、AGS-J)で引張破断強度を評価した。
比較例1において、約40℃程度に管理した作業環境で作業した。スプレー塗り2層からなる厚さ1.18mmのポリマーセメント層と、スプレー塗り2層からなる厚さ100μmの樹脂層とを形成し、構造物保護シートの合計厚さを1.28mmとした。それ以外は比較例1と同様とした。
比較例3において、約10℃程度に管理した作業環境で作業した。スプレー塗り2層からなる厚さ1.29mmのポリマーセメント層と、スプレー塗り2層からなる厚さ100μmの樹脂層とを形成し、構造物保護シートの合計厚さを1.39mmとした。それ以外は比較例1と同様とした。
比較例1~3について、上記実施例3~5と同様の強度と水蒸気透過率定した。50mm幅での測定結果は、比較例1では、強度が375N、水蒸気透過率が10.2g/m2・dayであった。比較例2では、強度が275N、水蒸気透過率が11.3gであった。比較例3では、強度が325N、水蒸気透過率が11.4gであった。比較例2は、塗工中の粘度上昇が激しく、使用時間はかなり短いと想定される。比較例3は、塗工乾燥後の表面が白っぽく変色した。比較例1~3のいずれも、メッシュ層が配設されていなかったため、実施例に比べて強度に劣り、また、現場でコンクリート上にスプレー塗工する作業を再現したものであるので、厚さバラツキは大きく、本発明の範囲である+100μmよりもかなり大きく、厚さバラツキは222μm(+111μm)~260μm(+130μm)の範囲内であった。
実施例1と同様にしてエマルジョン組成物を離型シート上に塗布した後、加熱処理をしてこれを硬化させて、樹脂層を形成した。硬化する過程でPPラミネート紙のマット加工が樹脂層に転写させることで意匠性を付与する。
その後実施例1と同様にして構造物保護シートを作製し、実施例1と同様にロール状に巻き取った。
このロール状の構造物保護シート1から10cm×10cmの大きさの構造物保護シートを切り出し、離型シートを剥がしたところ、良好に剥がすことができ、樹脂層の表面に良好なマット加工(つや消し加工)がなされていることを確認した。
PPラミネート紙にあらかじめエンボス加工を行う代わりに鏡面処理を施した以外は実施例6と同様にして構造物保護シートを作製した。
なお、鏡面処理はPPラミネート紙に、表面が鏡面であるドラムを押圧することによって行った。
PPラミネート紙にあらかじめエンボス加工を施すことをしなかった以外は実施例6と同様にして構造物保護シートを作製した。
実施例6、7及び比較例4により作成された構造物保護シートそれぞれ5cm×5cmの大きさにカットし、台紙状に並べて設置した。
すべて離型紙をはがした状態で、離型紙があった方向から卓上照明スタンドで均一に照明を当て、前記照明器具の反射像を視認にて確認した。
実施例6、7及び比較例4を観察した写真資料を図9(a)~(c)にそれぞれ示す。
比較例4による構造物保護シートは前記照明器具の形状が視認できる程度の反射を示した。
実施例7による構造物保護シートは、比較例1にも増して、前記照明器具の形状がはっきり認識できるほどの反射が認められた。
対して実施例6は照明器具の光が十分に散乱することにより、照明器具の存在が視認できないばかりか、反射光からは照明器具による光源の存在が認められないほど、反射光は均一でムラがなかった。
PPラミネート紙からなる厚さ130μmの離型シートを用いた。
その離型シート上に、アクリル系樹脂を含む樹脂層形成用組成物を塗工し、乾燥して単層からなる厚さ100μmの樹脂層を形成した。
その後、樹脂層上に、ポリマーセメント硬化層形成用組成物を塗布し乾燥することで単層からなる厚さ1.29mmのポリマーセメント硬化層を形成した。
こうして合計厚さ1.39mmの構造物保護シートを作成した。なお、この構造物保護シートは、約25℃に管理された工場内で連続生産され、離型シートを含んだ状態でロール状に巻き取った。
ポリマーセメント硬化層形成用組成物は、セメント混合物を45重量部含む水系のアクリルエマルジョンである。セメント混合物は、ポルトランドセメント70±5質量部、二酸化ケイ素10±5質量部、酸化アルミニウム2±1質量部、酸化チタン1~2質量部を少なくとも含むものであり、アクリルエマルジョンは、アクリル酸エステルモノマーを乳化剤を使用して乳化重合したアクリル酸系重合物53±2質量部、水43±2質量部を少なくとも含むものである。これらを混合したポリマーセメント硬化層形成用組成物を塗布乾燥して得られたポリマーセメント硬化層は、ポルトランドセメントをアクリル樹脂中に50質量%含有する複合層である。
建築用コンクリート基本ブロックに、プライマー層形成用樹脂組成物である商品名「アロンブルコート(登録商標)P-300」(東亞合成社)を150μmの厚みになるように塗布し、該塗布面の乾燥を待たずにウエットの状態のまま(プライマー層としたまま)、構造物保護シートのポリマーセメント硬化層側の面を直接圧着し、しかる後離型シートを剥離した。
その後、24時間放置することによってプライマー層を硬化させて硬化プライマー層とした。
この工程により、建築用コンクリート基本ブロックは、プライマー層のみを介してポリマーセメント硬化層、樹脂層の順に積層された。
実施例7に従って作製した構造物保護シートを、次のような工程でコンクリートに張り付けた。
建築用コンクリート基本ブロックに、プライマー層形成用樹脂組成物である商品名「アロンブルコート(登録商標)P-300」(東亞合成社)を150μmの厚みになるように塗布し、乾燥させ、さらにポリウレアウレタン樹脂の接着剤である商品名『ボンド(登録商標)VMネットレス中塗り』(コニシ株式会社)を200μmの厚みになるように塗布し、該塗布面の乾燥を待たずにウエットの状態のまま、構造物保護シートのポリマーセメント硬化層側の面を直接圧着し、しかる後離型シート4を剥離した。
その後、24時間放置して、プライマー層及び接着剤層を硬化させた。
このようにして、比較例5により得られた構造物保護シートをポリマーセメント硬化層が接着剤(層)と接するように、建築用コンクリート基本ブロックに張り付けた。
この工程により、建築用コンクリート基本ブロックは、プライマー層と接着剤層とを介してポリマーセメント硬化層、樹脂層の順に積層された。
実施例7、比較例5によって製造された、構造物保護シートによって補強された建築用コンクリートブロックについてそれぞれ、構造物保護シートの付着力を測定した。
付着力は、JIS A6909:2014『建築用仕上塗材』の項目7.10『付着強さ試験』に準拠して行った。ただし、項目7.10.2『試験の手順』a)において制御が求められている荷重速度は1,500N/minで試験を実施した。
実施例7と比較例5との間で剥離力にほとんど差がないことが明らかになった。すなわち、従前コンクリートの接着においてプライマー塗布とセットで行うことが必須であると思われていた接着剤層の塗工を省略しても、本願発明の構造物保護シートはコンクリート構造物に必要十分な接着力を示すことが明らかになった。
厚みが50μmとなるようにした以外は実施例1と同様にして樹脂層を形成した。
次に、形成した樹脂層上に密度1.0本/cm、ピッチ10mmであるメッシュ層を配設した。
次に、セメント混合物を45質量部含み、硬化促進剤としてカルシウムシリケート水和物を4質量%含む水系のアクリルエマルジョンをポリマーセメント硬化層形成用組成物として準備した。
ここで、セメント混合物は、ポルトランドセメント70±5質量部、二酸化ケイ素10±5質量部、酸化アルミニウム2±1質量部、酸化チタン1~2質量部を少なくとも含むものであり、アクリルエマルジョンは、アクリル酸エステルモノマーを乳化剤として使用して乳化重合したアクリル酸系重合物53±2質量部、水43±2質量部を少なくとも含むものである。これらを下記表1の条件の攪拌速度で混合したポリマーセメント硬化層形成用組成物を調製した。
上記ポリマーセメント硬化層形成用組成物を、樹脂層の上に塗工し風乾時間5分で乾燥させ、硬化温度60℃で硬化させて単層からなる厚さ1.29mmのポリマーセメント硬化層を形成し、樹脂層(S)とポリマーセメント硬化層(HC)との界面(S/HC界面)にメッシュ層が設けられた構成の構造物保護シートを作製した。
樹脂層の厚み、ポリマーセメント硬化層形成用組成物の硬化促進剤含有量、セッター/ベース比、風乾時間、硬化温度及び攪拌速度が下記表1となるよう変更した以外は参考例1と同様にして参考例2~9に係る構造物保護シートを作製した。
参考例1と同様にして準備したポリマーセメント硬化層形成用組成物を、樹脂層の上に乾燥前の厚さが1.0mmとなるように塗工した後、密度1.0本/cm、ピッチ10mmであるメッシュ層を配設した。次いで、そのメッシュ層の上にさらに、上記ポリマーセメント硬化層形成用組成物を、樹脂層の上に乾燥前の厚さが1.0mmとなるように塗工した後、これを乾燥させて、厚さ1.29mmのポリマーセメント硬化層を形成した以外は参考例1と同様にして参考例10に係る構造物保護シートを作製した。
樹脂層の厚み、ポリマーセメント硬化層形成用組成物の硬化促進剤含有量、セッター/ベース比、風乾時間、乾燥温度及び攪拌速度が下記表1となるよう変更した以外は、参考例10と同様にして参考例11~18に係る構造物保護シートを作製した。
次いで、引張治具をコンクリート側と反対側に万能試験機を用いて引張り層間剥離が生じる強度を付着強度として測定した。
なお、参考例1~9と参考例10~18は、夫々メッシュ層の配設位置が異なる以外は同じ条件となるように作製されたものであるが、それぞれの参考例を比較しても、メッシュ層がポリマーセメント硬化層と樹脂層との界面に配設された方が、メッシュ層がポリマーセメント硬化層中に配設されたものよりも付着強度が優れていた。
2 ポリマーセメント硬化層
3 樹脂層
3’ 未硬化の樹脂層
4 離型シート
5 メッシュ層
7 プライマー層
10 エンボスロール
21 構造物(コンクリート)
21’ コンクリート組成物(構造物形成組成物)
22 下塗り層
23 接着剤
24 型枠
Claims (16)
- 構造物側に設けられるポリマーセメント硬化層と、該ポリマーセメント硬化層上に設けられた樹脂層とを備える構造物保護シートであって、
水蒸気透過率が10~50g/m2・dayである
ことを特徴とする構造物保護シート。 - 建築用コンクリート基本ブロックに包んだ状態で5%硫酸水溶液に30日間浸漬後の硫酸浸透深さが0.1mm以下である請求項1記載の構造物保護シート。
- 前記ポリマーセメント硬化層は、セメント成分及び樹脂を含有する層であって、前記樹脂が10重量%以上、40重量%以下含有されている請求項1又は2記載の構造物保護シート。
- 2層以上重ねた状態で使用される請求項1、2又は3記載の構造物保護シート。
- JIS K 6781にある引裂荷重試験の項目の記載に従って測定した引裂荷重が3~20Nである請求項1、2、3又は4記載の構造物保護シート。
- 更にメッシュ層を備える請求項1、2、3、4又は5記載の構造物保護シート。
- 前記メッシュ層を前記ポリマーセメント硬化層と前記樹脂層との界面に備える請求項6記載の構造物保護シート。
- 前記ポリマーセメント硬化層に前記メッシュ層が存在する請求項6記載の構造物保護シート。
- 前記メッシュ層は、線ピッチ50mm~1.2mmである請求項6、7又は8記載の構造物保護シート。
- 前記メッシュ層は、ポリプロピレン系繊維、ビニロン系繊維、炭素繊維、アラミド繊維、ガラス繊維、ポリエステル繊維、ポリエチレン繊維、ナイロン繊維及びアクリル繊維からなる群より選択される少なくとも1種から構成される請求項6、7、8、9又は10記載の構造物保護シート。
- 前記樹脂層のいずれか一方の面に意匠性が付与されている請求項1、2、3、4、5、6、7、8、9又は10記載の構造物保護シート。
- 前記意匠性が、前記樹脂層の表面に凹凸形状を設けるか又は印刷によって付与されている請求項11記載の構造物保護シート。
- 前記意匠性の付与は、前記樹脂層の前記ポリマーセメント硬化層が設けられた側と反対側の面に施されている請求項11又は12記載の構造物保護シート。
- 請求項1、2、3、4、5、6、7、8、9、10、11、12又は13に記載の構造物保護シートのポリマーセメント硬化層が接着剤層を介して表面に貼り付けられていることを特徴とするコンクリートブロック。
- 請求項1、2、3、4、5、6、7、8、9、10、11、12又は13に記載の構造物保護シートを使用した補強された構造物の製造方法であって、構造物上に接着剤を塗布した後に前記構造物保護シートを貼り合わせることを特徴とする補強された構造物の製造方法。
- 前記構造物と前記接着剤との間に下塗り層を設ける、請求項15に記載の補強された構造物の製造方法。
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ZA2022/08744A ZA202208744B (en) | 2020-03-03 | 2022-08-04 | Structure protection sheet, concrete block, and method for manufacturing reinforced structure |
JP2023084014A JP2023111914A (ja) | 2020-03-03 | 2023-05-22 | 構造物保護シート、コンクリートブロック及び補強された構造物の製造方法 |
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WO2023074610A1 (ja) * | 2021-10-28 | 2023-05-04 | 恵和株式会社 | 構造物保護シート及び補強された構造物の製造方法 |
WO2023080133A1 (ja) * | 2021-11-04 | 2023-05-11 | 恵和株式会社 | 構造物保護シート、及び、構造物の表面保護方法 |
WO2023181381A1 (ja) * | 2022-03-25 | 2023-09-28 | 恵和株式会社 | 屋根の補修方法 |
WO2023181384A1 (ja) * | 2022-03-25 | 2023-09-28 | 恵和株式会社 | コンクリートの柱状物の保護方法 |
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- 2021-03-02 EP EP21764164.6A patent/EP4116087A4/en active Pending
- 2021-03-02 WO PCT/JP2021/007894 patent/WO2021177286A1/ja active Application Filing
- 2021-03-02 AU AU2021232418A patent/AU2021232418A1/en active Pending
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- 2021-03-02 JP JP2022504385A patent/JP7323699B2/ja active Active
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JP7323699B2 (ja) | 2023-08-08 |
IL295079A (en) | 2022-09-01 |
CN117429136A (zh) | 2024-01-23 |
JPWO2021177286A1 (ja) | 2021-09-10 |
EP4116087A4 (en) | 2024-03-20 |
TW202415542A (zh) | 2024-04-16 |
ZA202208744B (en) | 2023-12-20 |
JP2023111914A (ja) | 2023-08-10 |
TW202140265A (zh) | 2021-11-01 |
US20230107548A1 (en) | 2023-04-06 |
AU2021232418A1 (en) | 2022-08-25 |
CN115023343A (zh) | 2022-09-06 |
EP4116087A1 (en) | 2023-01-11 |
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