An impact and abrasion resistant material and method of making the same

Abstract

The application discloses an anti-impact and abrasion material and a preparation method thereof. The anti-impact and abrasion material is prepared from the following components in parts by weight: 40-45 parts of low-heat Portland cement with a strength grade not lower than 42.5, 8-13 parts of mineral admixture, 2-5 parts of barium sulfate, 37-43 parts of fine aggregate, 0.2-0.5 parts of water reducing agent, 0.1-0.3 parts of wetting agent, 0.1-0.8 parts of coagulant, 0.01-0.05 parts of reactive air-entraining material, 0.1-0.3 parts of air bubble inhibitor, 0.1-0.5 parts of nanometer material, 0.3-1.0 parts of redispersible latex powder, 2-5 parts of modified organic aggregate, 0.01-0.05 parts of cellulose ether, 0.3-0.8 parts of composite fiber, 1.0-3.0 parts of internal water-retaining agent and 14-18 parts of water. The application reduces the elastic modulus of the material and improves the impact toughness of the material under the premise of ensuring the crack resistance of the material, and the material is high-strength and dense, and can resist the impact and abrasion damage of media.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of hydraulic concrete materials, and particularly relates to an anti-erosion material and a preparation method thereof. BACKGROUND

[0002] The scouring and erosion of high-speed water flow containing sand to the concrete of the flow surface of hydraulic structures, and the cavitation damage, are common diseases of hydraulic discharge structures such as overflow dam, flood discharge tunnel (channel), sluice, etc. Especially when the flow speed is high and the water flow contains suspended load (sediment) or bed load (stone), the erosion and cavitation of the structures are more serious. In order to improve the service life of large-scale water conservancy and hydropower projects and ensure their safe and reliable operation, it is particularly required to have high anti-cavitation and anti-erosion ability under the condition of high-speed water flow. The cavitation damage can be basically eliminated or greatly reduced by improving the structure design, using high-performance concrete and reasonable energy dissipation facilities, and supplementing local water flow air mixing technology. However, the problem of erosion of high-speed water flow containing sand to the hydraulic concrete cannot be avoided. Therefore, a reliable material must be used to effectively repair the damaged parts of the concrete dam.

[0003] The existing anti-erosion materials in engineering can be basically divided into high-strength materials such as silica powder concrete, fiber reinforced concrete, iron steel sand concrete, steel plate, anti-erosion material, epoxy resin, and flexible materials such as polyurea elastomer and high-density polyurethane. The silica powder series anti-erosion concrete has large drying shrinkage and self-drying shrinkage, and is prone to cracking. The fiber reinforced concrete is not easy to disperse uniformly in the concrete during mixing, and is prone to winding into a bundle, which affects the performance and workability of the concrete. The iron steel sand concrete has good anti-erosion performance, but due to the large density of iron steel sand, segregation is easy to occur during concrete mixing, the cement consumption is large, and shrinkage deformation is easy to occur. Although the epoxy mortar has the advantages of easy adjustment of solidification process, high bonding strength, small shrinkage, good resistance to erosion and medium corrosion, and good resistance to leakage, the ordinary bisphenol A type epoxy resin is a brittle material, and the solidified product is relatively brittle, which leads to poor impact resistance and easy cracking. The linear expansion coefficient of the mortar prepared by the epoxy resin is greatly different from that of the concrete, and the interface is easy to separate, bulge and edge to rise when the environmental temperature changes. In addition, the epoxy resin needs to be prepared on site, and various component materials need to be heated and mixed separately, which is complicated in construction process and low in work efficiency. The polyurea elastomer is a new type of environmentally friendly material in recent years, and has obvious technical advantages in material performance, simplified construction and accelerated progress. However, due to the particularity of the technology, the polyurea has strict requirements on the gel time of the equipment, the mixing precision and the cleaning method, and also has high requirements on the operation technology. If the construction technology is not good, the polyurea cannot play its due advantages.

[0004] For example, the Chinese patent document with the publication number CN102674770B, authorized on July 30, 2014, discloses an "anti-impact mortar", which has good self-flowing property, no bleeding, and good durability, impermeability, frost resistance, and anti-impact and abrasion resistance. The raw material source is extensive, the operation is flexible, and the use is simple. The technical principle is: under the premise of ensuring the crack resistance of the mortar, the compactness and strength of the mortar material are improved to resist the impact and abrasion damage of the medium. However, the technical defect of the material is that the toughness is insufficient, when it is continuously subjected to strong impact, the strength is easy to reach the limit value or the fatigue limit value, although the material body is very hard, but due to the large brittleness, the surface will be hit and peeled off in blocks, and continue to expand to the depth to cause damage.

[0005] Therefore, in order to solve the problem of insufficient impact toughness of high-strength system materials for water discharge structures in water conservancy and hydropower engineering, it is necessary to study an anti-impact and abrasion material. SUMMARY

[0006] The technical problem to be solved by the present application is the insufficient impact toughness of high-strength system materials for water discharge structures in water conservancy and hydropower engineering, and the purpose is to provide an anti-impact and abrasion material, and a preparation method of the anti-impact and abrasion material.

[0007] The first object of the present application is to provide an anti-impact and abrasion material, which is composed of the following components by weight: low-heat portland cement with a strength grade not less than 42.5 40-45 parts, mineral admixture 8-13 parts, barium sulfate 2-5 parts, fine aggregate 37-43 parts, water reducing agent 0.2-0.5 parts, wetting agent 0.1-0.3 parts, coagulant 0.1-0.8 parts, reactive air-entraining material 0.01-0.05 parts, bubble inhibitor 0.1-0.3 parts, nanomaterial 0.1-0.5 parts, redispersible latex powder 0.3-1.0 parts, modified organic aggregate 2-5 parts, cellulose ether 0.01-0.05 parts, composite fiber 0.3-0.8 parts, internal water retention 1.0-3.0 parts, and water 14-18 parts.

[0008] In an optional embodiment, the content of dicalcium silicate in the cement clinker is greater than or equal to 55%, and the content of tricalcium aluminate is less than 5%.

[0009] In an optional embodiment, the mineral admixture is a mixed material of glass microbeads, corundum powder, and lithium slag powder, and the mixing ratio is glass microbeads: corundum powder: lithium slag powder = 1:3:2.

[0010] The specific surface area of the admixture is 5000m 2 / Kg-10000m 2 / Kg.

[0011] In an optional embodiment, the barium sulfate has a fineness of 600-1000 mesh;

[0012] The fine aggregate is one or a mixture of several of machine basalt sand, iron slag sand, and quartz sand, the Mohs hardness index of the fine aggregate is 10-20, and the fineness modulus is 2.3-3.2;

[0013] The water reducing agent is a polycarboxylic acid water reducing agent, and the water reducing rate is greater than or equal to 25%;

[0014] The wetting agent is any one of polyoxyethylene alkyl phenol ether, polyoxyethylene fatty alcohol ether, and polyoxyethylene polyoxypropylene block copolymer;

[0015] The setting accelerator is calcium formate.

[0016] In an optional embodiment, the reactive air entraining material is a hydrazine sulfate material;

[0017] The bubble inhibitor is any one of a polyether type, a silicone type, and a polyether-modified silicone type;

[0018] The nanomaterial is nanosilica, and the particle size of the nanosilica is 50-150 nm;

[0019] The redispersible latex powder is an acrylic latex powder.

[0020] In an optional embodiment, the modified organic aggregate is a modified rubber powder wetting agent material, and the fineness of the modified rubber powder wetting agent material is 100-200 mesh;

[0021] The preparation process of the modified rubber powder wetting agent material is as follows:

[0022] (1) Microwave treatment is performed on the surface of the superfine rubber powder to obtain expanded rubber powder;

[0023] (2) A sandwich interpenetration technique is used to blend high-activity inorganic material at 5%-8% of the mass of the expanded rubber powder with the expanded rubber powder, and the high-activity inorganic material is mechanically pressed into the surface pores of the expanded rubber powder.

[0024] In an optional embodiment, the fineness of the superfine rubber powder is 150-250 mesh, and the microwave treatment process is as follows: The superfine rubber powder is spread on a conveyor belt with a thickness controlled to be 0.1-0.5 mm, and continuously subjected to microwave radiation for 20-90 s to destroy the crosslinked network structure of the rubber powder into a linear structure to obtain expanded rubber powder.

[0025] The high-activity inorganic material is superfine metakaolin, and the fineness is 1500-3000 mesh.

[0026] In an optional embodiment, the cellulose ether is HEC.

[0027] In an alternative embodiment, the composite fiber is a composite of basalt fiber and POM fiber, mixed according to a weight ratio of basalt fiber:POM fiber of 1:3.

[0028] A second object of the present application is to provide a method for preparing an impact abrasion resistant material, which comprises mixing the components in a mixer according to the formula.

[0029] Compared with the prior art, the present application has the following advantages and beneficial effects:

[0030] The present application reduces the elastic modulus of the material and improves the impact toughness of the material under the premise of ensuring the crack resistance of the material, is high-strength and dense, and resists the impact abrasion and corrosion of the medium.

[0031] Specifically,

[0032] (1) In the present application, cement, mineral admixtures, nanomaterials, and bubble inhibitors jointly form a cementitious material system, and the main hydration product of the cementitious material system is CSH gel, which plays a great role in improving the strength; at the same time, the same workability can be achieved with a lower water-binder ratio, and the reduction in water consumption can also reduce the number of interconnected capillary pores in the cement hardened body. These effects jointly achieve the effects of improving strength and increasing density.

[0033] (2) In the present application, the modified organic aggregate and the redispersible latex powder as high-performance film-forming polymers can form a polymer film on the surface of the mortar particles, and part of the surface of the film has pores, while the pore surface is filled with mortar, which reduces stress concentration, produces a lubricating effect between mortar colloidal particles, and enables the components of the mortar to flow alone and relax under the action of external force without being damaged. In addition, the mortar forms a rigid skeleton after cement hydration, and the film formed by the polymer can improve the elasticity and toughness of the rigid skeleton.

[0034] (3) The present application uses space film-forming water locking, capillary pore freezable water gelation, and water retention technology in water-absorbing materials to enable water molecules to exist for a long time within a certain time, thereby improving water retention capacity, improving dry shrinkage performance, and further improving the anti-cracking performance of the material. DETAILED DESCRIPTION

[0035] To make the objects, technical solutions, and advantages of the present application clearer, further detailed descriptions of the present application are given below in combination with examples, and the illustrative embodiments of the present application and their descriptions are only used to explain the present application and do not limit the present application.

[0036] The application provides a kind of impact abrasion resistant material, which is composed of the following components by weight: low-heat Portland cement with strength grade not less than 42.5 40-45 parts, mineral admixture 8-13 parts, barium sulfate 2-5 parts, fine aggregate 37-43 parts, water reducing agent 0.2-0.5 parts, wetting agent 0.1-0.3 parts, coagulant 0.1-0.8 parts, reactive air-entraining material 0.01-0.05 parts, bubble inhibitor 0.1-0.3 parts, nanomaterial 0.1-0.5 parts, redispersible latex powder 0.3-1.0 parts, modified organic aggregate 2-5 parts, cellulose ether 0.01-0.05 parts, composite fiber 0.3-0.8 parts, internal water retaining agent 1.0-3.0 parts, and water 14-18 parts.

[0037] In terms of high strength and density:

[0038] In the application, cement, mineral admixture, nanomaterial and bubble inhibitor jointly form a cementitious material system, which is mainly composed of cement dominated by dicalcium silicate and tricalcium silicate, and the main hydration product of the cementitious material system is CSH gel. The cementitious body of the high-toughness impact abrasion resistant material of the application contains a high proportion of CSH gel, which plays a great role in improving the strength. The hydration theory of dicalcium silicate and tricalcium silicate requires less water, and the reaction on the macro level is that the same workability can be achieved with a lower water-binder ratio. The reduction of water consumption can also reduce the number of connected capillary pores in the hardened cement body. These effects jointly achieve the effects of improving strength and density.

[0039] In the cementitious material system, amorphous material (i.e. nanomaterial) is also added. The nanomaterial has a certain activity and needs to react under alkaline conditions. In the early stage of cement hydration, the content of dicalcium silicate and tricalcium silicate in cement is high, so the hydration reaction is slower than that of ordinary cement, and the alkalinity increases slowly. The reactivity of the amorphous silicon-containing material cannot be activated. In this stage, dicalcium silicate and tricalcium silicate react to form a CSH gel skeleton network. As the reaction proceeds, the CSH gel groups become larger and larger, and pores are formed between different gel bodies, containing higher alkaline pore fluid. Under normal circumstances, gel pores or capillary pores are formed, affecting the density. When the reaction reaches a certain degree, the alkalinity of the pore fluid reaches the threshold of the silicon-containing amorphous material, which can trigger the reaction. The silicon-containing amorphous material and the hydration product calcium hydroxide react to also generate CSH gel. The main reaction area is in the pores generated by the initial CSH gel, so the strength and density of the gel are greatly improved.

[0040] In terms of low elastic modulus and fatigue resistance:

[0041] The redispersible latex powder as a high performance film forming polymer can form a polymer film on the surface of the mortar particles, part of the surface of the film has pores, and the surface of the pores is filled with the mortar, so that the stress concentration is reduced, the lubricating effect between the mortar colloidal particles is generated, and the components of the mortar can flow alone and relax under the action of external force without being damaged. In addition, the mortar forms a rigid skeleton after the hydration of cement, and the film formed by the polymer can improve the elasticity and toughness of the rigid skeleton.

[0042] The modified rubber powder lubricant material adopts a sandwich insertion technology (i.e. hybrid technology), and high-activity inorganic materials are mechanically pressed into the surface pores of the rubber powder. These active materials can react with calcium hydroxide in the cement hydration product to also generate CSH gel, so that the modified rubber powder lubricant material has the characteristics of no obvious interface transition zone and dense structure inside the system, revealing the mechanism of the system having high deformation resistance, high impermeability and high durability. At the same time, the modified rubber particles play the role of "micro-springs" in the concrete.

[0043] In terms of low shrinkage and anti-cracking:

[0044] The incorporation of amorphous materials in high toughness and abrasion resistant materials can improve the performance of hardened cement paste. The amorphous material has the characteristics of strong pozzolanic activity, small particle size and large specific surface area. The mineral composition of the formed cementitious material system is mainly dicalcium silicate and tricalcium silicate, which also has the characteristic of chemical shrinkage. Therefore, the anti-cracking performance of the special material of anti-impact and abrasion resistant material is more important. It is crucial to study the deformation performance of high toughness and abrasion resistant material, especially the dry shrinkage performance.

[0045] The anti-cracking performance in the present patent application is solved by the following methods:

[0046] (a) Space film forming and water locking technology

[0047] A large amount of free water is introduced during the preparation of the mixture. The main purpose of the free water is to ensure the workability and workability of the mixture. Due to the change of humidity environment, these free water is easy to lose, on the one hand, causing the lack of hydration adsorption water of the cementitious material system in the later stage, on the other hand, causing the change of volume stability of the material, especially the loss of water during the hardening process of the cementitious material.

[0048] In order to solve this problem, in the material scheme of the present application, the redispersible latex powder, such as acrylic latex powder, is uniformly dispersed in the filler slurry by the dispersion effect of the high molecular polymer chain and the electric charge, and a water molecule film is formed around the polymer chain through the interaction with water molecules, a space molecular grid structure appears, and the slurry flows like a matrix during the rheological process, and always maintains homogeneity and stability.

[0049] (b) Capillary pore free water gelation technology

[0050] The free water and polyphenyl-acrylic acid amide macromolecular material introduced in the preparation of the mixture are connected with each other under certain conditions to form a space net structure, and the structure gap is filled with an aqueous solution as a dispersion medium, so that the special dispersion system can increase the viscosity of free water molecules and reduce the surface entropy, and it is difficult to lose in the system, thereby achieving the water retention effect.

[0051] (c) Water retention technology in water-absorbing material

[0052] Internal water retention is to obtain pre-wetted material in the interior of the mortar, and to release the absorbed water at a proper time to promote more effective hydration of cement and inhibit internal self-drying of the mortar, so as to solve the problem of excessive self-shrinkage of the mortar caused by self-drying, and to solve the problem of through cracks of externally restrained mortar and small cracks of internally restrained mortar. In the present application, the internal water retention is achieved by using the patent technology of the company, the application number of which is 201711147656.6, the application publication date is April 6, 2018, and the patent name is: a concrete water-retaining material.

[0053] The cracking performance of concrete is studied by using the characteristics of inorganic adsorbent materials and organic water-retaining materials. The composite material is designed to use inorganic adsorbent materials to absorb water, and to wrap organic water-retaining materials on the surface or in the pores of the inorganic adsorbent materials to achieve the purpose of reducing the water loss rate of inorganic materials. The material can greatly improve the water absorption capacity on the basis of the original material, and when the external conditions change, the hydrogen bond, ionic action and physical adsorption between water molecules and the innovative material can make the water molecules exist for a long time within a certain period of time, thereby improving the water retention capacity.

[0054] Through the combined action of the above (a), (b) and (c) three technologies, the water molecules can exist for a long time within a certain period of time, thereby improving the water retention capacity, improving the dry shrinkage performance, and further improving the anti-cracking performance.

[0055] Therefore, under the premise of ensuring the crack resistance of the material, the elastic modulus of the material is reduced, the impact toughness of the material is improved, the material is high-strength and dense, and the medium is resisted from being damaged by erosion.

[0056] As a preferred embodiment, the cement is a portland cement with a strength grade not lower than 42.5. The hydration heat of the portland cement selected by the present application is 3d≤280 KJ / Kg, 7d≤350 KJ / Kg, the content of dicalcium silicate in the cement clinker is greater than or equal to 55%, and the content of tricalcium aluminate is less than 5%. When applied to the present application, the mineral admixture, nanomaterial and bubble inhibitor synergistically act, which is beneficial to controlling the hydration process and the morphology of the hydration product in the synergistic action, so that the impact-resistant and wear-resistant mortar has the performance of moderate early strength and stable late strength growth.

[0057] As a preferred embodiment, the mineral admixture is a mixture of glass microbeads, corundum powder and lithium slag powder, and the weight ratio of glass microbeads: corundum powder: lithium slag powder is 1:3:2;

[0058] The specific surface area of the admixture is 5000m 2 / Kg~10000m 2 / Kg.

[0059] The glass microbeads have the particle characteristics of glass microbeads and potential chemical activity, and have excellent effects on reducing the water consumption of the impact-resistant wear-resistant mortar, increasing the fluidity of the mortar, improving the compactness of the mortar and the later strength; the corundum powder has stable chemical properties, the particle characteristics of glass microbeads, great rigidity and excellent wear-resistant performance; the lithium slag powder has an alkali-activated micro-expansion effect, and can maintain the volume stability of the material. And the mixing of the glass microbeads, the corundum powder and the lithium slag powder in a weight ratio of 1:3:2 has better effects on maintaining the workability of the mixture and the volume stability.

[0060] The specific surface area of the admixture is 5000m 2 / Kg~1000m 2 / Kg can ensure the stable growth of the later strength of the mortar. The inventors have found that if the specific surface area of the admixture is less than 5000m 2 / Kg, the workability of the mixture will be poor, and if it is higher than 10000m 2 / Kg, the hydration process of the cementitious material will be poor.

[0061] As a preferred embodiment, the fineness of the barium sulfate is 600-1000 mesh; the barium sulfate is selected as a white amorphous powder with a fineness of 600-1000 mesh. In the multi-component inorganic cementitious material system formed by the cement, the mineral admixture, the nano material and the bubble inhibitor, the barium sulfate can act as a crystal nucleus to form a chain-like accumulation body of the hydration products in the induction period and the acceleration period of the cement hydration, and improve the compactness and the crack resistance of the material.

[0062] The fine aggregate is one or a mixture of several of machine-made basalt sand, iron and steel slag sand and quartz sand, the Mohs hardness index of the fine aggregate is 10-20, which can ensure the impact-resistant wear-resistant strength of the impact-resistant wear-resistant mortar, and the fineness modulus is 2.3-3.2;

[0063] The water reducing agent is a polycarboxylic acid water reducing agent, and the water reducing rate is greater than or equal to 25%;

[0064] The wetting agent is any one of polyoxyethylene alkyl phenol ether, polyoxyethylene fatty alcohol ether, polyoxyethylene polyoxypropylene block copolymer; the wetting agent can change the surface tension of the powder material, so that the powder material is more easily dispersed into the system, increasing the specific surface area of the system, so that the hydration of the cementitious material system is more complete, and the compactness is higher.

[0065] The setting accelerator is calcium formate.

[0066] As a preferred embodiment, the reactive air entraining material is a hydrazine sulfate material; the reactive air entraining material can adjust the air entraining of the concrete, avoiding the problem that the conventional concrete air entraining agent produces gas too early in the mixing stage, and the air bubbles are destroyed in the transportation, paving and strong vibration stages, resulting in poor air entraining effect, thereby reducing the frost resistance and crack resistance of the concrete; and the reactive air entraining material can produce micro-expansion by generating gas, inhibit the plastic shrinkage in the early hydration stage, and reduce the risk of material cracking.

[0067] The reactive air entraining material is a patent technology of the company. Patent number: ZL202111013637.0.

[0068] The bubble inhibitor is any one of polyether type, silicone type, and polyether modified silicone type; the bubble inhibitor can eliminate the large bubbles generated by stirring between the aggregate and the mortar, and inside the mortar during the mixing process, improve the compactness of the concrete, and improve the mechanical properties of the concrete. Through experimental research, the polyether type, silicone type, and polyether modified silicone type bubble inhibitor have good compatibility with the material system.

[0069] The nano material is nano silicon dioxide, and the particle size of the nano silicon dioxide is 50-150 nm.

[0070] The redispersible latex powder is preferably an acrylic latex powder; the adhesive film formed after the acrylic latex powder material is hydrolyzed has strong adhesion to the aggregate and the cement hydration product; the adhesive film has good flexibility, and the elongation rate is greater than 300%, which can improve the toughness of the material.

[0071] As a preferred embodiment, the modified organic aggregate is a modified rubber powder wetting agent material, and the fineness of the modified rubber powder wetting agent material is 100-200 mesh.

[0072] The preparation process of the modified rubber powder wetting agent material is as follows:

[0073] (1) The surface of ordinary ultra-fine rubber powder is treated by microwave to form a porous structure on the surface, and expanded rubber powder is obtained.

[0074] (2) Using the sandwich interpenetration technology, the high-activity inorganic material is interlocked with the organic-inorganic material through mechanical chemical reaction according to 5%-10% of the mass of the rubber powder.

[0075] Specifically, the swelling treatment process: the mesh number of the superfine rubber powder is 150-200, the microwave treatment process: the superfine rubber powder is spread on a conveying belt, the thickness is controlled to be 0.1-0.5 mm, and the rubber powder is continuously subjected to microwave radiation, the radiation time is 20-90 s, the crosslinked network structure of the rubber powder is destroyed to be a linear structure, the oxygen-containing groups are increased, and the specific surface area of the material is increased, so that the activity of the rubber powder is changed. The hybrid technology (i.e. the sandwich interpenetration technology): the high-activity inorganic material is blended with the obtained swelling rubber powder at a certain proportion, the mechanical shear of three-dimensional solid phase is generated, the inorganic material is pressed into the pores of the swelling rubber powder through the force chemical reaction, and the material interlocking is formed.

[0076] The swelling rubber powder has a porous structure, the porous structure has the characteristics of increased oxygen-containing groups and increased specific surface area; the contact angle of the modified rubber powder and the wetting material after interlocking with the inorganic material is less than 45°, and the transition interface zone (ITZ) contains stable inorganic element distribution and relative content. The high-activity inorganic material is metakaolin. The modified rubber powder wetting agent material has little influence on the mechanical properties of the mortar material (the influence on the compressive strength is less than 5%), and can greatly reduce the elastic modulus of the mortar and improve the impact toughness of the mortar.

[0077] As a preferred embodiment, the cellulose ether preferably adopts HEC material which is an alkali swelling material, and can play a role in water retention in the alkaline environment of cement hydration, enhance the crack resistance of the mortar, and has little influence on the strength of the mortar.

[0078] The composite fiber preferably comprises basalt fiber and POM fiber. The basalt fiber and the POM fiber are used in combination, the basalt fiber has an elastic modulus in the range of 70 GPa-80 GPa, and an appearance size of 13 μm in diameter and 3 mm in length, and the POM fiber has an elastic modulus in the range of 5 GPa-10 GPa, and an appearance size of 200 μm in diameter and 6 mm in length. Through research, in order to ensure the flexibility of the system, the weight ratio of the rigid fiber to the flexible fiber is basalt fiber:POM fiber=1:3. The difference in the elastic modulus of the two fibers is used to improve the crack resistance of the mortar in the strength development process.

[0079] The sandwich water locking technology is adopted, the organic polymer material is encapsulated in the inorganic material by certain technical means, and a new internal anti-cracking material with a "core-shell" structure is prepared. The advantage of the material relative to the traditional inorganic material is that the physical action and chemical action (hydrogen bond, van der Waals force) act together to retain water, rather than single physical action, and the water retention efficiency is higher. If the organic material is compared to "core", then the inorganic material acts as "shell", which improves the water absorption and water retention capacity of the material, and at the same time, does not cause the adverse effect of the organic polymer material on the strength of the concrete. The prepared new material can realize self-humidity adjustment. When the internal water-retaining material is added into the concrete as an external additive, it slowly releases the encapsulated water to make up for the loss of water in the concrete in a high-temperature environment; in a humid environment, it absorbs water to keep the relative humidity inside the concrete, thereby realizing the intelligent transformation of the water locking to water releasing process in the concrete. The water absorption mechanisms of inorganic materials and organic materials are not the same, and the sandwich water locking technology is realized on the basis of the excellent performance of the two materials.

[0080] The present patent application is described in detail through specific examples.

[0081] Example 1

[0082] The components and their weights of the impact-resistant and wear-resistant mortar of the present example are as follows: cement 40 parts, mineral admixture 10 parts, barium sulfate 3 parts, fine aggregate 42 parts, water reducing agent 0.2 parts, wetting agent 0.2 parts, coagulant 0.1 parts, reactive air-entraining material 0.03 parts, bubble inhibitor 0.14 parts, nano material 0.2 parts, redispersible latex powder 0.7 parts, organic modified aggregate 2 parts, cellulose ether 0.03 parts, composite fiber 0.4 parts, internal water-retaining material 1 part, and water 14 parts.

[0083] Example 2

[0084] The components and their parts by weight of the impact-resistant and wear-resistant mortar of the present example are as follows: cement 41 parts, mineral admixture 8 parts, barium sulfate 2 parts, fine aggregate 43 parts, water reducing agent 0.2 parts, wetting agent 0.3 parts, coagulant 0.18 parts, reactive air-entraining material 0.01 parts, bubble inhibitor 0.1 parts, nano material 0.5 parts, redispersible latex powder 1 part, modified organic aggregate 2 parts, cellulose ether 0.01 parts, composite fiber 0.7 parts, internal water-retaining material 1 part, and water 15 parts.

[0085] Example 3

[0086] The components and their weights of the impact-resistant and wear-resistant mortar of the present embodiment are as follows: cement 45 parts, mineral admixture 8 parts, barium sulfate 2 parts, fine aggregate 40 parts, water reducing agent 0.25 part, wetting agent 0.1 part, coagulant 0.1 part, reactive air entraining material 0.03 part, bubble inhibitor 0.3 part, nanomaterial 0.1 part, redispersible latex powder 0.3 part, modified organic aggregate 2 part, cellulose ether 0.02 part, composite fiber 0.3 part, internal water retention 1.5 part, and water 18 parts.

[0087] Embodiment 4

[0088] The components and their weights of the impact-resistant and wear-resistant mortar of the present embodiment are as follows: cement 40 parts, mineral admixture 8 parts, barium sulfate 5 parts, fine aggregate 37 parts, water reducing agent 0.2 part, wetting agent 0.1 part, coagulant 0.1 part, reactive air entraining material 0.05 part, bubble inhibitor 0.1 part, nanomaterial 0.1 part, redispersible latex powder 0.5 part, organic modified aggregate 5 part, cellulose ether 0.05 part, composite fiber 0.8 part, internal water retention 3 part, and water 15 parts.

[0089] Embodiment 5

[0090] The components and their weights of the impact-resistant and wear-resistant mortar of the present embodiment are as follows: cement 40 parts, admixture 13 parts, barium sulfate 2 parts, fine aggregate 39 parts, water reducing agent 0.5 part, wetting agent 0.2 part, coagulant 0.8 part, reactive air entraining material 0.02 part, bubble inhibitor 0.1 part, nanomaterial 0.2 part, redispersible latex powder 0.3 part, organic modified aggregate 2.4 part, cellulose ether 0.02 part, composite fiber 0.46 part, internal water retention 1 part, and water 17 parts.

[0091] The specific selection of each component is as follows:

[0092] Cement: Portland cement with a strength of 42.5, the content of tricalcium silicate in cement clinker is not less than 55%, and the content of tricalcium aluminate is less than 5%.

[0093] Admixture: glass beads: corundum powder: lithium slag powder in a ratio of 1:3:2;

[0094] Barium sulfate: fineness of 500-1000 mesh;

[0095] Fine aggregate: machine-made basalt sand with a Mohs hardness index of 15 and a fineness modulus of 3.0;

[0096] Water reducing agent: polycarboxylic acid water reducing agent with a water reducing rate of 25%;

[0097] Wetting agent: polyoxyethylene fatty alcohol ether;

[0098] Coagulant: calcium formate.

[0099] Reactive air entraining material: hydrazine sulfate;

[0100] Bubble inhibitor: silicone type;

[0101] Nanomaterial: nanosilica, particle size 50 nm, specific surface area 18000 cm 2 / g;

[0102] Redispersible latex powder: acrylic;

[0103] Modified organic aggregate: modified rubber powder wetting agent material, mesh size 100 mesh;

[0104] Cellulose ether: HEC (hydroxyethyl cellulose ether);

[0105] Composite fiber: basalt fiber and POM fiber composite, weight ratio 1:3;

[0106] Accelerator: calcium formate;

[0107] Internal water retention: organic-inorganic composite material (existing patent technology).

[0108] Preparation method: weigh each component according to the above weight example, mix in a mixer for 10 min, the stirring line speed is 1.5 m / s, and the product is formed after mixing uniformly;

[0109] Use method: the anti-impact and wear-resistant material is added with appropriate amount of free water to make its consistency meet the use requirements; the conventional concrete material construction method is used during construction, and it is mainly used for water and electricity engineering repair.

[0110] It is particularly pointed out that the "parts" in the present application all refer to "weight parts", and in specific embodiments, the unit of "weight parts" can be unified, such as "g" or "kg" weight unit.

[0111] Comparative Example 1:

[0112] The raw materials of this comparative example do not contain modified organic aggregate, and the others are the same as Example 1.

[0113] Comparative Example 2:

[0114] The modified organic aggregate in the raw materials of this comparative example is ordinary rubber powder, and the others are the same as Example 1.

[0115] Comparative Example 3:

[0116] The raw materials of this comparative example do not contain internal water retention, and the others are the same as Example 1.

[0117] Comparative Example 4:

[0118] The weight ratio of glass beads, corundum powder and lithium slag powder in the raw materials of this comparative example is 1:2:3, and the others are the same as Example 1.

[0119] Comparative Example 5:

[0120] In the present comparative example, the composite fiber is basalt fiber, and the other conditions are the same as in Example 1.

[0121] Comparative Example 6:

[0122] In the present comparative example, the composite fiber is POM fiber, and the other conditions are the same as in Example 1.

[0123] Comparative Example 7:

[0124] In the present comparative example, the weight ratio of basalt fiber to POM fiber is 1:1, and the other conditions are the same as in Example 1.

[0125] Experimental Example: The consistency, compressive strength, durability index, elastic modulus and impact abrasion resistance of the impact-resistant and abrasion-resistant mortar prepared in each example were determined, and the test results are shown in Table 1 below:

[0126] Table 1: Test results of Examples 1-5

[0127]

[0128]

[0129] The consistency, compressive strength, durability index, elastic modulus and impact abrasion resistance of the mortar prepared in each comparative example were determined, and the test results are shown in Table 2 below:

[0130] Table 2: Test results of Comparative Examples 1-7

[0131]

[0132]

[0133] The performance data of the patent product with publication number CN102674770B and the name of "an impact-resistant and abrasion-resistant mortar" was also detected, which is the product according to Example 1 of the existing patent product. And the product of Example 1 of the present application was compared, and the results are shown in Table 3 below:

[0134] Table 3: Test results of the existing impact-resistant and abrasion-resistant mortar and the product of Example 1

[0135]

[0136] The above results show that the product of the embodiment 1 of the present application, compared with the existing anti-impact and anti-abrasion mortar, reduces the elastic modulus of the material by 30%-40%, increases the impact toughness of the material by 40%-50%, increases the crack resistance index by more than 50%, and increases the chemical adhesion of the material to the base concrete by 50%-60%. The existing patent product is more suitable for suspension damage, cavitation and air erosion damage, freeze-thaw and chemical erosion damage, and the material of the present application is suitable for suspension damage, push damage, cavitation and air erosion damage, freeze-thaw and chemical erosion damage, and pulsating water pressure lifting damage in various working conditions.

[0137] The following describes the anti-impact and anti-abrasion damage of the concrete:

[0138] Generally, the impact and abrasion damage of the concrete includes: suspension damage, push damage, cavitation and air erosion damage, freeze-thaw and chemical erosion damage, and interlayer lifting damage caused by pulsating water pressure. We believe that the high-speed sand-containing water flow discharge structure mainly subjected to suspension damage should select a material with better abrasion resistance; the discharge structure mainly subjected to push damage, cavitation and air erosion damage, freeze-thaw and chemical erosion damage should select a material with better impact toughness; and the discharge structure mainly subjected to interlayer lifting damage caused by pulsating water pressure should select a material mainly bonded to the base by chemical bonding.

[0139] The high-toughness anti-impact and anti-abrasion material provided by the present application improves the strength, compactness, deformation capacity, toughness, crack resistance, and adhesion to the base of the anti-impact and anti-abrasion material through technical means, has the characteristics of high impact and abrasion strength, high impact toughness, low elastic modulus, strong adhesion to the base, and excellent crack resistance, especially highlights the deformation toughness of the material, and can solve the problem of insufficient impact toughness of the high-strength system material used in the existing discharge structure of water conservancy and hydropower projects.

[0140] The above specific embodiments further specifically describe the purpose, technical solutions, and advantages of the present application, and it should be understood that the above are only specific embodiments of the present application and are not used to limit the protection scope of the present application, and any modification, equivalent replacement, improvement, etc. made within the spirit and principles of the present application should be included in the protection scope of the present application.

Claims

1. An impact and abrasion resistant material, characterized in that, It is composed of the following components by weight: low-heat Portland cement with strength grade not less than 42.5 40-45 parts, mineral admixture 8-13 parts, barium sulfate 2-5 parts, fine aggregate 37-43 parts, water reducing agent 0.2-0.5 parts, wetting agent 0.1-0.3 parts, setting accelerator 0.1-0.8 parts, reactive air entraining material 0.01-0.05 parts, bubble inhibitor 0.1-0.3 parts, nanomaterial 0.1-0.5 parts, redispersible latex powder 0.3-1.0 parts, modified organic aggregate 2-5 parts, cellulose ether 0.01-0.05 parts, composite fiber 0.3-0.8 parts, internal water-retaining material 1.0-3.0 parts, and water 14-18 parts; The modified organic aggregate is a modified rubber powder wetting agent material; The preparation process of the modified rubber powder wetting agent material is: (1) microwave treatment is performed on the surface of superfine rubber powder to obtain puffed rubber powder; (2) high-activity inorganic material is blended with the puffed rubber powder at 5%-8% of the mass of the puffed rubber powder by using sandwich interpenetration technology, and is mechanically pressed into the surface pores of the puffed rubber powder; The high-activity inorganic material is superfine metakaolin; The mineral admixture is a mixed material of glass microbeads, corundum powder and lithium slag powder; The nanomaterial is nanosilica; The composite fiber is a composite of basalt fiber and POM fiber, and the composite fiber is mixed according to a weight ratio of basalt fiber:POM fiber of 1:

3.

2. An impact and abrasion resistant material according to claim 1, wherein, The content of dicalcium silicate in the cement clinker is greater than or equal to 55%, and the content of tricalcium aluminate is less than 5%.

3. An impact and abrasion resistant material according to claim 1, wherein, The mineral admixture is mixed according to a weight ratio of glass microbeads:corundum powder:lithium slag powder of 1:3:2; The specific surface area of the blend is 5000 m 2 / Kg ~ 10000 m 2 / Kg.

4. The impact and abrasion resistant material of claim 1, wherein, The fineness of the barium sulfate is 500-1000 mesh; The fine aggregate is a mixture of one or more of machine-made basalt sand, iron-steel slag sand and quartz sand, the Mohs hardness index of the fine aggregate is 10-20, and the fineness modulus is 2.3-3.2; The water reducing agent is a polycarboxylic acid water reducing agent with a water reducing rate greater than or equal to 25%; The wetting agent is any one of polyoxyethylene alkyl phenol ether, polyoxyethylene fatty alcohol ether and polyoxyethylene polyoxypropylene block copolymer; The setting accelerator is calcium formate.

5. The impact and abrasion resistant material of claim 1, wherein, The reactive air entraining material is hydrazine sulfate material; The bubble inhibitor is any one of polyether type, silicone type and polyether modified silicone type; The particle size of the nanosilica is 50-150 nm; The redispersible latex powder is acrylic latex powder.

6. The impact and abrasion resistant material of claim 1, wherein, The fineness of the modified rubber powder wetting agent material is 100-200 mesh.

7. An impact and abrasion resistant material according to claim 6, wherein, The fineness of the superfine rubber powder is 150-250 mesh, and the microwave treatment process is as follows: the superfine rubber powder is spread on a conveying belt with a thickness controlled at 0.1-0.5 mm, and continuously subjected to microwave radiation for 20-90 s to destroy the crosslinked network structure of the rubber powder into linear structure, thereby obtaining puffed rubber powder; The fineness of the high-activity inorganic material is 1500-3000 mesh.

8. The impact and abrasion resistant material of claim 1, wherein, The cellulose ether is HEC.

9. The method for preparing an impact-resistant and abrasion-resistant material as described in claim 1, characterized in that, The components are uniformly mixed in a mixer according to the formula proportion to obtain the product.

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