Polyurethane + dense water glass mortar combined impermeable floor construction method

Abstract

This invention discloses a method for constructing a polyurethane + dense water glass mortar combined impermeable floor, belonging to the field of floor construction technology, including the following steps: (1) compacting the subgrade soil with a compaction coefficient ≥0.94%; (2) 150mm thick C15 plain concrete; (3) pasting a 0.2mm thick plastic film layer and cleaning it; (4) 170mm thick C30 fine stone impermeable concrete with an impermeability grade not lower than P8, reinforced with bidirectional Φ6@200 crack-resistant steel mesh, and the surface is sprinkled with 1:1 cement sand and polished as it is poured; (5) 1.5mm thick polyurethane coating; (6) 10~15mm thick dense water glass mortar bonding layer; (7) 40mm thick granite slab filled with epoxy asphalt mortar, with a joint width of 8-15mm. This invention uses C30 fine stone impermeable concrete, which has a higher density, making it easier to raise the slurry during the polishing process, thus improving work efficiency and shortening the construction period. After adjusting the thickness to 170mm and polishing, the polyurethane coating is applied directly. The leveling function is undertaken by the dense water glass mortar bonding layer, which shortens the construction period and ensures the construction quality.

Description

Technical Field

[0001] This invention belongs to the field of ground construction technology, specifically relating to a method for constructing impermeable ground using a combination of polyurethane and dense water glass mortar. Background Technology

[0002] Polyurethane flooring, used in cold hydrogenation units, offers excellent impermeability, simple construction, and low cost. Because it better meets the cost-reduction and efficiency-enhancing needs of the chemical industry, polyurethane flooring has gradually replaced the earlier but more complex epoxy resin flooring, becoming the leading choice for anti-corrosion and impermeable flooring in the chemical industry. Polyurethane combined with dense water glass mortar is a new, cost-effective, and impermeable flooring solution favored by the granular silicon production chemical industry.

[0003] The construction of anti-seepage flooring with a polyurethane + dense water glass mortar bonding layer is not only constrained by internal construction technology conditions, but also affected by multiple external constraints such as harsh construction conditions within the plant, difficulties in material transportation, and reduced construction efficiency. Meanwhile, due to the booming market for granular silica, plant construction periods are often lengthy. Summary of the Invention

[0004] To address the aforementioned problems, this invention discloses a method for constructing an impermeable floor using a combination of polyurethane and dense water glass mortar. The process is simple and shortens the construction period while ensuring floor quality.

[0005] To achieve the above objectives, the specific technical solution of this application is as follows:

[0006] The construction method for a polyurethane + dense water glass mortar-bonded impermeable floor includes the following steps:

[0007] (1) The subgrade soil is compacted, with a compaction coefficient ≥ 0.94%;

[0008] (2) 150mm thick C15 plain concrete, and clean it thoroughly;

[0009] (3) Apply a 0.2mm thick plastic film layer and clean it thoroughly;

[0010] (4) 170mm thick C30 fine stone impermeable concrete, with an impermeability grade of not less than P8, reinforced with bidirectional Φ6@200 crack-resistant steel mesh, and the surface is sprinkled with 1:1 cement sand and polished as it is poured;

[0011] (5) 1.5mm thick polyurethane coating;

[0012] (6) A 10-15mm thick dense water glass mortar bonding layer;

[0013] (7) For 40mm thick granite slabs, use epoxy asphalt mortar to fill the joints, with a joint width of 8-15mm.

[0014] Based on the above technical features, further, in step (1), the plain soil is backfilled in layers of 500mm, compacted in layers by a small road roller, and compacted in densely populated areas by a small excavator.

[0015] Based on the above technical features, further, the plastic film layer pasting method in step (3) includes spot pasting and full pasting.

[0016] Based on the above technical features, furthermore, before laying the spot-adhesive plastic film, a construction adhesive of about 100mm×100mm size is applied in a quincunx pattern every 300mm to 500mm on the cleaned C15 plain concrete to ensure that the laid plastic film will not be blown away by the wind again.

[0017] Based on the above technical features, the full-adhesion method is mainly used for the overlapping area of ​​plastic film, the inside and outside corners of equipment foundation, and the starting and ending edges of plastic film laying; the width of the construction adhesive applied to the cleaned C15 plain concrete should not be less than 150mm, the construction adhesive should be applied by roller, the coating should be uniform, and at least two coats should be applied.

[0018] Based on the above technical features, further, the plastic film fixing method in step (3) includes three overlapping forms: overlapping fixing, side strip fixing and pressure strip fixing.

[0019] Based on the above technical features, furthermore, the overlapping and fixing method is used for large-area plastic film laying work. The overlapping and fixing method is to lay the film along the long side, and the overlap length of adjacent plastic films shall not be less than 150mm.

[0020] Based on the above technical features, furthermore, the strip fixing is used at the junction of the floor and the foundation, as well as at the internal and external corners of the structure; the strip fixing method involves laying adjacent plastic films in parallel, and then pasting a strip plastic film in the center of the joint between adjacent plastic films, and the width of the strip plastic film shall not be less than 300mm.

[0021] Based on the above technical features, furthermore, the pressure strip is used for fixing parts such as the edge of the equipment foundation where it is not easy to fix with adhesive; the width of the pressure strip for fixing the plastic film shall not be less than 10mm, and the spacing of the cement nails used to fix the pressure strip shall not be greater than 250mm.

[0022] Based on the above technical features, further, in step (6), the consistency of the dense water glass mortar is maintained at 30-40 mm, and the construction of the dense water glass mortar is completed within 45 minutes.

[0023] Compared with the prior art, the beneficial effects of this application are as follows:

[0024] C30 fine aggregate impermeable concrete has higher density, making on-site leveling work smoother and grouting easier during polishing, which greatly improves work efficiency and shortens the construction period. Especially in areas with dense equipment foundations that require manual leveling and polishing, the advantages of fine aggregate concrete construction compared to ordinary concrete construction are more obvious.

[0025] After the C30 fine stone impermeable concrete is 170mm thick, it is polished and then the polyurethane coating is applied directly. The leveling function is undertaken by the dense water glass mortar bonding layer, which shortens the construction period. The leveling of the dense water glass bonding layer also ensures the construction quality. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the construction method for a polyurethane + dense water glass mortar combined impermeable floor according to the present invention;

[0027] Figure 2 This is a schematic diagram of the plastic film layer overlapping and fixing structure in this invention;

[0028] Figure 3 This is a schematic diagram of the plastic film layer support strip fixing structure in this invention;

[0029] Figure 4 This is a schematic diagram of the plastic film lamination strip fixing structure in this invention;

[0030] List of identifiers in attached diagrams:

[0031] 1. Plain soil; 2. C15 plain concrete; 3. Plastic film layer; 4. Impermeable concrete; 5. Polyurethane coating; 6. Dense water glass mortar bonding layer; 7. Granite slab; 8. Building water supply; 9. Cement nails. Detailed Implementation

[0032] The following is in conjunction with the appendix Figure 1-4 The present invention will be further illustrated by the following specific embodiments. It should be understood that the following specific embodiments are for illustrative purposes only and are not intended to limit the scope of the invention.

[0033] It should be noted that the terms "up", "down", "left", "right", "front" and "back" used in the following description refer to the directions in the attached diagram, while the terms "inside" and "outside" refer to the directions toward or away from the geometric center of a specific component, respectively.

[0034] like Figure 1 As shown, the construction method for a polyurethane + dense water glass mortar combined impermeable floor includes the following steps:

[0035] (1) The subgrade soil 1 is compacted, with a compaction coefficient ≥ 0.94%;

[0036] (2) 150mm thick C15 plain concrete 2, and clean it thoroughly;

[0037] (3) Apply a 0.2mm thick plastic film layer 3 and clean it thoroughly;

[0038] (4) 170mm thick impermeable concrete 4, preferably C30 fine stone impermeable concrete, with an impermeability grade of not less than P8, reinforced with bidirectional Φ6@200 crack-resistant steel mesh, and the surface is sprinkled with 1:1 cement sand and polished as it is poured;

[0039] (5) 1.5mm thick polyurethane coating 5;

[0040] (6) 10~15mm thick dense water glass mortar bonding layer 6;

[0041] (7) For 40mm thick granite slabs, use epoxy asphalt mortar to fill the joints, with a joint width of 8-15mm.

[0042] In step (1), the soil was backfilled in layers of 500mm, compacted in layers with a small roller, and compacted with a small excavator in areas with dense equipment. This construction plan achieved good construction results.

[0043] The soil compaction work and C15 plain concrete work in steps (1) and (2) need to be completed in sections before the installation of the first layer of equipment in the cold hydrogenation unit; this provides a basic temporary processing site for the installation of equipment and pipeline construction in the unit.

[0044] After the pressure test and purging of the first layer of equipment and pipelines in step (3) is completed, the scaffolding for the plastic film layer and subsequent structural layers will be removed, and construction will begin in stages. When constructing the plastic film, the base layer must be thoroughly cleaned, especially removing small, sharp particles such as welding slag, iron filings, and stones. Minimize unnecessary trampling during plastic film construction and set up a warning zone to prevent unauthorized personnel from entering the construction area. Protect the plastic film layer during rebar tying and spacer installation, and repair any damaged areas promptly to ensure the impermeability of the plastic film layer. In practice, using wide adhesive tape is a good method for quick repairs. The laying direction of the plastic film should be coordinated with the pouring direction of the C30 fine aggregate impermeable concrete as much as possible. Ensure that the C30 fine aggregate concrete pouring does not damage the overlapping parts of the plastic film. In addition, the use of fine aggregate concrete in the impermeable concrete construction also provides some protection for the overlapping parts of the plastic film. When pouring the impermeable concrete, avoid vertically impacting the plastic film with the concrete and take effective measures to reduce the impact of the impermeable concrete on the impermeability of the plastic film layer.

[0045] In step (3), the plastic film layer is laid and pasted using two methods: spot bonding and full bonding. For spot bonding, before laying the plastic film, apply approximately 100mm x 100mm pieces of construction adhesive 8 in a quincunx pattern every 300mm to 500mm on the cleaned C15 plain concrete. Then lay the plastic film, ensuring that the laid plastic film is not blown away by the wind. Full bonding is mainly used for overlapping areas of the plastic film, the corners of equipment foundations, and the beginning and ending edges of the plastic film. For full bonding, the width of the construction adhesive applied to the cleaned C15 plain concrete should not be less than 150mm. The construction adhesive should be applied by roller, with a uniform coating, at least two to three coats.

[0046] like Figure 2-4 As shown, the plastic film fixing methods in step (3) include three overlapping forms: overlapping fixing, strip fixing, and pressure strip fixing. Overlap fixing is used for large-area plastic film laying work. The overlapping fixing method is to lay the film along the long side, and the overlap length of adjacent plastic films shall not be less than 150mm. Strip fixing is used at the junction of the floor and the foundation, as well as the internal and external corners of the structure. The strip fixing method involves laying adjacent plastic films in parallel, and then pasting a strip plastic film in the center of the joint between adjacent plastic films. The width of the strip plastic film shall not be less than 300mm. Pressure strip fixing is used for parts that are not easy to fix, such as the edges of equipment foundations. The width of the pressure strip for fixing the plastic film shall not be less than 10mm, and the spacing of the cement nails 9 used to fix the pressure strip shall not be greater than 250mm.

[0047] In step (4), the thickness of the impermeable concrete is 170mm, preferably C30 fine aggregate impermeable concrete. After polishing, the polyurethane coating is applied directly. The leveling function is undertaken by the dense water glass mortar bonding layer, which shortens the construction period. The leveling of the dense water glass bonding layer also ensures the construction quality. The fine aggregate impermeable concrete has a higher density, making the on-site leveling work smoother and the slurry raising during polishing easier, which greatly improves work efficiency. Especially in areas with dense equipment foundations that require manual leveling and polishing, the advantages of fine aggregate concrete construction compared to ordinary concrete construction are more obvious.

[0048] When pouring large-area impermeable concrete, the pouring direction should be arranged reasonably according to the direction of the plastic film laying. This ensures that the flow of the impermeable concrete will not affect the quality of the plastic film laying.

[0049] The impermeable concrete 4 is internally reinforced with a bidirectional Φ6@200 anti-crack steel mesh, which is laid on a 0.2mm plastic film layer. This invention adopts a construction method that combines prefabricated mesh hoisting and partial on-site binding, which reduces pollution and damage to the plastic film layer and ensures the construction quality of the impermeable concrete.

[0050] Vibration compaction plays a crucial role in improving the quality of the impermeable concrete 4. The impermeable concrete 4 structural layer of this invention has a thickness of 170mm and is constructed using a combination of a plate vibrator and a 50-type vibrating rod. The plate vibrator is used to compact the large-area impermeable concrete floor, while the 50-type vibrating rod is used to compact areas around the equipment foundation that the plate vibrator cannot reach. The construction scheme using a plate vibrator and a 50-type vibrating rod yields excellent construction results.

[0051] Step (5) Polyurethane coating construction requires that the strength of the impermeable concrete reaches C25 or above, and the moisture content is less than 8%, and the relative humidity of the atmosphere is less than 80%. In this invention, after the impermeable concrete has been cured for 14 days, the polyurethane coating construction is carried out after ensuring that the strength of the impermeable concrete reaches C25 by testing test blocks of impermeable concrete under the same conditions.

[0052] The polyurethane coating 5 construction requires the floor surface to be flat to a level that meets the requirements of a 2-meter straightedge and ruler, with a height difference not exceeding 3 millimeters. The floor surface must be dense, free from looseness, sand, and delamination. After the impermeable concrete 4 has been ground to a satisfactory flatness, grinding dust and cement slurry must be thoroughly cleaned, especially in the dead corners of equipment foundations and drainage ditch sump areas. This invention uses compressed air cleaning and a vacuum cleaner to clean the impermeable concrete 4, which is particularly effective at removing cement slurry and fine particles.

[0053] In this invention, by simulating atmospheric temperature using a refrigerator, it was found through comparison of polyurethane coated specimens that the specimens performed well above 5°C.

[0054] In step (6), the dense water glass mortar bonding layer is mechanically mixed, and the order and amount of raw materials added must be strictly controlled. First, the powder, fine aggregate, and sodium fluorosilicate are added to the mixer according to the construction mix ratio and dry-mixed evenly. Then, water glass is gradually added until it is evenly mixed. The consistency of the dense water glass mortar for masonry should be maintained at 30-40 mm, and the water glass mortar should be applied within 45 minutes.

[0055] Step (7) When laying granite slabs 7, use civil decoration tile crosses to control the gaps between the granite slab floor panels. There are two main methods of using crosses: horizontal and vertical. This invention uses the vertical method for construction. The vertical method refers to placing a cross vertically between the granite floor panels when laying the granite slabs, which is convenient and quick to install.

[0056] In summary, the C30 fine-aggregate impermeable concrete used in this invention has higher density, making on-site leveling work smoother and slurry raising easier during polishing, greatly improving work efficiency and shortening the construction period. After adjusting the thickness to 170mm and polishing, the polyurethane coating is applied directly, and the leveling function is undertaken by the dense water glass mortar bonding layer, shortening the construction period. The leveling of the dense water glass bonding layer also ensures the construction quality.

[0057] It should be noted that the accompanying drawings merely illustrate the technical concept of the present invention and should not be used to limit the scope of protection of the present invention. For those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and all such improvements and modifications fall within the scope of protection of the claims of the present invention.

Claims

1. A method for constructing a waterproof floor using a combination of polyurethane and dense water glass mortar, characterized by: Includes the following steps: (1) The subgrade soil is compacted with a compaction coefficient of ≥0.94%. The subgrade soil is backfilled in layers of 500mm. Small road rollers are used for layer compaction. In areas with dense equipment, small excavators are used in conjunction with compaction. (2) 150mm thick C15 plain concrete; (3) A 0.2mm thick plastic film layer is pasted and cleaned. The plastic film layer is pasted using two methods: spot pasting and full pasting. For spot pasting, before laying the plastic film, apply a 100mm x 100mm piece of construction adhesive in a quincunx pattern every 300mm to 500mm on the cleaned C15 plain concrete to ensure that the laid plastic film is not blown away by the wind. The full pasting method is mainly used for plastic film overlap areas, the inside and outside corners of equipment foundations, and the starting and ending edges of plastic film laying. For full pasting, the width of the construction adhesive applied to the cleaned C15 plain concrete should not be less than 150mm. The construction adhesive should be applied by roller, with a uniform coating, at least twice. The plastic film is fixed in place using... The methods include three types of overlapping fixing: overlapping fixing, strip fixing, and pressure strip fixing. Overlap fixing is used for large-area plastic film laying. The overlapping fixing method is to lay the film along the long side, and the overlap length between adjacent plastic films shall not be less than 150mm. Strip fixing is used at the junction of the floor and the foundation, as well as at the internal and external corners of the structure. Strip fixing involves laying adjacent plastic films parallel to each other, and then pasting a strip plastic film in the center of the joint between adjacent plastic films. The width of the strip plastic film shall not be less than 300mm. Pressure strip fixing is used for the edges of equipment foundations where it is difficult to fix. The width of the pressure strip for pressure strip fixing shall not be less than 10mm, and the spacing of the cement nails used to fix the pressure strip shall not be greater than 250mm. (4) 170mm thick C30 fine stone impermeable concrete, with an impermeability grade of not less than P8, reinforced with bidirectional Φ6@200 crack-resistant steel mesh, and the surface is sprinkled with 1:1 cement sand and polished as it is poured; (5) 1.5mm thick polyurethane coating; (6) A 10-15mm thick dense water glass mortar bonding layer, the consistency of the dense water glass mortar is maintained at 30-40mm, and the construction of the dense water glass mortar is completed within 45 minutes; (7) For 40mm thick granite slabs, use epoxy asphalt mortar to fill the joints, with a joint width of 8-15mm.

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