Bridge concrete repair material and method

Abstract

A bridge concrete repairing material is composed of modified epoxy resin, curing agent, powder and thixotropic agent; the modified epoxy resin is composed of 100 parts of liquid epoxy resin, 10-15 parts of 1,4-butanediol diglycidyl ether, 10-20 parts of polypropylene glycol diglycidyl ether and 5-10 parts of benzyl alcohol; the curing agent is composed of 100 parts of cashew phenolic amine, 20-25 parts of N-aminoethylpiperazine, 20-30 parts of polyether amine D230 and 3-5 parts of 2,4,6-tris(dimethylaminomethyl)phenol; the powder is composed of 100 parts of ceramic powder, 0-100 parts of quartz powder and 50-100 parts of diabase powder; and the thixotropic agent is organic bentonite. The application further discloses a bridge concrete repairing method; the repairing material is not easy to crack under the long-term dynamic load of vehicles on the bridge deck and the internal and external temperature difference of the bridge structure, and can achieve long-term repairing effect.

Description

Technical Field

[0001] This invention belongs to the field of concrete repair technology, specifically relating to a bridge concrete repair material and repair method. Background Technology

[0002] Due to factors such as raw material quality and construction, concrete is prone to cracking. Once cracked, harmful substances from the outside can seep into the concrete, causing carbonation and corrosion, and reducing its performance. Therefore, repairing cracked or damaged concrete is crucial. Long-term dynamic loads from passing vehicles, uneven settlement of bridge foundations, concrete shrinkage, and temperature differences between the inside and outside of the bridge structure can all cause numerous cracks in the concrete structure, severely affecting its appearance. If left unchecked, these cracks will further develop, eventually shortening the service life of the bridge structure.

[0003] Currently, the main materials used to repair concrete defects are modified cement mortars. These mortars are modified by adding fibers, expanding agents, active oxides, polymer emulsions, and various admixtures, which can inhibit shrinkage and deformation to some extent, improving crack resistance and adhesion. However, because these materials still rely on cement hydrates as the binder, they are inherently brittle and have poor tensile strength. Under long-term dynamic loads, problems such as debonding and cracking of the repair material from the concrete are prone to occur. Summary of the Invention

[0004] In order to overcome the shortcomings of the existing technology, the present invention aims to provide a bridge concrete repair material that not only has strong tensile strength but also good toughness, and the repair material is not easy to debond or crack from the concrete.

[0005] Another objective of this invention is to provide a bridge concrete repair method based on the aforementioned bridge concrete repair material.

[0006] The objective of this invention is achieved through the following technical solution:

[0007] A bridge concrete repair material is composed of modified epoxy resin, curing agent, powder and thixotropic agent;

[0008] The modified epoxy resin, by weight, is composed of 100 parts liquid epoxy resin, 10-15 parts 1,4-butanediol diglycidyl ether, 10-20 parts polypropylene glycol diglycidyl ether, and 5-10 parts benzyl alcohol; the curing agent, by weight, is composed of 100 parts cashew phenol aldehyde amine, 20-25 parts N-aminoethylpiperazine, 20-30 parts polyetheramine D230, and 3-5 parts 2,4,6-tris(dimethylaminomethyl)phenol; the cashew phenol aldehyde amine, by weight, comprises 100 parts cashew phenol, 60-70 parts isoflavone diamine, and 10-12 parts paraformaldehyde; the powder, by weight, is composed of 100 parts ceramic powder, 1-100 parts quartz powder, and 50-100 parts diabase powder; the thixotropic agent is organic bentonite.

[0009] Preferably, the modified epoxy resin is prepared by mixing 100 parts by weight of liquid epoxy resin, 12 parts by weight of 1,4-butanediol diglycidyl ether, 18 parts by weight of polypropylene glycol diglycidyl ether, and 10 parts by weight of benzyl alcohol, which yields the best results.

[0010] More preferably, the liquid epoxy resin is at least one of E51, E54, and F51.

[0011] Preferably, the curing agent is a mixture of 100 parts cashew phenol amine, 22 parts N-aminoethylpiperazine, 25 parts polyetheramine D230, and 4 parts 2,4,6-tris(dimethylaminomethyl)phenol by weight, which is most effective.

[0012] Preferably, the powder is composed of 100 parts ceramic powder, 50 parts quartz powder, and 50 parts diabase powder by weight, which is the most effective.

[0013] More preferably, the ceramic powder has a mesh size of 325-400 mesh, the quartz powder has a mesh size of 400-800 mesh, and the diabase powder has a mesh size of 200-400 mesh.

[0014] Preferably, the organic bentonite is TY-166C type organic bentonite.

[0015] Preferably, the cashew phenol amine, by weight, comprises 100 parts cashew phenol, 65 parts isoflavone diamine, and 11 parts paraformaldehyde, and reacts at 100±5℃ for 3-4 hours for optimal effect.

[0016] A method for repairing bridge concrete includes the following steps:

[0017] (1) Clean the base surface and grind it to reveal a fresh concrete surface;

[0018] (2) The modified epoxy resin, the curing agent, the powder and the thixotropic agent are mixed evenly to prepare epoxy putty, and the epoxy putty is used to repair holes and cracks;

[0019] (3) The modified epoxy resin and the curing agent are mixed evenly to prepare an epoxy adhesive solution, and the epoxy adhesive solution is used as a primer.

[0020] (4) Mix the modified epoxy resin, the curing agent, the powder and the thixotropic agent evenly to prepare an epoxy coating, and apply two coats of epoxy coating.

[0021] Preferably, the thickness of each coat of epoxy coating is 750±50μm.

[0022] Preferably, the epoxy putty is composed of 100 parts modified epoxy resin, 30-40 parts curing agent, 400-500 parts powder, and 2-5 parts thixotropic agent.

[0023] Preferably, the epoxy adhesive is composed of 100 parts of modified epoxy resin and 30-40 parts of curing agent.

[0024] Preferably, the epoxy coating is composed of 100 parts of modified epoxy resin, 30-40 parts of curing agent, 200-300 parts of powder, and 10-12 parts of thixotropic agent.

[0025] The present invention has the following advantages and beneficial effects compared with the prior art:

[0026] The bridge concrete repair material of the present invention uses elastic epoxy resin as a cementing material, which not only has strong tensile strength but also good toughness. Under the conditions of long-term dynamic load of vehicles passing on the bridge deck and large temperature differences between the inside and outside of the bridge structure, the repaired cracks are not easy to debond or crack, and the repair effect lasts for a long time.

[0027] The epoxy adhesive in the repair material has a relatively low initial viscosity, allowing it to penetrate well into the micro-cracks and pores of concrete when used as a primer. This provides significant reinforcement to the concrete substrate, resulting in excellent adhesion between the repair material and the concrete. The epoxy coating in the repair material has almost 100% solids content, contains no volatile components, making it very environmentally friendly. It is also easy to apply, does not drip even with thick coats on vertical surfaces, dries quickly, and has high construction efficiency. Conventional epoxy coatings mostly contain volatile solvents, resulting in significant dripping on thick coats and low construction efficiency.

[0028] The bridge concrete repair material of the present invention is divided into four components: modified epoxy resin, thixotropic agent, curing agent, and powder. The material can be flexibly configured according to weather and working conditions to cope with complex construction situations and reduce the probability of unsuitable construction and rework due to errors. Detailed Implementation

[0029] The following specific embodiments further describe the inventive purpose of the present invention in detail. The embodiments cannot be described in detail here, but the implementation of the present invention is not limited to the following embodiments.

[0030] Example 1

[0031] According to the proportions in Table 1, E51 epoxy resin, 1,4-butanediol diglycidyl ether, polypropylene glycol diglycidyl ether, and benzyl alcohol were mixed to prepare a modified epoxy resin; according to the proportions in Table 1, cashew phenol, isoflavone diamine, and paraformaldehyde were reacted at 100±5℃ for 4h to prepare cashew phenol aldehyde amine, and then cashew phenol aldehyde amine was mixed with N-aminoethylpiperazine, polyetheramine D230, and 2,4,6-tris(dimethylaminomethyl)phenol to prepare a curing agent; according to the proportions in Table 1, 325 mesh ceramic powder, 400 mesh quartz powder, and 200 mesh diabase powder were mixed to prepare a powder.

[0032] The method for repairing bridge concrete cracks using concrete repair materials includes the following steps:

[0033] (1) Clean the base surface and grind it to reveal a fresh concrete surface;

[0034] (2) Mix 100 parts of modified epoxy resin, 30 parts of curing agent, 400 parts of powder and 5 parts of thixotropic agent obtained in the above steps evenly to prepare epoxy putty, and use epoxy putty to repair holes and cracks.

[0035] (3) Mix 100 parts of the modified epoxy resin and 30 parts of the curing agent obtained in the above steps to prepare an epoxy adhesive solution, and apply a primer coat with the epoxy adhesive solution.

[0036] (4) Mix 100 parts of modified epoxy resin, 30 parts of curing agent, 200 parts of powder and 12 parts of thixotropic agent obtained in the above steps to prepare epoxy coating. Apply two coats of epoxy coating, with the thickness of each coat controlled at 750±50μm and an interval of 4h in between.

[0037] Example 2

[0038] According to the proportions in Table 1, E51 epoxy resin, 1,4-butanediol diglycidyl ether, polypropylene glycol diglycidyl ether, and benzyl alcohol were mixed to prepare a modified epoxy resin; according to the proportions in Table 1, cashew phenol, isophorone diamine, and paraformaldehyde were reacted at 100±5℃ for 3.5h to prepare cashew phenol aldehyde amine, and then cashew phenol aldehyde amine was mixed with N-aminoethylpiperazine, polyetheramine D230, and 2,4,6-tris(dimethylaminomethyl)phenol to prepare a curing agent; according to the proportions in Table 1, 325 mesh ceramic powder, 400 mesh quartz powder, and 200 mesh diabase powder were mixed to prepare a powder.

[0039] The above-mentioned concrete repair materials are used to repair cracks in bridge concrete, and the method includes the following steps:

[0040] (1) Clean the base surface and grind it to reveal a fresh concrete surface;

[0041] (2) Mix 100 parts of modified epoxy resin, 35 parts of curing agent, 450 parts of powder and 3 parts of thixotropic agent obtained in the above steps evenly to prepare epoxy putty, and use epoxy putty to repair holes and cracks.

[0042] (3) Mix 100 parts of the modified epoxy resin and 35 parts of the curing agent obtained in the above steps to prepare an epoxy adhesive solution, and apply a primer coat with the epoxy adhesive solution.

[0043] (4) Mix 100 parts of modified epoxy resin, 35 parts of curing agent, 250 parts of powder and 11 parts of thixotropic agent obtained in the above steps to prepare epoxy coating. Apply two coats of epoxy coating, with the thickness of each coat controlled at 750±50μm and an interval of 3h in between.

[0044] Example 3

[0045] According to the proportions in Table 1, E51 epoxy resin, 1,4-butanediol diglycidyl ether, polypropylene glycol diglycidyl ether, and benzyl alcohol were mixed to prepare a modified epoxy resin; according to the proportions in Table 1, cashew phenol, isoflavone diamine, and paraformaldehyde were reacted at 100±5℃ for 3h to obtain cashew phenol aldehyde amine, and then cashew phenol aldehyde amine was mixed with N-aminoethylpiperazine, polyetheramine D230, and 2,4,6-tris(dimethylaminomethyl)phenol to prepare a curing agent; according to the proportions in Table 1, 325 mesh ceramic powder and 200 mesh diabase powder were mixed to prepare a powder.

[0046] The above-mentioned concrete repair materials are used to repair cracks in bridge concrete, and the method includes the following steps:

[0047] (1) Clean the base surface and grind it to reveal a fresh concrete surface;

[0048] (2) Mix 100 parts of modified epoxy resin, 40 parts of curing agent, 500 parts of powder and 2 parts of thixotropic agent obtained in the above steps evenly to prepare epoxy putty, and use epoxy putty to repair holes and cracks.

[0049] (3) Mix 100 parts of the modified epoxy resin and 40 parts of the curing agent obtained in the above steps evenly to prepare an epoxy adhesive solution, and apply a primer coat with the epoxy adhesive solution.

[0050] (4) Mix 100 parts of modified epoxy resin, 40 parts of curing agent, 300 parts of powder and 10 parts of thixotropic agent obtained in the above steps evenly to prepare epoxy coating. Apply two coats of epoxy coating, with the thickness of each coat controlled at 750±50μm and an interval of 2h in between.

[0051] Example 4

[0052] According to the proportions in Table 1, E51 epoxy resin, 1,4-butanediol diglycidyl ether, polypropylene glycol diglycidyl ether, and benzyl alcohol were mixed to prepare a modified epoxy resin; according to the proportions in Table 1, cashew phenol, isoflavone diamine, and paraformaldehyde were reacted at 100±5℃ for 3h to obtain cashew phenol aldehyde amine, and then cashew phenol aldehyde amine was mixed with N-aminoethylpiperazine, polyetheramine D230, and 2,4,6-tris(dimethylaminomethyl)phenol to prepare a curing agent; according to the proportions in Table 1, 325 mesh ceramic powder, 800 mesh quartz powder, and 400 mesh diabase powder were mixed to prepare a powder.

[0053] The above-mentioned concrete repair materials are used to repair cracks in bridge concrete, and the method includes the following steps:

[0054] (1) Clean the base surface and grind it to reveal a fresh concrete surface;

[0055] (2) Mix 100 parts of modified epoxy resin, 30 parts of curing agent, 500 parts of powder and 3 parts of thixotropic agent obtained in the above steps evenly to prepare epoxy putty, and use epoxy putty to repair holes and cracks.

[0056] (3) Mix 100 parts of the modified epoxy resin and 30 parts of the curing agent obtained in the above steps to prepare an epoxy adhesive solution, and apply a primer coat with the epoxy adhesive solution.

[0057] (4) Mix 100 parts of modified epoxy resin, 30 parts of curing agent, 250 parts of powder and 12 parts of thixotropic agent obtained in the above steps to prepare epoxy coating. Apply two coats of epoxy coating, with the thickness of each coat controlled at 750±50μm and an interval of 3h in between.

[0058] The raw material proportions of the bridge concrete repair materials in Examples 1-4 are shown in Table 1.

[0059] The performance test results of the bridge concrete repair materials in Examples 1-4 are shown in Table 2.

[0060] Table 1. Raw material ratios for each embodiment

[0061]

[0062] Table 2 Performance test results of bridge concrete repair materials

[0063]

[0064] As shown in Table 2, the epoxy adhesive used in the repair material has a low initial viscosity, less than 200 mPa·s, which allows for good penetration into micro-cracks during priming. The compressive strength and elongation at break tests of the cured adhesive show that it undergoes significant deformation before cracking under both compressive and tensile stresses, indicating that the cured material possesses a certain degree of elasticity. Due to the elasticity of this epoxy cementitious material, epoxy putty and epoxy coating also exhibit a certain degree of elasticity and will not undergo brittle fracture under stress. The compressive strength test results for epoxy putty and epoxy coating in Table 2 further confirm this point.

[0065] The above-described specific embodiments are preferred embodiments of the present invention and are not intended to limit the present invention. Any other changes or equivalent substitutions made without departing from the technical solution of the present invention are included within the protection scope of the present invention.

Claims

1. A bridge concrete repair material, characterized in that, It is composed of modified epoxy resin, curing agent, powder and thixotropic agent; The modified epoxy resin, by weight, is composed of 100 parts of liquid epoxy resin, 10-15 parts of 1,4-butanediol diglycidyl ether, 10-20 parts of polypropylene glycol diglycidyl ether, and 5-10 parts of benzyl alcohol. The curing agent, by weight, is a mixture of 100 parts cashew phenol amine, 20-25 parts N-aminoethylpiperazine, 20-30 parts polyetheramine D230, and 3-5 parts 2,4,6-tris(dimethylaminomethyl)phenol. The powder, by weight, is a mixture of 100 parts ceramic powder, 0-100 parts quartz powder, and 50-100 parts diabase powder. The thixotropic agent is organic bentonite; The cashew phenol aldehyde amine, by weight, comprises 100 parts cashew phenol, 60-70 parts isoflavone diamine, and 10-12 parts paraformaldehyde; Bridge concrete repair methods include the following steps: (1) Clean the base surface and grind it to reveal a fresh concrete surface; (2) The modified epoxy resin, the curing agent, the powder and the thixotropic agent are mixed evenly to prepare epoxy putty, and the epoxy putty is used to repair holes and cracks; (3) The modified epoxy resin and the curing agent are mixed evenly to prepare an epoxy adhesive solution, and the epoxy adhesive solution is used as a primer. (4) Mix the modified epoxy resin, the curing agent, the powder and the thixotropic agent evenly to prepare an epoxy coating, and apply two coats of epoxy coating.

2. The bridge concrete repair material according to claim 1, characterized in that, The liquid epoxy resin is one of E51, E54 or F51.

3. The bridge concrete repair material according to claim 1, characterized in that, The ceramic powder has a mesh size of 325-400, the quartz powder has a mesh size of 400-800, and the diabase powder has a mesh size of 200-400.

4. The bridge concrete repair material according to claim 1, characterized in that, The organic bentonite is TY-166C type organic bentonite.

5. A bridge concrete repair material according to claim 1, characterized in that, The thickness of each coat of the epoxy coating is 750±50μm.

6. The bridge concrete repair material according to claim 1, characterized in that, The epoxy putty is composed of 100 parts modified epoxy resin, 30-40 parts curing agent, 400-500 parts powder, and 2-5 parts thixotropic agent.

7. A bridge concrete repair material according to claim 1, characterized in that, The epoxy adhesive is composed of 100 parts modified epoxy resin and 30-40 parts curing agent.

8. A bridge concrete repair material according to claim 1, characterized in that, The epoxy coating is composed of 100 parts modified epoxy resin, 30-40 parts curing agent, 200-300 parts powder, and 10-12 parts thixotropic agent.

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