A cement concrete surface layer mirror repair layer, a repair method and a resulting product

Abstract

The application discloses a cement concrete surface mirror repairing layer, a repairing method and a product, and belongs to the technical field of building material concrete. The concrete surface mirror repairing layer comprises a bottom layer, a base layer and a surface layer arranged in sequence from bottom to top on the cement concrete surface, wherein the bottom layer is a glass steel agent, the base layer is a glass steel glaze, and the surface layer is a vitrified agent. Through the optimization design of the composition and the proportioning of the repairing layer, and through the cooperation of the components, the problems of concrete surface cracking, insufficient rebound strength, peeling, powdering, pits, honeycomb pitting, coarse aggregate exposure and the like can be effectively improved. The repairing method of the application makes the repaired concrete surface have both functionality and aesthetics, realizes the'mirror surface' effect, can effectively protect the base material from the erosion of water and chemicals, and has the characteristics of waterproofness, acid and alkali resistance, corrosion resistance, ultraviolet resistance and abrasion resistance.

Description

Technical Field

[0001] This invention relates to the field of building materials and concrete technology, and in particular to a mirror-finish repair layer for cement concrete, a repair method, and the resulting product. Background Technology

[0002] Concrete is one of the most common materials in modern construction. Microscopically, it has a porous structure with poor resistance to permeability and corrosion. Due to material and construction issues, surface cracking, insufficient rebound strength, peeling, powdering, pitting, honeycomb-like defects, and exposed coarse aggregate threaten the usability and safety of buildings, especially in structural engineering projects operating in harsh environments. External corrosive media also cause premature corrosion of the reinforcing steel within the concrete. The rapid deterioration of concrete structures is a pressing issue that needs to be addressed. Due to its widespread use and high repair costs, protective measures are typically implemented on the concrete surface.

[0003] A search revealed several patents published to improve the abrasion resistance of concrete. For example, Chinese patent application number 201811011229.X, filed on August 31, 2018, is titled: "A Method for Preparing and Pouring High-Hardness Abrasion-Resistant Concrete with an Added Surface Reinforcing Layer." This application improves the abrasion resistance of concrete by using high-hardness, strong, and clean aggregates, controlling appropriate concrete strength grade, water-cement ratio, and slump, and adding a hard abrasive reinforcing layer to the water-facing surface.

[0004] For example, Chinese patent application number 202010526269.9, filed on June 9, 2020, is entitled "Concrete Protective Layer Reinforcing Material, Composite Formwork Fabric, and Application of Concrete Protective Layer Reinforcing." The concrete protective layer reinforcing material provided in this application includes silica sol, nano-silica, and magnesium fluorosilicate. Furthermore, this application also provides a composite formwork fabric containing reinforcing materials, comprising a surface layer, an intermediate layer containing reinforcing materials, and a base layer; the intermediate layer is a stretchable deformable material layer, and contains concrete reinforcing materials. This application, through physical and chemical methods, can enhance the mechanical properties of the protective layer concrete to a certain extent, making the concrete surface smoother, denser, and simultaneously improving the durability of reinforced concrete structures.

[0005] For example, Chinese patent application number 202023233617.8, filed on December 29, 2020, is entitled "A Composite Coating Structure for Corrosion and Fire Resistance on Reinforced Concrete Surfaces." The composite coating structure provided in this application includes, in sequence from the surface of the reinforced concrete substrate outwards: a sealing coating, a zinc-rich coating, a fire-retardant coating, and a topcoat coating. The sealing coating is preferably a solvent-based butyltriethoxysilane or octyltriethoxysilane or an aqueous paste-like butyltriethoxysilane or octyltriethoxysilane that penetrates to a depth of [insert depth here] into the surface of the reinforced concrete building substrate. The resulting sealed coating. In this application, after sealing and strengthening the surface of the concrete substrate, a zinc-rich coating is applied to improve the corrosion resistance and durability of the reinforced concrete substrate.

[0006] All three technical solutions mentioned above use physical or chemical means to set a protective or reinforcing layer on the concrete surface to protect the concrete structure and improve the durability of the concrete matrix. However, none of the above applications can achieve a mirror-like finish on the concrete surface, and the concrete surface repair materials are limited, so the repair layer cannot combine functionality and aesthetics. Summary of the Invention

[0007] 1. The technical problem that the invention aims to solve

[0008] The purpose of this invention is to address the shortcomings of concrete structures, such as rough surface appearance, cracking, insufficient rebound strength, peeling, powdering, pitting, honeycomb texture, and exposed coarse aggregate. It provides a mirror-finish repair layer for cement concrete surfaces, a repair method, and the resulting product. The technical solution of this invention can achieve a high-quality, functional, and aesthetically pleasing mirror-finish concrete surface, while effectively protecting the concrete base material from moisture and chemical corrosion. It is cost-effective, has a long service life, and thus meets the needs of large-scale applications in the concrete market.

[0009] 2. Technical Solution

[0010] To achieve the above objectives, the technical solution provided by this invention is as follows:

[0011] Firstly, the cement concrete surface mirror repair layer of the present invention comprises a bottom layer, a base layer, and a top layer sequentially disposed on the cement concrete surface, wherein the bottom layer is a fiberglass agent, the base layer is a fiberglass glaze, and the top layer is a vitrifying agent.

[0012] The fiberglass agent comprises the following raw materials in parts by weight:

[0013] 100-115 parts synthetic resin, 15-25 parts glass fiber, 10-18 parts wollastonite, 7-12 parts accelerator, 2-3 parts flame retardant, 2-6 parts coupling agent, 5-10 parts colorant, and 1-3 parts antioxidant.

[0014] The fiberglass glaze comprises the following raw materials in parts by weight:

[0015] 100-120 parts resin, 20-45 parts steel wire, 5-8 parts diluent, 20-30 parts oxide, 15-25 parts filler, 1-5 parts coupling agent, 5-10 parts colorant, and 1-2 parts antioxidant;

[0016] The vitrifying agent comprises the following raw materials in parts by weight:

[0017] 100-115 parts epoxy resin, 30-50 parts silicate, 10-15 parts alkali metal oxide, 10-20 parts borate, 10-15 parts aluminate, 5-10 parts flux, 2-6 parts anti-settling agent, 1-5 parts stabilizer, 1-5 parts coupling agent, and 5-10 parts colorant.

[0018] Furthermore, the preparation methods of the aforementioned fiberglass agent, fiberglass glaze, and vitrifying agent are all simply by mixing the above components according to the mass proportions of the present invention and stirring until uniform.

[0019] Furthermore, the synthetic resin is at least two of unsaturated polyester resin, epoxy resin, phenolic resin, and polyurethane resin; the accelerator is at least one of halogenated phenol, amine, and phosphorous acid; and the flame retardant is at least one of aluminum hydroxide, magnesium hydroxide, and zinc oxide.

[0020] Furthermore, the resin is one of epoxy resin and polyamide resin; the diluent is at least one of dibutyl phthalate and propylene oxide butyl ether; the oxide is at least one of silicon oxide, boron oxide, and lead oxide; and the filler is at least one of calcium carbonate, wollastonite, bauxite, and mica powder.

[0021] Furthermore, the alkali metal oxide is at least one of sodium oxide and potassium oxide; the flux is at least one of fluoride and chloride.

[0022] Furthermore, the coupling agent is at least one of silanes, titanates, and aluminates.

[0023] Furthermore, the colorant is at least one of titanium dioxide, iron oxide, and carboxymethyl cellulose.

[0024] Furthermore, the antioxidant is at least one of phenolic, phosphorus, and sulfur-based antioxidants.

[0025] Secondly, the present invention provides a method for repairing the mirror finish of a cement concrete surface, wherein the repair layer is disposed on the cement concrete surface, specifically including the following steps:

[0026] Step 1: Clean the concrete surface, ensuring it is clean and free of oil and dust;

[0027] Step 2: Use a grinder to perform the first grinding of the concrete surface to make the concrete surface smooth.

[0028] Step 3: Add water to the fiberglass agent to prepare material A;

[0029] Step 4: Apply material A evenly to the concrete surface, ensuring no areas are missed. Allow it to moisten for 2 hours for deep penetration and hardening. When using 1 kg of fiberglass agent diluted with water, the average spraying area should not exceed 30 square meters.

[0030] Step 5: After material A has dried completely, if the concrete surface quality is poor, manually repair and fill it with fiberglass glaze mixed with stone powder.

[0031] Step 6: After the treatment in Step 5, polish a second time using a grinder;

[0032] Step 7: After the second round of polishing, polish a third time with cross-hatching to completely eliminate the scratches on the polishing pad; and in the first three rounds of polishing, the grit size of the diaphragm used increases with each polishing.

[0033] Step 8: Apply two coats of fiberglass glaze to the surface that has already been coated with fiberglass agent, with a 2-hour interval between coats;

[0034] Step 9: After the applied fiberglass glaze material has dried completely, add water to the vitrifier to prepare material B;

[0035] Step 10: Use a spray gun to evenly spray material B onto the cured fiberglass glaze surface. When 1 kg of fiberglass glaze is diluted with water before use, the average spraying area is 15-20 square meters.

[0036] Step 11: Use a cloth to evenly dampen the vitrifying agent adhering to the surface that needs to be polished;

[0037] Step 12: Polish when the moisture has slightly dried out, that is, when the moisture has just begun to evaporate; use a polishing machine or a high-powered polisher, or you can use a white polishing pad or a wool pad to polish back and forth.

[0038] It should be noted that if the cement concrete surface is still not bright enough after the above treatment, steps ten and twelve can be repeated until satisfactory results are achieved. In addition, the concrete mirror surface can be polished periodically to maintain its gloss and aesthetics.

[0039] Furthermore, in step two, a polishing machine with 50-grit resin grinding discs is used for polishing.

[0040] In step three, the fiberglass agent and water are mixed and stirred evenly in a ratio of 1:3 to 1:6 to obtain material A;

[0041] In step six, a polishing machine with 100-grit resin grinding discs is used for polishing;

[0042] In step seven, a polishing machine with 200-grit resin grinding discs is used for polishing;

[0043] In step nine, the vitrifier and water are mixed and stirred evenly in a 1:1 ratio to obtain material B;

[0044] In step 12, polishing is performed using a crystal polisher or a high-power polisher, or by using a white cleaning pad or a wool pad to polish back and forth.

[0045] Thirdly, a mirror-finish cement concrete product of the present invention is obtained by surface repair on the surface of cement concrete using the repair method of the present invention. The concrete product includes a cement concrete substrate and a mirror-finish repair layer disposed on the surface of the substrate.

[0046] 3. Beneficial effects

[0047] Compared with the prior art, the technical solution provided by this invention has the following significant advantages:

[0048] (1) A mirror-finish repair layer for cement concrete surface of the present invention comprises a bottom layer, a base layer and a top layer disposed sequentially on the surface of cement concrete. The bottom layer is a fiberglass agent, the base layer is a fiberglass glaze and the top layer is a vitrifier. By optimizing the composition and proportion of the repair layer, and through the joint cooperation of each component, it can effectively improve problems such as cracking, insufficient rebound strength, peeling, powdering, pitting, honeycomb surface and exposed coarse aggregate of concrete surface. Compared with existing cement concrete, it not only ensures that cement concrete is protected from the erosion of water and chemicals, and has the characteristics of waterproof, acid and alkali resistant, corrosion resistant, UV resistant and wear resistant, but also improves the flatness and smoothness of the concrete surface, thereby achieving a "mirror" effect. Moreover, the natural color of concrete is used as the finish, and no secondary modification is required, thus obtaining a completely uniform, high-quality concrete surface that is both functional and aesthetically pleasing.

[0049] (2) The cement concrete surface mirror repair layer of the present invention optimizes the composition and ratio of the fiberglass agent used in the bottom layer. Its main component is synthetic resin, and by selecting the type of synthetic resin, it has excellent adhesion and strength. At the same time, the addition of glass fiber can increase hardness and wear resistance, and the addition of accelerator can accelerate the curing reaction and improve production efficiency.

[0050] (3) The present invention provides a mirror-finish repair layer for cement concrete surfaces. By optimizing the composition and proportion of the fiberglass glaze used on the base layer, on the one hand, the oxides in the fiberglass glaze provide the basic framework of the glaze layer, determining its hardness and wear resistance; other additives in the fiberglass glaze, such as coupling agents and antioxidants, can improve the stability of the glaze layer, improve its processing performance, and prevent oxidation corrosion. On the other hand, in addition to resin, the main components of the fiberglass glaze also include steel wire. The addition of steel wire further enhances the mechanical strength and wear resistance of the fiberglass glaze, enabling it to withstand more physical impacts and chemical corrosion. In addition, steel wire can also improve the adhesion of the fiberglass glaze, making it adhere more tightly to the base material and less prone to peeling. Regarding colorants, the fiberglass glaze of the present invention can also precisely control the hue and gloss of the glaze layer by adjusting the type and amount of colorants.

[0051] (4) The present invention provides a mirror-finish repair layer for cement concrete surfaces. The vitrifying agent used in the surface layer is, in the prior art, a common vitrifying agent such as sodium silicate, boric acid, and lead. These components can lower the melting point of the glaze, making it easier for the glaze layer to form a uniform glassy structure during firing, mainly used to improve the hardness, wear resistance, and corrosion resistance of the glass surface. The present invention, based on existing common vitrifying agents, adds aluminates, which can synergistically interact with other components of the vitrifying agent, not only strengthening the vitrified film but also further improving its scratch resistance and wear resistance. Simultaneously, the vitrifying agent of the present invention also incorporates fluxes such as fluorides and chlorides, which can lower the melting point of the vitrifying agent to promote its reaction with the surface of the fiberglass glaze material at a lower temperature.

[0052] (5) In order to ensure the surface repair performance of cement concrete and meet the needs of different functions, the repair layer of the present invention can also add some auxiliary materials, such as adding colorants to adjust the color so that it is more in line with different decoration styles; adding diluents to adjust viscosity and fluidity so as to facilitate construction operations; and adding some special additives, such as UV stabilizers and antioxidants, to improve the weather resistance and durability of cement concrete.

[0053] (6) The present invention provides a method for repairing the surface of cement concrete with a mirror finish. By optimizing the composition, proportion and repair process of the repair layer, especially the pre- and post-repair treatment and the order of repair steps, the repair layer can be well attached to the surface of cement concrete to complete the mirror finish treatment of the concrete surface. This not only makes the concrete have a mirror effect, but also improves the surface quality of the concrete and enhances its strength, waterproofness, corrosion resistance, wear resistance and oxidation resistance.

[0054] (7) A mirror-finish cement concrete product of the present invention is repaired by the repair method of the present invention. The resulting product has both functionality and aesthetics, and its manufacturing cost is low and its economy is good. Attached Figure Description

[0055] Figure 1 This is a structural schematic diagram of the mirror-finish cement concrete product of the present invention; to facilitate the demonstration of the sequence of the bottom layer, base layer and surface layer set on the surface, the repair layer has been partially removed in this schematic diagram.

[0056] In the picture:

[0057] 1. Surface layer; 2. Fiberglass primer layer; 3. Fiberglass glaze base layer; 4. Vitrifier top layer; 5. Concrete substrate. Detailed Implementation

[0058] To further understand the content of this invention, it will now be described in detail with reference to specific embodiments.

[0059] Example 1

[0060] This embodiment of a method for repairing a mirror-like surface on cement concrete specifically includes the following steps:

[0061] Step 1: Clean the concrete surface, ensuring it is clean and free of oil and dust;

[0062] Step 2: Use a grinder with 50-grit resin grinding discs to perform the first grinding of the concrete surface to make the concrete surface smooth.

[0063] Step 3: Add water to the prepared fiberglass agent. Mix the fiberglass agent and water in a 1:5 ratio and stir well to prepare material A; wherein:

[0064] The fiberglass agent is composed of the following raw materials in parts by weight:

[0065] The composition includes 100 parts synthetic resin, 15 parts glass fiber, 10 parts wollastonite, 7 parts accelerator, 2 parts coupling agent, 2 parts flame retardant, 5 parts colorant, and 1 part antioxidant. Specifically, in this embodiment, the synthetic resin is an unsaturated polyester resin and an epoxy resin; the accelerator is a halogenated phenol; the coupling agent is a silicate ester coupling agent; the flame retardant is aluminum hydroxide; the antioxidant is tert-butylhydroxytoluene antioxidant; and the colorant is titanium dioxide.

[0066] Step 4: Apply material A evenly to the concrete surface, ensuring no areas are missed. Allow it to moisten for 2 hours for deep penetration and hardening. When 1 kg of fiberglass agent is diluted with water before use, the average spraying area is 28 square meters.

[0067] Step 5: After material A has dried completely, if the concrete surface quality is poor, manually repair and level it using fiberglass glaze mixed with stone powder; among which:

[0068] The fiberglass glaze is composed of the following raw materials in parts by weight:

[0069] The composition includes 100 parts resin, 20 parts steel wire, 5 parts diluent, 20 parts oxide, 15 parts filler, 1 part coupling agent, 1 part antioxidant, and 5 parts colorant. Specifically, in this embodiment, the resin is epoxy resin; the diluent is dibutyl phthalate; the filler is calcium carbonate; the oxide is silicon dioxide; the coupling agent is silicate ester coupling agent; the antioxidant is tert-butylhydroxytoluene antioxidant; and the colorant is titanium dioxide.

[0070] Step 6: After the treatment in step 5, polish a second time using a polisher with 100-grit resin grinding discs;

[0071] Step 7: After the second round of polishing, use a polisher with 200-grit resin polishing pads to polish a third time, alternating between horizontal and vertical polishing, to completely eliminate the scratches on the polishing pads.

[0072] Step 8: Apply two coats of fiberglass glaze to the surface that has already been coated with fiberglass agent, with a 2-hour interval between coats;

[0073] Step 9: After the applied fiberglass enamel material has completely dried, add water to the vitrifier. Mix the vitrifier and water in a 1:1 ratio and stir well to prepare material B; where:

[0074] The vitrifying agent is composed of the following raw materials in parts by mass:

[0075] The composition includes 100 parts epoxy resin, 30 parts silicate, 10 parts alkali metal oxide, 10 parts borate, 10 parts aluminate, 5 parts flux, 1 part coupling agent, 2 parts anti-settling agent, 1 part stabilizer, and 5 parts colorant. Specifically, in this embodiment, the alkali metal oxide is sodium oxide; the anti-settling agent is a high-efficiency polyurethane anti-settling agent; the stabilizer is a calcium carbonate stabilizer; the flux is sodium chloride; the coupling agent is a silicate coupling agent; the antioxidant is tert-butylhydroxytoluene antioxidant; and the colorant is titanium dioxide.

[0076] Step 10: Use a spray gun to evenly spray material B onto the cured fiberglass glaze surface. When 1 kg of fiberglass glaze is diluted with water before use, the average spraying area is 18 square meters.

[0077] Step 11: Use a cloth to evenly dampen the vitrifying agent adhering to the surface that needs to be polished;

[0078] Step 12: After the moisture has slightly dried, polish the surface. Use a polishing machine or a high-powered polisher, or you can use a white polishing pad or a wool pad to polish back and forth until the concrete surface achieves a mirror finish.

[0079] In this embodiment, the above-described repair method is used to repair the cement concrete surface, thereby forming three repair layers on the concrete surface, specifically: Figure 1 The fiberglass agent base layer 2, the fiberglass glaze base layer 3, and the vitrified agent surface layer 4 are all present in the fiberglass agent base layer.

[0080] Meanwhile, the specific structure of the mirror-finish cement concrete product obtained by adopting the above solution in this embodiment is as follows: Figure 1 As shown, the product includes a concrete substrate 5, and a fiberglass primer 2, a fiberglass glaze base layer 3, and a vitrifier top layer 4, which are layered on top of the surface layer 1 of the concrete substrate 5.

[0081] The performance of the obtained mirror-finish cement concrete products was tested, and the test results are shown in Table 1.

[0082] Example 2

[0083] This embodiment of a method for repairing a mirror-like surface on cement concrete specifically includes the following steps:

[0084] Step 1: Clean the concrete surface, ensuring it is clean and free of oil and dust;

[0085] Step 2: Use a grinder with 50-grit resin grinding discs to perform the first grinding of the concrete surface to make the concrete surface smooth.

[0086] Step 3: Add water to the prepared fiberglass agent, mixing the fiberglass agent and water in a 1:3 ratio and stirring thoroughly to prepare material A; wherein:

[0087] The fiberglass agent is composed of the following raw materials in parts by weight:

[0088] The composition includes 100 parts synthetic resin, 20 parts glass fiber, 14 parts wollastonite, 9 parts accelerator, 4 parts coupling agent, 2 parts flame retardant, 7 parts colorant, and 2 parts antioxidant. Specifically, in this embodiment, the synthetic resin is phenolic resin and polyurethane resin; the accelerator is amine; the coupling agent is titanate coupling agent; the flame retardant is magnesium hydroxide; the antioxidant is sodium phosphate antioxidant; and the colorant is iron oxide.

[0089] Step 4: Apply material A evenly to the concrete surface, ensuring no areas are missed. Allow it to moisten for 2 hours for deep penetration and hardening. When 1 kg of fiberglass agent is diluted with water before use, the average spraying area is 29 square meters.

[0090] Step 5: After material A has dried completely, if the concrete surface quality is poor, manually repair and level it using fiberglass glaze mixed with stone powder; among which:

[0091] The fiberglass glaze is composed of the following raw materials in parts by weight:

[0092] The composition includes 100 parts resin, 30 parts steel wire, 6 parts diluent, 25 parts oxide, 20 parts filler, 3 parts coupling agent, 1 part antioxidant, and 7 parts colorant. Specifically, in this embodiment, the resin is polyamide resin; the diluent is propylene oxide butyl ether; the filler is wollastonite; the oxide is boron oxide; the coupling agent is titanate coupling agent; the antioxidant is sodium phosphate antioxidant; and the colorant is iron oxide.

[0093] Step 6: After the treatment in step 5, polish a second time using a polisher with 100-grit resin grinding discs;

[0094] Step 7: After the second round of polishing, use a polisher with 200-grit resin polishing pads to polish a third time, alternating between horizontal and vertical polishing, to completely eliminate the scratches on the polishing pads.

[0095] Step 8: Apply two coats of fiberglass glaze to the surface that has already been coated with fiberglass agent, with a 2-hour interval between coats;

[0096] Step 9: After the applied fiberglass enamel material has completely dried, add water to the vitrifier. Mix the vitrifier and water in a 1:1 ratio and stir well to prepare material B; where:

[0097] The vitrifying agent is composed of the following raw materials in parts by mass:

[0098] The composition includes 100 parts epoxy resin, 40 parts silicate, 12 parts alkali metal oxide, 15 parts borate, 12 parts aluminate, 7 parts flux, 3 parts coupling agent, 4 parts anti-settling agent, 3 parts stabilizer, and 8 parts colorant. Specifically, in this embodiment, the alkali metal oxide is potassium oxide; the anti-settling agent is a high-efficiency polyurethane anti-settling agent; the stabilizer is a calcium carbonate stabilizer; the flux is sodium fluoride; the coupling agent is a titanate coupling agent; the antioxidant is sodium phosphate; and the colorant is iron oxide.

[0099] Step 10: Use a spray gun to evenly spray material B onto the cured fiberglass glaze surface. When 1 kg of fiberglass glaze is diluted with water before use, the average spraying area is 15 square meters.

[0100] Step 11: Use a cloth to evenly dampen the vitrifying agent adhering to the surface that needs to be polished;

[0101] Step 12: After the moisture has slightly dried, polish the surface. Use a polishing machine or a high-powered polisher, or you can use a white polishing pad or a wool pad to polish back and forth until the concrete surface achieves a mirror finish.

[0102] In this embodiment, the above-described repair method is used to repair the cement concrete surface, thereby forming three repair layers on the concrete surface, specifically: Figure 1 The fiberglass agent base layer 2, the fiberglass glaze base layer 3, and the vitrified agent surface layer 4 are all present in the fiberglass agent base layer.

[0103] Meanwhile, the structure of the mirror-finish cement concrete product obtained by adopting the above scheme in this embodiment is the same as that in Embodiment 1.

[0104] The performance of the obtained mirror-finish cement concrete products was tested, and the test results are shown in Table 1.

[0105] Example 3

[0106] This embodiment of a method for repairing a mirror-like surface on cement concrete specifically includes the following steps:

[0107] Step 1: Clean the concrete surface, ensuring it is clean and free of oil and dust;

[0108] Step 2: Use a grinder with 50-grit resin grinding discs to perform the first grinding of the concrete surface to make the concrete surface smooth.

[0109] Step 3: Add water to the prepared fiberglass agent. Mix the fiberglass agent and water in a 1:6 ratio and stir well to prepare material A; wherein:

[0110] The fiberglass agent is composed of the following raw materials in parts by weight:

[0111] The composition includes 115 parts synthetic resin, 18 parts glass fiber, 16 parts wollastonite, 10 parts accelerator, 3 parts coupling agent, 2.5 parts flame retardant, 8 parts colorant, and 2.5 parts antioxidant. Specifically, in this embodiment, the synthetic resin is unsaturated polyester resin or phenolic resin; the accelerator is phosphorous acid; the coupling agent is aluminate coupling agent; the flame retardant is zinc oxide; the antioxidant is alkylphenol sulfide; and the colorant is carboxymethyl cellulose.

[0112] Step 4: Apply material A evenly to the concrete surface, ensuring no areas are missed. Allow it to moisten for 2 hours for deep penetration and hardening. When 1 kg of fiberglass agent is diluted with water before use, the average spraying area is 27 square meters.

[0113] Step 5: After material A has dried completely, if the concrete surface quality is poor, manually repair and level it using fiberglass glaze mixed with stone powder; among which:

[0114] The fiberglass glaze is composed of the following raw materials in parts by weight:

[0115] The composition includes 120 parts resin, 35 parts steel wire, 7 parts diluent, 23 parts oxide, 18 parts filler, 2 parts coupling agent, 1.5 parts antioxidant, and 6 parts colorant. Specifically, in this embodiment, the resin is epoxy resin; the diluent is dibutyl phthalate; the filler is bauxite; the oxide is lead oxide; the coupling agent is aluminate coupling agent; the antioxidant is alkylphenol sulfide; and the colorant is carboxymethyl cellulose.

[0116] Step 6: After the treatment in step 5, polish a second time using a polisher with 100-grit resin grinding discs;

[0117] Step 7: After the second round of polishing, use a polisher with 200-grit resin polishing pads to polish a third time, alternating between horizontal and vertical polishing, to completely eliminate the scratches on the polishing pads.

[0118] Step 8: Apply two coats of fiberglass glaze to the surface that has already been coated with fiberglass agent, with a 2-hour interval between coats;

[0119] Step 9: After the applied fiberglass enamel material has completely dried, add water to the vitrifier. Mix the vitrifier and water in a 1:1 ratio and stir well to prepare material B; where:

[0120] The vitrifying agent is composed of the following raw materials in parts by mass:

[0121] The composition includes 115 parts epoxy resin, 35 parts silicate, 13 parts alkali metal oxide, 17 parts borate, 13 parts aluminate, 8 parts flux, 2 parts coupling agent, 3 parts anti-settling agent, 2 parts stabilizer, and 7 parts colorant. Specifically, in this embodiment, the alkali metal oxide is sodium oxide; the anti-settling agent is a high-efficiency polyurethane anti-settling agent; the stabilizer is a calcium carbonate stabilizer; the flux is sodium fluoride; the coupling agent is an aluminate coupling agent; the antioxidant is an alkylphenol sulfide antioxidant; and the colorant is carboxymethyl cellulose.

[0122] Step 10: Use a spray gun to evenly spray material B onto the cured fiberglass glaze surface. When 1 kg of fiberglass glaze is diluted with water before use, the average spraying area is 20 square meters.

[0123] Step 11: Use a cloth to evenly dampen the vitrifying agent adhering to the surface that needs to be polished;

[0124] Step 12: After the moisture has slightly dried, polish the surface. Use a polishing machine or a high-powered polisher, or you can use a white polishing pad or a wool pad to polish back and forth until the concrete surface achieves a mirror finish.

[0125] In this embodiment, the above-described repair method is used to repair the cement concrete surface, thereby forming three repair layers on the concrete surface, specifically: Figure 1 The fiberglass agent base layer 2, the fiberglass glaze base layer 3, and the vitrified agent surface layer 4 are all present in the fiberglass agent base layer.

[0126] Meanwhile, the structure of the mirror-finish cement concrete product obtained by adopting the above scheme in this embodiment is the same as that in Embodiment 1.

[0127] The performance of the obtained mirror-finish cement concrete products was tested, and the test results are shown in Table 1.

[0128] Example 4

[0129] This embodiment of a method for repairing a mirror-like surface on cement concrete specifically includes the following steps:

[0130] Step 1: Clean the concrete surface, ensuring it is clean and free of oil and dust;

[0131] Step 2: Use a grinder with 50-grit resin grinding discs to perform the first grinding of the concrete surface to make the concrete surface smooth.

[0132] Step 3: Add water to the prepared fiberglass agent. Mix the fiberglass agent and water in a 1:4 ratio and stir well to prepare material A; wherein:

[0133] The fiberglass agent is composed of the following raw materials in parts by weight:

[0134] The composition includes 115 parts synthetic resin, 25 parts glass fiber, 18 parts wollastonite, 12 parts accelerator, 6 parts coupling agent, 3 parts flame retardant, 10 parts colorant, and 3 parts antioxidant. Specifically, the synthetic resin in this embodiment is an unsaturated polyester resin and a polyurethane resin; the accelerator is a halogenated phenol and an amine; the coupling agent is a silicate coupling agent and a titanate coupling agent; the flame retardant is aluminum hydroxide and magnesium hydroxide; the antioxidant is tert-butylhydroxytoluene antioxidant and sodium phosphate antioxidant; and the colorant is titanium dioxide and iron oxide.

[0135] Step 4: Apply material A evenly to the concrete surface, ensuring no areas are missed. Allow it to moisten for 2 hours for deep penetration and hardening. When using 1 kg of fiberglass agent diluted with water, the average spraying area is 30 square meters.

[0136] Step 5: After material A has dried completely, if the concrete surface quality is poor, manually repair and level it using fiberglass glaze mixed with stone powder; among which:

[0137] The fiberglass glaze is composed of the following raw materials in parts by weight:

[0138] The composition includes 120 parts resin, 45 parts steel wire, 8 parts diluent, 30 parts oxide, 25 parts filler, 5 parts coupling agent, 2 parts antioxidant, and 10 parts colorant. Specifically, in this embodiment, the resin is polyamide resin; the diluent is dibutyl phthalate and propylene oxide butyl ether; the filler is mica powder; the oxide is silicon dioxide and boron oxide; the coupling agent is silicate coupling agent and titanate coupling agent; the antioxidant is tert-butylhydroxytoluene antioxidant and sodium phosphate antioxidant; and the colorant is titanium dioxide and iron oxide.

[0139] Step 6: After the treatment in step 5, polish a second time using a polisher with 100-grit resin grinding discs;

[0140] Step 7: After the second round of polishing, use a polisher with 200-grit resin polishing pads to polish a third time, alternating between horizontal and vertical polishing, to completely eliminate the scratches on the polishing pads.

[0141] Step 8: Apply two coats of fiberglass glaze to the surface that has already been coated with fiberglass agent, with a 2-hour interval between coats;

[0142] Step 9: After the applied fiberglass enamel material has completely dried, add water to the vitrifier. Mix the vitrifier and water in a 1:1 ratio and stir well to prepare material B; where:

[0143] The vitrifying agent is composed of the following raw materials in parts by mass:

[0144] The composition includes 115 parts epoxy resin, 50 parts silicate, 15 parts alkali metal oxide, 20 parts borate, 15 parts aluminate, 10 parts flux, 5 parts coupling agent, 6 parts anti-settling agent, 5 parts stabilizer, and 10 parts colorant. Specifically, in this embodiment, the alkali metal oxide is sodium oxide and potassium oxide; the anti-settling agent is a high-efficiency polyurethane anti-settling agent; the stabilizer is a calcium carbonate stabilizer; the flux is sodium fluoride and sodium chloride flux; the coupling agent is a silicate coupling agent and a titanate coupling agent; the antioxidant is tert-butylhydroxytoluene antioxidant and sodium phosphate antioxidant; and the colorant is titanium dioxide and iron oxide.

[0145] Step 10: Use a spray gun to evenly spray material B onto the cured fiberglass glaze surface. When 1 kg of fiberglass glaze is diluted with water before use, the average spraying area is 18 square meters.

[0146] Step 11: Use a cloth to evenly dampen the vitrifying agent adhering to the surface that needs to be polished;

[0147] Step 12: After the moisture has slightly dried, polish the surface. Use a polishing machine or a high-powered polisher, or you can use a white polishing pad or a wool pad to polish back and forth until the concrete surface achieves a mirror finish.

[0148] In this embodiment, the above-described repair method is used to repair the cement concrete surface, thereby forming three repair layers on the concrete surface, specifically: Figure 1 The fiberglass agent base layer 2, the fiberglass glaze base layer 3, and the vitrified agent surface layer 4 are all present in the fiberglass agent base layer.

[0149] Meanwhile, the structure of the mirror-finish cement concrete product obtained by adopting the above scheme in this embodiment is the same as that in Embodiment 1.

[0150] The performance of the obtained mirror-finish cement concrete products was tested, and the test results are shown in Table 1.

[0151] Example 5

[0152] This embodiment of a method for repairing a mirror-like surface on cement concrete specifically includes the following steps:

[0153] Step 1: Clean the concrete surface, ensuring it is clean and free of oil and dust;

[0154] Step 2: Use a grinder with 50-grit resin grinding discs to perform the first grinding of the concrete surface to make the concrete surface smooth.

[0155] Step 3: Add water to the prepared fiberglass agent. Mix the fiberglass agent and water in a 1:5 ratio and stir well to prepare material A; wherein:

[0156] The fiberglass agent is composed of the following raw materials in parts by weight:

[0157] The composition includes 100 parts synthetic resin, 20 parts glass fiber, 18 parts wollastonite, 7 parts accelerator, 3 parts coupling agent, 2 parts flame retardant, 10 parts colorant, and 1 part antioxidant. Specifically, in this embodiment, the synthetic resin is an unsaturated epoxy resin or a phenolic resin; the accelerator is a halogenated phenol and phosphorous acid; the coupling agent is a silicate coupling agent and an aluminate coupling agent; the flame retardant is aluminum hydroxide and zinc oxide; the antioxidant is a tert-butylhydroxytoluene antioxidant and an alkylphenol sulfide antioxidant; and the colorant is titanium dioxide and carboxymethyl cellulose.

[0158] Step 4: Apply material A evenly to the concrete surface, ensuring no areas are missed. Allow it to moisten for 2 hours for deep penetration and hardening. The average usage is approximately 30 square meters when diluted with water per kilogram.

[0159] Step 5: After material A has dried completely, if the concrete surface quality is poor, manually repair and level it using fiberglass glaze mixed with stone powder; among which:

[0160] The fiberglass glaze is composed of the following raw materials in parts by weight:

[0161] The composition includes 100 parts resin, 20 parts steel wire, 8 parts diluent, 30 parts oxide, 20 parts filler, 5 parts coupling agent, 1 part antioxidant, and 5 parts colorant. Specifically, in this embodiment, the resin is epoxy resin; the diluent is dibutyl phthalate and propylene oxide butyl ether; the filler is calcium carbonate and wollastonite; the oxide is silicon dioxide and potassium oxide; the coupling agent is silicate coupling agent and aluminate coupling agent; the antioxidant is tert-butylhydroxytoluene antioxidant and alkylphenol sulfide antioxidant; and the colorant is titanium dioxide and carboxymethyl cellulose.

[0162] Step 6: After the treatment in step 5, polish a second time using a polisher with 100-grit resin grinding discs;

[0163] Step 7: After the second round of polishing, use a polisher with 200-grit resin polishing pads to polish a third time, alternating between horizontal and vertical polishing, to completely eliminate the scratches on the polishing pads.

[0164] Step 8: Apply two coats of fiberglass glaze to the surface that has already been coated with fiberglass agent, with a 2-hour interval between coats;

[0165] Step 9: After the applied fiberglass enamel material has completely dried, add water to the vitrifier. Mix the vitrifier and water in a 1:1 ratio and stir well to prepare material B; where:

[0166] The vitrifying agent is composed of the following raw materials in parts by mass:

[0167] The composition comprises 100 parts epoxy resin, 30 parts silicate, 10 parts alkali metal oxide, 20 parts borate, 15 parts aluminate, 5 parts flux, 3 parts coupling agent, 6 parts anti-settling agent, 5 parts stabilizer, and 8 parts colorant. Specifically, in this embodiment, the alkali metal oxide is sodium oxide and potassium oxide; the anti-settling agent is a high-efficiency polyurethane anti-settling agent; the stabilizer is a calcium carbonate stabilizer; the flux is sodium fluoride and sodium chloride flux; the coupling agent is a silicate coupling agent and an aluminate coupling agent; the antioxidant is a tert-butylhydroxytoluene antioxidant and an alkylphenol sulfide antioxidant; and the colorant is titanium dioxide and carboxymethyl cellulose.

[0168] Step 10: Use a spray gun to evenly spray material B onto the cured fiberglass glaze surface. When 1 kg of fiberglass glaze is diluted with water before use, the average spraying area is 17 square meters.

[0169] Step 11: Use a cloth to evenly dampen the vitrifying agent adhering to the surface that needs to be polished;

[0170] Step 12: After the moisture has slightly dried, polish the surface. Use a polishing machine or a high-powered polisher, or you can use a white polishing pad or a wool pad to polish back and forth until the concrete surface achieves a mirror finish.

[0171] In this embodiment, the above-described repair method is used to repair the cement concrete surface, thereby forming three repair layers on the concrete surface, specifically: Figure 1 The fiberglass agent base layer 2, the fiberglass glaze base layer 3, and the vitrified agent surface layer 4 are all present in the fiberglass agent base layer.

[0172] Meanwhile, the structure of the mirror-finish cement concrete product obtained by adopting the above scheme in this embodiment is the same as that in Embodiment 1.

[0173] The performance of the obtained mirror-finish cement concrete products was tested, and the test results are shown in Table 1.

[0174] Comparative Example 1

[0175] The surface treatment method for cement concrete in this comparative example is epoxy flooring treatment, which includes the following steps:

[0176] 1. Grind and remove impurities from the substrate and roughen the concrete surface.

[0177] 2. Primer:

[0178] Apply the primer evenly to the substrate using a trowel. Depending on the weather conditions, the primer will dry in 6 hours. Check the primer application; if it is completely absorbed by the substrate, you can reapply it to a thickness of about 0.15 mm.

[0179] 3. Intermediate coat:

[0180] Mix the intermediate coating A / B agent (i.e., epoxy base and curing agent) evenly according to the ratio, add 1.5 times the amount of No. 6 quartz sand and stir evenly. Then, use a notched trowel to evenly spread it on the primer to a thickness of about 1mm.

[0181] 4. Sanding and applying coating:

[0182] After the intermediate coat is completely dry, sand it. Small cracks on the substrate or damaged areas on the ground can be covered with epoxy resin to obtain a smooth and complete surface before applying the topcoat.

[0183] 5. After uniformly mixing the topcoat agents A and B according to the specified ratio, apply the mixture using a roller, employing a cross-hatching method to ensure even distribution. Alternatively, use a dedicated roller to apply the resin. After the first topcoat has dried, apply the second topcoat using the same method. Personnel may enter the area after 48 hours, and heavy machinery may enter after seven days. The thickness should be approximately 1mm.

[0184] The components of Agent A used are as follows:

[0185] It is composed of silicate cement, rapid-hardening sulfoaluminate cement, quartz sand, and composite admixtures, with the following weight percentage range: silicate cement 22%, rapid-hardening sulfoaluminate cement 22%, quartz sand 52%, and the remainder being composite admixtures 4%.

[0186] The components of Agent B are as follows: 28% polyethylene acrylic resin, 9.5% epoxy resin, 2.5% curing agent, and 60% water.

[0187] The mirror-finish cement concrete products obtained in the above embodiments and comparative examples were tested, and the test results are shown in Table 1.

[0188] Table 1. Test results of basic performance of concrete in various embodiments and comparative examples of the present invention.

[0189]

Claims

1. A mirror-finish repair layer for cement concrete surfaces, characterized in that, The repair layer comprises a base layer, a substrate, and a surface layer, sequentially disposed on the cement concrete surface. The base layer is a fiberglass reinforced polymer (FRP) agent, the substrate is a fiberglass glaze, and the surface layer is a vitrifying agent. The fiberglass agent comprises the following raw materials in parts by weight: The composition comprises 100-115 parts synthetic resin, 15-25 parts glass fiber, 10-18 parts wollastonite, 7-12 parts accelerator, 2-3 parts flame retardant, 2-6 parts coupling agent, 5-10 parts colorant, and 1-3 parts antioxidant; wherein the synthetic resin is at least two of unsaturated polyester resin, epoxy resin, phenolic resin, and polyurethane resin. The fiberglass glaze comprises the following raw materials in parts by weight: The composition includes 100-120 parts resin, 20-45 parts steel wire, 5-8 parts diluent, 20-30 parts oxide, 15-25 parts filler, 1-5 parts coupling agent, 5-10 parts colorant, and 1-2 parts antioxidant; the resin is one of epoxy resin and polyamide resin. The vitrifying agent comprises the following raw materials in parts by weight: 100-115 parts epoxy resin, 30-50 parts silicate, 10-15 parts alkali metal oxide, 10-20 parts borate, 10-15 parts aluminate, 5-10 parts flux, 2-6 parts anti-settling agent, 1-5 parts stabilizer, 1-5 parts coupling agent, and 5-10 parts colorant.

2. The concrete surface mirror repair layer according to claim 1, characterized in that, The accelerator is at least one of halogenated phenols, amines, and phosphorous acid; the flame retardant is at least one of aluminum hydroxide, magnesium hydroxide, and zinc oxide.

3. The concrete surface mirror repair layer according to claim 1, characterized in that, The diluent is at least one of dibutyl phthalate and propylene oxide butyl ether; the oxide is at least one of silicon oxide, boron oxide, and lead oxide; and the filler is at least one of calcium carbonate, wollastonite, bauxite, and mica powder.

4. The concrete surface mirror repair layer according to claim 1, characterized in that, The alkali metal oxide is at least one of sodium oxide and potassium oxide; the flux is at least one of fluoride and chloride.

5. The concrete surface mirror repair layer according to any one of claims 1-4, characterized in that, The coupling agent is at least one of silanes, titanates, and aluminates.

6. The concrete surface mirror repair layer according to any one of claims 1-4, characterized in that, The colorant is at least one of titanium dioxide, iron oxide, and carboxymethyl cellulose.

7. The concrete surface mirror repair layer according to any one of claims 1-4, characterized in that, The antioxidant is at least one of phenolic, phosphorus, and sulfur antioxidants.

8. A method for repairing the mirror finish on the surface of cement concrete, characterized in that, Applying the repair layer as described in any one of claims 1-7 to the surface of cement concrete specifically includes the following steps: Step 1: Clean the concrete surface, ensuring it is clean and free of oil and dust; Step 2: Perform the first round of grinding on the concrete surface to make it smooth. Step 3: Add water to the fiberglass agent to prepare material A; Step 4: Apply material A evenly to the concrete surface, ensuring no areas are missed. Allow it to moisten for 2 hours for deep penetration and hardening. When using 1 kg of fiberglass agent diluted with water, the average spraying area should not exceed 30 square meters. Step 5: After material A has dried completely, if the concrete surface quality is poor, manually repair and fill it with fiberglass glaze mixed with stone powder. Step Six: After the treatment in Step Five, polish a second time; Step 7: After the second round of polishing, polish a third time with horizontal and vertical cross-grits to completely eliminate the scratches on the polishing pad; and in the first three rounds of polishing, the grit size of the diaphragm used for each round increases. Step 8: Apply two coats of fiberglass glaze to the surface that has already been coated with fiberglass agent, with a 2-hour interval between coats; Step 9: After the applied fiberglass glaze material has dried completely, add water to the vitrifier to prepare material B. Step 10: Spray material B evenly onto the cured fiberglass glaze surface. When 1 kg of fiberglass glaze is diluted with water before use, the average spraying area is 15-20 square meters. Step 11: Evenly apply the vitrifying agent adhering to the surface to be polished; Step 12: After the moisture has evaporated, polish the surface. Use a polishing machine or a high-powered polisher, or you can use a white polishing pad or a wool pad to polish back and forth.

9. The method for repairing a mirror-like surface on a concrete surface according to claim 8, characterized in that, In step two, a polishing machine with 50-grit resin grinding discs is used for polishing; In step three, the fiberglass agent and water are mixed and stirred evenly in a mass ratio of 1:3 to 1:6 to obtain material A; In step six, a polishing machine with 100-grit resin grinding discs is used for polishing; In step seven, a polishing machine with 200-grit resin grinding discs is used for polishing; In step nine, the vitrifying agent and water are mixed and stirred evenly at a mass ratio of 1:1 to obtain material B; In step 12, polishing is performed using a crystal polisher or a high-power polisher, or by using a white cleaning pad or a wool pad to polish back and forth.

10. A mirror-finish cement concrete product, characterized in that, The concrete product obtained by surface repair of cement concrete surface using the method described in any one of claims 8-9 includes a cement concrete substrate and a mirror repair layer disposed on the surface of the substrate.

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