Processing method of fiber polymer guniting material

Abstract

The invention relates to the technical field of building guniting materials, in particular to a processing method of a fiber polymer guniting material which comprises the following materials in parts by mass: 30-50 parts of cement, 30-40 parts of natural sand, 5-10 parts of fiber polymer, 3-7 parts of silica fume, 3-5 parts of copolymer emulsion, 1-2 parts of phosphate, 0.1-0.5 part of retarder, 0.02-0.06 part of tackifier and 0.03-0.1 part of water reducing agent. Wherein the fiber polymer comprises the following materials in parts by mass: 20-40 parts of polyester, 15-30 parts of nylon, 10-20 parts of acrylic fibers, 20-30 parts of glass fibers, 5-10 parts of carbon fibers and 1-2 parts of polyethylene glycol. According to the prepared fiber polymer guniting material, the toughness of the material is enhanced, the cracking and bursting phenomena of the guniting material are effectively prevented, and the structural stability and durability are improved; the adhesion with a construction interface is improved, and the delaminating problem is reduced; and a wet-type guniting process is adopted, so that dust generated in the construction process is reduced.

Description

Technical Field

[0001] The invention relates to the technical field of building spraying materials, in particular to a processing method of a fiber polymer spraying material. Background Art

[0002] As a key construction material, shotcrete is mainly used in tunnels, underground projects, slope protection and foundation pit protection. Due to its rapid solidification characteristics, shotcrete is widely used in rapid slope repair, surrounding rock support, tunnel repair and reinforcement, plugging and road repair projects, providing an efficient construction solution.

[0003] As the construction environment becomes increasingly complex, traditional shotcrete materials face challenges in meeting the needs of high-efficiency and high-quality construction. The limitations of the material are gradually exposed. Traditional shotcrete materials are prone to cracking and bursting in actual applications. These problems usually stem from the excessive rigidity and insufficient flexibility of the material itself, which leads to cracks under stress or environmental changes. Insufficient adhesion between the shotcrete material and the construction interface may lead to delamination problems between the material layer and the substrate, affecting the stability and durability of the structure. The dust generated during the construction process is of high concentration, which seriously pollutes the working environment, not only causing construction safety hazards, but also endangering the physical and mental health of construction workers. Summary of the invention

[0004] 1. Technical issues to be resolved

[0005] In view of the deficiencies in the prior art, the present invention provides a method for processing fiber polymer spraying materials to solve the problems of spraying materials being prone to cracking and bursting, insufficient adhesion between the spraying materials and the construction interface, and high dust concentration generated by the spraying materials during the construction process.

[0006] (II) Technical solution

[0007] To achieve the above objectives, the present invention is implemented by the following technical scheme, specifically a method for processing fiber polymer spraying material, comprising the following steps:

[0008] S1: Preheating polyester, nylon and acrylic in dry air to remove moisture from the surface of the materials to ensure the smooth progress of subsequent processes. Pickling glass fiber and carbon fiber with nitric acid at a concentration of 65% to 70%, at a temperature of 80°C to 90°C, for 6 to 8 hours, to remove impurities and oxides from the glass fiber and carbon fiber; then heat-treating the glass fiber and carbon fiber to remove moisture from the surface of the glass fiber and carbon fiber, mixing polyester, nylon, acrylic and the pickled and heat-treated glass fiber and carbon fiber, and then adding polyethylene glycol with a molecular weight of 8000 as a dispersant, mixing evenly and melt spinning to obtain fiber polymer.

[0009] S2: First, the vinyl monomer, sodium dodecylbenzene sulfonate as an emulsifier and water are mixed together. At room temperature, the components are stirred evenly using a stirring device to form a stable pre-emulsion. Next, the pre-emulsion is heated to 70°C to 90°C, and the initiator azobisisobutyronitrile (AI BN) is added under an atmosphere of an inert gas (such as nitrogen or argon). The reaction temperature is controlled within this temperature range and maintained for 40min to 60min. After the polymerization reaction is completed, the entire system is cooled to room temperature. In order to adjust the solid content of the copolymer emulsion to 40% to 45%, this can be achieved by evaporating part of the water or adding an appropriate amount of water.

[0010] S3: Before preparing the fiber polymer spraying material, all raw materials need to be prepared in proportion. These raw materials include cement, natural sand, silica fume, fiber polymer (from S1), copolymer emulsion (from S2), retarder, phosphate, viscosity enhancer and water reducer. Add the dry ingredients such as cement, natural sand and silica fume into the mixing tank first, start the mixing equipment to fully stir to ensure that the dry components are evenly mixed. Then, slowly add the fiber polymer and copolymer emulsion into the mixing tank, and continue to stir to ensure that the components can be fully fused and form a uniform slurry. Add retarder, phosphate, viscosity enhancer and water reducer in proportion, and after sufficient stirring and fusion, a uniform and high-performance fiber polymer spraying material can be obtained.

[0011] The fiber polymer comprises the following materials in parts by weight: 30-50 parts of cement, 30-40 parts of natural sand, 5-10 parts of fiber polymer, 3-7 parts of silica fume, 3-5 parts of copolymer emulsion, 1-2 parts of phosphate, 0.1-0.5 parts of retarder, 0.02-0.06 parts of viscosity enhancer and 0.03-0.1 parts of water reducer.

[0012] The polyester is 20 to 40 parts, nylon is 15 to 30 parts, acrylic fiber is 10 to 20 parts, glass fiber is 20 to 30 parts, carbon fiber is 5 to 10 parts and polyethylene glycol is 1 to 2 parts.

[0013] The cement is silicate cement.

[0014] The natural sand is any one or more of river sand, sea sand, mountain sand and lake sand.

[0015] The vinyl monomer in the copolymer emulsion consists of ethylene and vinyl acetate, and the mass ratio of ethylene to vinyl acetate is 3:7.

[0016] The phosphate consists of potassium hydrogen phosphate and calcium phosphate, and the mass ratio of potassium hydrogen phosphate to calcium phosphate is 2:1.

[0017] The retarder is any one or two of boric acid, borax, sodium citrate and potassium tartrate.

[0018] The tackifier is at least one of cellulose ether, guar gum, xanthan gum and rosin resin.

[0019] The water reducer is at least one of a naphthalene-based water reducer, a sodium lignin sulfonate water reducer, a polycarboxylic acid water reducer and an amino water reducer.

[0020] (III) Beneficial effects

[0021] The present invention provides a method for processing fiber polymer spraying material, which has the following beneficial effects:

[0022] 1. The fiber polymer spraying material prepared by the present invention has enhanced toughness of the material due to the addition of fiber polymer, effectively preventing cracking and bursting of the spraying material, and improving the stability and durability of the structure.

[0023] 2. The fiber polymer spraying material prepared by the present invention improves the adhesion with the construction interface and reduces the delamination problem.

[0024] 3. The present invention adopts a wet spraying process, which reduces the generation of dust during the construction process, improves the working environment, and protects the health of construction workers. DETAILED DESCRIPTION

[0025] The technical solutions in the embodiments of the present invention are described clearly and completely below. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0026] Embodiment 1:

[0027] An embodiment of the present invention provides a method for processing a fiber polymer spraying material, comprising the following steps:

[0028] S1: Weigh 45 parts of polyester, 20 parts of nylon, 15 parts of acrylic fiber, 25 parts of glass fiber, 8 parts of carbon fiber and 15 parts of polyethylene glycol. Preheat the polyester, nylon and acrylic fiber in dry air to remove moisture from the surface of the materials to ensure the smooth progress of subsequent processes. Pickle the glass fiber and carbon fiber with nitric acid at a concentration of 65% to 70%, the treatment temperature is 80℃ to 90℃, and the treatment time is 6 to 8 hours to remove impurities and oxides from the glass fiber and carbon fiber; then heat treat the glass fiber and carbon fiber to remove moisture on the surface of the glass fiber and carbon fiber, mix the polyester, nylon, acrylic fiber and the pickled and heat-treated glass fiber and carbon fiber, and then add polyethylene glycol with a molecular weight of 8000 as a dispersant, mix evenly and melt-spin to obtain a fiber polymer.

[0029] S2: Mix the vinyl monomer, sodium dodecylbenzene sulfonate as an emulsifier and water together. At room temperature, use a stirring device to stir the components evenly to form a stable pre-emulsion. Then, heat the pre-emulsion to 78°C and add the initiator azobisisobutyronitrile (AI BN) under an atmosphere of inert gas (such as nitrogen or argon). Control the reaction temperature within this temperature range and maintain the insulation time for 50 minutes. After the polymerization reaction is completed, cool the entire system to room temperature. In order to adjust the solid content of the copolymer emulsion to 40% to 45%, this can be achieved by evaporating part of the water or adding an appropriate amount of water.

[0030] S3: Weigh 45 parts of cement, 35 parts of natural sand, 7 parts of fiber polymer, 6 parts of silica fume, 4 parts of copolymer emulsion, 1.5 parts of phosphate, 0.3 parts of retarder, 0.05 parts of viscosity enhancer and 0.08 parts of water reducer. Add the dry ingredients such as cement, natural sand and silica fume into the mixing tank first, start the mixing equipment to stir thoroughly to ensure that the dry ingredients are evenly mixed. Then, slowly add the fiber polymer and copolymer emulsion into the mixing tank and continue stirring to ensure that the components can be fully fused and form a uniform slurry. Add the auxiliaries such as retarder, phosphate, viscosity enhancer and water reducer in proportion, and after sufficient stirring and fusion, a uniform and high-performance fiber polymer spraying material can be obtained.

[0031] The operation is carried out by wet spraying, and the fiber polymer spraying material and water are mixed and stirred in a mass ratio of 5:1 and then the spraying operation is carried out.

[0032] Embodiment 2:

[0033] The main difference between this embodiment and embodiment 1 is that the fiber polymer is composed of 35 parts of polyester, 25 parts of nylon, 12 parts of acrylic fiber, 30 parts of glass fiber, 7 parts of carbon fiber and 1.2 parts of polyethylene glycol. The fiber polymer spraying material is composed of 40 parts of cement, 38 parts of natural sand, 6 parts of fiber polymer, 5 parts of silica fume, 3 parts of copolymer emulsion, 1.2 parts of phosphate, 0.4 parts of retarder, 0.04 parts of tackifier and 0.06 parts of water reducer. In addition, this embodiment is consistent with embodiment 1 in other aspects, including but not limited to the raw material ratio, preparation method, operating conditions, etc., all of which follow the specific steps and parameters described in embodiment 1.

[0034] Embodiment 3:

[0035] The main difference between this embodiment and embodiment 1 is that the fiber polymer is composed of 25 parts of polyester, 30 parts of nylon, 20 parts of acrylic fiber, 20 parts of glass fiber, 10 parts of carbon fiber and 2 parts of polyethylene glycol. The fiber polymer spraying material is composed of 35 parts of cement, 40 parts of natural sand, 5 parts of fiber polymer, 4 parts of silica fume, 5 parts of copolymer emulsion, 1 part of phosphate, 0.3 parts of retarder, 0.03 parts of tackifier and 0.05 parts of water reducer. In addition, this embodiment is consistent with embodiment 1 in other aspects, including but not limited to the raw material ratio, preparation method, operating conditions, etc., all of which follow the specific steps and parameters described in embodiment 1.

[0036] Embodiment 4:

[0037] The main difference between this embodiment and embodiment 1 is that the fiber polymer is composed of 40 parts of polyester, 15 parts of nylon, 10 parts of acrylic fiber, 30 parts of glass fiber, 5 parts of carbon fiber and 1.8 parts of polyethylene glycol. The fiber polymer spraying material is composed of 42 parts of cement, 33 parts of natural sand, 8 parts of fiber polymer, 7 parts of silica fume, 3.5 parts of copolymer emulsion, 1.2 parts of phosphate, 0.3 parts of retarder, 0.06 parts of tackifier and 0.1 parts of water reducer. In addition, this embodiment is consistent with embodiment 1 in other aspects, including but not limited to the raw material ratio, preparation method, operating conditions, etc., all of which follow the specific steps and parameters described in embodiment 1.

[0038] Embodiment 5:

[0039] The main difference between this embodiment and embodiment 1 is that the fiber polymer is composed of 32 parts of polyester, 27 parts of nylon, 10 parts of acrylic fiber, 30 parts of glass fiber, 9 parts of carbon fiber and 1.2 parts of polyethylene glycol. The fiber polymer spraying material is composed of 38 parts of cement, 37 parts of natural sand, 9 parts of fiber polymer, 6.5 parts of silica fume, 4.5 parts of copolymer emulsion, 1.8 parts of phosphate, 0.5 parts of retarder, 0.02 parts of tackifier and 0.09 parts of water reducer. In addition, this embodiment is consistent with embodiment 1 in other aspects, including but not limited to the raw material ratio, preparation method, operating conditions, etc., all of which follow the specific steps and parameters described in embodiment 1.

[0040] Comparative Example 1:

[0041] The main difference of Comparative Example 1 is that no fiber polymer is added in Comparative Example 1. Apart from this, Comparative Example 1 is consistent with Example 1 in other aspects, including but not limited to the raw material ratio, preparation method, operating conditions, etc., all of which follow the specific steps and parameters described in Example 1.

[0042] Comparative Example 2:

[0043] The main difference of Comparative Example 2 is that no copolymer emulsion is added in Comparative Example 2. Apart from this, Comparative Example 2 is consistent with Example 1 in other aspects, including but not limited to the raw material ratio, preparation method, operating conditions, etc., all following the specific steps and parameters described in Example 1.

[0044] Flat plate restraint anti-cracking test: Cast the fiber polymer spraying materials prepared in Examples 1 to 5 and Comparative Examples 1 to 2 on a flat plate with a size of 800mm×600mm×100mm to ensure uniform thickness; cure the cast flat plate specimens under standard curing conditions for 28 days, regularly observe whether cracks appear on the surface of the specimens, and record the time, length, width and distribution of the cracks. Use a crack width meter or similar precision measuring tool to measure the width of the cracks to assess the severity of the cracks. Record the number of cracks and analyze the distribution density of the cracks. The specific test results are shown in Table 1:

[0045] Table 1

[0046]

[0047]

[0048] Pull-out test: Select red bricks as the substrate to ensure that their surface is flat. The fiber polymer spraying material prepared in Examples 1 to 5 and Control Examples 1 to 2 is evenly sprayed on the surface of the red brick to form a covering layer with a thickness of about 20 mm × 20 mm × 5 mm as a sample. The red bricks sprayed with the spraying material are cured under standard curing conditions for 28 days to ensure that the material achieves the expected performance. A portable pulling instrument is used to fix the pulling head and the sample. The pulling force is evenly applied through the pulling instrument until the sample is separated from the surface of the substrate. The maximum tensile strength value at this time is recorded. The adhesion strength between the spraying material and the substrate is evaluated based on the recorded maximum tensile strength value, and the failure mode is analyzed to evaluate the adhesion performance of the material. The specific test results are shown in Table 2:

[0049] Table 2

[0050]

[0051]

[0052] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for processing a fiber polymer spraying material, characterized in that: The following steps are involved: S1: preheating polyester, nylon and acrylic fiber in dry air to remove surface moisture, and removing impurities and oxides of glass fiber and carbon fiber by pickling and heat treatment; mixing polyester, nylon, acrylic fiber and glass fiber and carbon fiber treated with silane coupling agent, and then adding polyethylene glycol with a molecular weight of 8000 as a dispersant, mixing evenly and then melt spinning to obtain fiber polymer; S2: Mixing a vinyl monomer, sodium dodecylbenzene sulfonate as an emulsifier and water, stirring at room temperature to form a stable pre-emulsion, heating the pre-emulsion to 70°C to 90°C, adding an initiator azobisisobutyronitrile (AIBN) under an inert gas atmosphere, controlling the reaction temperature to 70°C to 90°C, and keeping the temperature for 40min to 60min. After the polymerization is completed, cooling the reaction system to room temperature, filtering to obtain a copolymer emulsion, and adjusting the solid content of the copolymer emulsion by evaporating or adding an appropriate amount of water, so that the solid content of the copolymer emulsion is 40% to 45%; S3: Add cement, natural sand, silica fume, fiber polymer, copolymer emulsion, retarder, phosphate, viscosity enhancer and water reducer into a stirring tank in proportion, and stir evenly to obtain a fiber polymer spraying material.

2. The method for processing a fiber polymer spraying material according to claim 1, characterized in that: The fiber polymer spraying material comprises the following materials in parts by weight: 30-50 parts of cement, 30-40 parts of natural sand, 5-10 parts of fiber polymer, 3-7 parts of silica fume, 3-5 parts of copolymer emulsion, 1-2 parts of phosphate, 0.1-0.5 parts of retarder, 0.02-0.06 parts of viscosity enhancer and 0.03-0.1 parts of water reducer.

3. The method for processing a fiber polymer spraying material according to claim 2, characterized in that: The fiber polymer comprises the following raw materials in parts by weight: 20-40 parts of polyester, 15-30 parts of nylon, 10-20 parts of acrylic fiber, 20-30 parts of glass fiber, 5-10 parts of carbon fiber and 1-2 parts of polyethylene glycol.

4. The method for processing a fiber polymer spraying material according to claim 2, characterized in that: The cement is silicate cement, and the natural sand is any one or more of river sand, sea sand, mountain sand, and lake sand.

5. The method for processing a fiber polymer spraying material according to claim 2, characterized in that: The vinyl monomer in the copolymer emulsion consists of ethylene and vinyl acetate, and the mass ratio of ethylene to vinyl acetate is 3:

7.

6. The method for processing a fiber polymer spraying material according to claim 2, characterized in that: The phosphate consists of potassium hydrogen phosphate and calcium phosphate, and the mass ratio of potassium hydrogen phosphate to calcium phosphate is 2:

1.

7. The method for processing a fiber polymer spraying material according to claim 2, characterized in that: The retarder is any one or two of boric acid, borax, sodium citrate and potassium tartrate.

8. The method for processing a fiber polymer spraying material according to claim 2, characterized in that: The tackifier is at least one of cellulose ether, guar gum, xanthan gum and rosin resin.

9. The method for processing a fiber polymer spraying material according to claim 2, characterized in that: The water reducer is at least one of a naphthalene-based water reducer, a sodium lignin sulfonate water reducer, a polycarboxylic acid water reducer and an amino water reducer.

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