Surface coating process of a fireproof composite board and the fireproof composite board

Abstract

The present invention relates to the technical field of cement-based building materials, and in particular to a surface coating process for a fireproof composite board and a fireproof composite board. The present invention provides an inorganic coating material, and applies the inorganic coating material to a substrate to prepare a composite fireproof composite board, wherein the coating material is composed of a base material and a surface material, the base material has strong bonding force, and the surface material has excellent fireproof performance. The prepared composite fireproof composite board has excellent fireproof performance and fire-resistant integrity.

Description

Technical Field

[0001] The present invention relates to the technical field of cement-based building materials, in particular to a surface coating process of a fireproof composite board and the fireproof composite board. Background Art

[0002] In order to meet the fire protection requirements during the building decoration process, fireproof boards are often used as building decoration materials. Commonly used fireproof boards include polystyrene boards, extruded boards, cement foam boards, etc. However, although organic boards such as polystyrene boards and extruded boards can achieve non-combustible grades, they will still melt at high temperatures, and cement foam boards have low strength and are prone to deformation at high temperatures.

[0003] In recent years, fireproof composite panels have been widely used and are composed of multiple layers of functional materials. CN101549979A discloses a moisture-proof and fireproof board, CN101696099A discloses a special fireproof mortar for extruded boards to form a fireproof protective layer on the surface of the extruded boards, CN104671822A discloses a foamed magnesium cement EPS particle A-grade non-combustible board, CN105350705A discloses a fiber cement composite board, and CN114888955A discloses a prefabricated exterior wall panel. However, in the prior art, composite panels usually add a large amount of organic functional materials, and the bonding strength of each layer is weak. In particular, after being exposed to high temperatures, the surface layer is easily separated from the base layer, and the integrity is poor. Summary of the Invention

[0004] In order to solve the problems existing in the prior art, the present invention provides an inorganic coating material, and applies it to a substrate to prepare a composite fireproof board, wherein the coating material is composed of a base material and a surface material, the base material has strong bonding force, and the surface material has excellent fireproof performance. The prepared composite composite board has excellent fireproof performance and fire-resistant integrity.

[0005] Specifically, the coating material for fireproof composite panels of the present invention is composed of a base material and a surface material.

[0006] The base material is composed of the following raw materials in parts by weight: 350-380 parts of early-strength ordinary Portland cement, 50-80 parts of fly ash, 130-150 parts of water glass, 15-20 parts of polyaluminum phosphate, 8-10 parts of anhydrous magnesium carbonate whiskers, 2-3 parts of fumed nano-silica, and 80-90 parts of water.

[0007] The fabric is composed of the following raw materials in parts by weight: 300-350 parts of sulphoaluminate cement, 40-60 parts of metakaolin, 30-50 parts of silica fume, 20-25 parts of activated dealkalized red mud, 40-50 parts of hollow microspheres, 1000-1200 parts of 0.5-1.5 mm waste refractory brick particles, 10-15 parts of calcium sulfate whiskers, 6-10 parts of water reducer, 4-5 parts of sodium hexametaphosphate, 3-5 parts of retarder, and 150-170 parts of water.

[0008] The present invention adopts early-strength ordinary Portland cement and fly ash as cementitious materials, compounded with a large amount of water glass, and added with fumed nano-silica to enhance the high-temperature bonding effect together with the water glass. Anhydrous magnesium carbonate whiskers are used to improve the crack resistance of the base material at high temperatures. Polyaluminum phosphate can adjust the viscosity of the base material and promote the coagulation of the base material, thereby facilitating subsequent fabric construction.

[0009] The present invention adopts sulphoaluminate cement, metakaolin, silica fume and activated dealkalized red mud as gelling materials, which have good mechanical properties and fireproofing effects. Hollow microspheres and waste refractory brick particles can resist flame erosion, and calcium sulfate whiskers are used to improve the fireproofing effect. Sodium hexametaphosphate can adjust the homogeneity of the fabric slurry. The water reducer can reduce water consumption and improve the fluidity of the slurry. The retarder is added to adjust the coagulation time of the fabric slurry to ensure the progress of the coating process.

[0010] Preferably, the early-strength ordinary Portland cement is P·O42.5R cement.

[0011] Preferably, the water glass has a solid content of 35-40% and a modulus of 2.0-2.4.

[0012] Preferably, the hollow microspheres are at least one of hollow glass microspheres and hollow ceramic microspheres, and have a particle size of 50-100 μm.

[0013] Preferably, the sulphoaluminate cement is grade 42.5.

[0014] Preferably, the activated dealkalized red mud preparation process comprises: mixing red mud with a dealkalizing agent and water, filtering, calcining, and grinding after cooling. Specifically, red mud, calcium oxide, and water are mixed and stirred at a mass ratio of 1:(0.1-0.2):(3-5) at 60-70°C for 5-7 hours, filtering, calcining at 850-1000°C for 3-4 hours, and grinding to a particle size of less than 45 μm after cooling.

[0015] Red mud is an industrial solid waste generated in the aluminum smelting process. It has a high alkali content but has certain gelling activity. The present invention dealkalizes the red mud and then activates it at high temperature to eliminate potassium and sodium ions and increase the calcium ion content. It is then ground after calcination to improve the gelling activity. Using it together with metakaolin and silica fume as auxiliary gelling materials can increase the viscosity of the fabric slurry, and combining it with sodium hexametaphosphate to improve the dispersion stability of hollow microspheres and waste refractory brick particles.

[0016] Preferably, the waste refractory brick particles are obtained by crushing and screening waste refractory bricks. The present invention adds waste refractory brick particles as fine aggregate and utilizes its high temperature resistance to improve the high temperature and fireproof effect of the fireproof composite board.

[0017] Preferably, the water reducer is a polycarboxylate water reducer.

[0018] Preferably, the retarder is at least one of sodium gluconate, boric acid, and sucrose.

[0019] Preferably, the anhydrous magnesium carbonate whiskers have a diameter of 0.2-0.5 μm and a length of 3-10 μm.

[0020] The present invention also relates to a surface coating process for a fireproof composite board, which is coated with the above-mentioned coating material and specifically comprises the following steps:

[0021] 1) Prepare the substrate,

[0022] 2) Prepare primer slurry and coat the substrate.

[0023] 3) Prepare the surface slurry. After the base material slurry has initially set, apply the surface slurry and perform maintenance after final setting.

[0024] Preferably, the substrate is a calcium silicate board, a magnesium oxychloride board or a gypsum board.

[0025] Preferably, the coating thickness of the primer slurry is 2-3 mm.

[0026] Preferably, the fabric slurry coating thickness is 3-5 mm.

[0027] The present invention also relates to a fireproof composite board, which is specifically prepared by the above process.

[0028] The present invention has the following technical advantages:

[0029] 1. The present invention adds fly ash, silica fume, activated dealkalized red mud, and waste refractory brick particles to prepare base material and fabric, realizing high-value recycling of bulk industrial solid waste, low carbon and environmental protection, cost reduction and efficiency improvement,

[0030] 2. The base material of the present invention has good bonding force, can be integrated with the substrate and fabric, has good high temperature stability, and has good fireproof effect on the fabric.

[0031] 3. The present invention coats the base material and the surface material onto the substrate to prepare the fireproof composite board, which has good fireproof effect and excellent effects of not deforming or cracking at high temperature. DETAILED DESCRIPTION

[0032] To characterize the effectiveness of the present invention, fireproof composite panels were prepared and tested. The test used early-strength ordinary Portland cement (PO42.5R), 42.5-grade sulfoaluminate cement, 36% waterglass solids, a modulus of 2.4, and a hollow microsphere particle size of 50-100 μm. The activated dealkalized red mud preparation process involved mixing red mud, calcium oxide, and water at a mass ratio of 1:0.1:5 at 70°C for 6 hours, filtering, calcining at 950°C for 3 hours, and grinding after cooling to a particle size of less than 45 μm. The waste refractory brick particle size ranged from 0.5 to 1.5 mm. During the preparation process, a 4 mm thick calcium silicate board was used as the base material, with a 2 mm base slurry coating thickness and a 4 mm top slurry coating thickness. The testing process included fluidity testing of the base and top slurries, tensile strength testing of the fireproof composite panels, and tensile strength testing after high-temperature treatment at 1000°C for 2 hours.

[0033] Example 1

[0034] The coating material is composed of a base material and a surface material. The base material is composed of the following raw materials in parts by weight: 370 parts of PO42.5R cement, 60 parts of fly ash, 150 parts of water glass, 19 parts of polyaluminum phosphate, 9 parts of anhydrous magnesium carbonate whiskers, 3 parts of fumed nanosilica, and 88 parts of water. The surface material is composed of the following raw materials in parts by weight: 320 parts of sulphoaluminate cement, 60 parts of metakaolin, 50 parts of silica fume, 20 parts of activated dealkalized red mud, 45 parts of hollow ceramic microspheres, 1100 parts of waste refractory brick particles, 12 parts of calcium sulfate whiskers, 8 parts of water reducer, 5 parts of sodium hexametaphosphate, 4 parts of retarder, and 160 parts of water.

[0035] After testing, the fluidity of the base material slurry is 210mm, and the workability is good; the fluidity of the surface material slurry is 230mm, and the workability is good; the tensile strength of the fireproof composite board is 1.6MPa, and the tensile strength after high temperature treatment is 1.4MPa; the board has no warping, cracking, or falling off.

[0036] Example 2

[0037] The coating material is composed of a base material and a surface material. The base material is composed of the following raw materials in parts by weight: 360 parts of PO42.5R cement, 80 parts of fly ash, 130 parts of water glass, 16 parts of polyaluminum phosphate, 8 parts of anhydrous magnesium carbonate whiskers, 2 parts of fumed nanosilica, and 88 parts of water. The surface material is composed of the following raw materials in parts by weight: 340 parts of sulphoaluminate cement, 50 parts of metakaolin, 30 parts of silica fume, 25 parts of activated dealkalized red mud, 49 parts of hollow glass microspheres, 1100 parts of waste refractory brick particles, 15 parts of calcium sulfate whiskers, 9 parts of water reducer, 4 parts of sodium hexametaphosphate, 4 parts of retarder, and 162 parts of water.

[0038] After testing, the fluidity of the base material slurry is 200mm, and the workability is good; the fluidity of the surface material slurry is 210mm, and the workability is good; the tensile strength of the fireproof composite board is 1.4MPa, and the tensile strength after high temperature treatment is 1.2MPa; the board has no warping, cracking, or falling off.

[0039] Comparative Example 1

[0040] The coating material is composed of a base material and a surface material. The base material is composed of the following raw materials in parts by weight: 370 parts of PO42.5R cement, 60 parts of fly ash, 150 parts of water glass, 19 parts of polyaluminum phosphate, 9 parts of aluminum silicate fiber, 3 parts of fumed nanosilica, and 88 parts of water. The surface material is composed of the following raw materials in parts by weight: 320 parts of sulphoaluminate cement, 60 parts of metakaolin, 50 parts of silica fume, 20 parts of activated dealkalized red mud, 45 parts of hollow ceramic microspheres, 1100 parts of waste refractory brick particles, 12 parts of PVA fiber, 8 parts of water reducer, 5 parts of sodium hexametaphosphate, 4 parts of retarder, and 160 parts of water.

[0041] After testing, the fluidity of the base material slurry is 220mm, and the workability is good. The fluidity of the surface material slurry is 210mm, and the workability is good. The tensile strength of the fireproof composite board is 1.2MPa, and the tensile strength after high temperature treatment is 0.6MPa. There is no warping of the board, cracks in the surface layer, and no falling off.

[0042] Comparative Example 2

[0043] The coating material is composed of a base material and a surface material. The base material is composed of the following raw materials in parts by weight: 420 parts of PO42.5R cement, 60 parts of fly ash, 20 parts of water glass, 100 parts of acrylic emulsion, 9 parts of anhydrous magnesium carbonate whiskers, 3 parts of fumed nano-silica, and 88 parts of water. The surface material is composed of the following raw materials in parts by weight: 320 parts of sulphoaluminate cement, 60 parts of metakaolin, 50 parts of silica fume, 20 parts of activated dealkalized red mud, 45 parts of hollow ceramic microspheres, 1100 parts of quartz sand, 12 parts of calcium sulfate whiskers, 8 parts of water reducer, 5 parts of sodium hexametaphosphate, 4 parts of retarder, and 160 parts of water.

[0044] After testing, the fluidity of the base material slurry is 190mm, and the workability is good. The fluidity of the surface material slurry is 210mm, and the workability is good. The tensile strength of the fireproof composite board is 0.9MPa, and the tensile strength after high temperature treatment is 0.3MPa. There is no warping of the board, cracking of the surface layer and the bottom layer, and partial falling off of the surface layer.

[0045] Comparative Example 3

[0046] The coating material is composed of a base material and a surface material. The base material is composed of the following raw materials in parts by weight: 400 parts of PO42.5R cement, 60 parts of fly ash, 40 parts of sulfoaluminate cement, 10 parts of aluminum hydroxide, 9 parts of anhydrous magnesium carbonate whiskers, 3 parts of nano-silicon dioxide, and 160 parts of water. The surface material is composed of the following raw materials in parts by weight: 320 parts of sulfoaluminate cement, 60 parts of metakaolin, 50 parts of silica fume, 20 parts of activated dealkalized red mud, 45 parts of hollow ceramic microspheres, 1100 parts of waste refractory brick particles, 12 parts of calcium sulfate whiskers, 8 parts of water reducer, 5 parts of sodium hexametaphosphate, 4 parts of retarder, and 160 parts of water.

[0047] After testing, the fluidity of the base material slurry is 220mm, and the workability is good. The fluidity of the surface material slurry is 230mm, and the workability is good. The tensile strength of the fireproof composite board is 0.9MPa, and the tensile strength after high temperature treatment is 0.4MPa. The board has no warping, cracking, or partial detachment of the surface layer.

[0048] Comparative Example 4

[0049] The coating material is composed of a base material and a surface material. The base material is composed of the following raw materials in parts by weight: 370 parts of PO42.5R cement, 60 parts of fly ash, 150 parts of water glass, 19 parts of polyaluminum phosphate, 9 parts of anhydrous magnesium carbonate whiskers, 3 parts of fumed nanosilica, and 88 parts of water. The surface material is composed of the following raw materials in parts by weight: 320 parts of sulfoaluminate cement, 60 parts of fly ash, 50 parts of mineral powder, 20 parts of red mud, 45 parts of hollow ceramic microspheres, 1100 parts of waste refractory brick particles, 12 parts of calcium sulfate whiskers, 8 parts of water reducer, 5 parts of sodium hexametaphosphate, 4 parts of retarder, and 160 parts of water.

[0050] After testing, the fluidity of the base material slurry is 210mm, with good workability; the fluidity of the surface material slurry is 240mm, with slight compaction; the tensile strength of the fireproof composite board is 1.2MPa, and the tensile strength after high-temperature treatment is 0.6MPa. The board has no warping, cracks in the surface layer, and partial falling off.

[0051] Comparative Example 5

[0052] In this comparative example, only the fabric formula of Example 1 was used as the coating material, and the coating thickness was 6 mm to prepare a fireproof composite board, and a tensile strength test was performed for comparison.

[0053] After testing, the tensile strength of the fireproof composite board is 0.8MPa, and the tensile strength after high-temperature treatment is 0.2MPa. The board is slightly warped, the coating layer has cracks, and some parts have not fallen off.

[0054] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A fireproof composite board, characterized in that: The surface is coated with cement-based coating. The coating material is composed of a base material and a fabric. The base material is composed of the following raw materials by weight: 350-380 parts of early strength ordinary Portland cement, 50-80 parts of fly ash, 130-150 parts of water glass, 15-20 parts of polyaluminum phosphate, 8-10 parts of anhydrous magnesium carbonate whiskers, 2-3 parts of fumed nano-silica, and 80-90 parts of water. The fabric is composed of the following raw materials in parts by weight: 300-350 parts of sulphoaluminate cement, 40-60 parts of metakaolin, 30-50 parts of silica fume, 20-25 parts of activated dealkalized red mud, 40-50 parts of hollow microspheres, 1000-1200 parts of 0.5-1.5 mm waste refractory brick particles, 10-15 parts of calcium sulfate whiskers, 6-10 parts of water reducer, 4-5 parts of sodium hexametaphosphate, 3-5 parts of retarder, and 150-170 parts of water. The preparation process of the activated dealkalized red mud is as follows: red mud, calcium oxide, and water are mixed and stirred at a mass ratio of 1:(0.1-0.2):(3-5) at 60-70° C. for 5-7 hours, filtered, calcined at 850-1000° C. for 3-4 hours, and ground to a particle size of less than 45 μm after cooling.

2. The fireproof composite board according to claim 1, characterized in that: The water glass has a solid content of 35-40% and a modulus of 2.0-2.

4.

3. The fireproof composite board according to claim 1, characterized in that: The hollow microspheres are at least one of hollow glass microspheres and hollow ceramic microspheres, and have a particle size of 50-100 μm.

4. The fireproof composite board according to claim 1, characterized in that: The waste refractory brick particles are obtained by crushing and screening the waste refractory bricks.

5. The fireproof composite board according to claim 1, characterized in that: The water reducer is a polycarboxylate water reducer.

6. The fireproof composite board according to claim 1, characterized in that: The retarder is at least one of sodium gluconate, boric acid and sucrose.

7. A surface coating process for a fireproof composite board, comprising coating with the coating material according to any one of claims 1 to 6, characterized in that: The steps include: 1) Prepare the substrate, 2) Prepare primer slurry and coat the substrate. 3) Prepare the surface slurry. After the base material slurry has initially set, apply the surface slurry and perform maintenance after final setting.

8. The surface coating process of the fireproof composite board according to claim 7, characterized in that: The coating thickness of the base material slurry is 2-3mm, and the coating thickness of the surface material slurry is 3-5mm.