High-crack-resistance self-leveling concrete mortar component and manufacturing method thereof

Abstract

The invention relates to the technical field of mortar, in particular to a high-crack-resistance self-leveling concrete mortar component which is composed of high-strength Portland cement, sulphoaluminate cement, aggregate, fly ash, a polycarboxylate superplasticizer, redispersible rubber powder, a stabilizer, an expanding agent, graphene oxide, modified polymer emulsion and a cellulose ether derivative. The mortar has the advantages of improving the mortar performance and improving the mortar strength and durability, the additives such as the polycarboxylate superplasticizer, the redispersible rubber powder, the stabilizer, the expanding agent, the graphene oxide and the modified polymer emulsion are added, the anti-sagging performance, thixotropy and anti-settling performance of the mortar are all remarkably improved, more labor is saved during construction, and the construction efficiency is improved. According to the present invention, the comprehensive cost is reduced, the components can significantly improve the fluidity and the adhesion of the mortar, improve the strength and the durability of the mortar, and control the curing time and the environmental conditions.

Description

Technical Field

[0001] The invention relates to the technical field of mortar, in particular to a highly crack-resistant self-leveling concrete mortar component and a manufacturing method thereof. Background Art

[0002] Common mortars include cement mortar, mixed mortar (or cement lime mortar), lime mortar and clay mortar, which are made by mixing inorganic cementitious materials with fine aggregate and water in proportion, also known as mortar, and are used for masonry and plastering projects. They can be divided into masonry mortar and plastering mortar. The former is used for masonry of bricks, stones, blocks, etc. and component installation; the latter is used for plastering of walls, floors, roofs and beam-column structures to meet the requirements of protection and decoration. Other common mortar materials are made of gypsum, lime paste or clay mixed with fibrous reinforcing materials and water to form a paste, called ash, paste, mud or glue. Commonly used are hemp knife lime (lime paste mixed with hemp knife), paper tendon lime (lime paste mixed with paper tendon), gypsum lime (lime paste and paper tendon or glass fiber mixed with gypsum) and mixed plaster (a small amount of lime and wheat straw or rice straw mixed with clay).

[0003] Mortar is an adhesive material used for bricklaying in construction. It is synthesized by adding water to a certain proportion of sand and a binder (cement, lime paste, clay, etc.). However, the mortar prepared by the prior art has fluctuations in performance. For example, indicators such as strength, impermeability, and durability are unstable, which affects the quality of the project. If water reducers, stabilizers and other ingredients are not added or are added unreasonably, the fluidity and adhesion of the mortar will be affected, thereby reducing its strength and durability. In addition, the lack of effective temperature and humidity control measures may cause the mortar to crack and dry too quickly during the curing process, affecting its final performance. Finally, the curing time also needs to be strictly controlled. If the curing time is too short or too long, it will affect the strength development and stability of the mortar. Therefore, there is an urgent need for a highly crack-resistant self-leveling concrete mortar component and a production method thereof to solve the above problems. Summary of the invention

[0004] In order to solve the problems raised by the above background technology, the present invention proposes a highly crack-resistant self-leveling concrete mortar component and a manufacturing method thereof.

[0005] The purpose of the present invention can be achieved through the following technical solutions:

[0006] A highly crack-resistant self-leveling concrete mortar component, comprising two symmetrically arranged building templates, and a plurality of threaded sleeves arranged in parallel in pairs are arranged on both sides of the building templates, the interior of each threaded sleeve is threadedly connected to two symmetrically arranged threaded rods, each threaded rod is threadedly connected to a clamping plate 1, and an operating block for driving the threaded rod to rotate is arranged at the end of each threaded rod;

[0007] The pre-clamping mechanism is arranged on the threaded sleeve and is used for pre-clamping two building templates.

[0008] As a further preferred embodiment of the present technical solution: the pre-clamping mechanism includes a connecting block fixedly mounted on the threaded sleeve, each of the connecting blocks is fixedly mounted with a sleeve, the interior of each of the sleeves is slidably connected to two connecting rods, a spring is arranged between the two connecting rods, and a clamping plate 2 is arranged at one end of each connecting rod away from the spring.

[0009] As a further preferred embodiment of the technical solution: a clamping block is installed on each of the second clamping plates, and a clamping slot for matching with the clamping block is provided on the outer wall of the building template.

[0010] As a further preferred embodiment of the present invention, the following components are included:

[0011] The proportion of high-strength Portland cement is 30%-40%, the proportion of sulphoaluminate cement is 15%-30%, the proportion of high-belite sulphoaluminate cement is 10%-20%, the proportion of aggregate is 20%-30%, the proportion of fly ash is 8%-15%, the dosage of polycarboxylic acid water reducer is 0.5%-1%, the dosage of redispersible rubber powder is 0.2%-0.5%, the dosage of stabilizer is 0.3%-0.8%, the dosage of expansion agent is 1%-5%, the dosage of graphene oxide is 0.01%-0.1%, the dosage of modified polymer emulsion is 1%-5%, and the dosage of cellulose ether derivative is 0.1%-0.5%.

[0012] As a further preferred embodiment of the present technical solution: the specific steps include:

[0013] S1. Premixing high-strength Portland cement, sulphoaluminate cement, high-belite sulphoaluminate cement, aggregate and fly ash by a mixer;

[0014] S2, adding polycarboxylate water reducer, redispersible rubber powder, stabilizer, expander, graphene oxide, modified polymer emulsion and cellulose ether derivative into the premixed material and stirring;

[0015] S3. Pour the mixed mortar into a maturation container and let it stand, and spray and humidify it through the spray system.

[0016] As a further preferred embodiment of the present technical solution: the stirring time in step S1 is set to 5-10 minutes, and the rotation speed is controlled at 500-1000 rpm.

[0017] As a further preferred embodiment of the present technical solution: the stirring time in step S2 is set to 5-10 minutes, and the rotation speed is controlled at 600-1200 rpm.

[0018] As a further preferred embodiment of the present technical solution: the standing condition described in step S3 is that if the greenhouse temperature is 15°C-30°C, the standing time is 24 hours; if the temperature exceeds 30°C, the standing time is shortened to 16 hours; if the temperature is lower than 15°C, the standing time is extended to 36 hours, and the spraying humidity is maintained in the range of 45%-70%.

[0019] Compared with the prior art, the present invention has the following beneficial effects:

[0020] 1. In the present invention, by adding a variety of additives, the anti-sagging, thixotropy, anti-settling and other properties of the mortar are significantly improved, which makes the construction more labor-saving and reduces the overall cost. These ingredients can significantly improve the fluidity and adhesion of the mortar, while improving its strength and durability. By controlling the aging time and environmental conditions, such as temperature and humidity, it is ensured that the mortar is cured in a suitable environment, which helps to improve the final performance of the mortar, including compressive strength and flexural strength, and ensure the quality of the mortar.

[0021] 2. In the present invention, the two clamping plates 2 are closely fitted to the building formwork, which significantly enhances the stability of the building formwork during the pouring process, ensures the safety of the pouring operation, and also achieves close clamping and precise positioning of the edge of the building formwork by adjusting the distance between the two clamping plates 1. This double clamping and positioning mechanism effectively prevents displacement or deformation of the formwork during the pouring process, laying a solid foundation for ultimately constructing a high-quality, high-precision building structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a schematic diagram of the three-dimensional structure of a highly crack-resistant self-leveling concrete mortar component;

[0023] Figure 2 for Figure 1 A three-dimensional schematic diagram of the local structure split state;

[0024] Figure 3 A flow chart was prepared for the present invention.

[0025] Legend: 1. Building formwork; 2. Slot; 3. Block; 4. Clamping plate 1; 5. Threaded sleeve; 6. Threaded rod; 7. Operating block; 8. Connecting block; 9. Sleeve; 10. Spring; 11. Linking rod; 12. Clamping plate 2. DETAILED DESCRIPTION

[0026] The technical solution of the present invention will be clearly and completely described below in conjunction with the embodiments. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all of the embodiments. 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.

[0027] See also Figure 1-Figure 3 The present application provides a highly crack-resistant self-leveling concrete mortar component, comprising two symmetrically arranged building templates 1, and a plurality of threaded sleeves 5 arranged in parallel in pairs are provided on both sides of the building template 1, and the interior of each threaded sleeve 5 is threadedly connected to two symmetrically arranged threaded rods 6, each of the threaded rods 6 is threadedly connected to a clamping plate 4, and an operating block 7 for driving the threaded rod 6 to rotate is provided at the end of each threaded rod 6.

[0028] Among them, when the clamping plate 2 12 is driven to fit tightly with the building template 1, a clamping block 3 is installed on each of the clamping plates 2 12, and a clamping slot 2 for matching use is opened on the outer wall of the building template 1, and the clamping plate 1 4 also moves accordingly, driving the clamping block 3 thereon to be clamped into the inside of the clamping slot 2.

[0029] Specifically, by rotating the operating block 7, the operating block 7 drives the threaded rod 6 to rotate in the inner cavity of the threaded sleeve 5. As the threaded rod 6 rotates and advances, the clamping plate 4 is gradually guided and firmly close to the building formwork 1, thereby achieving the positioning and firm clamping of the clamping plate 4, which is beneficial to improving the stability of the building formwork during pouring. The pre-clamping mechanism is arranged on the threaded sleeve 5 and is used to pre-clamp the two building formworks 1.

[0030] The pre-clamping mechanism includes a connection block 8 fixedly mounted on the threaded sleeve 5, a sleeve 9 fixedly mounted on each of the connection blocks 8, two linkage rods 11 slidably connected inside each of the sleeves 9, a spring 10 is arranged between the two linkage rods 11, and a clamping plate 2 12 is arranged at one end of each linkage rod 11 away from the spring 10. Specifically, in the preparation stage before cement pouring, the sleeve 9 needs to be placed on the side of the building template 1 first, and the clamping plate 2 12 is driven to fit closely with the building template 1 by means of the elastic potential energy stored in the spring 10.

[0031] Embodiment 1:

[0032] A highly crack-resistant self-leveling concrete mortar component, the mortar composition is composed of high-strength silicate cement, sulphoaluminate cement, aggregate, fly ash, a polycarboxylic acid water reducer, specifically ViscoCrete-530P, a redispersible rubber powder, specifically HW5111, a stabilizer, specifically DOWFAX8390, an expansion agent, specifically S-AC high-performance concrete expansion agent, graphene oxide, a modified polymer emulsion, specifically BLJ-963M / F, and a cellulose ether derivative, specifically KY10, and all the following embodiments and comparative examples adopt this standard.

[0033] It should be noted that quartz sand is used as coarse aggregate and calcium carbonate powder is used as fine aggregate, and the proportion of fine aggregate sand is greater than that of quartz sand.

[0034] A method for preparing a highly crack-resistant self-leveling concrete mortar component, the method comprising the following steps:

[0035] S1. Pre-mix 35% of high-strength silicate cement, 20% of sulphoaluminate cement, 15% of high-belite sulphoaluminate cement, and 25% of aggregate, including 15% of fine bone sand, 10% of quartz sand, and 10% of fly ash in a mixer. Set the mixing time to 7 minutes and control the speed at 750rpm to ensure that all materials are fully mixed and evenly without caking.

[0036] S2. Add 0.75% polycarboxylic acid water reducer, 0.35% redispersible rubber powder, 0.55% stabilizer, 3% expander, 0.05% graphene oxide, 3% modified polymer emulsion and 0.3% cellulose ether derivative into the premixed material and stir. Set the stirring time to 7 minutes and control the speed at 900 rpm to ensure that all materials are fully mixed and evenly without caking.

[0037] It should be noted that in step S2, microwave-assisted stirring is used, and microwave heating is used to accelerate the heating of the interior and surface of the material at the same time, thereby accelerating the hydration reaction of the cement.

[0038] S3. Pour the mixed mortar into a special aging container and leave it in a greenhouse for 24 hours at a temperature of 25°C.

[0039] It should be noted that in step S3, the humidity in the ripening container is maintained at 50% by the spray system.

[0040] Embodiment 2:

[0041] On the basis of Example 1, a highly crack-resistant self-leveling concrete mortar component is provided, wherein the mortar composition is composed of high-strength silicate cement, sulphoaluminate cement, aggregate, fly ash, polycarboxylic acid water reducer, redispersible rubber powder, stabilizer, expansion agent, graphene oxide, modified polymer emulsion, and cellulose ether derivative.

[0042] It should be noted that quartz sand is used as coarse aggregate and calcium carbonate powder is used as fine aggregate, and the proportion of fine aggregate sand is greater than that of quartz sand.

[0043] A method for preparing a highly crack-resistant self-leveling concrete mortar component, the method comprising the following steps:

[0044] S1. Pre-mix high-strength Portland cement (10%), sulphoaluminate cement (25%), high-belite sulphoaluminate cement (10%), aggregate (20%), of which fine bone sand (12%), quartz sand (8%) and fly ash (12%) in a mixer. Set the mixing time to 8 minutes and the speed to 800 rpm to ensure that all materials are fully mixed and evenly without caking.

[0045] S2. Add 0.6% polycarboxylic acid water reducer, 0.4% redispersible rubber powder, 0.6% stabilizer, 2% expander, 0.03% graphene oxide, 4% modified polymer emulsion and 0.25% cellulose ether derivative into the premixed material and stir. Set the stirring time to 8 minutes and control the speed at 1000 rpm to ensure that all materials are fully mixed and evenly without caking.

[0046] It should be noted that in step S2, microwave-assisted stirring is used, and microwave heating is used to accelerate the heating of the interior and surface of the material at the same time, thereby accelerating the hydration reaction of the cement.

[0047] S3. Pour the mixed mortar into a special aging container and leave it to stand for 24 hours at a greenhouse humidity of 22°C.

[0048] It should be noted that in step S3, the humidity in the ripening container is maintained at 55% by the spray system.

[0049] Embodiment three:

[0050] On the basis of Example 2, a highly crack-resistant self-leveling concrete mortar component is provided, wherein the mortar composition is composed of high-strength silicate cement, sulphoaluminate cement, aggregate, fly ash, polycarboxylic acid water reducer, redispersible rubber powder, stabilizer, expansion agent, graphene oxide, modified polymer emulsion, and cellulose ether derivative.

[0051] It should be noted that quartz sand is used as coarse aggregate and calcium carbonate powder is used as fine aggregate, and the proportion of fine aggregate sand is greater than that of quartz sand.

[0052] A method for preparing a highly crack-resistant self-leveling concrete mortar component, the method comprising the following steps:

[0053] S1. Pre-mix high-strength Portland cement (30%), sulphoaluminate cement (15%), high-belite sulphoaluminate cement (20%), aggregate (30%), of which fine bone sand (18%), quartz sand (12%) and fly ash (15%) in a mixer. Set the mixing time to 6 minutes and control the speed at 900 rpm to ensure that all materials are fully mixed and evenly without caking.

[0054] S2. Add 0.8% polycarboxylic acid water reducer, 0.3% redispersible rubber powder, 0.4% stabilizer, 4% expander, 0.07% graphene oxide, 2% modified polymer emulsion and 0.36% cellulose ether derivative into the premixed material and stir. Set the stirring time to 6 minutes and control the speed at 1100 rpm to ensure that all materials are fully mixed and evenly without caking.

[0055] It should be noted that in step S2, microwave-assisted stirring is used, and microwave heating is used to accelerate the heating of the interior and surface of the material at the same time, thereby accelerating the hydration reaction of the cement.

[0056] S3. Pour the mixed mortar into a special aging container and leave it in a greenhouse for 24 hours at a temperature of 28°C.

[0057] It should be noted that in step S3, the humidity in the ripening container is maintained at 45% by the spray system.

[0058] Comparative Example 1:

[0059] On the basis of all the above embodiments, a highly crack-resistant self-leveling concrete mortar component is provided, wherein the mortar composition is composed of high-strength silicate cement, sulphoaluminate cement, aggregate, fly ash, polycarboxylic acid water reducer, redispersible rubber powder, stabilizer, expansion agent, graphene oxide, modified polymer emulsion, and cellulose ether derivative.

[0060] It should be noted that quartz sand is used as coarse aggregate and calcium carbonate powder is used as fine aggregate, and the proportion of fine aggregate sand is greater than that of quartz sand.

[0061] A method for preparing a highly crack-resistant self-leveling concrete mortar component, the method comprising the following steps:

[0062] S1. Pre-mix 40% of high-strength silicate cement, 25% of sulphoaluminate cement, 10% of high-belite sulphoaluminate cement, 20% of aggregate, including 12% of fine bone sand, 8% of quartz sand and 12% of fly ash in a mixer. Set the mixing time to 8 minutes and control the speed at 800rpm to ensure that all materials are fully mixed and evenly without caking.

[0063] S2. Add 0.6% polycarboxylate water reducer, 0.4% redispersible rubber powder, 0.6% stabilizer and 2% expander to the premixed material. Set the stirring time to 8 minutes and the speed to 1000 pm to ensure that all materials are fully mixed and evenly without caking.

[0064] It should be noted that in step S2, microwave-assisted stirring is used, and microwave heating is used to accelerate the heating of the interior and surface of the material at the same time, thereby accelerating the hydration reaction of the cement.

[0065] S3. Pour the mixed mortar into a special aging container and leave it in a greenhouse for 24 hours at a temperature of 22°C.

[0066] It should be noted that in step S3, the humidity in the ripening container is maintained at 5% by the spray system.

[0067] Comparative Example 2:

[0068] On the basis of all the above embodiments and comparative example 1, a highly crack-resistant self-leveling concrete mortar component is provided, wherein the mortar composition is composed of high-strength silicate cement, sulphoaluminate cement, aggregate, fly ash, polycarboxylic acid water reducer, redispersible rubber powder, stabilizer, expansion agent, graphene oxide, modified polymer emulsion, and cellulose ether derivative.

[0069] It should be noted that quartz sand is used as coarse aggregate and calcium carbonate powder is used as fine aggregate, and the proportion of fine aggregate sand is greater than that of quartz sand.

[0070] A method for preparing a highly crack-resistant self-leveling concrete mortar component, the method comprising the following steps:

[0071] S1. Pre-mix 35% of high-strength silicate cement, 20% of sulphoaluminate cement, 15% of high-belite sulphoaluminate cement, and 25% of aggregate, including 15% of fine bone sand, 10% of quartz sand, and 10% of fly ash in a mixer. Set the mixing time to 7 minutes and control the speed at 750rpm to ensure that all materials are fully mixed and evenly without caking.

[0072] S2. Add 0.5% polycarboxylate water reducer to the premixed material, set the stirring time to 7 minutes, and control the speed at 900 rpm to ensure that all materials are fully mixed and uniform without lumps.

[0073] It should be noted that in step S2, microwave-assisted stirring is used, and microwave heating is used to accelerate the heating of the interior and surface of the material at the same time, thereby accelerating the hydration reaction of the cement.

[0074] S3. Pour the mixed mortar into a special aging container and leave it in a greenhouse for 24 hours at a temperature of 25°C.

[0075] It should be noted that in step S3, the humidity in the ripening container is maintained at 50% by the spray system.

[0076] In summary, in combination with all the above embodiments and comparative examples, the material ratio diagram is shown in Table 1 and the test data diagram is shown in Table 2:

[0077] Table 1:

[0078]

[0079] Table 2:

[0080]

[0081] From Table 1 and Table 2, we know that:

[0082] In Example 1, Example 2 and Example 3, as the proportion of high-strength Portland cement and sulphoaluminate cement increases, the compressive strength and flexural strength are improved, but the linear expansion rate decreases slightly. This is because the hydration reaction of high-strength Portland cement and sulphoaluminate cement is more complete, forming more hydration products and improving the strength.

[0083] In Comparative Examples 1 and 2, the addition of polycarboxylic acid water-reducing agent, redispersible rubber powder, stabilizer, expansion agent, graphene oxide and modified polymer emulsion significantly improved the performance of the mortar. The water-reducing agent and redispersible rubber powder improved the fluidity and adhesion of the mortar, the stabilizer and expansion agent improved the stability of the mortar, and the graphene oxide and modified polymer emulsion enhanced the strength and durability of the mortar.

[0084] The above embodiments are only used to illustrate the technical method of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical method of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical method of the present invention.

Claims

1. A highly crack-resistant self-leveling concrete mortar component, characterized in that: The invention comprises two symmetrically arranged building templates (1), and a plurality of threaded sleeves (5) arranged in parallel in pairs are provided on both sides of the building template (1), the interior of each threaded sleeve (5) is threadedly connected to two symmetrically arranged threaded rods (6), and each threaded rod (6) is threadedly connected to a clamping plate (4); The pre-clamping mechanism is arranged on the threaded sleeve (5) and is used for pre-clamping two building templates (1).

2. A highly crack-resistant self-leveling concrete mortar component according to claim 1, characterized in that: The pre-clamping mechanism comprises a connecting block (8) fixedly mounted on a threaded sleeve (5), a sleeve (9) fixedly mounted on each of the connecting blocks (8), two connecting rods (11) slidably connected inside each of the sleeves (9), a spring (10) being arranged between the two connecting rods (11), and a clamping plate 2 (12) being arranged at one end of each of the connecting rods (11) away from the spring (10).

3. A highly crack-resistant self-leveling concrete mortar component according to claim 2, characterized in that: Each of the second clamping plates (12) is provided with a clamping block (3), and a clamping slot (2) for matching with the clamping block is provided on the outer wall of the building template (1).

4. A highly crack-resistant self-leveling concrete mortar component according to claim 3, characterized in that: Includes the following ingredients: The proportion of high-strength Portland cement is 30%-40%, the proportion of sulphoaluminate cement is 15%-30%, the proportion of high-belite sulphoaluminate cement is 10%-20%, the proportion of aggregate is 20%-30%, the proportion of fly ash is 8%-15%, the dosage of polycarboxylic acid water reducer is 0.5%-1%, the dosage of redispersible rubber powder is 0.2%-0.5%, the dosage of stabilizer is 0.3%-0.8%, the dosage of expansion agent is 1%-5%, the dosage of graphene oxide is 0.01%-0.1%, the dosage of modified polymer emulsion is 1%-5%, and the dosage of cellulose ether derivative is 0.1%-0.5%.

5. The method for manufacturing a highly crack-resistant self-leveling concrete mortar component according to claim 4, characterized in that: The specific steps include: S1. Premixing high-strength Portland cement, sulphoaluminate cement, high-belite sulphoaluminate cement, aggregate and fly ash by a mixer; S2, adding polycarboxylate water reducer, redispersible rubber powder, stabilizer, expander, graphene oxide, modified polymer emulsion and cellulose ether derivative into the premixed material and stirring; S3. Pour the mixed mortar into a maturation container and let it stand, and spray and humidify it through the spray system.

6. The method for manufacturing a highly crack-resistant self-leveling concrete mortar component according to claim 5, characterized in that: The stirring time in step S1 is set to 5-10 minutes, and the rotation speed is controlled at 500-1000 rpm.

7. The method for manufacturing a highly crack-resistant self-leveling concrete mortar component according to claim 5, characterized in that: The stirring time in step S2 is set to 5-10 minutes, and the rotation speed is controlled at 600-1200 rpm.

8. The method for manufacturing a highly crack-resistant self-leveling concrete mortar component according to claim 5, characterized in that: The standing condition described in step S3 is that if the greenhouse temperature is 15°C-30°C, the standing time is 24 hours; if the temperature exceeds 30°C, the standing time is shortened to 16 hours; if the temperature is lower than 15°C, the standing time is extended to 36 hours, and the spraying humidity is maintained in the range of 45%-70%.

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