Ultra-high-performance self-leveling mortar material for misfire anti-static terrace as well as preparation method and application of ultra-high-performance self-leveling mortar material

Abstract

The invention provides an ultra-high-performance self-leveling mortar material for a misfire anti-static floor as well as a preparation method and application of the ultra-high-performance self-leveling mortar material. Portland cement, sulphoaluminate cement and gypsum are used as cementing materials, mineral powder, silica fume and other active cementing materials, filler, aggregate, conductive powder, polymer fibers and additives are matched to form a product, and the prepared material has low shrinkage; the self-leveling mortar has the advantages of no ignition, antistatic property and high compressive strength, and the strength of the self-leveling mortar is 2-3 times that of common self-leveling mortar; thin-layer construction can be achieved, the construction thickness is small, the structural load bearing is greatly reduced, the material consumption is reduced, and the manufacturing cost is comprehensively reduced.

Description

Technical Field

[0001] This application belongs to the technical field of floor paint preparation, and particularly relates to a super-high-performance self-leveling mortar material for non-sparking and anti-static floors, its preparation method and application. Background Art

[0002] In special fields such as heavy industrial sites like chemical factories, oil and gas extraction platforms, pharmaceutical production workshops, electronic manufacturing workshops, aerospace manufacturing workshops, ammunition depots, data centers, heavy electromechanical manufacturing workshops, and warehouses for inflammable and explosive items, there are high requirements for the use performance of building materials, such as non-sparking, anti-static, and high load-bearing capacity; currently, the compressive strength of existing self-leveling mortar materials is usually between 16 MPa and 50 MPa, and they do not have non-sparking and anti-static properties, so they cannot be applied.

[0003] Existing ultra-high-performance concretes are usually materials composed of a silicate cement as a binder, mineral powder, silica fume, fly ash, slag, etc. as active materials combined with fillers, aggregates, steel fibers, and additives; they have the characteristic of high compressive strength, usually with a compressive strength between 120 MPa and 200 MPa, and are commonly used in bridge engineering, building engineering, power engineering, and national defense engineering. However, their materials have the defect of large shrinkage and do not have non-sparking and anti-static properties, so they are not suitable for industrial floors with special requirements.

[0004] How to ensure the compressive strength of floor materials while achieving special performance requirements such as non-sparking and anti-static is a problem that needs to be solved. Summary of the Invention

[0005] The embodiments of this application provide a super-high-performance self-leveling mortar material for non-sparking and anti-static floors, its preparation method and application to solve the problems existing in the related technology. The technical solutions are as follows:

[0006] In the first aspect, the embodiments of this application provide a super-high-performance self-leveling mortar material for non-sparking and anti-static floors, including the following components by weight:

[0007] Component A: 20 - 30 parts of portland cement, 6.5 - 10 parts of sulfoaluminate cement, 1.5 - 3 parts of gypsum, 5 - 7.5 parts of mineral powder, 4 - 6 parts of silica fume, 40 - 60 parts of aggregate, 0.8 - 1.2 parts of conductive powder, 0.05 - 0.15 parts of polymer fiber, 0.1 - 0.3 parts of retarder, 1.5 - 6.5 parts of filler;

[0008] Component B: 9 - 12 parts of water reducer, 0.8 - 1.0 of defoamer, 0.2 - 0.3 parts of preservative, 90 - 100 parts of water;

[0009] The mass ratio of component A to component B is 1:0.1 - 0.11.

[0010] In one embodiment, the sulfoaluminate cement is a low-alkalinity sulfoaluminate cement with a strength grade of 42.5.

[0011] In one embodiment, the Portland cement is of the grade P·Ⅱ 52.5 or P·Ⅱ 52.5R.

[0012] In one embodiment, the gypsum is natural anhydrite powder with a mesh number of 200 - 400 meshes.

[0013] In one embodiment, the mineral powder is of the grade S105 or S140.

[0014] In one embodiment, the silica fume has a silica content of ≥85%; the 28-day activity index is ≥115.

[0015] In one embodiment, the retarder is one or a combination of two or more of tartaric acid, citric acid, or sodium gluconate powder.

[0016] In one embodiment, the filler is dolomite powder with a mesh number of 1000 - 1500 meshes.

[0017] In one embodiment, the aggregate is graded dolomite sand with a mesh number of 20 - 140 meshes and a Mohs hardness between 3.5 and 4.0.

[0018] In one embodiment, the polymer fiber is polypropylene hard fiber; the diameter range of the polypropylene hard fiber is 0.02 mm - 0.04 mm, and the length is one or a combination of two or more of 6 mm, 9 mm, or 12 mm.

[0019] In one embodiment, the conductive powder is conductive carbon black with a mesh number of 1000 - 1500 meshes.

[0020] In one embodiment, the defoamer is a polyether defoamer.

[0021] In one embodiment, the preservative is a Kathon preservative.

[0022] In one embodiment, the water reducer is a polycarboxylate liquid water reducer with a solid active ingredient of ≥40% and a water reduction rate of ≥30%.

[0023] Second, the embodiments of the present application provide a preparation method for a super high-performance self-leveling mortar material for a non-sparking and anti-static floor, including the following steps:

[0024] Weigh the component A materials according to the formula ratio and mix them thoroughly.

[0025] Weigh the component B material according to the formula ratio and disperse it evenly.

[0026] According to the ratio of component A and component B, weigh the liquid component B and mix it evenly; stir slowly, and slowly add the weighed powder component A while stirring; after the material is wetted, start high-speed stirring; obtain the ultra-high-performance self-leveling mortar material for non-sparking and anti-static floor.

[0027] In one embodiment, the mass ratio of component A to component B is 1:0.1 - 0.11.

[0028] In one embodiment, the speed of slow stirring is 5 - 10 rpm.

[0029] In one embodiment, the speed of high-speed stirring is 25 - 30 rpm; the stirring time is 3 - 5 min.

[0030] In a third aspect, the embodiment of the present application provides an application of the ultra-high-performance self-leveling mortar material for non-sparking and anti-static floor, and coat the ultra-high-performance self-leveling mortar material for non-sparking and anti-static floor with a thickness of 10 - 30 mm.

[0031] The advantages or beneficial effects in the above technical solutions at least include:

[0032] The ultra-high-performance self-leveling mortar material for non-sparking and anti-static floor of the present application is a product composed of portland cement, sulfoaluminate cement, and gypsum as gelling materials, and is further combined with other active gelling materials such as mineral powder and silica fume, as well as fillers, aggregates, conductive powder, polymer fibers, and additives. The prepared material itself has low shrinkage; it not only has non-sparking and anti-static properties, but also has high compressive strength, which is 2 - 3 times the strength of ordinary self-leveling mortar; it can achieve thin-layer construction, with a small construction thickness, greatly reducing the structural load, reducing the material consumption, and comprehensively reducing the cost.

[0033] The above summary is only for the purpose of the specification and is not intended to be limiting in any way. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features of the present application will be readily apparent by reference to the following detailed description. Detailed Embodiments

[0034] In the following, only some exemplary embodiments are simply described. As those skilled in the art can recognize, the described embodiments can be modified in various different ways without departing from the spirit or scope of the present application. Therefore, the description is considered to be exemplary in nature rather than restrictive.

[0035] When concrete materials collide or rub against metal materials, although they do not cause ignition, they often cause sparks. If they encounter flammable components in the environment, they can still cause a fire. Especially in some special environments, higher requirements are placed on the non-sparking performance or static electricity effect of concrete. Currently, the strength of non-sparking anti-static mortar is low, and the compressive strength of building floor decoration is generally up to 60 MPa at most, which limits its application in scenarios with high-strength requirements.

[0036] Therefore, the present application provides a super high-performance self-leveling mortar material for non-sparking anti-static floor, its preparation method and application.

[0037] A super high-performance self-leveling mortar material for non-sparking anti-static floor, comprising the following components by weight:

[0038] Component A: 20 - 30 parts of portland cement, 6.5 - 10 parts of sulfoaluminate cement, 1.5 - 3 parts of gypsum, 5 - 7.5 parts of mineral powder, 4 - 6 parts of silica fume, 40 - 60 parts of aggregate, 0.8 - 1.2 parts of conductive powder, 0.05 - 0.15 parts of polymer fiber, 0.1 - 0.3 parts of retarder, 1.5 - 6.5 parts of filler;

[0039] Component B: 9 - 12 parts of water reducing agent, 0.8 - 1.0 of defoamer, 0.2 - 0.3 parts of preservative, 90 - 100 parts of water;

[0040] The mass ratio of Component A to Component B is 1:0.1 - 0.11.

[0041] A product composed of portland cement, sulfoaluminate cement, and gypsum as gelling materials, and further combined with other active gelling materials such as mineral powder and silica fume, as well as fillers, aggregates, conductive powder, polymer fiber, and additives. Using a multi-component composite system as the gelling material solves the problem of large shrinkage rate of the original single-component system. Further improves the volume stability of the product. Greatly improves its compressive strength, which is 2 - 3 times that of ordinary self-leveling mortar; at the same time, it also has low shrinkage and high compressive characteristics, meeting the application requirements of special fields.

[0042] In one embodiment, the sulfoaluminate cement is a low-alkalinity sulfoaluminate cement with a strength grade of 42.5.

[0043] In one embodiment, the portland cement is of grade P·Ⅱ52.5 or P·Ⅱ52.5R. Sulfoaluminate cement and portland cement are the basic components. The combination of sulfoaluminate cement and portland cement provides sufficient adhesiveness; while having relatively high strength, it also has an extremely low shrinkage rate.

[0044] In one embodiment, the gypsum is natural anhydrite powder, and the mesh number of the natural anhydrite powder is 200 - 400 mesh.

[0045] In one embodiment, the mineral powder is S105 or S140 grade mineral powder.

[0046] In one embodiment, the silicon dioxide content in the silica fume is ≥85%; the 28-day activity index is ≥115.

[0047] In one embodiment, the retarder is one or more compositions of tartaric acid, citric acid or sodium gluconate powder.

[0048] In one embodiment, the filler is dolomite powder, and the mesh number of the dolomite powder is 1000 mesh - 1500 mesh.

[0049] In one embodiment, the aggregate is graded dolomite sand, the mesh number of the graded dolomite sand is 20 mesh - 140 mesh, and the Mohs hardness is between 3.5 and 4.0. The addition of dolomite powder and dolomite sand can prevent the material from igniting during the friction with metal. The combined use of powder and sand and gravel can better form different particle sizes, and three-dimensionally weaken the ignition property inside and on the surface of the material.

[0050] In one embodiment, the polymer fiber is polypropylene hard fiber; the diameter range of the polypropylene hard fiber is 0.02mm - 0.04mm, and the lengths are one or more compositions of 6mm, 9mm or 12mm. The polymer fiber makes the material have a certain toughness.

[0051] In one embodiment, the conductive powder is conductive carbon black, and the mesh number of the conductive carbon black is 1000 mesh - 1500 mesh. The conductive powder increases the conductivity of the material, and the charges in the environment can be more efficiently introduced into the ground, making the material have antistatic property.

[0052] In one embodiment, the defoamer is polyether defoamer. In this application, by adding a liquid defoamer, the porosity of the material is reduced, and the density and strength of the product are improved.

[0053] In one embodiment, the preservative is Kathon preservative.

[0054] In one embodiment, the water reducer is polycarboxylate liquid water reducer, the solid active ingredient ≥40%, and the water reduction rate ≥30%. In this application, by adding a high-performance polycarboxylate liquid water reducer, the water demand for mixing the material is greatly reduced, and the fluidity and hydration strength are improved.

[0055] All the components of the ultra-high performance self-leveling mortar material for the non-combustible and antistatic floor in this application are combined to generally improve the strength of the electro-mortar and make it have high compressive strength.

[0056] The embodiment of the present application provides a preparation method of a super high-performance self-leveling mortar material for a non-sparking and anti-static floor, including the following steps:

[0057] Weigh the A-component materials according to the formula ratio and mix them evenly;

[0058] Weigh the B-component materials according to the formula ratio and disperse them evenly;

[0059] According to the ratio of the A and B components, weigh and mix the liquid B component evenly; stir slowly and slowly add the weighed powder A component; after the material is wetted, start high-speed stirring; to obtain the super high-performance self-leveling mortar material for the non-sparking and anti-static floor.

[0060] In one embodiment, the mass ratio of component A to component B is 1:0.1 - 0.11.

[0061] In one embodiment, the speed of slow stirring is 5 - 10 rpm.

[0062] In one embodiment, the time of high-speed stirring is 25 - 30 rpm; the stirring time is 3 - 5 min.

[0063] In the present application, the components are divided into component A and component B. By mixing the liquid components and slowly adding the powder component to the liquid, uniform configuration can be achieved.

[0064] The embodiment of the present application provides an application of the super high-performance self-leveling mortar material for a non-sparking and anti-static floor, and coats the super high-performance self-leveling mortar material for a non-sparking and anti-static floor with a thickness of 10 - 30 mm.

[0065] The designed construction thickness of the original material usually requires 50 mm - 80 mm. In the case of a low shrinkage rate of the material of the present application, by adjusting or controlling the particle size of the coarse aggregate, the product construction thickness is 10 mm - 30 mm; the material consumption is saved, the structural load is greatly reduced, the cost is comprehensively reduced, and the actual application requirements can be met.

[0066] The following is further illustrated with specific examples.

[0067] Example

[0068] The sulfoaluminate cement is a low-alkalinity sulfoaluminate cement with a strength grade of 42.5; the Portland cement is of the P·Ⅱ 52.5R grade; the gypsum is natural anhydrous gypsum powder with a mesh size of 200 - 400; the mineral powder is of the S140 grade; the silica fume has a silica content of ≥85%; the 28-day activity index is ≥115; the filler is dolomite powder with a mesh size of 1000 - 1500; the aggregate is graded dolomite sand with a mesh size of 20 - 140 and a Mohs hardness between 3.5 - 4.0; the polymer fiber is polypropylene hard fiber with a diameter range of 0.02 mm - 0.04 mm and is a composition of lengths of 6 mm, 9 mm, and 12 mm in a mass ratio of 1:1:1; the conductive powder is conductive carbon black with a mesh size of 1000 - 1500;

[0069] The retarder is a composition of tartaric acid, citric acid, and sodium gluconate in a mass ratio of 1:1:1;

[0070] The defoamer is polyether defoamer 193; the preservative is Kathon preservative 130S; the water reducer is polycarboxylate water reducer SPT-160UX.

[0071] The compositions of Examples 1 - 5 are shown in Table 1:

[0072] Table 1

[0073]

[0074]

[0075] The preparation method is as follows:

[0076] Weigh 2 kg of the component A materials according to the formula ratio and mix them evenly; weigh 1 kg of the component B materials according to the formula ratio and disperse them evenly; according to the mixing ratio of components A and B, weigh an appropriate amount of the liquid component B and pour it into the cement mortar mixer, start slow stirring at 5 - 10 rpm, and slowly add the weighed powder component A while stirring; after the materials are all wetted, start high-speed stirring at 25 - 30 rpm for 3 - 5 minutes to obtain a super high-performance self-leveling mortar material for non-sparking and anti-static floor.

[0077] Measure the fluidity according to the standard test method and prepare test specimens for measuring other indicators. The results of Examples 1 - 5 are shown in Table 3.

[0078] Comparative Example 1

[0079] 550 parts of Portland cement, 250 parts of mineral powder, 100 parts of silica fume, 100 parts of heavy calcium, and 1000 parts of quartz sand. 24 parts of water reducer and 190 parts of clean water. The preparation method is the same as that of the examples.

[0080] Comparative Example 2

[0081] 600 parts of portland cement, 150 parts of mineral powder, 150 parts of silica fume, 100 parts of heavy calcium carbonate, 1000 parts of quartz sand, 24 parts of water reducing agent, 190 parts of clean water, and the preparation method is the same as that of the example.

[0082] Comparative Example 3

[0083] The difference between Comparative Example 3 and Example 1 is that dolomite powder and graded dolomite sand are not added, and the other components and preparation methods are the same as those of Example 1.

[0084] Comparative Example 4

[0085] The difference between Comparative Example 4 and Example 1 is that conductive powder is not added, and the other components and preparation methods are the same as those of Example 1.

[0086] Comparative Example 5

[0087] The difference between Comparative Example 5 and Example 1 is that portland cement is used to replace the sulfoaluminate cement, and the other components and preparation methods are the same as those of Example 1.

[0088] Comparative Example 6

[0089] 40 parts of high belite sulfoaluminate cement, 45 parts of 20 - 140 mesh quartz sand, made up with 325 mesh heavy calcium powder, 0.15 parts of water reducing agent, 0.1 part of defoaming agent, 0.1 part of cellulose ether, 0.15 parts of retarder, 0.05 parts of lithium sulfate, and mixed evenly according to powder∶water = 1∶0.18 (mass ratio) to obtain ordinary self-leveling mortar, and the average value of its compressive strength is 52.4 MPa.

[0090] The fluidity is measured according to the standard test method and specimens are prepared for forming to measure other indexes. The fluidity test method: use a truncated cone mold that meets the requirements of 4.2 in GB / T 1345 - 2011, and the glass plate is a square glass plate with a diameter of 300 mm and no scratches on the surface. Wipe the mold and the glass plate clean with a wet cloth and dry them. Then place the mold with the large end down and flat on the horizontally placed glass plate, pour the mixed paste into the mold and level it with the top of the mold. Immediately lift the mold 50 mm upward and hold it for 10 - 15 seconds to make the specimen flow freely onto the glass plate. After 5 minutes, measure the diameters in two perpendicular directions with a ruler, and take the average value of the two diameters as the result, accurate to 1 mm. The non - ignition property and antistatic property are tested according to Appendix B and Appendix C of JC / T 2653 - 2022 standard respectively. The dimensional change rate and tensile bond strength are tested according to the methods of 7.4 and 7.5 in JC / T 985 - 2017 standard respectively. The compressive strength is tested according to the cube compressive strength test method in item 9 of JGJ / T 70 - 2009 standard. The results of Comparative Examples 1 - 5 are shown in Table 2.

[0091] Table 2

[0092]

[0093]

[0094] It can be known from the experimental results that: from Comparative Examples 1-2 and Comparative Example 5, it can be seen that when only Portland cement is used, the shrinkage rate of the material is poor, while when sulfoaluminate cement and gypsum are compounded with Portland cement, the obtained product has high strength and extremely low shrinkage rate at the same time. From Comparative Examples 1-2 and Comparative Example 3, it can be seen that by adding aggregate dolomite and filler dolomite powder, which are special materials with low Mohs hardness, it is possible to prevent the material from igniting during the process of rubbing against metal. In Comparative Example 4, without adding conductive powder, the antistatic property of the material is poor. And Comparative Examples 1-2 also show that through polymer fibers, the material has certain toughness. By adding defoaming agents, the material has higher density and reduces the porosity inside the material. Comparative Example 6 is an ordinary self-leveling mortar of the prior art, and the average value of its compressive strength is 52.4 MPa, while the compressive strength of the mortar of the present application reaches 2-3 times of it.

[0095] In the description of this specification, the descriptions with reference to terms such as "one embodiment", "some embodiments", "example", "specific example", or "some examples" etc. mean that the specific features, structures, materials or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present application. Moreover, the specific features, structures, materials or characteristics described can be combined in a suitable manner in any one or more embodiments or examples. In addition, without contradiction, those skilled in the art can combine and combine the different embodiments or examples described in this specification and the features of different embodiments or examples.

[0096] In addition, the terms "first" and "second" are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, the features defined with "first" and "second" can explicitly or implicitly include at least one of the features. In the description of the present application, "a plurality of" means two or more, unless otherwise specifically defined.

[0097] As mentioned above, the above is only the specific implementation manner of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art within the technical scope disclosed in the present application can easily think of various changes or substitutions, and these should all be covered within the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims.

Claims

1. An ultra-high performance self-leveling mortar material for non-flammable anti-static floor, characterized in that: The composition comprises the following components in parts by weight: Component A: 20-30 parts of Portland cement, 6.5-10 parts of sulphoaluminate cement, 1.5-3 parts of gypsum, 5-7.5 parts of mineral powder, 4-6 parts of silica powder, 40-60 parts of aggregate, 0.8-1.2 parts of conductive powder, 0.05-0.15 parts of polymer fiber, 0.1-0.3 parts of retarder, and 1.5-6.5 parts of filler; Component B: 9-12 parts of water reducing agent, 0.8-1.0 parts of defoaming agent, 0.2-0.3 parts of preservative, 90-100 parts of water; The mass ratio of component A to component B is 1:0.1-0.

11.

2. The ultra-high performance self-leveling mortar material for non-inflammable anti-static flooring according to claim 1 is characterized in that: Sulphoaluminate cement is low-alkalinity sulphoaluminate cement with a strength grade of 42.5; The silicate cement is of grade P·Ⅱ52.5 or P·Ⅱ52.5R.

3. The ultra-high performance self-leveling mortar material for non-flammable anti-static flooring according to claim 1 is characterized in that: The gypsum is natural anhydrous gypsum powder, and the mesh number of the natural anhydrous gypsum powder is 200-400 mesh; The mineral powder is S105 or S140 grade mineral powder; The silicon dioxide content in the silicon micropowder is ≥85%; the 28-day activity index is ≥115; The retarder is one or a combination of two or more of tartaric acid, citric acid or sodium gluconate powder.

4. The ultra-high performance self-leveling mortar material for non-flammable anti-static flooring according to claim 1 is characterized in that: The filler is dolomite powder, and the mesh number of the dolomite powder is 1000-1500 mesh; The aggregate is graded dolomite sand, the mesh number of the graded dolomite sand is 20-140 mesh, and the Mohs hardness is between 3.5-4.0; The polymer fiber is a polypropylene hard fiber; the polypropylene hard fiber has a diameter ranging from 0.02 mm to 0.04 mm and a length of 6 mm, 9 mm or 12 mm, respectively, or a combination of two or more thereof.

5. The ultra-high performance self-leveling mortar material for non-flammable anti-static flooring according to claim 1 is characterized in that: The conductive powder is conductive carbon black, and the mesh size of the conductive carbon black is 1000-1500 mesh.

6. The ultra-high performance self-leveling mortar material for non-flammable anti-static flooring according to claim 1 is characterized in that: The defoaming agent is a polyether defoaming agent; The preservative is Kathon preservative.

7. The ultra-high performance self-leveling mortar material for non-flammable anti-static flooring according to claim 1 is characterized in that: The water reducing agent is a polycarboxylic acid liquid water reducing agent, with a solid effective content of ≥40% and a water reducing rate of ≥30%.

8. A method for preparing an ultra-high performance self-leveling mortar material for a non-flammable anti-static floor, characterized in that: The following steps are involved: Weigh the A component materials according to the formula ratio and mix them thoroughly; Weigh the B component materials according to the formula ratio and disperse them evenly; According to the ratio of A and B components, weigh the liquid B component and mix it evenly; slowly stir and slowly add the weighed amount of powder A component; after the material is moistened, start high-speed stirring; and obtain the ultra-high performance self-leveling mortar material for the non-flammable antistatic floor.

9. The method for preparing the ultra-high performance self-leveling mortar material for the non-inflammable antistatic floor according to claim 8, characterized in that: The mass ratio of component A to component B is 1:0.1-0.11; The stirring speed is 5-10 rpm; The high-speed stirring time is 25-30rpm; the stirring time is 3-5min.

10. Application of an ultra-high performance self-leveling mortar material for non-flammable anti-static floor, characterized in that: The non-flammable antistatic floor is coated with 10-30 mm of ultra-high performance self-leveling mortar material.

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