Micro-expansion hydrophobic foam concrete floor system based on ordinary Portland cement

Abstract

The invention relates to the field of building acoustic functional materials, and discloses a micro-expansion hydrophobic foam concrete floor system based on ordinary Portland cement. The system comprises a structural layer, an FC interface agent layer, a micro-expansion hydrophobic foam concrete layer, an FC interface agent layer and a decoration layer from bottom to top. Ordinary Portland cement and slag powder are used as curing components, large-dosage gypsum is used as an expansion component, silica fume, a tackifier, a water repellent, a water reducing agent and other modified components are added, micro-expansion hydrophobic foam concrete is prepared in a physical foaming mode, and firm bonding between the foam concrete and a structural layer and between the foam concrete and a decoration layer is achieved through an FC interface agent. The closed tiny foam holes in the foam can effectively absorb and reflect sound waves and block noise transmission; and the low elastic modulus is beneficial to efficiently absorbing and dispersing impact energy and reducing the structural vibration response, so that good sound insulation and vibration reduction functions are achieved. The floor system has the characteristics of micro-expansion, no cracking and low water absorption rate, raw materials are inorganic materials, and the floor system is environment-friendly and durable and has remarkable popularization significance.

Description

Technical Field

[0001] The present invention relates to the field of building floor engineering, in particular to a floor system based on ordinary silicate micro-expansion hydrophobic foam concrete with sound insulation and vibration reduction functions, which is suitable for new construction or renovation of buildings that are sensitive to sound environment and vibration. Background Art

[0002] When decorating the floors of domestic buildings, the common practice is to lay dry-mixed mortar as a cushion layer on the concrete structure layer, and then lay floor tiles or stone slabs on it; or to use wet-mixed cement mortar as a cushion layer, and then lay wooden floors on it. Regardless of whether dry-mixed or wet-mixed mortar is used, the elastic modulus of the cement mortar layer after hardening is in the range of 10 to 20 GPa, and it has a strong ability to transmit vibrations. Therefore, when there is airborne sound or solid impact vibration on the floor, the generated structural noise will be transmitted to the adjacent space to form scattering, causing noise. Floor noise greatly reduces the comfort of living in a house. In addition to causing insomnia and psychological discomfort, long-term exposure to floor impact sounds (such as footsteps, furniture dragging sounds, etc.) may also lead to psychological problems such as anxiety, depression, and insomnia; the impact of noise also often causes conflicts between neighbors, disputes are frequent, and cause social problems.

[0003] There are several common methods for floor sound insulation and vibration reduction, and their advantages and disadvantages are analyzed as follows:

[0004] 1. Resilient surface: Laying resilient materials such as carpet and cork flooring can reduce noise by 15-30dB. Its advantages are simple construction and low cost; its disadvantages are that it is ineffective against floor resonance and has a moderate sound insulation effect.

[0005] 2. Flexible underlayment: A flexible underlayment such as polyurethane or polyethylene is laid on the structural slab, and then a layer of fine stone concrete is poured on top. This method offers advantages in reducing noise by 30-45dB, providing excellent sound insulation, and blocking solid-borne sound. However, its disadvantages are the poor durability of organic materials, and the tendency for flexible materials to deform over time, resulting in hollowing and deformation of the floor or tiles. Concrete seeping into the gaps in the elastic underlayment can reduce sound insulation by up to 30%. Furthermore, the cost is relatively high.

[0006] 3. Gypsum underlayment: This method works similarly to flexible underlayment, utilizing the low strength and low modulus of gypsum to reduce noise. Its advantage is that gypsum is an inorganic material, making it environmentally friendly and pollution-free. Its disadvantage is that gypsum-based underlayment is weak, requiring a layer of fine stone concrete to be poured on top for leveling or reinforcement before applying the finishing layer, resulting in high costs and complex production processes.

[0007] 4. Sound insulation coatings: By spraying polymer damping materials (such as polyurethane), sound insulation can reach 20-35dB. Its advantages are thin thickness (commonly used thickness range is 3-8mm), small space occupation, and fast application. Its disadvantages are that coating application depends on the flatness of the base surface, the effect of a single layer is limited, and organic materials have poor durability and are prone to flaking and pollution after aging.

[0008] Foam concrete is a lightweight concrete with a certain strength and a wet density ranging from 400 to 800 kg / m 3 The compressive strength can be adjusted within a range of 0.8 to 5.0 MPa by adjusting the raw materials and mix ratio. The elastic modulus ranges from 0.2 to 0.5 GPa, which is only 1 / 20 to 1 / 100 of that of cement mortar. Due to its low elastic modulus, foam concrete can serve as a flexible energy-absorbing layer, effectively absorbing airborne sound and buffering impact vibrations in the floor. The material also has self-leveling properties, simple construction process, and low cost, making it an ideal flexible cushioning material.

[0009] However, conventional foam concrete suffers from significant shrinkage. Furthermore, foam concrete is a porous material with a high water absorption capacity, which can lead to a decrease in strength and unstable volume. This can also lead to cracking after pouring, which in turn can cause cracks in the floor or tiles, disrupting the continuity of the sound insulation layer. Furthermore, foam concrete exhibits poor adhesion to structural layers and tile adhesives, necessitating the development of specialized interface agents to address this bonding issue. Summary of the Invention

[0010] In response to the deficiencies of the above-mentioned prior art, the present invention proposes a micro-expansion hydrophobic foam concrete sound insulation and vibration reduction floor system. This system modifies the foam concrete to have the properties of micro-expansion, hydrophobicity, and higher strength (relative to ordinary foam concrete), and achieves a firm bond between the foam concrete and the structural layer and the decoration layer by applying an FC interface agent. The modified foam concrete acts as a flexible sound insulation and vibration isolation buffer layer, achieving the effect of sound insulation and vibration reduction. All materials used are inorganic, environmentally friendly, durable and odorless; self-leveling construction increases speed and reduces cost.

[0011] To achieve the above object, the technical solution of the present invention is:

[0012] A micro-expanding hydrophobic foam concrete floor system based on ordinary Portland cement is characterized by comprising, from bottom to top, a structural layer, an FC interface agent layer, a micro-expanding hydrophobic foam concrete sound insulation and vibration reduction layer, an FC interface agent layer, and a ceramic tile or floor finishing layer.

[0013] The structural layer is the surface layer of a reinforced concrete floor slab or a surface layer of a steel structure floor slab.

[0014] The micro-expansion hydrophobic foam concrete is composed of the following raw materials in terms of mass ratio:

[0015] 420-560 parts of ordinary Portland cement;

[0016] 180-240 parts of slag powder (grade S95 and above);

[0017] 80-120 parts of gypsum (α-type hemihydrate gypsum / anhydrous phosphogypsum);

[0018] 50-80 parts of silica fume;

[0019] 5-15 parts of water repellent;

[0020] 2 to 3.5 parts of foaming agent;

[0021] 1 to 3 parts of water reducing agent;

[0022] 182-350 parts of water.

[0023] The ordinary Portland cement used in the micro-expansion hydrophobic foam concrete is PO 42.5, PO 42.5R, PO 52.5 or PO 52.5R cement.

[0024] The gypsum is α-type hemihydrate gypsum or anhydrous phosphogypsum, and the slag powder is S95 grade or above.

[0025] The hydrophobic agent is a compound of organic silicon powder and calcium stearate in a mass ratio of 1:3 to 1:6; the foaming agent is a plant protein-based or high molecular synthetic surfactant type, with a foam density of 25 to 35 kg / m 3 .

[0026] The gypsum reacts with C3A in cement to generate ettringite, and the foamed concrete is made to have micro-expansion by controlling the amount of gypsum added.

[0027] The FC interface agent is a water-based epoxy interface agent, which is made of water-based epoxy resin with good environmental protection, no odor and no harmful substances, and is composed of the following components in parts by mass:

[0028] 300-500 parts of water-based epoxy emulsion (non-ionic, epoxy equivalent weight 180-220 g / eq);

[0029] 150-250 parts of modified amine curing agent (cashew nut shell liquid modified polyamide, amine value 200-250 mgKOH / g);

[0030] Functional filler (quartz sand and silica fume mass ratio 2:1 to 4:1) 200 to 400 parts;

[0031] Silane coupling agent (γ-aminopropyltriethoxysilane KH-550) 5-30 parts;

[0032] 1 to 5 parts of rheological additives.

[0033] The quartz sand used in the FC interface agent has a particle size of 1.5 to 2.0 mm; the rough quartz sand provides mechanical interlocking force, thereby increasing the bonding force of the interface; the silica fume particle size used is 0.1 to 1.0 μm; the coating amount of the interface agent is 0.3 to 0.5 kg / m 2 .

[0034] The performance of the micro-expansion hydrophobic foam concrete sound insulation and vibration reduction floor system meets the following requirements:

[0035] Wet density: 500~700kg / m 3 ;

[0036] 28d compressive strength: 2.0~4.0MPa;

[0037] Elastic modulus: 0.2~0.4GPa.

[0038] Linear expansion rate: 0.01~0.30%;

[0039] Volume water absorption: ≤4%;

[0040] Interface agent bonding strength: ≥1.5MPa;

[0041] Weighted sound insulation: ≥55dB;

[0042] Weighted normalized impact sound pressure level: ≤70dB.

[0043] The construction method of the micro-expansion hydrophobic foam concrete sound insulation and vibration reduction floor system is characterized by comprising the following steps:

[0044] Step 1: Clean the base slurry of the structural layer, moisten it with water for 3 hours, and then apply FC interface agent;

[0045] Step 2: Pour self-leveling foam concrete slurry with a thickness of 30-80mm, use spray curing and cover with film curing for 72 hours;

[0046] Step 3: Apply FC interface agent after 7 days of curing;

[0047] Step 4: Step 4: Laying the decoration layer: Wooden floors and carpets need to be covered with PE moisture-proof film, and tiles / stones need to be laid with special adhesives.

[0048] Through the above technical solution, the beneficial effects of the present invention are:

[0049] 1. Micro-expansion control: Calcium sulfide in ordinary Portland cement reacts with gypsum to form ettringite, giving foamed concrete micro-expansion properties (linear expansion rate: 0.01-0.10%). This completely eliminates cracking caused by shrinkage in the foamed concrete, preventing cracking in the finishing layer and the resulting reduction in sound insulation and vibration reduction. Using ordinary Portland cement also directly reduces costs.

[0050] 2. Hydrophobic Modification: The hydrophobic agent is a combination of organosilicon powder (which forms a hydrophobic film through chemical adsorption) and calcium stearate (which relies on physical pore closure and pore wall modification). This optimizes the pore structure while also achieving surface hydrophobicity. The resulting foamed concrete has a volumetric water absorption rate of ≤4%, making it extremely unlikely to leak even after a short period of waterlogging. (Optimizing the structure and clarifying the modes of action of the two hydrophobic agents)

[0051] 3. Lightweight and high strength: When the wet density of foam concrete is 635kg / m 3 When the foam concrete surface is coated with the interface agent, the compressive strength can reach 2.9MPa, which significantly reduces the floor load (about 30%). After the foam concrete surface is coated with the interface agent, there is no need to pour mortar or fine stone concrete leveling layer, and the decoration layer can be laid directly.

[0052] 4. Sound insulation and vibration reduction: Micro-expanding hydrophobic foam concrete is a relatively flexible material placed between the decoration layer and the structural layer. Its elastic modulus (0.2-0.4GPa) is only 1 / 20-1 / 100 of the elastic modulus of concrete, ceramic tiles or wooden floors. Therefore, it can be used as a flexible energy-absorbing layer to effectively absorb the air sound of the floor and buffer the impact vibration energy from the floor.

[0053] 5. Inorganic and environmentally friendly: All materials used are inorganic, environmentally friendly and durable, no pollution and no odor, and are environmentally friendly. BRIEF DESCRIPTION OF THE DRAWINGS

[0054] Figure 1 This is a structural diagram of the sound insulation and vibration reduction floor system of the present invention;

[0055] Figure identification: 1. structural layer 2. FC interface agent layer 3. micro-expanding hydrophobic foam concrete sound insulation and vibration reduction layer 4. FC interface agent layer 5. decoration layer. DETAILED DESCRIPTION

[0056] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0057] In order to better understand the present invention and not to limit the scope of the present invention, all numbers used in this application to express dosage, mass ratio, and other numerical values should be understood as modified by the word "about" in all cases. Therefore, unless otherwise specified, the numerical parameters listed in the specification and the appended claims are approximate values, which may be changed according to the different ideal properties to be obtained. Each numerical parameter should at least be regarded as obtained based on the reported significant figures and by conventional rounding methods.

[0058] It should be noted that the order of description of the following embodiments is not intended to limit the preferred order of the embodiments. In addition, in the description of this application, the term "including" means "including but not limited to". Various embodiments of the present invention may be presented in the form of a range; it should be understood that the description in the form of a range is merely for convenience and brevity and should not be understood as a rigid limitation on the scope of the invention; therefore, it should be considered that the range description has specifically disclosed all possible sub-ranges and single numerical values within the range. For example, the range description from 1 to 6 should be considered to have specifically disclosed sub-ranges, such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6, etc., as well as single numbers within the range, such as 1, 2, 3, 4, 5 and 6, regardless of the range. In addition, whenever a numerical range is indicated herein, it is meant to include any cited number (fractional or integer) within the indicated range.

[0059] Although this specification has shown and described a number of embodiments of the present invention, it will be apparent to those skilled in the art that such embodiments are provided by way of example only. Those skilled in the art will conceive of many modifications, changes, and alternatives without departing from the concept and spirit of the present invention. It should be understood that in practicing the present invention, various alternatives to the embodiments of the present invention described herein may be adopted. The appended claims are intended to define the scope of protection of the present invention and therefore cover modular compositions, equivalents, or alternatives within the scope of these claims.

[0060] Example 1: A residential floor

[0061] Structural layer: 120mm thick reinforced concrete slab, remove cement slurry and moisten with clean water for 3h.

[0062] First layer of FC primer: 2.2mm thick, with the following components by weight: 440 parts epoxy resin emulsion, 183 parts modified amine curing agent, 300 parts functional filler, 18 parts silane coupling agent, and 3 parts rheological additive. The coating weight is 0.3kg / m².

[0063] The functional filler contains 175 parts of quartz sand with a particle size of 1.5 to 2.0 mm; 68 parts of silica fume with a particle size of 0.1 to 1.0 μm; and the coating amount of the interface agent is 0.3 to 0.5 kg / m 2 .

[0064] Micro-expanding hydrophobic foam concrete: pouring thickness 55mm, foam concrete by mass ratio: 450 parts of PO 42.5 cement, 191 parts of S95 grade slag powder; 105 parts of anhydrous phosphogypsum, 65 parts of silica fume, 8.6 parts of water repellent, 2.2 parts of foaming agent, 2 parts of water reducer, and 220 parts of water.

[0065] Second layer of FC primer: 2.2mm thick, containing: 440 parts epoxy resin emulsion, 183 parts modified amine curing agent, 300 parts functional filler, 18 parts silane coupling agent, and 3 parts rheological additive. Applied at 0.3kg / m².

[0066] The functional filler contains 175 parts of quartz sand with a particle size of 1.5 to 2.0 mm; 68 parts of silica fume with a particle size of 0.1 to 1.0 μm; and the coating amount of the interface agent is 0.3 to 0.5 kg / m 2 .

[0067] The water repellent is compounded with 1.5 parts of silicone powder and 7.1 parts of calcium stearate.

[0068] The wet density of the foamed concrete is 597 kg / m 3 , compressive strength 2.3MPa, elastic modulus 0.26GPa.

[0069] Decoration layer: composite wood flooring, with 3mm thick PE moisture-proof film underneath.

[0070] Performance: linear expansion rate 0.22%, water absorption rate 3.5%, interface agent bonding strength 1.8MPa, weighted sound insulation 58dB, weighted normalized impact sound pressure level: 55dB.

[0071] Example 2: A hotel floor

[0072] Structural layer: 100mm thick reinforced concrete slab, remove cement slurry and moisten with clean water for 3h.

[0073] The first layer of FC interface agent: the thickness of the interface agent is 2.0mm, the mass ratio of the interface agent components is: 440 parts of epoxy resin emulsion, 183 parts of modified amine curing agent, 300 parts of functional filler, 18 parts of silane coupling agent, and 3 parts of rheological additive. The coating amount of the interface agent is 0.3kg / m 2 .

[0074] The functional filler contains 175 parts of quartz sand with a particle size of 1.5 to 2.0 mm; 68 parts of silica fume with a particle size of 0.1 to 1.0 μm; and the coating amount of the interface agent is 0.3 to 0.5 kg / m 2 .

[0075] Micro-expanding hydrophobic foam concrete: pouring thickness 62mm, foam concrete by mass ratio: 510 parts of PO 42.5 cement, 205 parts of S95 grade slag powder; 95 parts of α-type hemihydrate gypsum, 72 parts of silica fume, 9.2 parts of water repellent, 2.5 parts of foaming agent, 2.4 parts of water reducer, 260 parts of water.

[0076] Second layer of FC primer: 2.2mm thick, containing: 440 parts epoxy resin emulsion, 183 parts modified amine curing agent, 300 parts functional filler, 18 parts silane coupling agent, and 3 parts rheological additive. Applied at 0.3kg / m².

[0077] The hydrophobic agent organic silicon powder 1.5 parts and calcium stearate 7.1 parts are compounded.

[0078] The foamed concrete has a wet density of 635 kg / m3, a compressive strength of 2.9 MPa, and an elastic modulus of 0.31 GPa.

[0079] Decoration layer: 12mm thick carpet, with 3mm thick PE moisture-proof film underneath.

[0080] Performance: linear expansion rate 0.15%, water absorption rate 2.9%, interface agent bonding strength 1.8MPa, weighted sound insulation 65dB, weighted normalized impact sound pressure level 51dB.

[0081] Example 3: Renovation of a hospital floor

[0082] Structural layer: 120mm thick reinforced concrete slab, remove cement slurry and moisten with clean water for 3h.

[0083] The first layer of FC interface agent: the thickness of the interface agent is 2.0mm, the mass ratio of the interface agent components is: 440 parts of epoxy resin emulsion, 183 parts of modified amine curing agent, 300 parts of functional filler, 18 parts of silane coupling agent, and 3 parts of rheological additive. The coating amount of the interface agent is 0.3kg / m 2 .

[0084] The functional filler contains 175 parts of quartz sand with a particle size of 1.5 to 2.0 mm; 68 parts of silica fume with a particle size of 0.1 to 1.0 μm; and the coating amount of the interface agent is 0.4 to 0.45 kg / m 2 .

[0085] Micro-expanding hydrophobic foam concrete: pouring thickness 55mm, foam concrete by mass ratio: 530 parts of PO 42.5 cement, 195 parts of S95 grade slag powder; 102 parts of α-type hemihydrate gypsum, 66 parts of silica fume, 8.5 parts of water repellent, 2.2 parts of foaming agent, 2.8 parts of water reducer, and 257 parts of water.

[0086] The second layer of FC interface agent: the thickness of the interface agent is 2.5mm, the mass ratio of the interface agent components is: 440 parts of epoxy resin emulsion, 183 parts of modified amine curing agent, 300 parts of functional filler, 18 parts of silane coupling agent, and 3 parts of rheological additive. The coating amount of the interface agent is 0.36kg / m 2 .

[0087] The hydrophobic agent organic silicon powder 1.5 parts and calcium stearate 7.1 parts are compounded.

[0088] The wet density of the foamed concrete is 652 kg / m 3 , compressive strength 3.3MPa, elastic modulus 0.34GPa.

[0089] Decoration layer: 10mm special tile adhesive is used to bond 6mm thick floor tiles, and 3mm thick PE moisture-proof film is laid underneath.

[0090] Performance: linear expansion rate 0.16%, water absorption rate 2.1%, interface agent bonding strength 1.8MPa, weighted sound insulation 65dB, weighted normalized impact sound pressure level 51dB.

Claims

1. A slightly expansive hydrophobic foam concrete floor system based on ordinary Portland cement, characterized by: From bottom to top, it includes a structural layer (1), an FC interface agent layer (2), a micro-expansion hydrophobic foam concrete sound insulation and vibration reduction layer (3), an FC interface agent layer (4), and a decoration layer (5).

2. The floor system according to claim 1, characterized in that: The mass ratio of the raw materials of the micro-expansion hydrophobic foam concrete layer (3) is as follows: 420-560 parts of ordinary Portland cement; 180-240 parts of slag powder (grade S95 and above); 80-120 parts of gypsum (α-type hemihydrate gypsum / anhydrous phosphogypsum); 50-80 parts of silica fume; 5-15 parts of water repellent; 2 to 3.5 parts of foaming agent; 1 to 3 parts of water reducing agent; 182-350 parts of water. The hydrophobic agent is prepared by compounding organic silicon powder and calcium stearate in a mass ratio of 1:3 to 1:6; The foaming agent is a plant protein-based foaming agent or a high molecular synthetic surfactant-type foaming agent, and the foam density is 25-35 kg / m 3 ; The ordinary Portland cement is PO 42.5, PO 42.5R, PO 52.5 or PO 52.5R cement.

3. The floor system according to claim 1, characterized in that: The FC interface agent layers (2) and (4) are water-based epoxy interface agents, and their composition by mass ratio is: 300-500 parts of water-based epoxy emulsion (non-ionic, epoxy equivalent weight 180-220 g / eq); 150-250 parts of modified amine curing agent (cashew nut shell liquid modified polyamide, amine value 200-250 mgKOH / g); Functional filler (quartz sand and silica fume mass ratio 2:1 to 4:1) 200 to 400 parts; Silane coupling agent (γ-aminopropyltriethoxysilane KH-550) 5-30 parts; 1 to 5 parts of rheological additives. The floor system according to claim 3 is characterized in that the particle size of the quartz sand is 1.5 to 2.0 mm, the particle size of the silica fume is 0.1 to 1.0 μm, and the coating amount of the interface agent is 0.3 to 0.5 kg / m 2 .

4. The floor system according to claim 1, characterized in that: The properties of the foamed concrete layer (3) meet the following requirements: Linear expansion rate: 0.01% to 0.30%; Volume water absorption: ≤4%; Thermal conductivity: ≥0.20W / (m·K); Weighted sound insulation: ≥55dB; Weighted normalized impact sound pressure level: ≤70dB.

5. The construction method of the micro-expansion hydrophobic foam concrete sound insulation and vibration reduction floor system according to any one of claims 1 to 4, characterized in that The following steps are involved: Step 1: Clean the base slurry of the structural layer, moisten it with water for 3 hours, and then apply FC interface agent; Step 2: Pour self-leveling foam concrete slurry with a thickness of 30-80mm, use spray curing and cover with film curing for 72 hours; Step 3: Apply FC interface agent after 7 days of curing; Step 4: Lay the decoration layer, add PE moisture-proof film to the wooden floor and carpet respectively, and lay the tiles / stone with special adhesive.

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