Terrace repairing material and repairing method

Abstract

The invention discloses a floor repairing material and a repairing method. The floor repairing material comprises a component A and a component B. The component A comprises modified epoxy resin, nano silicon dioxide, chopped silicon fibers, a thixotropic agent and filler. The component B comprises an amine curing agent, an active filler, quartz sand and a coupling agent; the mass ratio of the component A to the component B is 2: 1. The floor repairing method comprises the following steps: respectively preparing the component A and the component B; preprocessing the to-be-repaired area; pouring the repaired area by using a terrace repairing material, and maintaining; the surface of the repaired area is coated with acrylic polyurethane finish paint and maintained; compared with the prior art, the terrace repairing material provided by the invention forms a rigid-flexible composite reinforcing system by introducing the chopped silicon fiber and combining with the flexible chain segment of the modified resin, and has excellent durability and ideal service life; the repairing method does not need to dismantle the whole plate of the original floor, the repairing speed is high, and the cost is low.

Description

Technical Field

[0001] The present invention relates to the technical field of floor repair, and in particular to a floor repair material and a repair method. Background Art

[0002] Some places, such as gas stations and parking lots, experience frequent daily traffic of all sizes. As cement floors age and become overloaded, they and access roads experience severe wear and tear, including flaking, cracking, roughness, sanding, shelling, and exposed stone. During construction, improper mix proportions or construction methods, improper maintenance, rain or water exposure, and premature use can also lead to severe "exposed stone," impacting the performance of the floor or pavement. Currently, the primary repair methods for new and existing cement concrete floors or pavements experiencing surface spalling and exposed stone include full-slab demolition and reconstruction, asphalt sand overlay, and epoxy mortar overlay.

[0003] Among the current floor repair methods, the entire slab demolition and reconstruction method is labor-intensive and time-consuming, with long downtimes that severely impact normal facility operations. Furthermore, it is unscientific and uneconomical for a floor with exposed sand and gravel that meets the required bearing capacity and the overall strength of the old concrete. Asphalt overlays result in significant color variation and a short service life. Epoxy mortar overlays cause the upper and lower layers to deform out of sync and are prone to aging, leading to bond failure and peeling. Ordinary cement mortar, however, will quickly peel and flake due to its weak bond. Summary of the Invention

[0004] The purpose of the present invention is to overcome the above technical deficiencies and propose a floor repair material and repair method to solve the technical problems that the existing repair methods have poor repair effects or are too costly.

[0005] In order to achieve the above technical objectives, the present invention adopts the following technical solutions: In a first aspect, the present invention provides a floor repair material comprising: Component A comprises, by mass percentage, 30% to 45% of a modified epoxy resin, 5% to 10% of nano-silica, 8% to 15% of chopped silicon fiber, 1% to 3% of a thixotropic agent, and the remainder being filler; Component B comprises, by mass percentage, 25% to 45% of an amine curing agent, 15% to 30% of quartz sand, 1% to 3% of a coupling agent, and the remainder being an active filler; The mass ratio of the component A to the component B is 2:1.

[0006] In some embodiments, the component A further comprises 1% to 5% by mass of pigment.

[0007] In some embodiments, the chopped silicon fibers have a diameter of 0.05 to 0.2 mm and a length of 1 to 3 mm.

[0008] In some embodiments, the thixotropic agent is bentonite.

[0009] In a second aspect, the present invention further provides a floor repair method using a floor repair material, which comprises the following steps: preparing the component A and the component B respectively; Pre-treatment of the area to be repaired; Mixing the component A and the component B to obtain the floor repair material, using the floor repair material to pour and repair the repair area and maintain; Apply acrylic polyurethane topcoat to the repaired area and cure.

[0010] In some embodiments, the method for preparing the component A is: adding modified epoxy resin, nano-silica, and silicon fiber into a grinder, cyclically grinding until the chopped silicon fiber is evenly dispersed, then adding fillers and pigments, and stirring at low speed for 25-35 minutes.

[0011] In some embodiments, the method for preparing the second component is: premixing the amine curing agent and the coupling agent, adding quartz sand and active filler, and stirring at high speed for 3-7 minutes.

[0012] In some embodiments, the method for pre-treating the repair area is: for pits, grinding to remove the loose layer on the surface; for cracks, cutting into V-shaped grooves with a groove depth greater than or equal to 5 cm; then using a high-pressure water gun to rinse the pits or V-shaped grooves and blow dry them, and then spraying anti-corrosion glue.

[0013] In some embodiments, when the floor repair material is used to pour and repair the repair area, the thickness of a single pouring is less than or equal to 8 cm, and each pouring and repair is cured for 24 hours.

[0014] In some embodiments, the method of applying the acrylic polyurethane topcoat to the repaired area surface is: firstly rolling the acrylic polyurethane topcoat on the repaired area surface, and then spraying the acrylic polyurethane topcoat.

[0015] Compared with the existing technology, the floor repair material provided by the present invention introduces chopped silicon fibers and combines them with flexible chain segments of modified resin to form a rigid-flexible composite reinforcement system. After repair, it not only has good wear resistance, high strength, and resistance to chemical media erosion, but also is anti-slip, anti-cracking, and moisture-proof, with excellent durability and ideal service life; and this repair method does not require the removal of the entire original floor board, and the repair speed is fast and the cost is low. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1The present invention provides a flow chart of a floor repair method. DETAILED DESCRIPTION

[0017] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0018] In order to solve the technical problems that existing repair methods have poor repair effects or are too costly, the present invention provides a floor repair material and a repair method, which can achieve rapid repair of damaged floors.

[0019] The floor repair material includes component A and component B, and the mass ratio of component A to component B is 2:1.

[0020] Component A comprises, by mass percentage, 30% to 45% of modified epoxy resin, 5% to 10% of nano-silica, 8% to 15% of chopped silicon fiber, 1% to 3% of thixotropic agent, and the remainder is filler; Component B includes, by mass percentage, 25% to 45% of an amine curing agent, 15% to 30% of quartz sand, 1% to 3% of a coupling agent, and the remainder being an active filler.

[0021] The viscosity of the floor repair material obtained by mixing according to the above ratio is ≥10 4 mPa・s, actual drying time at 25℃≤24 hours, bonding strength reaches concrete rupture.

[0022] The floor repair material provided by the present invention forms a rigid-flexible composite reinforcement system by introducing chopped silicon fibers and combining them with flexible chain segments of modified resin. After repair, the material not only has good wear resistance, high strength, and resistance to chemical corrosion, but also is anti-slip, anti-crack, and moisture-proof, and has excellent durability and an ideal service life.

[0023] In this embodiment, the modified epoxy resin accounts for 30% to 45% of the total mass of Component A, including but not limited to 30%, 32%, 34%, 36%, 38%, 40%, 42%, 44%, 45%, etc. If the content of the modified epoxy resin is too low, the resin matrix will not be able to fully wrap the chopped silicon fibers and fillers, the interface adhesion will be insufficient, and the repair layer and the concrete matrix will be easily peeled off; the proportion of flexible segments will decrease, the material toughness will be insufficient, the impact resistance will be significantly reduced, and it will be easy to crack under dynamic loads. If the content of the modified epoxy resin is too high, the rigidity after curing will be too strong (elongation at break <20%), it will be difficult to adapt to the deformation of the matrix, and cracks will be generated due to internal stress concentration during hot and cold cycles; the viscosity of the system will increase significantly, the construction operability will deteriorate, and bubbles or voids will be easily formed.

[0024] Nano-silica accounts for 5% to 10% of the total mass of Component A, including but not limited to 5%, 6%, 7%, 8%, 9%, 10%, etc. If the nano-silica content is too low, the nano-particles will not have sufficient reinforcing effect on the resin matrix, the density of the repair material will decrease, local peeling or pinholes will appear in the acid and alkali resistance, and the weather resistance will deteriorate; the compressive strength growth will be limited, and it will not be able to meet the needs of heavy-load scenarios. If the nano-silica content is too high, the agglomeration of nano-particles will be aggravated, the dispersion uniformity will decrease, and the mechanical properties of the material will be reduced; the system will be too thixotropic, the fluidity will deteriorate during construction, and it will be difficult to penetrate and fill fine cracks.

[0025] The chopped silicon fiber accounts for 8% to 15% of the total mass of Component A, including but not limited to 8%, 9%, 10%, 11%, 12%, 13%, 14%, and 15%. If the chopped silicon fiber content is too low, the fiber reinforcement effect will be insufficient, and a rigid-flexible composite system that effectively bridges cracks will not be formed. The crack resistance will be significantly reduced, and brittle fracture will easily occur under impact loads, and energy cannot be absorbed through the fiber network. If the chopped silicon fiber content is too high, the fibers will be entangled with each other, making grinding and dispersion difficult. Fiber agglomerates will form during construction, reducing the density of the material and possibly affecting the surface smoothness after curing.

[0026] The amine curing agent accounts for 25% to 45% of the total mass of Component B, including but not limited to 25%, 27%, 30%, 33%, 36%, 39%, 42%, 45%, etc. If the amine curing agent content is too low, the cross-linking reaction of the modified epoxy resin will be incomplete, resulting in insufficient hardness, reduced wear resistance, and unreacted active groups susceptible to chemical corrosion. It will also cause swelling or peeling when soaked in gasoline or salt water. If the amine curing agent content is too high, the curing reaction will be accelerated, the pot life will be shortened to less than 30 minutes, and local gelation will be prone to uneven mixing during large-scale construction. After curing, the internal stress will increase, the elongation at break will decrease, and the fatigue resistance will be reduced.

[0027] Quartz sand accounts for 15% to 30% of the total mass of Component B, including but not limited to 15%, 18%, 21%, 24%, 27%, and 30%. If the quartz sand content is too low, the aggregate support will be insufficient, the compressive strength of the repair material will decrease, and the surface will be prone to sanding under heavy loads. The curing shrinkage rate will increase, forming gaps between the resin and the matrix, affecting long-term durability. If the quartz sand content is too high, the resin matrix will not be able to fully encapsulate the sand particles, weakening the interfacial adhesion. Although the compressive strength will increase in the short term, aggregate will be prone to shedding in the long term. The construction fluidity will deteriorate, requiring an increase in the amount of diluent, which may lead to a decrease in mechanical properties after curing.

[0028] In some embodiments, component A further comprises 1% to 5% by weight of pigment, including but not limited to 1%, 2%, 3%, 4%, 5%, etc. The color of the pigment is determined according to the color of the original floor, reducing or even eliminating the color difference between the repaired area and the original floor, thereby improving the aesthetics.

[0029] In some embodiments, the coupling agent is a silane coupling agent, and the surface of the silicone fiber forms a Si-OC bond through the silane coupling agent, chemically bonding with the resin matrix to prevent fiber pullout and improve the durability of the repair material.

[0030] In some embodiments, the modified epoxy resin has an elongation at break of 20%.

[0031] In some embodiments, the function of nano-silica is to fill pores, thereby increasing the acid and alkali resistance of the repair material by 30%.

[0032] In some embodiments, the chopped silicon fibers have a diameter of 0.05 to 0.2 mm and a length of 1 to 3 mm.

[0033] In some embodiments, the thixotropic agent is bentonite, which acts to prevent the fibers from settling.

[0034] In some embodiments, the amine curing agent uses polyetheramine D400, which can extend the pot life to 60 minutes and is suitable for large-area construction.

[0035] In some embodiments, the active filler is a mixture of metakaolin and silica fume in a mass ratio of 1:1, which can form a CSH gel at the concrete interface, enhance the connection strength, and make the repaired structure less likely to fall off.

[0036] In some embodiments, the quartz sand is graded from 0.1 to 0.5 mm and has a compressive strength of 70 MPa.

[0037] The performance indicators of the floor repair material provided by the present invention are shown in the following table:

[0038] In another embodiment, the present invention further provides a floor repair method using the above-mentioned floor repair material, which comprises the following steps: S1. Prepare component A and component B separately for use.

[0039] S2. Pre-process the area to be repaired.

[0040] S3. Mix component A and component B to obtain floor repair material, use the floor repair material to pour the repair area, and perform maintenance.

[0041] S4. Apply an acrylic polyurethane topcoat to the repaired area and allow it to cure. The polyurethane segments absorb impact energy, while the silicone fibers bridge cracks. This increases the fracture energy by two times compared to conventional epoxy materials, resulting in better crack resistance.

[0042] In some embodiments, the method for preparing component A in step S1 is to add modified epoxy resin, nano-silica, and silicon fiber into a grinder according to the above-mentioned ratio. The grinder can adopt a three-roll grinder with a gap of 0.05mm. During the cyclic grinding process, the silicon fiber is ground into chopped silicon fiber. Until the chopped silicon fiber is evenly dispersed, fillers and pigments are added and stirred at low speed for 25-35 minutes, including but not limited to 25 minutes, 26 minutes, 27 minutes, 28 minutes, 29 minutes, 30 minutes, 31 minutes, 32 minutes, 33 minutes, 34 minutes, and 35 minutes. The low speed here is generally 10 to 30 rpm, including but not limited to 10 rpm, 15 rpm, 20 rpm, 25 rpm, and 30 rpm.

[0043] In some embodiments, the method for preparing component B in step S1 is to premix the amine curing agent and the coupling agent according to the above ratio, add quartz sand and the active filler, and stir at high speed for 3-7 minutes, including but not limited to 3 minutes, 4 minutes, 5 minutes, 6 minutes, and 7 minutes. The high speed here is generally 100-500 rpm, including but not limited to 100 rpm, 150 rpm, 200 rpm, 250 rpm, 300 rpm, 350 rpm, 400 rpm, 450 rpm, and 500 rpm.

[0044] In some embodiments, the pretreatment method for the repaired area in step S2 is to grind away the loose layer on the surface of a pit. If the repaired area is a crack, the crack is cut into a V-shaped groove with a depth of greater than or equal to 5 cm. The pit or V-shaped groove is then rinsed with a high-pressure water gun and dried, and then sprayed with an anti-corrosion adhesive. The anti-corrosion adhesive can be a moisture-curing low-molecular-weight epoxy resin cross-linked anti-corrosion adhesive.

[0045] In some embodiments, in step S3, component A and component B are stirred electrically for 8-12 minutes, including but not limited to 8 minutes, 9 minutes, 10 minutes, 11 minutes, and 12 minutes, to obtain a floor repair material.

[0046] In some embodiments, in step S3, the repaired area is irrigated with floor repair material and cured for 22-26 hours, including but not limited to 22 hours, 23 hours, 24 hours, 25 hours, and 26 hours. The area is then ground flat using a grinder, with the flatness requirement being a 2-meter-long ruler with an allowable error of no more than 2 mm.

[0047] In some embodiments, the thickness of a single pouring in step S3 is less than or equal to 8 cm. If the depth of the pit or V-shaped groove is greater than 8 cm, multiple pourings are required. Each pouring is followed by curing for 22-26 hours, including but not limited to 22 hours, 23 hours, 24 hours, 25 hours, and 26 hours. The next pouring is then performed until the pit or V-shaped groove is filled.

[0048] In some embodiments, the method for applying an acrylic polyurethane topcoat to the repaired area in step S4 is: first, roll-coating the acrylic polyurethane topcoat on the repaired area, and then spray-coating the acrylic polyurethane topcoat. The wet film thickness of the acrylic polyurethane topcoat for both roll-coating and spray-coating is 0.08-0.12 mm, including but not limited to 0.08 mm, 0.09 mm, 0.10 mm, 0.11 mm, and 0.12 mm. After spraying, the area is cured for 24 hours.

[0049] Example 1 The floor of a factory workshop had 5cm deep pits and 2mm wide cracks due to long-term overload, and sand and stone were exposed on the surface.

[0050] The material formula of the floor repair material is as follows: Component A includes 30% modified epoxy resin, 5% nano-silica, 8% chopped silicon fiber, 2% thixotropic agent, and 55% filler by mass; Component B includes 25% amine curing agent, 15% quartz sand, 2% coupling agent, and 58% active filler by mass.

[0051] Repaired according to the above repair method, trucks can pass without cracks 24 hours after the repair is completed.

[0052] Example 2 The floor of a gas station was repaired because the floor had 10mm deep grooves and cracks caused by vehicles running over it.

[0053] The material formula of the floor repair material is as follows: Component A includes 40% epoxy resin, 8% nano-silica, 12% silicone fiber, 2% thixotropic agent, and 38% filler by mass; Component B includes 35% polyetheramine, 25% quartz sand, 2% coupling agent, and 38% active filler by mass.

[0054] According to the above repair method, small passenger cars can pass without cracks 24 hours after the repair is completed, and the cost is reduced by 30% compared with the traditional solution.

[0055] Example 3 The floor of a warehouse had 7cm deep pits and 4mm wide cracks due to long-term overload, and sand and stone were exposed on the surface.

[0056] The material formula of the floor repair material is as follows: Component A includes 45% modified epoxy resin, 10% nano-silica, 15% chopped silicon fiber, 2% thixotropic agent, and 28% filler by mass; Component B includes 45% amine curing agent, 30% quartz sand, 2% coupling agent, and 23% active filler by mass.

[0057] Repaired according to the above repair method, trucks can pass without cracks 24 hours after the repair is completed.

[0058] Comparative Example 1 Compared with Example 1, the only difference is that the weight proportion of the modified epoxy resin in Component A is 25%, and the reduced amount of modified epoxy resin corresponds to the increase in filler. Repair according to the above repair method was completed. A truck passed through 24 hours after the repair was completed, and cracks appeared in the repaired area.

[0059] Comparative Example 2 Compared with Example 3, the only difference is that the weight proportion of the modified epoxy resin in Component A is 50%, and the increase in the amount of modified epoxy resin corresponds to the reduction in filler. After repair according to the above repair method, cracks appeared in the repaired area 24 hours after the repair was completed.

[0060] Comparative Example 3 Compared with Example 1, the only difference is that the weight proportion of nano-silica in Component A is 2%, and the reduction in the amount of nano-silica corresponds to the increase in filler. Repairs were made according to the above repair method. A truck passed by 24 hours after the repair was completed, and cracks appeared in the repaired area.

[0061] Comparative Example 4 Compared with Example 3, the only difference is that the weight proportion of nano-silica in Component A is 15%, and the increase in the amount of nano-silica corresponds to the reduction in filler. Repairs were made according to the above repair method. A truck passed by 24 hours after the repair was completed, and cracks appeared in the repaired area.

[0062] Comparative Example 5 Compared with Example 1, the only difference is that the weight proportion of chopped silicon fiber in Component A is 5%, and the reduction in the amount of chopped silicon fiber corresponds to the increase in filler. Repair according to the above repair method was completed. A truck passed 24 hours after the repair was completed, and cracks appeared in the repaired area.

[0063] Comparative Example 6 Compared to Example 3, the only difference is that the weight percentage of chopped silicon fiber in Component A is 20%. The increase in the amount of chopped silicon fiber corresponds to the reduction in filler. After repair using the above repair method, the repaired area was uneven 24 hours after completion. Cracking occurred in the repaired area after a truck passed through.

[0064] Comparative Example 7 Compared with Example 1, the only difference is that the weight proportion of the amine curing agent in Component B is 20%. The reduction in the amount of amine curing agent corresponds to the increase in active filler. Following the above repair method, a truck passed through 24 hours after the repair was completed, and surface wear appeared in the repaired area.

[0065] Comparative Example 8 Compared to Example 3, the only difference is that the weight percentage of quartz sand in Component B is 50%. The increased amount of quartz sand corresponds to a reduced amount of active filler. Following the above repair method, the repaired area was uneven 24 hours after completion. Cracking occurred in the repaired area after a truck passed through.

[0066] Comparative Example 9 Compared with Example 1, the only difference is that the weight proportion of quartz sand in Component B is 10%, and the reduction in the amount of quartz sand corresponds to the increase in active filler. According to the above repair method, a truck passed through 24 hours after the repair was completed, and the surface of the repaired area showed sanding.

[0067] Comparative Example 10 Compared to Example 3, the only difference is that the weight percentage of the amine curing agent in Component B is 50%. The increase in the amount of amine curing agent corresponds to a decrease in the amount of active filler. Following the above repair method, the repaired area was uneven 24 hours after completion. Cracking occurred in the repaired area after a truck passed through.

[0068] In order to make the above embodiments and comparative examples more intuitive, some of the formulations are summarized in Table 1.

[0069] Table 1

[0070] It can be seen from Table 1 that compared with Example 1, the modified epoxy resin content of Component A in Comparative Example 1 is too low, resulting in the repair area being unable to withstand the load of the vehicle and cracking. The nano-silica content of Component A in Comparative Example 3 is too low, and similarly, after the test run, the repair area cracked. The chopped silicon fiber content of Component A in Comparative Example 5 is too low, and similarly, after the test run, the repair area cracked. The amine curing agent content of Component B in Comparative Example 7 is too low, and obvious wear and tear appears on the surface of the repair area after the test run. The quartz sand content of Component B in Comparative Example 9 is too low, and sanding appears on the surface of the repair area after the test run.

[0071] Compared with Example 3, the modified epoxy resin content of Component A in Comparative Example 2 is too high, resulting in stress concentration in the repair area, and cracks appear before the test run. The nano-silica content of Component A in Comparative Example 4 is too high, resulting in the repair area being unable to withstand the load of the vehicle and cracking. The chopped silicon fiber content of Component A in Comparative Example 6 is too high, the surface of the repair area is uneven, and after the test run, the repair area cracks. The amine curing agent content of Component B in Comparative Example 8 is too high, the material mixing is uneven, the repair area is uneven, and cracks appear after the test run. The quartz sand content of Component B in Comparative Example 10 is too high, and the quartz sand in the repair area falls off after the test run.

[0072] The specific embodiments of the present invention described above do not limit the scope of protection of the present invention. Any other corresponding changes and modifications made based on the technical concept of the present invention should be included in the scope of protection of the claims of the present invention.

Claims

1. A floor repair material, characterized in that: include: Component A comprises, by mass percentage, 30% to 45% of a modified epoxy resin, 5% to 10% of nano-silica, 8% to 15% of chopped silicon fiber, 1% to 3% of a thixotropic agent, and the remainder being filler; Component B comprises, by mass percentage, 25% to 45% of an amine curing agent, 15% to 30% of quartz sand, 1% to 3% of a coupling agent, and the remainder being an active filler; The mass ratio of the component A to the component B is 2:

1.

2. The floor repair material according to claim 1, characterized in that: The component A further comprises 1% to 5% of pigment in terms of mass percentage.

3. The floor repair material according to claim 1, characterized in that: The chopped silicon fibers have a diameter of 0.05 to 0.2 mm and a length of 1 to 3 mm.

4. The floor repair material according to claim 1, characterized in that: The thixotropic agent is bentonite.

5. A floor repair method, characterized in that: Using the floor repair material according to any one of claims 1 to 4 comprises the following steps: preparing the component A and the component B respectively; Pre-treatment of the area to be repaired; Mixing the component A and the component B to obtain the floor repair material, and using the floor repair material to pour and repair the repair area and maintain the repair area; Apply acrylic polyurethane topcoat to the repaired area and cure.

6. The floor repair method according to claim 5, characterized in that: The method for preparing the component A is as follows: adding modified epoxy resin, nano-silica and silicon fiber into a grinder, cyclically grinding until the chopped silicon fiber is evenly dispersed, then adding fillers and pigments, and stirring at a low speed for 25-35 minutes.

7. The floor repair method according to claim 5, characterized in that: The method for preparing the second component is: premixing the amine curing agent and the coupling agent, adding quartz sand and active filler, and stirring at high speed for 3-7 minutes.

8. The floor repair method according to claim 5, characterized in that: The method for pre-treatment of the repair area is: for pits, grind and remove the loose layer on the surface; for cracks, cut into V-shaped grooves with a groove depth greater than or equal to 5 cm; then use a high-pressure water gun to rinse the pits or V-shaped grooves and blow them dry, and then spray anti-corrosion glue.

9. The floor repair method according to claim 5, characterized in that: When the floor repair material is used to pour and repair the repair area, the thickness of a single pouring is less than or equal to 8 cm, and each pouring and repair is followed by curing for 22-26 hours.

10. The floor repair method according to claim 5, characterized in that: The method of applying acrylic polyurethane topcoat to the surface of the repaired area is: first roll-coat the acrylic polyurethane topcoat on the surface of the repaired area, and then spray-coat the acrylic polyurethane topcoat.

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