A quick-curing environment-friendly grouting material and a preparation process thereof

Abstract

The application belongs to the technical field of grouting materials, and provides a fast-curing environment-friendly grouting material and a preparation process thereof.The grouting material is prepared by mixing A agent, B agent, filler and water in a mass ratio of (9-17):(1-4):(2-5):(40-60).The A agent comprises 100-200 parts of silicate cement, 300-600 parts of sulphoaluminate cement, 50-100 parts of fly ash, 4-10 parts of octylsilane, 12-30 parts of ammonium sulfate and 14-26 parts of polyurethane emulsion, all in terms of mass fraction.The B agent comprises 1-3 parts of glass fiber, 2-5 parts of thickening agent, 8-20 parts of water-based acrylic emulsion, 3.5-6.5 parts of soybean protein, 2-6 parts of expanding agent, 3-5 parts of nano silicon dioxide and 1.5-2.5 parts of nano calcium carbonate, all in terms of mass fraction.The application realizes fast curing of the grouting material, greatly shortens the construction time, and the prepared grouting material has good mechanical properties, durability and stability;at the same time, the grouting material uses environment-friendly raw materials, reduces the negative impact on the environment, and meets the concept of green and sustainable development.

Description

Technical Field

[0001] This invention relates to the field of grouting materials technology, specifically to a fast-curing environmentally friendly grouting material and its preparation process. Background Technology

[0002] Grouting materials are the main substances that fill and consolidate fissures and pores in formations, and are crucial for achieving water plugging or reinforcement. Grouting materials can be classified into granular grouts, chemical grouts, and fine mineral grouts. Currently used granular grouting materials mainly include single-component cement grout, clay-cement grout, and cement-water glass grout. Chemical grouts are close to true solutions and possess unique properties such as low viscosity, good injectability, and precise control of gel time. However, chemical grouts are relatively expensive and often have toxicity and environmental pollution issues, so they are generally used to treat formations where granular grouts cannot be injected, such as those with fine fissures and silty sand layers. Fine mineral grouts are a newly developed type of grouting material. Their composition design focuses on combinations of different natural minerals, artificial minerals, and special functional materials to achieve breakthroughs in key performance aspects such as grout properties, consolidation performance, and long-term durability. The slurry properties of certain fine mineral slurries, such as slurry stability, slurry viscosity, injectability, adjustability of gel time, consolidation strength, and volume of the consolidated body, have approached or exceeded those of high-performance chemical slurries.

[0003] Grouting materials are commonly used in civil engineering for foundation reinforcement, crack repair, and waterproofing of underground projects. Different compositions and properties can be selected based on the specific application requirements. For example:

[0004] Chinese patent application number CN201910224614.0 and publication number CN110118852B discloses a method for evaluating the grouting effect of polymer grouting materials and the grouting materials themselves. It primarily compares the grouting parameters with those of relatively mature cement grouting materials, selecting the appropriate grouting parameters for polymer grouting materials by comparing filling rates. The provided polymer grouting material comprises two components, A and B. Component A consists of isocyanate, foaming agent, foam stabilizer, antistatic agent, epoxy resin, and epoxy resin prepolymer diluent; component B consists of phosphoric acid, citric acid, polyol, water-soluble trihydroxy polyether, curing agent, flame retardant, and plasticizer. Using this evaluation method, grouting parameters can be optimized, shortening grouting time during anchor bolt construction, saving grouting materials, achieving good filling effects, safely and efficiently enhancing the bearing capacity of the surrounding rock, applying high preload to the grouting anchor cables, and improving the support strength of the surrounding rock.

[0005] Chinese patent application number CN201910367002.7 and publication number CN110054458B discloses a composite grouting material and its preparation method. This invention relates to the field of composite grouting technology, and its raw materials, by weight fraction, include: cement, wetting agent, and modifier. The invention also discloses a method for preparing the composite grouting material, which involves mixing the aforementioned raw materials. The resulting composite grouting material has the advantages of underwater anti-dispersion properties and lower cost compared to special grouting materials.

[0006] While existing grouting materials have made some progress in performance and application, they still have some shortcomings. For example, some grouting materials have long curing times, making it difficult to meet the needs of rapid construction. In addition, with increasing environmental protection requirements, more and more grouting materials need to meet environmental standards to reduce their negative impact on the environment. Therefore, developing a grouting material that can both cure quickly and meet environmental requirements is particularly important. Summary of the Invention

[0007] The purpose of this invention is to provide a fast-curing, environmentally friendly grouting material and its preparation process to solve the problems mentioned in the background art.

[0008] To achieve the above objectives, the present invention provides the following technical solution: The first aspect of the present invention provides a fast-curing environmentally friendly grouting material, wherein the grouting material is composed of agent A, agent B, filler and water in a mass ratio of (9-17):(1-4):(2-5):(40-60);

[0009] By weight, Agent A comprises 100-200 parts silicate cement, 300-600 parts sulfoaluminate cement, 50-100 parts fly ash, 4-10 parts octylsilane, 12-30 parts ammonium sulfate, and 14-26 parts polyurethane emulsion.

[0010] By weight, Agent B comprises 1-3 parts glass fiber, 2-5 parts thickener, 8-20 parts water-based acrylic emulsion, 3.5-6.5 parts soybean protein, 2-6 parts expanding agent, 3-5 parts nano silica, and 1.5-2.5 parts nano calcium carbonate.

[0011] Preferably, the filler includes, but is not limited to, gypsum, lime powder and silica fume, wherein the mass ratio of gypsum, lime powder and silica fume is (3-5):(2-3):(1-5).

[0012] Preferably, the mass ratio of silicate cement, sulfoaluminate cement and fly ash is 2:6:1.

[0013] Preferably, the thickener is one or more of cellulose-based thickeners, alginate-based thickeners, and starch-based thickeners.

[0014] Preferably, the expanding agent is one or more of bauxite, calcium hydroxide, and sulfoaluminate.

[0015] Preferably, agent B further includes calcium chloride and sodium carbonate, wherein the mass fractions of calcium chloride and sodium carbonate are 0.6-1.5 parts and 0.9-1.4 parts, respectively.

[0016] A second aspect of the present invention provides a process for preparing the grouting material described in the first aspect of the present invention, comprising the following steps:

[0017] S1, Preparation of Agent A:

[0018] Add silicate cement, sulfoaluminate cement, fly ash, octylsilane, ammonium sulfate, and polyurethane emulsion to a mixing device, set the speed, and stir for 25-35 minutes to obtain Agent A;

[0019] S2, Preparation of Agent B:

[0020] Glass fiber, thickener, water-based acrylic emulsion, soybean protein, and swelling agent are added to a mixing device and stirred for 10-15 minutes. Then, nano-silica and nano-calcium carbonate are added, and stirring is continued for 5-15 minutes to obtain agent B.

[0021] S3, Preparation of grouting material:

[0022] Add water and filler to a high-speed mixer and mix for 3-5 minutes. Then add agent A and agent B and continue mixing for 10-15 minutes to obtain the grouting material.

[0023] Preferably, the rotation speed for preparing agent A in step S1 is 600-800 rpm.

[0024] Preferably, the rotation speed for preparing agent B in step S2 is 300-400 rpm.

[0025] Preferably, the rotational speed of S3 is 1000-1200 rpm and the temperature is 40-45℃.

[0026] This invention has at least the following beneficial effects:

[0027] This invention provides a fast-curing environmentally friendly grouting material and its preparation process, which realizes rapid curing of the grouting material, greatly shortens the construction time, and the resulting grouting material has good mechanical properties, durability and stability; at the same time, the grouting material uses environmentally friendly raw materials, reducing the negative impact on the environment and conforming to the concept of green and sustainable development. Detailed Implementation

[0028] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0029] Example 1

[0030] This embodiment provides a fast-curing, environmentally friendly grouting material, which is composed of agent A, agent B, filler and water in a mass ratio of 9:1:2:40;

[0031] By weight, Agent A comprises 100 parts silicate cement, 300 parts sulfoaluminate cement, 50 parts fly ash, 4 parts octylsilane, 12 parts ammonium sulfate, and 14 parts polyurethane emulsion.

[0032] By weight, Agent B comprises 1 part glass fiber, 2 parts thickener, 8 parts water-based acrylic emulsion, 3.5 parts soybean protein, 2 parts expanding agent, 3 parts nano silica, and 1.5 parts nano calcium carbonate.

[0033] The filler includes gypsum, lime powder and silica fume, and the mass ratio of gypsum, lime powder and silica fume is 3:2:1.

[0034] The mass ratio of silicate cement, sulfoaluminate cement and fly ash is 2:6:1.

[0035] The thickener is a cellulose-based thickener; the expanding agent is bauxite.

[0036] The preparation process of the above grouting materials includes the following steps:

[0037] S1, Preparation of Agent A:

[0038] Silicate cement, sulfoaluminate cement, fly ash, octylsilane, ammonium sulfate, and polyurethane emulsion are added to a mixing device, the speed is set to 600 rpm, and the mixture is stirred for 35 minutes to obtain Agent A.

[0039] S2, Preparation of Agent B:

[0040] Glass fiber, thickener, water-based acrylic emulsion, soybean protein, and expansion agent are added to a mixing device and stirred at 300 rpm for 15 minutes. Then, nano silica and nano calcium carbonate are added, and stirring is continued for 15 minutes to obtain agent B.

[0041] S3, Preparation of grouting material:

[0042] Water and filler are added to a high-speed mixer, the temperature is raised to 45°C, and the mixture is stirred at 1000 rpm for 5 minutes. Then, agent A and agent B are added, and the mixture is stirred for another 15 minutes to obtain the grouting material.

[0043] Example 2

[0044] This embodiment provides a fast-curing, environmentally friendly grouting material, which is composed of agent A, agent B, filler and water in a mass ratio of 11:3:4:50;

[0045] By weight, Agent A comprises 160 parts silicate cement, 480 parts sulfoaluminate cement, 80 parts fly ash, 9 parts octylsilane, 15 parts ammonium sulfate, and 20 parts polyurethane emulsion.

[0046] By weight, Agent B comprises 2 parts glass fiber, 3 parts thickener, 12 parts water-based acrylic emulsion, 5 parts soybean protein, 4 parts expanding agent, 3.5 parts nano silica, and 2 parts nano calcium carbonate.

[0047] The fillers include, but are not limited to, gypsum, lime powder and silica fume, wherein the mass ratio of gypsum, lime powder and silica fume is 4:2.5:3.

[0048] The mass ratio of silicate cement, sulfoaluminate cement and fly ash is 2:6:1.

[0049] The thickener is an alginate thickener; the expanding agent is calcium hydroxide.

[0050] The preparation process of the above grouting materials includes the following steps:

[0051] S1, Preparation of Agent A:

[0052] Silicate cement, sulfoaluminate cement, fly ash, octylsilane, ammonium sulfate, and polyurethane emulsion are added to a mixing device, the speed is set to 700 rpm, and the mixture is stirred for 30 minutes to obtain Agent A.

[0053] S2, Preparation of Agent B:

[0054] Glass fiber, thickener, water-based acrylic emulsion, soybean protein, and expansion agent are added to a mixing device and stirred at 350 rpm for 12 minutes. Then, nano silica and nano calcium carbonate are added, and stirring is continued for 10 minutes to obtain agent B.

[0055] S3, Preparation of grouting material:

[0056] Water and filler are added to a high-speed mixer, the temperature is raised to 42°C, and the mixture is stirred at 1100 rpm for 4 minutes. Then, agent A and agent B are added, and the mixture is stirred for another 12 minutes to obtain the grouting material.

[0057] Example 3

[0058] This embodiment provides a fast-curing, environmentally friendly grouting material, which is composed of agent A, agent B, filler and water in a mass ratio of 17:4:5:60;

[0059] By weight, Agent A comprises 200 parts silicate cement, 600 parts sulfoaluminate cement, 100 parts fly ash, 10 parts octylsilane, 30 parts ammonium sulfate, and 26 parts polyurethane emulsion.

[0060] By weight, Agent B comprises 3 parts glass fiber, 5 parts thickener, 20 parts water-based acrylic emulsion, 6.5 parts soybean protein, 6 parts expanding agent, 5 parts nano silica, and 2.5 parts nano calcium carbonate.

[0061] The fillers include, but are not limited to, gypsum, lime powder and silica fume, wherein the mass ratio of gypsum, lime powder and silica fume is 5:3:5.

[0062] The mass ratio of silicate cement, sulfoaluminate cement and fly ash is 2:6:1.

[0063] The thickener is a starch-based thickener; the leavening agent is a sulfoaluminate.

[0064] The preparation process of the above grouting materials includes the following steps:

[0065] S1, Preparation of Agent A:

[0066] Silicate cement, sulfoaluminate cement, fly ash, octylsilane, ammonium sulfate, and polyurethane emulsion are added to a mixing device, the speed is set to 800 rpm, and the mixture is stirred for 25 minutes to obtain Agent A.

[0067] S2, Preparation of Agent B:

[0068] Glass fiber, thickener, water-based acrylic emulsion, soybean protein, and expansion agent are added to a mixing device and stirred at 400 rpm for 10 minutes. Then, nano silica and nano calcium carbonate are added, and stirring is continued for 5 minutes to obtain agent B.

[0069] S3, Preparation of grouting material:

[0070] Water and filler are added to a high-speed mixer, the temperature is raised to 40°C, and the mixture is stirred at 1200 rpm for 3 minutes. Then, agent A and agent B are added, and the mixture is stirred for another 10 minutes to obtain the grouting material.

[0071] Example 4

[0072] This embodiment provides a fast-curing, environmentally friendly grouting material, which is composed of agent A, agent B, filler and water in a mass ratio of 9:1:2:40;

[0073] By weight, Agent A comprises 100 parts silicate cement, 300 parts sulfoaluminate cement, 50 parts fly ash, 4 parts octylsilane, 12 parts ammonium sulfate, and 14 parts polyurethane emulsion.

[0074] By weight, Agent B comprises 1 part glass fiber, 2 parts thickener, 8 parts water-based acrylic emulsion, 3.5 parts soybean protein, 2 parts expanding agent, 3 parts nano silica, 1.5 parts nano calcium carbonate, 0.6 parts calcium chloride, and 0.9 parts sodium carbonate.

[0075] The remaining technical features are the same as in Example 1.

[0076] Example 5

[0077] This embodiment provides a fast-curing, environmentally friendly grouting material, which is composed of agent A, agent B, filler and water in a mass ratio of 11:3:4:50;

[0078] By weight, Agent A comprises 160 parts silicate cement, 480 parts sulfoaluminate cement, 80 parts fly ash, 9 parts octylsilane, 15 parts ammonium sulfate, and 20 parts polyurethane emulsion.

[0079] By weight, Agent B comprises 2 parts glass fiber, 3 parts thickener, 12 parts water-based acrylic emulsion, 5 parts soybean protein, 4 parts expanding agent, 3.5 parts nano silica, 2 parts nano calcium carbonate, 0.7 parts calcium chloride, and 1.3 parts sodium carbonate.

[0080] The remaining technical features are the same as in Example 2.

[0081] Example 6

[0082] This embodiment provides a fast-curing, environmentally friendly grouting material, which is composed of agent A, agent B, filler and water in a mass ratio of 17:4:5:60;

[0083] By weight, Agent A comprises 200 parts silicate cement, 600 parts sulfoaluminate cement, 100 parts fly ash, 10 parts octylsilane, 30 parts ammonium sulfate, and 26 parts polyurethane emulsion.

[0084] By weight, Agent B comprises 3 parts glass fiber, 5 parts thickener, 20 parts water-based acrylic emulsion, 6.5 parts soybean protein, 6 parts expanding agent, 5 parts nano silica, 2.5 parts nano calcium carbonate, 1.5 parts calcium chloride, and 1.4 parts sodium carbonate.

[0085] The remaining technical features are the same as in Example 3.

[0086] In the above embodiments 1-6:

[0087] Silicate cement and sulfoaluminate cement serve as the main cementing materials, providing the basic strength and curing properties of the grouting material; the addition of fly ash can improve the fluidity and workability of the material, while also increasing the strength development in the later stages; octylsilane greatly enhances the grouting material's resistance to freezing, cracking, and wear.

[0088] Ammonium sulfate, as a coagulant, can shorten the curing time of grouting materials; polyurethane emulsion can enhance the adhesion and elasticity of grouting materials, improving their overall performance; glass fiber can increase the toughness and crack resistance of grouting materials; thickeners are used to adjust the viscosity of grouting materials, making them easier to apply; water-based acrylic emulsions can improve the water resistance and durability of grouting materials; soybean protein, as a natural binder, is not only environmentally friendly but also improves the bonding performance of grouting materials; expansion agents generate micro-expansion during the curing process of grouting materials, filling pores and improving density and strength.

[0089] Nano-silica and nano-calcium carbonate, as nanomaterials, can significantly improve the mechanical properties and durability of grouting materials; calcium chloride and sodium carbonate can further adjust the curing time and performance of grouting materials, making them more adaptable to different construction environments and needs.

[0090] Through the synergistic effect of the above components, the grouting material prepared by this invention not only cures rapidly but also has excellent environmental performance, effectively reducing negative impacts on the environment and meeting the high requirements of modern engineering for grouting materials.

[0091] A series of relevant performance tests were conducted on the products prepared in Examples 1-6 above, and the results are as follows:

[0092]

[0093]

[0094] In summary, compared with existing technologies, the grouting material of this invention significantly shortens the setting time, enabling rapid curing and improving construction efficiency. Simultaneously, it exhibits high compressive strength, demonstrating excellent mechanical properties. Regarding freeze-thaw resistance, the grouting material maintains stable performance after multiple freeze-thaw cycles, with a moderate plastic expansion rate, indicating that the grouting material of this invention possesses good durability and stability.

[0095] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or basic characteristics. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within the present invention.

[0096] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A fast-curing, environmentally friendly grouting material, characterized in that, The grouting material is composed of agent A, agent B, filler and water in a mass ratio of (9-17):(1-4):(2-5):(40-60); By weight, Agent A comprises 100-200 parts silicate cement, 300-600 parts sulfoaluminate cement, 50-100 parts fly ash, 4-10 parts octylsilane, 12-30 parts ammonium sulfate, and 14-26 parts polyurethane emulsion. By weight, Agent B comprises 1-3 parts glass fiber, 2-5 parts thickener, 8-20 parts water-based acrylic emulsion, 3.5-6.5 parts soybean protein, 2-6 parts expanding agent, 3-5 parts nano silica, and 1.5-2.5 parts nano calcium carbonate. The filler includes gypsum, lime powder and silica fume, and the mass ratio of gypsum, lime powder and silica fume is (3-5):(2-3):(1-5); The mass ratio of silicate cement, sulfoaluminate cement and fly ash is 2:6:

1.

2. The environmentally friendly, fast-curing grouting material according to claim 1, characterized in that: The thickener is one or more of the following: cellulose thickener, alginate thickener, and starch thickener.

3. The environmentally friendly, fast-curing grouting material according to claim 1, characterized in that: The expanding agent is one or more of bauxite, calcium hydroxide, and sulfoaluminate.

4. The environmentally friendly, fast-curing grouting material according to claim 1, characterized in that: Agent B further includes calcium chloride and sodium carbonate, wherein the mass fractions of calcium chloride and sodium carbonate are 0.6-1.5 parts and 0.9-1.4 parts, respectively.

5. The preparation process of the grouting material according to any one of claims 1 to 4, characterized in that, Includes the following steps: S1, Preparation of Agent A: Add silicate cement, sulfoaluminate cement, fly ash, octylsilane, ammonium sulfate, and polyurethane emulsion to a mixing device, set the speed, and stir for 25-35 minutes to obtain Agent A; S2, Preparation of Agent B: Glass fiber, thickener, water-based acrylic emulsion, soybean protein, and swelling agent are added to a mixing device and stirred for 10-15 minutes. Then, nano-silica and nano-calcium carbonate are added, and stirring is continued for 5-15 minutes to obtain agent B. S3, Preparation of grouting material: Add water and filler to a high-speed mixer and mix for 3-5 minutes. Then add agent A and agent B and continue mixing for 10-15 minutes to obtain the grouting material.

6. The preparation process of the grouting material according to claim 5, characterized in that: The rotation speed for preparing agent A in S1 is 600-800 rpm.

7. The preparation process of the grouting material according to claim 5, characterized in that: The rotation speed for preparing agent B in S2 is 300-400 rpm.

8. The preparation process of the grouting material according to claim 5, characterized in that: The rotational speed of S3 is 1000-1200 rpm, and the temperature is 40-45℃.

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