Polymer composite mortar material for building outer wall waterproof layer and preparation method thereof

Abstract

The application relates to the technical field of building materials, and discloses a polymer composite mortar material for a waterproof layer of a building outer wall and a preparation method of the polymer composite mortar material, wherein the waterproof layer of the building outer wall comprises, in sequence from top to bottom, an interface treatment layer, a vitrified microbead mortar leveling layer, a bottom mortar layer in which glass fiber mesh cloth is embedded, a surface mortar layer and a polymer cement waterproof layer; the material of the surface mortar layer and the bottom mortar layer is the polymer composite mortar material. Through the technical scheme, the problems of heavy load, low bonding strength, poor crack resistance and easy falling of the waterproof layer of the building outer wall in the related art are solved.

Description

Technical Field

[0001] This invention relates to the field of building materials technology, specifically to a polymer composite mortar material for waterproofing layers of building exterior walls and its preparation method. Background Technology

[0002] The "General Specification for Waterproofing of Building and Municipal Engineering" (GB 55030-2022) stipulates the following for the waterproofing design of building exterior walls: The waterproofing of building exterior walls should be designed holistically based on the environmental category of the project's location. For exterior walls with a Class I waterproofing rating, two or more waterproofing layers should be installed; for Class II waterproofing, one or more waterproofing layers should be installed. When using two layers of waterproofing, one layer of waterproof mortar and one layer of waterproof coating or other waterproofing material should be installed.

[0003] Traditional methods for first-level waterproofing of building exterior walls involve: first, spraying an interface agent onto the base wall surface; then applying a 15mm thick vitrified microsphere insulation mortar leveling layer; next, applying a 5mm thick crack-resistant mortar layer with embedded alkali-resistant fiberglass mesh; followed by a 5mm thick polymer waterproof mortar layer; then spraying a 1.5mm thick JS-II or JS-III polymer cement waterproof coating; and finally, applying two coats of putty followed by one coat of stone-like paint or water-based sand coating for finishing. This traditional waterproofing method, including leveling, crack resistance, waterproofing, and finishing, results in a self-load of approximately 35.0 kg / m² for the exterior wall waterproofing layer structure. 2 Furthermore, the mortar layer in the waterproof layer has low bonding strength and poor crack resistance, which increases the risk of the waterproof layer on the building's exterior walls falling off.

[0004] Therefore, based on the above reasons, there is an urgent need to develop a lightweight, crack-resistant, anti-detachment, high-bonding-strength, waterproof and finishing integrated polymer composite mortar material that meets the Class I waterproofing design requirements for building exterior wall engineering in the "General Specification for Waterproofing of Building and Municipal Engineering" (GB55030-2022). Summary of the Invention

[0005] This invention proposes a polymer composite mortar material for waterproofing layers of building exterior walls and its preparation method, which solves the problems of heavy load, low bonding strength, poor crack resistance, and easy detachment of waterproofing layers for building exterior walls in related technologies.

[0006] The technical solution of the present invention is as follows:

[0007] This invention proposes a polymer composite mortar material for waterproofing layers of building exterior walls. The waterproofing layer comprises, sequentially disposed on the wall surface, an interface treatment layer, a vitrified microsphere mortar leveling layer, a bottom mortar layer with embedded glass fiber mesh, a top mortar layer, and a polymer cement waterproofing layer; the materials of the top mortar layer and the bottom mortar layer are both polymer composite mortar materials.

[0008] The surface mortar layer and the bottom mortar layer each independently include the following components by weight: 260-305 parts of ordinary silicate cement, 40-50 parts of rapid-hardening sulfoaluminate cement, 40-50 parts of talc powder, 525-622 parts of quartz sand, 10-15 parts of redispersible latex powder, and 20-40 parts of silica aerogel.

[0009] The particle size distribution of quartz sand in the bottom mortar layer and the top mortar layer is different;

[0010] The quartz sand in the bottom mortar layer includes quartz sand with a particle size of 20 mesh ≤ < 40 mesh, quartz sand with a particle size of 40 mesh ≤ < 70 mesh, and quartz sand with a particle size of 70 mesh ≤ 120 mesh.

[0011] The quartz sand in the surface mortar layer includes quartz sand with a particle size of 40 mesh ≤ < 70 mesh and quartz sand with a particle size of 70 mesh ≤ 120 mesh.

[0012] As a further technical solution, the mass ratio of quartz sand with a particle size of 20 mesh ≤ < 40 mesh, quartz sand with a particle size of 40 mesh ≤ < 70 mesh, and quartz sand with a particle size of 70 mesh ≤ 120 mesh in the bottom mortar layer is 1:6.5~7.5:1~3.

[0013] As a further technical solution, the material of the interface treatment layer includes one of acrylic emulsion interface agent, styrene-butadiene emulsion interface agent, and styrene-acrylic emulsion interface agent.

[0014] As a further technical solution, the vitrified microsphere mortar leveling layer comprises the following components in parts by weight: 560 parts of P.O42.5 cement, 440 parts of vitrified microspheres, 3 parts of polypropylene fiber with a diameter of 6mm, 10-15 parts of Wacker 5010N latex powder, 5 parts of HPMC cellulose ether with a viscosity of 150,000, and 712.6-716.1 parts of water.

[0015] As a further technical solution, the surface mortar layer and the bottom mortar layer each independently include the following components in parts by weight: 2-3 parts cellulose ether, 4-6 parts waterproofing agent, 0.1-0.3 parts air-entraining agent, 0.3-0.5 parts starch ether, 0.1-0.3 parts water-reducing agent, 2-3 parts lignocellulose, and 1-1.5 parts polypropylene fiber.

[0016] The polymer composite mortar material of this invention achieves lightweighting of both the base and surface mortar layers by incorporating appropriate amounts of hydrophilic silica aerogel and air-entraining agents. Before setting, an appropriate amount of rapid-hardening sulfoaluminate cement reduces drying shrinkage by shortening the setting time, while appropriate amounts of cellulose ether and lignocellulose further reduce drying shrinkage through water retention. After setting, chemical shrinkage is reduced by incorporating an appropriate amount of polypropylene fiber to resist cracking. The incorporation of an appropriate amount of organosilicon waterproofing agent improves the mortar's impermeability, thus achieving the waterproofing properties of the polymer composite mortar material. The consistency, anti-sagging, workability, and bond strength of the polymer composite mortar material are adjusted by the dosage of water-reducing agents, starch ethers, talc, and redispersible latex powder, endowing the polymer composite mortar material with lightweighting, crack resistance, waterproofing, and finishing properties.

[0017] As a further technical solution, the quartz sand in the bottom mortar layer is composed of quartz sand with a mass ratio of 1:7:1~3, consisting of quartz sand with a particle size of 20 mesh ≤ < 40 mesh, quartz sand with a particle size of 40 mesh ≤ < 70 mesh, and quartz sand with a particle size of 70 mesh ≤ 120 mesh.

[0018] As a further technical solution, the quartz sand in the bottom mortar layer is composed of quartz sand with a mass ratio of 1:7:2, consisting of quartz sand with a particle size of 20 mesh ≤ < 40 mesh, quartz sand with a particle size of 40 mesh ≤ < 70 mesh, and quartz sand with a particle size of 70 mesh ≤ 120 mesh.

[0019] As a further technical solution, the quartz sand in the surface mortar layer is composed of quartz sand with a mass ratio of 6:3~5, consisting of quartz sand with a particle size of 40 mesh ≤ < 70 mesh and quartz sand with a particle size of 70 mesh ≤ ≤ 120 mesh.

[0020] As a further technical solution, the quartz sand in the surface mortar layer is composed of quartz sand with a mass ratio of 6:4, consisting of quartz sand with a particle size of 40 mesh ≤ < 70 mesh and quartz sand with a particle size of 70 mesh ≤ ≤ 120 mesh.

[0021] The particle size distribution of quartz sand in the surface mortar and the base mortar not only directly affects their workability but also significantly influences their bond strength. The particle size and gradation distribution of quartz sand can alter the particle surface area, packing structure, and stress transfer mechanism, thereby affecting the bond strength of the surface mortar layer, the base mortar layer, and the monolithic mortar (monolithic mortar is the sum of the surface mortar layer and the base mortar layer; in the following text, monolithic mortar refers to the sum of the surface mortar layer and the base mortar layer) in the waterproof layer. In this invention, the bottom mortar layer of the polymer composite mortar material for building exterior wall waterproofing consists of quartz sand with a particle size of 20 mesh ≤ < 40 mesh, 40 mesh ≤ < 70 mesh, and 70 mesh ≤ ≤ 120 mesh in a mass ratio of 1:7:2. The top mortar layer consists of quartz sand with a particle size of 40 mesh ≤ < 70 mesh and 70 mesh ≤ ≤ 120 mesh in a mass ratio of 6:4. This can further improve the bonding strength and crack resistance of the building exterior wall waterproofing layer.

[0022] As a further technical solution, the underlying mortar layer comprises the following components by weight: 270 parts ordinary silicate cement, 42 parts rapid-hardening sulfoaluminate cement, 42 parts talc powder, 14 parts redispersible latex powder, 2.8 parts cellulose ether, 5.5 parts waterproofing agent, 0.25 parts air-entraining agent, 0.45 parts starch ether, 2.8 parts lignocellulose, 0.15 parts water-reducing agent, 1.4 parts polypropylene fiber, 35 parts silica aerogel, and 583.65 parts quartz sand.

[0023] As a further technical solution, the surface mortar layer comprises the following components by weight: 270 parts ordinary silicate cement, 42 parts rapid-hardening sulfoaluminate cement, 42 parts talc powder, 14 parts redispersible latex powder, 2.8 parts cellulose ether, 5.5 parts waterproofing agent, 0.25 parts air-entraining agent, 0.45 parts starch ether, 2.8 parts lignocellulose, 0.18 parts water-reducing agent, 1.4 parts polypropylene fiber, 35 parts silica aerogel, and 583.62 parts quartz sand.

[0024] The performance of the surface mortar layer, the bottom mortar layer, and the overall mortar is determined by the types and amounts of its constituent components. Variations in the amounts of different components directly affect the physicochemical reactions, structural formation, and interactions within the mortar, leading to differences in final performance. In this invention, the components in the bottom mortar layer and the surface mortar layer of the polymer composite mortar material for building exterior wall waterproofing are limited as described above, resulting in the optimal overall performance of the waterproofing layer.

[0025] As a further technical solution, the only difference between the bottom mortar layer and the top mortar layer is the particle size distribution of the quartz sand.

[0026] As a further technical solution, the air-entraining agent includes sodium dodecylbenzenesulfonate, the water-reducing agent includes polycarboxylate water-reducing agent, and the waterproofing agent includes organosilicon waterproofing agent.

[0027] As a further technical solution, the cellulose ether includes hydroxyethyl methyl cellulose ether, the starch ether includes carboxymethyl starch, the lignocellulose is chemically modified lignocellulose, preferably carboxymethyl cellulose, the polypropylene fiber includes PP-ST polypropylene chopped fiber, and the silica aerogel is hydrophilic.

[0028] As a further technical solution, the ordinary silicate cement is P.O42.5 grade; the rapid-hardening sulfoaluminate cement is R.SAC42.5 grade; the talc powder has a particle size of 800 mesh; and the redispersible latex powder is 5010N redispersible latex powder.

[0029] As a further technical solution, the polymer cement waterproof layer uses JS-II or JS-III type polymer cement waterproof material.

[0030] As a further technical solution, the polymer cement waterproofing material includes one of Oriental Rainbow Jishitu 100, Oriental Rainbow Jishitu 120, Dega K11 flexible type, Keshun C301, and Keshun 303.

[0031] As a further technical solution, the coating thickness of the interface treatment layer is 0.2~0.5mm.

[0032] As a further technical solution, the thickness of the vitrified microsphere mortar leveling layer is 15mm, and the thickness of the polymer cement waterproof layer is 1.5mm.

[0033] As a further technical solution, the thickness of the surface mortar layer is 2mm, and the thickness of the bottom mortar layer is 3mm.

[0034] In this invention, the exterior wall waterproofing layer uses a 3mm thick base mortar layer + a 2mm thick top mortar layer in a synergistic manner to reduce chemical shrinkage and achieve crack resistance of the polymer composite mortar material. The 2mm thick top mortar layer can replace traditional finishing treatment (with excellent workability), giving the polymer composite mortar material lightweight, crack resistance, waterproofing, high bonding strength, and finishing properties. The crack resistance, waterproofing, and bonding strength of the 3mm + 2mm polymer composite mortar material can achieve the effect of traditional 5mm thick crack-resistant mortar + 5mm thick polymer waterproof mortar.

[0035] This invention also proposes a method for preparing a polymer composite mortar material for waterproofing layers of building exterior walls, which includes the following steps: mixing each component in the surface mortar layer and the bottom mortar layer with water to obtain polymer composite mortar materials for the surface mortar layer and the bottom mortar layer respectively.

[0036] As a further technical solution, the water is added at a water-to-material ratio of 0.23.

[0037] The present invention also proposes an application of a polymer composite mortar material for waterproofing layers of building exterior walls, wherein the polymer composite mortar material includes a polymer composite mortar material prepared by a method for preparing polymer composite mortar materials for waterproofing layers of building exterior walls or the polymer composite mortar material for waterproofing layers of building exterior walls.

[0038] The specific application is as follows: first, spray an interface agent on the surface of the base wall, then apply a leveling layer of vitrified microsphere thermal insulation mortar, then apply a polymer composite mortar for the bottom mortar layer, then lay an alkali-resistant glass fiber mesh, then apply a polymer composite mortar for the top mortar layer, and finally spray a polymer cement waterproof decorative coating.

[0039] The working principle and beneficial effects of this invention are as follows:

[0040] In order to reduce the structural load of the waterproof layer of building exterior walls while achieving the same waterproof effect and high bonding strength of the mortar layer, this invention has developed a polymer composite mortar material for waterproof layers of building exterior walls.

[0041] Traditional method for first-level waterproofing of building exterior walls: First, spray an interface agent on the surface of the base wall, then apply a 15mm thick vitrified microsphere thermal insulation mortar leveling layer, then apply a 5mm thick layer of crack-resistant mortar with embedded alkali-resistant glass fiber mesh, then apply a 5mm thick layer of polymer waterproof mortar, then spray a 1.5mm thick JS-II or JS-III polymer cement waterproof coating, and finally apply two coats of putty plus one coat of real stone paint or water-based sand coating for finishing.

[0042] In the existing technology, only one layer of glass fiber mesh anti-crack mortar is set in the vitrified microsphere mortar leveling layer and the polymer cement waterproof layer. However, the adhesion of the anti-crack mortar layer varies depending on the characteristics of the bonding material. The components in vitrified microsphere mortar and polymer cement mortar are different. Therefore, it is difficult for a single mortar layer to meet the bonding strength requirements of two layers of different component materials at the same time.

[0043] The primary waterproofing layer for the exterior wall of this invention comprises, in sequence, an interface treatment layer, a vitrified microsphere mortar leveling layer, a base mortar layer with embedded fiberglass mesh, a surface mortar layer, and a polymer cement waterproofing layer. The self-load of the waterproofing layer structure is approximately 20.0 kg / m². 2The load-bearing capacity is only 61.3% of that of traditional anti-cracking mortar layers for building exterior walls. By limiting the particle size distribution of quartz sand in the bottom and top mortar layers, the overall bonding strength of the waterproof layer can be improved. When the polymer composite mortar material of this invention is applied to the waterproof layer of building exterior walls, the waterproof performance, crack resistance, and bonding strength of the waterproof layer can all meet the performance requirements to a high degree, greatly reducing the risk of the waterproof layer falling off.

[0044] Moreover, this new waterproof structure in the present invention combines the traditional waterproofing and finishing processes into one. Furthermore, since the polymer composite mortar material in the present invention possesses properties such as lightweight, crack resistance, high bonding strength, waterproofing, and finishing, the waterproofing process for building exterior walls can be simplified. Detailed Implementation

[0045] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. 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 of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0046] In the following embodiments and comparative examples:

[0047] I. The performance testing methods are as follows:

[0048] (1) Working time and compression-flexure ratio: The test results were determined according to the crack-resistant mortar specified in the "Materials for External Wall Insulation System of Adhesive Powder Polystyrene Particles" (JG / T 158-2013);

[0049] (2) The mortar specimens were tested for impermeability, bond strength, frost resistance and water absorption rate according to the test methods specified in section 3.4 of the "General Specification for Waterproofing of Building and Municipal Engineering" (GB 55030-2022) for cement-based waterproof materials.

[0050] (3) 28-day shrinkage rate, apparent density, and setting time: The test methods were carried out in accordance with the "Standard for Test Methods of Basic Performance of Building Mortar" (JGJ / T 70-2009);

[0051] (4) Workability: The workability shall be carried out in accordance with the method specified in the standard "Putty for Building Exterior Walls" (JG / T 157-2009).

[0052] II. The specific composition of the vitrified microsphere mortar leveling layer, polymer cement waterproofing material, and interface treatment layer materials are as follows:

[0053] (1) Vitrified microsphere mortar leveling layer, including the following components by weight: 560 kg of P.O42.5 cement, 440 kg of vitrified microspheres, 3 kg of polypropylene fiber with a diameter of 6 mm, 10 kg of Wacker 5010N latex powder, 5 kg of HPMC cellulose ether with a viscosity of 150,000, and 712.6 kg of water.

[0054] (2) The polymer cement waterproofing material is Oriental Rainbow Jishi Coating 100;

[0055] (3) The interface treatment layer material is acrylic emulsion interface agent, and the coating thickness of the interface treatment layer is 0.2 mm.

[0056] Example 1

[0057] A method for preparing a polymer composite mortar material for waterproofing building exterior walls includes the following steps:

[0058] After mixing the components of the materials for the bottom mortar layer and the top mortar layer with water (water-to-material ratio of 0.23), polymer composite mortar materials for the bottom mortar layer and the top mortar layer are obtained respectively.

[0059] Preparation method of building exterior wall waterproof layer: On the wall surface, an interface treatment layer, a 15mm thick vitrified microsphere mortar leveling layer, a 3mm thick base mortar layer with embedded glass fiber mesh, a 2mm thick surface mortar layer, and a 1.5mm thick polymer cement waterproof layer are set in sequence.

[0060] The dosage of each component of the base mortar and surface mortar materials is shown in Table 1, and the performance test results are shown in Table 2.

[0061] Table 1. Materials and dosage of each component of the base mortar layer and the top mortar layer.

[0062]

[0063] Table 2. Performance test results of polymer composite mortar material in Example 1

[0064]

[0065] The test results in Table 2 show that both the base mortar layer and the top mortar layer prepared with polymer composite mortar material meet the performance requirements for crack-resistant mortar in "Materials for External Wall Insulation Systems with Adhesive Powdered Polystyrene Particles" (JG / T 158-2013), and also meet the performance requirements for polymer cement waterproof mortar in "General Specification for Waterproofing of Building and Municipal Engineering" (GB 55030-2022). Compared with the base mortar and the monolithic mortar, the 28-day shrinkage rate of the top mortar is close to the technical index value of dry-mixed ordinary waterproof mortar in "Premixed Mortar" (GB / T 25181-2019). Therefore, the 3mm+2mm two-layer mortar construction method can effectively reduce the risk of mortar cracking.

[0066] The apparent density of ordinary crack-resistant or waterproof mortar is generally 2000 kg / m³. 3 Therefore, the apparent density of the base layer, top layer, and overall mortar is reduced by about 20%. In addition, through construction tests, the top layer mortar is smooth and glossy without any obstacles when applied, while the base layer mortar or overall mortar has obstacles when applied, and the poor smoothness affects the finishing effect. The overall mortar has a bonding strength of up to 1.7MPa, which can effectively reduce the risk of waterproof layer peeling off.

[0067] Therefore, the polymer composite mortar material obtained by using the proportions in this embodiment basically possesses lightweight, crack resistance, waterproofness, high adhesion, and finishing properties, providing a material basis for simplifying the construction process of first-level waterproofing for building exterior walls and reducing the risk of leveling layer mortar falling off.

[0068] Example 2

[0069] Compared with Example 1, the only difference in this example is that the dosage of each component in the bottom mortar layer and the top mortar layer is different; the dosage of each component in the bottom mortar layer and the top mortar layer in this example is shown in Table 3, and the performance test results are shown in Table 4.

[0070] Table 3. Dosage of each component in the base mortar layer and the surface mortar layer

[0071]

[0072] Table 4. Performance test results of polymer composite mortar materials in Example 2

[0073]

[0074] As shown in Table 4, both the base mortar layer and the top mortar layer prepared with polymer composite mortar material meet the performance requirements for crack-resistant mortar in "Materials for External Thermal Insulation Systems of Polystyrene Particles for Buildings" (JG / T 158-2013) and the performance requirements for polymer cement waterproof mortar in "General Specification for Waterproofing of Buildings and Municipal Engineering" (GB 55030-2022). The 28-day shrinkage rate of both the base mortar and the top mortar layer meets the technical requirements for dry-mixed ordinary waterproof mortar in "Premixed Mortar" (GB / T 25181-2019). The apparent density of both the base mortar layer and the top mortar layer is reduced by approximately 24% compared to ordinary crack-resistant mortar or waterproof mortar. The overall mortar bonding strength reaches 2.0 MPa, which can better prevent the risk of detachment of the building's external wall waterproof layer. Furthermore, the workability test revealed that the top mortar layer can be smoothly and glossily applied without obstruction during plastering. The polymer composite mortar material prepared in this embodiment has better overall performance than the polymer composite mortar material prepared in Example 1.

[0075] Example 3

[0076] Compared with Example 1, the only difference in this example is that the amount of each component in the bottom mortar layer and the top mortar layer is different; the amount of each component in the bottom mortar layer material and the top mortar layer material in this example is shown in Table 5, and the measurement results are shown in Table 6.

[0077] Table 5. Dosage of each component in the base mortar layer and the top mortar layer

[0078]

[0079] Table 6. Performance test results of polymer composite mortar materials in Example 3

[0080]

[0081] As shown in Table 6, both the base mortar layer and the top mortar layer prepared with the polymer composite mortar material meet the performance requirements for crack-resistant mortar in the standard "Materials for External Wall Insulation Systems with Adhesive Powdered Polystyrene Particles" (JG / T 158-2013), and also meet the performance requirements for polymer cement waterproof mortar in the standard "General Specification for Waterproofing of Building and Municipal Engineering" (GB 55030-2022). The apparent density of both the base and top layers is reduced by approximately 22.5% compared to ordinary crack-resistant or waterproof mortar, and the overall bond strength of the mortar is 1.8 MPa. The overall performance of the polymer composite mortar prepared in this embodiment is better than that of Example 1, but slightly worse than that of the polymer composite mortar prepared in Example 2.

[0082] Example 4

[0083] Compared with Example 1, the only difference in this example is that the amount of each component in the bottom mortar layer and the top mortar layer is different; the amount of each component in the bottom mortar layer and the top mortar layer in this example is shown in Table 7, and the measurement results are shown in Table 8.

[0084] Table 7. Dosage of each component in the base mortar layer and the top mortar layer

[0085]

[0086] Table 8 Performance test results of polymer composite mortar materials in Example 4

[0087]

[0088] As shown in Table 8, both the base mortar and top mortar prepared from the polymer composite mortar material meet the performance requirements for crack-resistant mortar in the "Materials for External Wall Insulation Systems of Polystyrene Particles" (JG / T 158-2013) and the performance requirements for polymer cement waterproof mortar in the "General Specification for Waterproofing of Building and Municipal Engineering" (GB 55030-2022). The apparent density of both the base mortar and top mortar is about 19% lower than that of ordinary crack-resistant or waterproof mortar. The overall bonding strength of the mortar is 1.5 MPa, which is lower than that of Examples 1-3, but still meets the performance requirements. The overall performance of the polymer composite mortar prepared in this example is lower than that of the polymer composite mortar in Examples 1-3.

[0089] Example 5

[0090] Compared with Example 2, the only difference in this example is that the particle size distribution of the quartz sand in the bottom mortar layer is: composed of quartz sand with a mass ratio of 1:7:1, consisting of quartz sand with a particle size of 20 mesh ≤ particle size < 40 mesh, quartz sand with a particle size of 40 mesh ≤ particle size < 70 mesh, and quartz sand with a particle size of 70 mesh ≤ particle size ≤ 120 mesh.

[0091] Example 6

[0092] Compared with Example 2, the only difference in this example is that the particle size distribution of the quartz sand in the bottom mortar layer is: composed of quartz sand with a mass ratio of 1:7:3, consisting of quartz sand with a particle size of 20 mesh ≤ < 40 mesh, quartz sand with a particle size of 40 mesh ≤ < 70 mesh, and quartz sand with a particle size of 70 mesh ≤ 120 mesh.

[0093] Example 7

[0094] Compared with Example 2, the only difference in this example is that the particle size distribution of the quartz sand in the surface mortar layer is: it consists of quartz sand with a mass ratio of 6:3, which is 40 mesh ≤ particle size < 70 mesh and quartz sand with a mass ratio of 70 mesh ≤ particle size ≤ 120 mesh.

[0095] Example 8

[0096] Compared with Example 2, the only difference in this example is that the particle size distribution of the quartz sand in the surface mortar layer is: it consists of quartz sand with a mass ratio of 6:5, which is 40 mesh ≤ particle size < 70 mesh and quartz sand with a mass ratio of 70 mesh ≤ particle size ≤ 120 mesh.

[0097] The results of the determination of the overall mortar bonding strength in Examples 5-8 are shown in Table 9 below.

[0098] Table 9 Results of Overall Mortar Bond Strength Test

[0099]

[0100] As shown in Table 9, the bonding strength of the overall mortar in Examples 5-8 of this invention is lower than that in Example 2. However, the bottom mortar layer and top mortar layer prepared by the polymer composite mortar material in Examples 5-8 all meet the performance requirements of crack-resistant mortar in "Materials for External Wall Insulation Systems of Adhesive Powder Polystyrene Particles" (JG / T 158-2013), and also meet the performance requirements of polymer cement waterproof mortar in "General Specification for Waterproofing of Building and Municipal Engineering" (GB 55030-2022). The 28-day shrinkage rate of both the bottom mortar and top mortar meets the technical requirements of dry-mixed ordinary waterproof mortar in "Premixed Mortar" (GB / T 25181-2019).

[0101] Comparative Example 1

[0102] Compared with Example 3, the only difference in this comparative example is that neither the bottom layer mortar nor the top layer mortar contains silica aerogel; the test results are shown in Table 10.

[0103] Table 10 Performance test results of polymer composite mortar materials in Example 3 and Comparative Example 1

[0104]

[0105] As can be seen from the measurement results in Table 10, the apparent density of both the bottom mortar layer and the top mortar layer without silica aerogel is 2000 kg / m³. 3 Its apparent density is similar to that of ordinary crack-resistant mortar or waterproof mortar. However, by incorporating silica aerogel, the apparent density of polymer composite mortar can be reduced by 22.5%. Therefore, by incorporating a certain amount of silica aerogel, the lightweight nature of polymer composite mortar materials can be achieved.

[0106] Comparative Example 2

[0107] Compared with Example 3, the only difference in this comparative example is that neither the bottom mortar layer nor the top mortar layer contains waterproofing agent. The test results are shown in Tables 11-12.

[0108] Table 11 Performance Indicators of Polymer Composite Mortar Base Layer

[0109]

[0110] Table 12 Performance Indicators of Polymer Composite Mortar Surface Layer

[0111]

[0112] The measured results in Tables 11 and 12 show that the impermeability pressure of the base and surface mortar specimens without silicone waterproofing agent does not meet the performance index requirements for polymer cement waterproofing mortar in the "General Specification for Waterproofing of Building and Municipal Engineering" (GB 55030-2022). Therefore, by adding a certain amount of silicone waterproofing agent, polymer composite mortar materials can be given certain waterproofing properties.

[0113] Comparative Example 3

[0114] Compared with Example 3, the only difference in this comparative example is that neither the bottom mortar layer nor the top mortar layer contains polypropylene fibers. The test results are shown in Tables 13-14.

[0115] Table 13 Performance Indicators of the Underlying Mortar Layer

[0116]

[0117] Table 14 Performance Indicators of Surface Mortar Layer

[0118]

[0119] The test results in Tables 13 and 14 show that the compression-flexural ratio of the bottom and top mortar layers without polypropylene fibers does not meet the performance requirements for crack-resistant mortar in the standard "Materials for External Wall Insulation Systems with Adhesive Powdered Polystyrene Particles" (JG / T 158-2013). Therefore, incorporating a certain amount of polypropylene fibers can impart certain crack-resistant properties to polymer composite mortar materials.

[0120] Comparative Example 4

[0121] Compared with Example 3, the only difference in this comparative example is that the bottom mortar layer does not contain quartz sand with a particle size of 20 mesh ≤ < 40 mesh, and the amount of quartz sand with a particle size of 40 mesh ≤ < 70 mesh and quartz sand with a particle size of 70 mesh ≤ 120 mesh in the bottom mortar is the same as that in the surface mortar.

[0122] The measurement results are shown in Tables 15 and 16.

[0123] Table 15 Test results of shrinkage performance of the base mortar

[0124]

[0125] Table 16 Results of the test of the bond strength of the integral mortar in Comparative Example 4

[0126]

[0127] As can be seen from the measurement results in Tables 15 and 16, compared with Example 3, the shrinkage rate of the bottom polymer composite mortar in Comparative Example 4 increased after 28 days, while the overall bonding strength of the mortar was the same as that in Example 3.

[0128] Comparative Example 5

[0129] Compared with Example 3, the only difference in this comparative example is that the surface mortar layer contains quartz sand with a particle size of 20 mesh ≤ < 40 mesh, and the amount of quartz sand with a particle size of 20 mesh ≤ < 40 mesh, 40 mesh ≤ < 70 mesh, and 70 mesh ≤ < 120 mesh in the surface mortar is the same as the amount in the bottom mortar layer.

[0130] The measurement results are shown in Tables 17 and 18.

[0131] Table 17 Performance Indicators of Surface Mortar Layer

[0132]

[0133] Table 18 Performance Indicators of Integral Mortar Layer

[0134]

[0135] As can be seen from the test results in Tables 17-18, in Comparative Example 5, the quartz sand was composed of quartz sand with a mass ratio of 1:7:2, consisting of quartz sand with a particle size of 20 mesh ≤ < 40 mesh, quartz sand with a particle size of 40 mesh ≤ < 70 mesh, and quartz sand with a particle size of 70 mesh ≤ 120 mesh. The mortar application was hindered and the surface was rough, which affected the finishing effect. Furthermore, the overall bonding strength of the mortar was lower than that in Example 3.

[0136] Comparative Example 6

[0137] Compared with Example 3, the only difference in this comparative example is the different particle size distribution of quartz sand in the bottom mortar layer and the top mortar layer, as shown in Table 19. The measurement results are shown in Table 20 below.

[0138] Table 19. Particle size distribution of quartz sand in base mortar and surface mortar

[0139]

[0140] Table 20 Test performance of integral mortar layer

[0141]

[0142] As can be seen from the test results in Table 20, if the particle size distribution of quartz stone in the surface mortar layer and the bottom mortar layer is interchanged, the overall bonding strength of the resulting mortar is basically the same as that in Example 3, but the workability is worse, the smoothness of the outer layer of mortar is worse, and the finishing effect is affected.

[0143] Comparative Example 7

[0144] Compared with Example 3, the only difference in this comparative example is that:

[0145] The particle size distribution of the quartz sand in the bottom mortar layer is as follows: it consists of quartz sand with a mass ratio of 1:2:7, which are 20 mesh ≤ particle size < 40 mesh, 40 mesh ≤ particle size < 70 mesh, and 70 mesh ≤ particle size ≤ 120 mesh.

[0146] The particle size distribution of the quartz sand in the surface mortar layer is as follows: it consists of quartz sand with a mass ratio of 6:4, with a particle size of 40 mesh ≤ particle size < 70 mesh and quartz sand with a particle size of 70 mesh ≤ particle size ≤ 120 mesh.

[0147] Comparative Example 8

[0148] Compared with Example 3, the only difference in this comparative example is that:

[0149] The particle size distribution of the quartz sand in the bottom mortar layer is as follows: it consists of quartz sand with a mass ratio of 1:7:2, which are 20 mesh ≤ particle size < 40 mesh, 40 mesh ≤ particle size < 70 mesh, and 70 mesh ≤ particle size ≤ 120 mesh.

[0150] The particle size distribution of the quartz sand in the surface mortar layer is as follows: it consists of quartz sand with a mass ratio of 4:6, with a particle size of 40 mesh ≤ particle size < 70 mesh and quartz sand with a particle size of 70 mesh ≤ particle size ≤ 120 mesh.

[0151] Table 21 Performance test results of monolithic mortars in Comparative Examples 7-8

[0152]

[0153] In Comparative Examples 7 and 8, the particle size distribution of quartz sand, which constitutes the largest proportion of the base mortar and surface mortar, was changed. As a result, the overall bond strength and workability of the mortar in Comparative Examples 7 and 8 were much lower than those in Example 3. The reason for this is that the consistency of the mortar in Comparative Examples 7 and 8 was reduced or almost non-existent, which made it impossible to form the specimens, thus resulting in poorer bond strength and workability.

[0154] The base mortar layer and top mortar layer prepared from the polymer composite mortar materials in Comparative Examples 1-6 all meet the performance requirements for crack-resistant mortar in "Materials for External Wall Insulation Systems of Polystyrene Particles" (JG / T 158-2013), and also meet the performance requirements for polymer cement waterproof mortar in "General Specification for Waterproofing of Building and Municipal Engineering" (GB 55030-2022). The 28-day shrinkage rate of both the base mortar and top mortar meets the technical requirements for dry-mixed ordinary waterproof mortar in "Premixed Mortar" (GB / T 25181-2019), while Comparative Examples 7-8 do not simultaneously meet the requirements of the above standards.

[0155] Comparative Example 9

[0156] Compared with Example 3, the only difference in this comparative example is that:

[0157] Both the base mortar and the top mortar were replaced with 5mm thick Class I waterproof traditional crack-resistant mortar or traditional polymer waterproof mortar for exterior walls. The mix proportions of Class I waterproof traditional crack-resistant mortar and traditional polymer waterproof mortar for exterior walls are shown in Table 22, and the test results are shown in Table 23.

[0158] Table 22 Dosage of each component in traditional crack-resistant mortar and traditional polymer waterproof mortar for Grade I waterproofing of building exterior walls

[0159]

[0160] Table 23 Performance test results of the two mortar materials in Comparative Example 9

[0161]

[0162] As shown in Table 23, while traditional crack-resistant mortar meets the performance requirements of crack-resistant mortar in the "Materials for External Thermal Insulation Systems of Polystyrene Particles" (JG / T 158-2013), its impermeability and frost resistance do not meet the requirements of polymer cement waterproof mortar in the "General Specification for Waterproofing of Building and Municipal Engineering" (GB 55030-2022). Furthermore, while the waterproofing performance of traditional waterproof mortar meets the requirements of polymer cement waterproof mortar in the "General Specification for Waterproofing of Building and Municipal Engineering" (GB 55030-2022), its compressive-flexural ratio does not meet the performance requirements of crack-resistant mortar in the "Materials for External Thermal Insulation Systems of Polystyrene Particles" (JG / T 158-2013). Therefore, in traditional Class I waterproofing construction, achieving crack-resistant and waterproof effects can only be achieved by increasing the thickness of the crack-resistant and waterproof mortar layer.

[0163] Compared to Example 3, its base and top mortar layers simultaneously possess crack resistance and waterproofing properties, and its performance indicators are significantly improved compared to traditional crack-resistant or waterproof mortars. Therefore, while meeting the requirements for crack resistance and waterproofing, the thickness of two mortar layers can be reduced, achieving the goal of reducing the load on the waterproofing layer structure itself. Taking Comparative Example 9 and Example 3 as examples: the apparent density of the crack-resistant and waterproof mortar in Comparative Example 9 is 2000 kg / m³. 3 A 10mm thick mortar layer weighs 20.0kg per square meter; the apparent density of the polymer composite mortar in Example 3 is 1550kg / m³. 3 A 5mm thick mortar layer weighs 7.75kg per square meter. Compared to traditional crack-resistant mortar layers for waterproofing, the load is reduced by approximately 61.3%.

[0164] Compared with Example 3, the bonding strength of traditional crack-resistant mortar or polymer waterproof mortar is much lower than that of the integral mortar in Example 3. Therefore, the present invention not only reduces the risk of waterproof layer falling off by reducing the load on the waterproof layer itself, but also further improves the bonding strength of the integral mortar in the waterproof layer, which can further avoid the risk of waterproof layer falling off.

[0165] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A polymer composite mortar material for waterproofing layers of building exterior walls, characterized in that, The building exterior wall waterproofing layer consists of an interface treatment layer, a vitrified microsphere mortar leveling layer, a bottom mortar layer with embedded glass fiber mesh, a top mortar layer, and a polymer cement waterproofing layer, which are sequentially arranged on the wall surface; the materials of the top mortar layer and the bottom mortar layer are both polymer composite mortar materials. The surface mortar layer and the base mortar layer each independently comprise the following components by weight: 260-305 parts ordinary silicate cement, 40-50 parts rapid-hardening sulfoaluminate cement, 40-50 parts talc powder, 525-622 parts quartz sand, 10-15 parts redispersible latex powder, 20-40 parts silica aerogel, 2-3 parts cellulose ether, 4-6 parts waterproofing agent, 0.1-0.3 parts air-entraining agent, 0.3-0.5 parts starch ether, 0.1-0.3 parts water-reducing agent, 2-3 parts lignocellulose, and 1-1.5 parts polypropylene fiber; The particle size distribution of quartz sand in the bottom mortar layer and the top mortar layer is different; The quartz sand in the bottom mortar layer is composed of quartz sand with a mass ratio of 1:7:2, consisting of quartz sand with a particle size of 20 mesh ≤ < 40 mesh, quartz sand with a particle size of 40 mesh ≤ < 70 mesh, and quartz sand with a particle size of 70 mesh ≤ 120 mesh. The quartz sand in the surface mortar layer consists of quartz sand with a mass ratio of 6:4, consisting of quartz sand with a particle size of 40 mesh ≤ < 70 mesh and quartz sand with a particle size of 70 mesh ≤ ≤ 120 mesh.

2. The polymer composite mortar material for waterproofing building exterior walls according to claim 1, characterized in that, The air-entraining agent includes sodium dodecylbenzenesulfonate, the water-reducing agent includes polycarboxylate water-reducing agent, and the waterproofing agent includes silicone waterproofing agent.

3. The polymer composite mortar material for waterproofing building exterior walls according to claim 1, characterized in that, The polymer cement waterproof layer uses JS-II or JS-III type polymer cement waterproof material.

4. The polymer composite mortar material for waterproofing building exterior walls according to claim 1, characterized in that, The thickness of the vitrified microsphere mortar leveling layer is 15mm, and the thickness of the polymer cement waterproof layer is 1.5mm.

5. The polymer composite mortar material for waterproofing building exterior walls according to claim 1, characterized in that, The thickness of the surface mortar layer is 2mm, and the thickness of the bottom mortar layer is 3mm.

6. A method for preparing a polymer composite mortar material for waterproofing building exterior walls, used to prepare the polymer composite mortar material for waterproofing building exterior walls as described in any one of claims 1 to 5, characterized in that, Includes the following steps: After mixing each component of the surface mortar layer and the bottom mortar layer with water, polymer composite mortar materials for the surface mortar layer and the bottom mortar layer are obtained respectively.

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