Epoxy terrazzo floor system with multi-layer composite anti-crack structure and method

Abstract

The invention relates to the technical field of epoxy terrazzo terraces, and provides an epoxy terrazzo terrace system with a multi-layer composite anti-crack structure and a method, the epoxy terrazzo terrace system comprises a base layer, an anti-crack mortar layer, a three-layer composite anti-crack structure and an epoxy terrazzo surface layer which are sequentially arranged from bottom to top; the three-layer composite anti-cracking structure comprises an elastic resin layer, a rigid resin layer and a glass fiber cloth layer which are sequentially arranged from bottom to top. According to the epoxy terrazzo three-layer anti-crack structure based on rigid resin stress relay diffusion, the problems that an existing epoxy terrazzo system cracks frequently under the action of complex stress, the service life is short, and maintenance is frequent are effectively solved through a soft-rigid-fiber cooperative stress control mechanism.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of epoxy terrazzo floor, and particularly relates to an epoxy terrazzo floor system with a multi-layer composite anti-cracking structure and a method. BACKGROUND

[0002] With the improvement of the functional and aesthetic needs of modern large public buildings, the physical properties, service life and aesthetics of the floor system are increasingly valued. Epoxy terrazzo has been widely used in high-end places due to its strong decorative, wear-resistant, easy-to-clean, seamless and beautiful advantages. However, the existing epoxy terrazzo construction system generally has the problem of insufficient anti-cracking performance in long-term use, especially in areas with frequent structural settlement, temperature and humidity changes or load concentration, which is prone to cracking, affecting the safety and appearance integrity.

[0003] Traditional solutions mainly include: 1. Single anti-cracking design, such as laying fiberglass cloth or setting rigid resin layer on the base layer; 2. Using flexible resin or soft material as a buffer layer. However, these single measures have limited effect in dealing with multi-source complex stress, lack of hierarchical anti-cracking mechanism, and are difficult to effectively control the crack source and system buffer stress. In addition, the elastic modulus transition between materials is insufficient, which is easy to form a new stress concentration point at the interface, leading to new damage. The existing technology cannot balance the flexibility of the buffer, the rigidity of the support and the anti-cracking performance, and a new type of floor anti-cracking structure system with gradient elastic modulus design and multi-level collaborative stress dispersion mechanism is needed to improve its overall performance in complex use environment.

[0004] In addition, the existing anti-cracking design often uses flexible absorption layer or fiberglass reinforced layer alone or in combination, but such solutions lack a transition structure between materials, which is easy to form a stress concentration area at the flexible-rigid interface or fiber laying interface, becoming a crack source point. Especially under the conditions of multiple temperature and humidity changes or load impact, interface delamination, crack penetration and other problems still occur frequently, which is difficult to guarantee the integrity and service life of the floor for a long time. Therefore, a new anti-cracking structure system with reasonable structure transition, material collaborative characteristics and stress path regulation ability is needed to effectively improve the overall performance and crack control ability of the floor system. SUMMARY

[0005] In view of the deficiencies of the prior art, the present application provides an epoxy terrazzo floor system with a multi-layer composite anti-cracking structure and a method, based on a three-layer anti-cracking structure of epoxy terrazzo with rigid resin stress relay diffusion, through a "flexible-rigid-fiber" collaborative stress control mechanism, effectively solving the problems of frequent cracking, short service life and frequent maintenance of the existing epoxy terrazzo system under complex stress.

[0006] To achieve the above-mentioned purpose, the present application provides the following technical solutions: In a first aspect, the present application provides an epoxy terrazzo floor system with a multi-layer composite crack-resistant structure, comprising, from bottom to top, a base layer, a crack-resistant mortar layer, a three-layer composite crack-resistant structure, and an epoxy terrazzo surface layer; the three-layer composite crack-resistant structure comprises, from bottom to top, an elastic resin layer, a rigid resin layer, and a glass fiber cloth layer.

[0007] Further, the elastic resin layer is an elastic epoxy resin layer with a thickness of 0.3-1.0 mm; the Shore hardness of the elastic resin layer is A60 to A70.

[0008] Further, the rigid resin layer is an epoxy resin layer with a thickness of 0.5-1.2 mm; the Shore hardness of the rigid resin layer is D70 to D80.

[0009] Further, the glass fiber cloth layer is wrapped with epoxy resin and is adhesively laid on the rigid resin layer.

[0010] Further, the glass fiber cloth layer has a grammage of 160 g / m² to 200 g / m², and adjacent glass fiber cloth layers are overlapped, with an overlapping width of no less than 50 mm.

[0011] Further, the base layer comprises a single-layer bidirectional steel mesh and a lightweight concrete layer laid on the single-layer bidirectional steel mesh; a non-woven fabric is arranged between the lightweight concrete layer and the crack-resistant mortar layer.

[0012] In a second aspect, the present application provides a construction method of an epoxy terrazzo floor system with a multi-layer composite crack-resistant structure, comprising the following steps: constructing a base layer on a structural floor slab; constructing a crack-resistant mortar layer on the base layer; constructing a three-layer composite crack-resistant structure: applying an elastic epoxy resin on the crack-resistant mortar layer to form an elastic resin layer, and curing at room temperature; after the elastic resin layer is completely cured, applying an epoxy resin layer on the elastic resin layer to form a rigid resin layer, and ensuring that the surface is free of bubbles and delamination, and curing at room temperature until completely dry; laying a glass fiber cloth layer on the rigid resin layer, and using epoxy resin to fully soak and bond the glass fiber cloth layer to the rigid resin layer, and ensuring that there are no bubbles and wrinkles, and the whole is cured and formed after laying; after the three-layer composite crack-resistant structure is completely cured, laying an epoxy terrazzo surface layer.

[0013] Further, the elastic resin layer is an elastic epoxy resin layer with a thickness of 0.3-1.0 mm; the Shore hardness of the elastic resin layer is A60 to A70.

[0014] Further, the rigid resin layer is an epoxy resin layer with a thickness of 0.5-1.2 mm; the Shore hardness of the rigid resin layer is D70 to D80.

[0015] Further, the glass fiber cloth layer has a grammage of 160 g / m2 to 200 g / m2, and adjacent glass fiber cloth layers are overlapped, and the overlapping width is not less than 50 mm.

[0016] The beneficial effects of the present application are: the present application forms a low-to-high elastic modulus gradient system by constructing a three-layer composite anti-cracking structure composed of an elastic resin layer, a rigid resin layer and a glass fiber cloth layer, which realizes a synergistic stress control mechanism of "flexible buffer-rigid support-fiber stretching". The rigid resin layer is arranged in the middle layer, and through its high modulus attribute, it disperses and delays the stress absorbed by the lower flexible layer, at the same time, it serves as a barrier layer for crack propagation, reduces the concentrated stress points, effectively prevents micro-cracks from forming and expanding, and improves the cohesion and interface stability of the structure. The rigid resin layer in the present application not only exists as a structure reinforcing layer, but also as a synergistic intermediate layer between the elastic resin layer and the glass fiber cloth layer. Through the "modulus step" effect, it realizes the secondary dispersion and horizontal diffusion of stress in the structure. The rigid layer effectively blocks the direct transmission of deformation stress absorbed by the flexible layer upwards, thereby delaying crack triggering and weakening stress peaks, forming a key connecting component of the "flexible-rigid-fiber" multi-level anti-cracking system. Through this design, the stress conduction synergy, structure modulus matching synergy and crack barrier synergy among the three layers are realized, which significantly improves the overall anti-cracking ability and durability of the system, especially under the condition of multiple source stress superposition, it has outstanding engineering adaptability and stability.

[0017] Through simulation and actual measurement data verification, compared with the traditional double-layer anti-cracking structure (such as "elastic + glass fiber" structure), the epoxy terrazzo floor system configured with the three-layer composite anti-cracking structure of the present application has an improved stress dispersion rate of about 42%, a crack appearance delay time of about 2.3 times, and an edge and corner integrity rate of more than 95%, which exhibits better anti-cracking stability and service life in a multi-source cross stress environment.

[0018] The floor system is particularly suitable for tropical high-temperature and high-humidity areas such as Southeast Asia, and can effectively deal with floor deformation caused by temperature and humidity changes and structure settlement, improving engineering applicability and stability.

[0019] It is suitable for high-standard durable floor engineering of airports, high-speed rail stations, commercial complexes and the like, and has good industrialization promotion potential.

[0020] In summary, the present application provides a high-performance anti-cracking solution for an epoxy terrazzo floor system that takes into account novel structural design and practical technical effects, and has important technical innovation and wide application prospects. BRIEF DESCRIPTION OF DRAWINGS

[0021] Figure 1The structural schematic diagram of the epoxy terrazzo floor system with the multilayer composite anti-cracking structure of the present application.

[0022] Figure 2 The structural schematic diagram of the three-layer composite anti-cracking structure of the present application.

[0023] Figure 3 The method flow schematic diagram of the present application.

[0024] In the figure: 1.1-single layer bidirectional steel mesh; 1.2-lightweight concrete layer; 2.1-non-woven fabric; 2.2-anti-cracking mortar layer; 2.3-expansion joint; 3-three-layer composite anti-cracking structure; 3.1-elastic resin layer; 3.2-rigid resin layer; 3.3-glass fiber cloth layer; 4-epoxy terrazzo surface layer; 4.1-dense protective layer; 5-L-shaped copper strip. DETAILED DESCRIPTION

[0025] The present application is further described in detail below in combination with the accompanying drawings and specific examples.

[0026] As shown in Figure 1 , Figure 2 The epoxy terrazzo floor system with the multilayer composite anti-cracking structure, comprising, from bottom to top, a base layer, an anti-cracking mortar layer 2.2, a three-layer composite anti-cracking structure 3, and an epoxy terrazzo surface layer 4; the three-layer composite anti-cracking structure 3 comprises, from bottom to top, an elastic resin layer 3.1, a rigid resin layer 3.2, and a glass fiber cloth layer 3.3.

[0027] The elastic resin layer 3.1 is a 0.3-1.0 mm thick elastic epoxy resin layer; the Shore hardness of the elastic resin layer 3.1 is A60 to A70. The rigid resin layer 3.2 is a 0.5-1.2 mm thick epoxy resin layer; the Shore hardness of the rigid resin layer 3.2 is D70 to D80. The glass fiber cloth layer 3.3 is wrapped with epoxy resin and is adhesively laid on the rigid resin layer 3.2. The glass fiber cloth layer 3.3 has a grammage of 160 g / m² to 200 g / m², and adjacent glass fiber cloth layers 3.3 are overlapped, with an overlapping width of not less than 50 mm.

[0028] The base layer comprises a single layer bidirectional steel mesh 1.1 and a lightweight concrete layer 1.2 laid on the single layer bidirectional steel mesh 1.1; a non-woven fabric 2.1 is arranged between the lightweight concrete layer 1.2 and the anti-cracking mortar layer 2.2. A dense protective layer 4.1 is further arranged on the epoxy terrazzo surface layer 4.

[0029] An expansion joint 2.3 is further arranged on the lightweight concrete layer 1.2 and the anti-cracking mortar layer 2.2, and a 3 mm x 8 mm L-shaped copper strip 5 is embedded as a structural separation at the expansion joint 2.3 or the interface between the floor system and different materials such as ceramic tiles, marble, equipment, etc.

[0030] The rigid resin layer 3.2 of the present application not only provides high-strength support, but also forms a modulus gradient transition zone between the upper and lower layers of materials (the elastic resin layer 3.1 and the glass fiber cloth layer 3.3), effectively reducing the interface stress concentration and improving the structural consistency and mechanical coordination of the overall composite layer. As an intermediate layer, it also plays a buffering barrier role in absorbing stress of the lower layer and delays the crack propagation along the stress path upward, which is a key component of the three-layer structure anti-cracking synergy mechanism. This sequential design is not arbitrary superposition, but a mechanical optimization result based on the elastic modulus of the material and the stress diffusion path. The rigid resin layer 3.2 must be located between the elastic resin layer 3.1 and the glass fiber cloth layer 3.3 to play the stress redistribution and "buffer relay" function; if the construction sequence is reversed or the rigid resin layer 3.2 is omitted, the stress absorbed by the elastic resin layer 3.1 cannot be smoothly transferred to the glass fiber cloth layer 3.3, thereby increasing the risk of interface stress concentration and easily causing early damage such as delamination and cracking.

[0031] After the elastic resin layer 3.1 absorbs the small deformation of the base layer, the stress is diffused and buffered through the rigid resin layer 3.2, avoiding concentrated transmission to the glass fiber cloth layer 3.3 to cause interface warping or fiber shear failure. Therefore, the rigid resin layer 3.2 plays a dual role of "relay diffuser" and "distributed buffer" in the stress transmission path, which can realize multi-level dispersion of crack propagation path, delay development and partition dissipation of stress energy while keeping the structure of the glass fiber cloth layer 3.3 and the performance of the elastic resin layer 3.1 unchanged.

[0032] This structural combination forms a multi-level coupled anti-cracking mechanism of "flexible absorption-rigid diffusion-fiber blocking", which belongs to a nonlinear stress path design and has novelty and synergy in mechanical behavior, and is a composite performance improvement means not provided by the prior art.

[0033] As shown in Figure 3 Based on the same inventive concept, the present application also provides a construction method of an epoxy terrazzo floor system with a multi-layer composite anti-cracking structure, comprising the following steps: Step 1, base layer treatment A single-layer bidirectional steel mesh 1.1 is laid on the structural floor, then a light weight concrete layer 1.2 is laid, the thickness is determined according to the design requirements, and standard curing is carried out for 7 days; (2) Cut a 6m x 6m grid expansion joint 2.3 on the concrete surface of the light weight concrete layer 1.2, the joint width of the expansion joint 2.3 is 3mm, and the depth is 40mm, to control the deformation stress concentration caused by thermal expansion and contraction of the structure. Clean the structure base layer to ensure no dust, oil stains and moisture.

[0034] Step 2, anti-cracking mortar layer 2.2 construction (also known as anti-cracking leveling layer construction) (1) On the lightweight concrete layer 1.2 of step 1, lay 120 g / m2 non-woven fabric 2.1 as an interface isolation layer; (2) Spread a 50 mm thick anti-cracking mortar layer 2.2 with a ratio of SRS leveling mortar additive: cement: medium sand = 1:2:3. Use a troweling machine to perform surface finishing treatment; (3) After 72 hours of maintenance, cut the expansion joint 2.3 again, 6 m x 6 m, with a width of 3 mm and a depth of 20 mm; (4) Clean the whole body to ensure no dust, oil stains and clear water for the adhesion of the resin layer.

[0035] Step 3, elastic resin layer 3.1 construction (1) Use a roller to evenly apply a special primer with a unit coverage of not less than 100 g / m2; (2) Prepare the elastic epoxy resin and apply it with a thickness of 0.5 mm ± 0.2 mm to form a flexible anti-cracking inhibition layer, which is cured at room temperature for not less than 24 hours (based on 25°C).

[0036] Step 4, rigid resin layer 3.2 construction After the elastic resin layer 3.1 is completely cured, evenly apply the high modulus epoxy resin layer with a thickness control of 0.8 mm ± 0.3 mm, and ensure that the surface is free of bubbles and delamination, and is completely dry after curing at room temperature.

[0037] Step 5, glass fiber cloth layer 3.3 laying Lay 160 g / m2 anti-cracking glass fiber cloth horizontally on the rigid resin layer 3.2 to form the glass fiber cloth layer 3.3, with an overlapping width of not less than 50 mm between adjacent cloths. Use epoxy resin to fully soak and bond the anti-cracking glass fiber cloth to the resin layer, ensuring that there are no bubbles or wrinkles, and the whole is cured and formed after laying.

[0038] Step 6, epoxy terrazzo surface layer 4 construction (1) After the three-layer composite anti-cracking structure 3 is completely cured, lay a 10-12 mm thick epoxy terrazzo surface layer 4. Mix the A component (main agent) and the B component (curing agent) of the resin in a ratio of 4:1, then add aggregates with a particle size of ≤10 mm, with a resin: aggregate mass ratio of 1:3; (2) Spread the mixed material on the glass fiber cloth layer 3.3 and compact it with a screed, ensuring that the final apparent density is ≥2.2 g / cm3; (3) After 48 hours of curing at room temperature, perform three-stage grinding in sequence: Coarse grinding: use a 15 kW heavy-duty grinder with a 50 mesh diamond grinding wheel, and use a 2 m ruler to detect flatness with an error of ±3 mm; Medium grinding: Replace with 120-mesh resin grinding discs, add water for wet grinding, and expose uniform aggregate texture; Grouting: After medium grinding and drying for 8 hours, use fine grout (aggregate particle size ≤ 5mm) with the same ratio as epoxy terrazzo surface layer 4 to perform grouting treatment with a thickness of 0.3 to 0.5mm, and cure for 12 hours; Fine grinding: Dry grinding with 300-mesh resin grinding discs, with a final surface roughness Ra≤0.5μm.

[0039] Step 7: Gap and Joint Treatment (1) At the expansion joint 2.3 or at the junction of different materials such as tiles, marble, and equipment, embed a 3mm×8mm L-shaped copper strip 5 as a structural separator, and fix it with epoxy glue and dry fine sand. The elevation error is controlled within ±2mm. (2) The expansion joint 2.3 is filled with elastic polyurethane sealing material to absorb the displacement deformation caused by thermal expansion and contraction of the material, and to ensure the integrity and durability of the system.

[0040] Step 8: Surface densification and protection treatment Apply a penetrating epoxy protective agent using a high-speed polishing machine, and repeat the treatment three times to form a dense protective film with a thickness of 0.1 to 0.2 mm, which enhances the surface's resistance to pollution, water stains, and wear.

[0041] Step 9: Quality Control and Effectiveness Verification Verification was achieved through stress simulation calculations and on-site measurement results: Compared to traditional flooring structures, the epoxy terrazzo flooring system of this invention, with its multi-layered composite crack-resistant structure, increases the stress dispersion rate by no less than 40%, reduces the probability of floor cracking by more than 60%, and significantly improves the integrity of corner areas, meeting the requirements of high-standard engineering applications.

[0042] The above are merely preferred embodiments of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principle of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. An epoxy terrazzo flooring system with a multi-layered composite crack-resistant structure, characterized in that, It includes, from bottom to top, a base layer, a crack-resistant mortar layer, a three-layer composite crack-resistant structure, and an epoxy terrazzo surface layer; the three-layer composite crack-resistant structure includes, from bottom to top, an elastic resin layer, a rigid resin layer, and a fiberglass cloth layer.

2. The epoxy terrazzo flooring system with a multi-layered composite crack-resistant structure according to claim 1, characterized in that, The elastic resin layer is a 0.3-1.0 mm thick elastic epoxy resin layer; the Shore hardness of the elastic resin layer is A60 to A70.

3. The epoxy terrazzo flooring system with a multi-layered composite crack-resistant structure according to claim 1, characterized in that, The rigid resin layer is an epoxy resin layer with a thickness of 0.5-1.2 mm; the Shore hardness of the rigid resin layer is D70 to D80.

4. The epoxy terrazzo flooring system with a multi-layer composite crack-resistant structure according to claim 1, characterized in that, The fiberglass cloth layer is wrapped with epoxy resin and bonded to the rigid resin layer.

5. The epoxy terrazzo flooring system with a multi-layered composite crack-resistant structure according to claim 1, characterized in that, The weight of the fiberglass cloth layer is 160g / m² to 200g / m², and adjacent fiberglass cloth layers overlap with an overlap width of not less than 50mm.

6. The epoxy terrazzo flooring system with a multi-layered composite crack-resistant structure according to claim 1, characterized in that, The base layer includes a single-layer bidirectional steel mesh and a lightweight concrete layer laid on the single-layer bidirectional steel mesh; a non-woven fabric is provided between the lightweight concrete layer and the crack-resistant mortar layer.

7. A construction method for an epoxy terrazzo flooring system with a multi-layered composite crack-resistant structure, characterized in that, Includes the following steps: Construct the base layer on the structural floor slab; Apply a crack-resistant mortar layer to the base layer; Construction of a three-layer composite crack-resistant structure: Apply elastic epoxy resin to the crack-resistant mortar layer to form an elastic resin layer, which is then cured at room temperature; after the elastic resin layer has fully cured, apply an epoxy resin layer on top of the elastic resin layer to form a rigid resin layer, ensuring that there are no bubbles or delamination on the surface, and cure at room temperature until completely dry; lay a fiberglass cloth layer on the rigid resin layer, and use epoxy resin to fully impregnate and bond the fiberglass cloth layer to the rigid resin layer, ensuring that there are no bubbles or wrinkles, and cure the entire structure after installation. After the three-layer composite crack-resistant structure has fully cured, the epoxy terrazzo surface layer is laid.

8. The construction method of the epoxy terrazzo flooring system with a multi-layer composite crack-resistant structure according to claim 7, characterized in that, The elastic resin layer is a 0.3-1.0 mm thick elastic epoxy resin layer; the Shore hardness of the elastic resin layer is A60 to A70.

9. The construction method of the epoxy terrazzo flooring system with a multi-layer composite crack-resistant structure according to claim 7, characterized in that, The rigid resin layer is an epoxy resin layer with a thickness of 0.5-1.2 mm; the Shore hardness of the rigid resin layer is D70 to D80.

10. The construction method of the epoxy terrazzo flooring system with a multi-layer composite crack-resistant structure according to claim 7, characterized in that, The weight of the fiberglass cloth layer is 160g / m² to 200g / m², and adjacent fiberglass cloth layers overlap with an overlap width of not less than 50mm.

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