Environment-friendly mortar composition comprising powder obtained by processing waste glass fibers and process for maintaining and reinforcing structure by using composition

Abstract

The invention provides an environment-friendly mortar composition containing powder obtained by processing waste glass fibers and a process for maintaining and reinforcing a structure by using the composition. According to the method, waste glass fibers (such as glass fibers) generated by building material heat insulation plates are used as materials for maintaining mortar to maintain damaged parts of concrete structures, so that environmental damage caused by waste landfill and the like is reduced, waste recycling is reduced, the economic benefit of waste is reduced, and the economic benefit of the concrete structures is improved. Meanwhile, the technical cost of manufacturing wastes is also reduced. The invention relates to an environment-friendly mortar composition for maintaining a concrete structure and a process for maintaining and reinforcing the concrete structure by using the composition.

Description

Technical Field

[0001] This invention relates to an environmentally friendly mortar composition including powder obtained from processing waste glass fiber, and a process for repairing and reinforcing structures using it. Specifically, it proposes how to utilize waste glass fiber (such as glass fiber) generated from building insulation boards as a repair mortar material for repairing damaged parts of concrete structures, thereby reducing environmental damage caused by waste landfilling, reducing waste recycling, lowering the economic benefits of waste disposal, and also reducing the technical costs of waste production. The invention also relates to an environmentally friendly mortar composition for concrete structure repair and a process for repairing and reinforcing concrete structures using this composition. Background Technology

[0002] After construction, reinforced concrete structures, in addition to salt damage or neutralization, alkali-aggregate reaction, and chemical corrosion, deteriorate due to factors such as water penetration causing steel corrosion and expansion, leading to a decline in long-term durability and usability. If these structures continue to deteriorate, they will eventually lead to the risk of structural collapse, thus requiring continuous management and maintenance.

[0003] Delamination, initial defects, or cracks on the structural surface can promote the movement of deteriorating factors, thereby accelerating the deterioration process. Therefore, in order to ensure the stability and performance of reinforced concrete structures, it is necessary to carry out repair and reinforcement in the early stages of deterioration to inhibit further deterioration and improve durability.

[0004] Therefore, under normal circumstances, after the concrete containing deteriorating factors such as concrete deterioration, steel corrosion, or other reasons causing the structural section to peel off or fall off is removed, in order to restore the section to its original performance and shape, the section repair material is filled or sprayed for repair.

[0005] In the past, the main repair and reinforcement materials used for cross-section repair were cement-based mortar or polymer cement mortar. These traditional repair and reinforcement materials are mostly aimed at inhibiting the deterioration of existing structures and improving their durability. They only focus on improving strength or adhesion during the first application. The surface is easily damaged again shortly after the application, so there are often problems in repair and reinforcement projects.

[0006] For example, Korean Patent Publication No. 2006-0079447 proposes a method for manufacturing a mortar composition by adding CSA (Calcium Sulfoaluminate) and a specified high-micron binder. However, the mortar composition manufactured using the aforementioned materials uses expensive Hauyne-based cement, leading to increased construction costs, and does not achieve satisfactory results in terms of initial setting time and strength.

[0007] In addition, when using existing repair and reinforcement methods, moisture and oxygen seep into the tiny gaps, causing oxygen to corrode the steel bars and water to degrade the concrete. As a result, the repair and reinforcement effect is not lasting, and there is a problem that repair and reinforcement projects need to be carried out frequently.

[0008] As a related technology, Korean Patent No. 10-0582840 proposes to prepare a high-toughness, high-fire-resistant mortar composition by mixing polymer cement mortar, short fibers, refractory powder and other materials in a certain proportion, thereby improving the durability, fire resistance, differential thermal properties and explosion resistance of building and civil structures.

[0009] In addition, Korean Patent No. 10-0659458 proposes a technique to utilize magnetized filling refractory mortar made by mixing polypropylene powder, glass beads, resin beads and other heat-absorbing substances, organic fibers, water-reducing agents and proportioned water into a mixture of cement, blast furnace slag powder, limestone powder and other materials, and a dry mortar composed of residual aggregate, expansion agent, shrinkage reduction agent and other materials. The refractory mortar is then poured and hardened in the space formed between the surface of the concrete component and the panel.

[0010] Furthermore, Korean Patent No. 10-1117634 is a refractory mortar composition composed of a binder containing cement, slag and an expanding agent, silica gel powder, inorganic salt additives containing silane flame and potassium sulfate, additives containing EVA resin and PP resin, melamine rheology modifiers, thickeners, etc. By adding the aforementioned inorganic salt additives, stable pressure resistance and high temperature resistance can be achieved.

[0011] In addition, Korean Patent No. 10-1016156 proposes a refractory mortar composed of binder, Pfizer, melamine rheology modifier and aggregate to be applied to the surface of concrete structures. By increasing the amount of Pfizer added, the refractory mortar is given excellent strength and the fire resistance and heat insulation of the concrete structures are improved.

[0012] Similarly, it is understood that most previous technologies claimed to improve thermal insulation and durability by adjusting the proportion of some components in the concrete composition or by adding materials, but the degree of improvement was not significant.

[0013] In addition, most repair mortar compositions have historically been inadequate in terms of durability and physical properties, especially in harsh environments, where the development of technologies to increase fire resistance and fire resistance remains sluggish.

[0014] On the other hand, glass fibers, such as glass fiber, are widely used as insulation materials in building insulation boards. These glass fibers are discarded when buildings are demolished or building materials are disposed of, causing environmental problems.

[0015] These glass fibers have been partially recycled, but the recycling rate is not high. Due to their own aggregation, they are difficult to mix with other materials, especially for building materials, or research on building materials is still not active.

[0016] Therefore, utilizing recycled glass fiber (RGF) from construction sites or waste generated at construction sites as powder for concrete structure repair mortar can reduce environmental damage caused by waste landfill, achieve the effects of waste reuse and saving waste disposal costs, stabilize cement prices, and reduce carbon emissions. The development of industrial waste reuse technologies is therefore essential. Summary of the Invention

[0017] The problem that the invention aims to solve

[0018] This invention was developed to overcome the problems and limitations of traditional technologies. When repairing damaged concrete structures, it not only possesses excellent adhesion and durability, but also good resistance to salt, neutralization, and chemical conditions. Its durability and physical properties ensure long-term maintenance of repair effects while also exhibiting good chemical resistance and seismic resistance. It is suitable for repair work in harsh environments and meets requirements for low rebound, compressive strength, and torsional strength. These technologies can be used to manufacture concrete structures that meet environmentally friendly construction requirements and mortars with excellent engineering performance. I would like to provide the technology.

[0019] In addition, a method was proposed to reuse glass fiber (such as glass fiber) generated from building material insulation boards as a material for repair mortar, so as to reduce the environmental damage caused by waste landfill, achieve the effect of waste reuse and save waste costs. Thus, while achieving economic benefits, it provides construction methods for building repair mortar and repair concrete for the reuse of industrial waste and the manufacturing technology of building materials to reduce carbon emissions.

[0020] means for solving problems

[0021] To accomplish the aforementioned task, the present invention includes the following steps:

[0022] (1) Chipping the sections of the concrete structure that need repair until undamaged sections are visible;

[0023] (2) Apply primer to the polished concrete section;

[0024] (3) Spraying a mortar composition for section repair onto the section surface on which the primer is sprayed; and

[0025] (4) Spray a surface protectant onto the surface of the mortar composition for repairing the cross section.

[0026] The single-sided repair mortar composition is for powders with a fineness of 3000-6000 cm⁻¹. 2 The waste glass fibers collected from the insulation board are processed to obtain a 100-part complex consisting of 50-80% by weight powder, 3-20% by weight shrinkage reducer, 0.5-1.5% by weight polymer resin, 0.2-2% by weight fiber, 1-5% by weight silica fume, 0.5-5.0% by weight clinker, 0.5-5.0% by weight plastic, 0.5-5% by weight α-type hemihydrate gypsum, 0.01-5% by weight fly ash, 0.01-5% by weight microsilica, 20-200 parts by weight silica sand, 0.5-5 parts by weight metal salt thickener, and water.

[0027] In one embodiment of the present invention, a method for obtaining powder by processing waste glass fiber powder collected from the heat insulation board includes the following steps:

[0028] (a) Prepare powders of cement, blast furnace slag powder or a combination thereof, and feed them into a powdering equipment;

[0029] (b) The recycled glass fiber (RGF) collected by the insulation board is fed into the un-crushed equipment in (a);

[0030] (c) Crush the ingredients fed into the un-crushed equipment;

[0031] (d) Collect the powder obtained in (c) above; and

[0032] (e) The powder obtained in (d) is mixed with ordinary Portland cement in a ratio of 100 parts by weight to 1 to 50 parts by weight.

[0033] Additionally, in one embodiment of the invention, the micro-pulverizing equipment of (b) is characterized as a pinmill, fine impact mill, ball mill, or vertical mill.

[0034] In addition, in one embodiment of the present invention, the waste glass fiber used in the un-crushed equipment in (b) is characterized by having a weight of 0.1 to 50% compared to the weight of the powder 100 including the cement and blast furnace slag powder.

[0035] In another embodiment of the invention, the polymer resin is characterized by using any one or a mixture of two or more selected from vinyl vinyl acetate (EVA), NR (Natural Rubber), NBR (Natural Rubber-Butadien Rubber), SBR (Styrene-Butadien Rubber), and polyvinyl acetate resins.

[0036] In another embodiment of the invention, the metal salt-based thickener is characterized by using one or more of the following: calcium, calcium chloride, calcium hydroxide, calcium nitrate, magnesium chloride, magnesium sulfate, lithium carbonate, lithium hydroxide, and lithium sulfate.

[0037] Invention Effects

[0038] The environmentally friendly mortar composition of the present invention and the structural repair and reinforcement process using the mortar composition have the following advantages.

[0039] First, by using blast furnace slag powder and fly ash, the reactive active silica (SiO2) of the material exhibits strong properties that may lead to chemical corrosion caused by harmful gases, especially sulfuric acid gas.

[0040] To improve the workability of concrete structures, mortar compositions made from processed waste glass fiber powder are used. This allows for rapid construction even in tunnels, bridges, buildings, and railway structures subjected to impact or vibration, resulting in excellent workability and operability. In particular, for sites with severe vibration or concrete structures, the adhesion strength and compressive strength are enhanced, thus improving durability issues such as mortar spalling.

[0041] In addition, the physical strength of the reinforced surface, such as compressive strength, torsional strength, and tensile strength, is enhanced. The micronized additives added to the binder enhance the adhesion strength to the concrete surface, improve durability and water resistance, and have good chemical resistance and waterproofing properties, as well as good resistance to freeze-thaw cycles and salt damage.

[0042] Currently, as an industrial byproduct or even industrial waste, there is a technology that can provide powdered materials for concrete structure repair mortar to replace waste glass fibers, which have almost no recycling value. In other words, existing waste glass fibers, which are subject to many limitations in reuse due to their own agglomeration phenomenon, can be used as powdered materials for repair mortar. Therefore, they can replace some cement, blast furnace slag powder, and fly ash, achieving resource reuse while helping to stabilize cement prices and reducing carbon emissions through resource reuse. Attached Figure Description

[0043] Figures 1 to 8 The results of experiments conducted according to the present invention on the state of waste glass fibers contained in powders used for repair mortar materials are shown.

[0044] Figures 9 to 18 The results of experiments conducted according to the present invention on the powder state of a repair mortar material are shown.

[0045] Explanation of reference numerals in the attached figures

[0046] 1: Distribution panel enclosure; 10: Seismic protection device

[0047] 100: Main body of the seismic resisting device; 110: Fixing tools

[0048] 130: Skateboard 140: First Spring

[0049] 145: Bending section; 150: Bearing

[0050] 160: Bearing housing; 165: Bearing housing groove

[0051] 170: Second spring component; 180: Lower plate

[0052] 190: Tapping the component 191: Tapping the head of the component Detailed Implementation

[0053] The present invention will now be described in more detail.

[0054] As described above, the environmentally friendly mortar composition according to the present invention and the structural repair and reinforcement process using the same include the following stages. That is, it includes the following steps:

[0055] (1) Chipping the sections of the concrete structure that need repair until undamaged sections are visible;

[0056] (2) Apply primer to the polished concrete section;

[0057] (3) Spraying a mortar composition for section repair onto the section surface on which the primer is sprayed; and

[0058] (4) Spray a surface protectant onto the surface of the mortar composition for repairing the cross section.

[0059] The following is a detailed explanation of each stage.

[0060] 1. Chipping of concrete structure sections

[0061] In concrete structures, cracks develop due to deterioration and other factors. Over time, the compressive strength of the concrete and the tensile strength of the reinforcing steel gradually decrease. The concrete exposed at the cracks undergoes neutralization, leading to corrosion of the reinforcing steel. Safety diagnostics and inspections are necessary. If this phenomenon is observed, the cross-sections of the concrete structure must be repaired to ensure the long-term lifespan of the building.

[0062] The chipping stage involves removing cracked concrete and exposed reinforcing steel from concrete structures that require repair according to safety diagnoses and inspections, until undeteriorated concrete is exposed. This process uses machinery to break and grind the cross-section. At this stage, the outermost surface of the ground concrete should ideally be rough to facilitate mortar adhesion.

[0063] 2. Apply makeup primer

[0064] Apply primer to the polished concrete cross-section.

[0065] The primer used in this invention is used to improve the water resistance and durability of the structure and enhance its adhesion to the mortar surface formed later.

[0066] The primer used in this invention may be composed of, but is not limited to, cement, mixed materials, liquid sodium silicate, liquid polysiloxane and water.

[0067] Specifically, the primer used in this invention can be composed of 10-30 parts by weight of cement, 5-20 parts by weight of mixture, 15-45 parts by weight of liquid sodium silicate, 5-20 parts by weight of liquid polysilane and 55-80 parts by weight of water.

[0068] The cement and composite materials penetrate into the structural damage caused by the external environment, thus reinforcing the structure from harmful substances and increasing its durability.

[0069] In this invention, the mixed material is preferably a mixture of slag powder and fly ash in a ratio of about 10:1 to 5.

[0070] The liquid sodium silicate is obtained by dissolving water-soluble sodium silicate in water, with a mixing ratio of water to sodium silicate of approximately 100:20 to 100 by weight.

[0071] The liquid polysilane is polymerized by mixing silane monomers in an organic solvent. More specifically, one or more silane monomers selected from dichloromethylphenylsilane, dichlorodimethylsilane, dichlorodiphenylsilane, dichlorohexamethylsilane, and dichloroethylenemethylsilane can be mixed in an organic solvent, a metal catalyst can be dispersed, polymerization can be carried out, the resulting polymer can be filtered, the silicon polymer can be separated, and then dissolved in an organic solvent for use.

[0072] The primer obtained from the above composition can densely fill and expand the pores on the surface of the structure, thereby strengthening the adhesion to the mortar that will be sprayed later and improving the water resistance, durability and other physical properties.

[0073] 3. Spraying of mortar composition for cross-section repair

[0074] Chipping is performed on the concrete section to remove deteriorated concrete and corroded reinforcing bars. After applying a primer, a mortar composition is applied for repair.

[0075] The mortar composition used in this invention is a composition designed to recycle industrial waste and ensure its rapid hardening properties and adhesion strength to concrete structures.

[0076] In other words, after processing waste glass fibers collected from insulation boards with a powder density of 3000–6000 cm² / g, the resulting product contains 50–80% by weight of powder, 3–20% by weight of shrinkage and emission reduction agent, 0.5–1.5% by weight of polymer resin, 0.2–2% by weight of fiber, 1–5% by weight of silica fume, 0.5–5.0% by weight of clinker, 0.5–5.0% by weight of plastic, 0.5–5% by weight of α-type hemihydrate gypsum, 0.5–5% to 0.5% to 5% by weight of Flyash, up to 5% by weight of Freon, up to 50% by weight of Freon, and silica fume weight combined with the weight of silica fume, and the following components are used by weight: 0.01–5% to 0.5%, 0.01–5%, 0.01–5%, 0.01–5%, and water.

[0077] Previously, there were technologies that recycled industrial waste for use as binders in concrete or mortar, such as those using industrial waste or by-products like blast furnace slag powder or fly ash.

[0078] Currently, both domestically and internationally, the amount of fly ash supplied by coal-fired power plants is gradually decreasing due to the shutdown of aging power plants, and the production of blast furnace slag, a byproduct of steel mills with high carbon emissions, is also decreasing. Therefore, rising cement prices are contributing to increased construction costs at construction sites, necessitating the development of countermeasures.

[0079] This invention is a technology that can partially replace blast furnace slag and fly ash, industrial byproducts previously used as cement materials. It involves processing waste glass fibers collected from building waste insulation boards to obtain powder, which is then used as a material to partially replace existing blast furnace slag and fly ash.

[0080] Insulation boards are waste materials generated during construction projects or building demolition, mainly consisting of waste glass fibers such as fiberglass. These waste glass fibers exhibit severe clumping, making them difficult to mix with other components and thus hard to use in cement powders. This invention provides a method to solve these problems.

[0081] In this invention, the powder obtained after processing the waste glass fibers collected from the heat insulation board is manufactured in the following order. That is, it includes the following steps:

[0082] (a) Prepare powders of cement, blast furnace slag powder or a combination thereof, and feed them into a powdering equipment;

[0083] (b) The recycled glass fiber (RGF) collected by the insulation board is fed into the un-crushed equipment in (a);

[0084] (c) Crush the ingredients fed into the un-crushed equipment;

[0085] (d) Collect the powder obtained in (c) above; and

[0086] (e) The powder obtained in (d) is mixed with ordinary Portland cement in a ratio of 100 parts by weight to 1 to 50 parts by weight.

[0087] The following is a detailed explanation.

[0088] First, prepare the cement, blast furnace slag powder or a combination thereof contained in the existing cement powder and put them into the un-crushed equipment.

[0089] Next, the recycled glass fiber (RGF) collected by the heat insulation board is fed into the micro-pulverizing equipment described in (a).

[0090] Figure 1 These are microscope images of regular waste glass fibers collected from insulation panels. Figure 2 It is an SEM image.

[0091] like Figure 1 and Figure 2 As shown, RGF (Recycled Glass Fiber) produced by companies that manufacture heat insulation boards using glass fiber is pulverized once for easy disposal. However, since the RGF is in the shape of a fiber, agglomeration between fibers can occur.

[0092] like Figure 1 and Figure 2 As shown, the thickness of a typical RGF is about 1 to 10 micrometers, and its length varies greatly.

[0093] Figure 1 and Figure 2 As shown, to solve the common problem of RGF—fiber agglomeration—a crushing device (or uncrushed device) is used to crush the uncrushed fibers. Figure 3 and Figure 4 .

[0094] exist Figure 3 and Figure 4 In the process, RGF after being processed by the crushing equipment shows that the agglomeration phenomenon is alleviated, but after crushing, it is still fundamentally in fibrous shape and cannot completely solve the agglomeration phenomenon.

[0095] In addition, Figure 3 and Figure 4 From this, we can roughly understand that the thickness of the pulverized RGF is about 1 to 10 micrometers, and we can also see... Figure 1 and Figure 2 Conventional RGF thickness and Figure 3 and Figure 4 The thicknesses of the pulverized RGF particles are almost identical.

[0096] Figure 3 The crushed RGF and Figure 1 The fiber length of ordinary RGF varies slightly. This may be because the agglomeration of RGF is eliminated during the crushing process, and it also has the effect of shearing part of the RGF. However, it is understood that the crushing itself is not used to shear the fibers, but rather the fibers are partially sheared during the crushing process, resulting in a reduction in length.

[0097] Figure 5 The particle size distribution curves of uncrushed RGF using the Fine Impact Mill (FIM) are shown, with an average particle size of 38.78 micrometers and the largest particle size distribution around 20 micrometers.

[0098] After RGF is crushed, the aggregate is mixed in the mixer at degrees 6, 7 and 8. At this point, black aggregate is used to clearly show the mixing state of RGF and aggregate.

[0099] The pulverized RGF exhibits a certain degree of elimination of [likely referring to a specific type of oxidative stress]. Figure 3 The same agglomeration phenomenon can also be observed if the RGF is mixed in a mixer to combine the crushed RGF with the aggregate. Figure 7 Such pulverized RGF disperses well in the aggregate, but it can also be seen that... Figure 6 This phenomenon of re-aggregation between fragmented RGFs (reaggregation).

[0100] Just as re-agglomeration occurs when RGF is mixed with aggregates, if RGF is first crushed and then mixed with existing cement powders such as cement or blast furnace slag powder, re-agglomeration will occur. It is expected that the agglomeration of crushed RGF mixed in cement concrete during cement concrete manufacturing will make it difficult to achieve the side effects of increasing toughness, reducing cracks, and increasing durability.

[0101] Furthermore, if the weight ratio of crushed RGF is excessively increased, the RGF may aggregate in one area instead of being uniformly dispersed.

[0102] This invention involves pre-mixing RGF with a small amount of cement or blast furnace slag powder in a certain proportion, then performing a fine pulverization process using a micro-pulverizing device. The powder obtained through this process is then mixed into existing cement powder in a certain proportion, thereby solving the problem of RGF re-agglomeration and enabling its use in cement powder in a certain proportion.

[0103] In this invention, the micro-pulverizing equipment can be a vertical grinder, ball mill, pin mill, fine impact mill, etc., and can be selected according to durability, micro-pulverizing efficiency, factory conditions, etc.

[0104] When manufacturing RSGF (Recycled Short Glass Fiber) powder for cement concrete, raw material RGF and blast furnace slag powder (SP) or cement powder can be mixed and pulverized in a certain proportion using micro-pulverization equipment such as vertical mill, fine mill, FineImpcat Mill or ball mill, and then stored in the product warehouse for shipment.

[0105] In this type of un-pulverized equipment, RGF can be mixed to a ratio of 1% to 99%. However, in order to ensure that RGF is uniformly un-pulverized, non-agglomerated, and efficiently pulverized, it is recommended to control the weight ratio of RGF to powder between 0.1% and 50%, with the most suitable weight ratio being between 3% and 30%.

[0106] Figure 9 The image shows the unique particle size distribution curves of SPR5 and SP when 95% cement is mixed with SPR and 5% RGF5 by weight. The SP powder, also of grade 4000, has a particle size of 12.83 micrometers. In contrast, when RGF and SP are mixed at 5% and then uncrushed by FIM, the average particle size of SPR5 is actually increased. This is related to... Figure 9 Compared to SPR particles larger than 100 micrometers in the weight map, GFR has an average particle size of almost 11 micrometers. This represents a significant change.

[0107] In this case, the invisible particle size distribution in SP is due to the presence of particles larger than 100 micrometers in the uncrushed RGF particles at degree 5. Therefore, it is expected that in SP, as RGF increases from 5% to 10%, 20%, 30%, the more it is mixed, the more particles larger than 100 micrometers will be distributed.

[0108] from Figure 10 Microscopic images of SPR5 Figure 11 The SEM images show that the RSGF particles within SPR5 do not exhibit agglomeration. This indicates that a mixed-pulverization method, which involves mixing and pulverizing raw material RGF with powders such as SP / cement, can achieve efficient dispersion and pulverization.

[0109] Furthermore, a SEM image of a paste made by mixing 5% RSGF with SP (SPR5) and OPC (Ordinary Portland Cement) at 500x magnification is shown to be D12. It can be confirmed that RSGF is mixed within the red circle, with no local agglomeration and good dispersion.

[0110] This indicates that during milling operations, cement or blast furnace slag powder can be pulverized more effectively by RGF, in addition to eliminating the agglomeration of RGF, resulting in smaller particle sizes. This may be due to the following reasons.

[0111] 1. Eliminating internal stress: Large particles may generate internal stress, which is more easily eliminated by external forces during the micronization process. Therefore, micronization with small particles can eliminate internal stress and better break down materials.

[0112] 2. Interactions between particles: If particles of different sizes are mixed together, smaller particles may penetrate or become trapped between larger particles, which leads to strong interactions between larger and smaller particles, thus making the material break down more effectively.

[0113] According to the present invention, waste glass fiber, which was previously subject to many restrictions on reuse or recycling due to its own agglomeration, can be used in cement mortar powder. Therefore, it can partially replace blast furnace slag powder, fly ash, etc., which lead to the increase in cement prices. This not only achieves the effect of resource reuse, but also helps to stabilize cement prices and reduce carbon emissions through resource reuse.

[0114] In this invention, the powder obtained after processing the waste glass fiber preferably has a specific surface area of ​​3000–6000 cm². 2 Powder of approximately / g.

[0115] In this invention, the powder obtained by processing the waste glass fiber is composed of components with potential hydraulic properties. When it reacts with cement during hydration, the scavenging effect is activated, which helps to improve the bonding with the concrete structure, increase strength, and improve workability.

[0116] The powder obtained from the waste glass fiber powder possesses potential hydraulic properties. While this potential hydraulic property itself does not solidify, it reacts with calcium hydroxide (Ca(OH)2) at room temperature in the presence of water to form a stable, insoluble compound, thus hardening it and acting as a pozzolan. In other words, the calcium oxide (CaO) component in the blast furnace slag powder reacts with water to form calcium hydroxide (Ca(OH)2), which then slowly reacts with the silica (SiO2) and alumina (Al2O3) dissolved from the waste glass fiber to form insoluble calcium silicate hydrate (CSH gel) or calcium aluminum hydrate (CAH gel), making the structure denser and contributing to the strength and bonding force of the mortar. The performance of the powder obtained from the waste glass fiber used in this invention varies depending on the powder fineness; this invention recommends using a powder fineness of 3000–6000 cm⁻¹. 2 / g. The powder size is less than 3000cm³. 2 At / g, the scorazorl reaction may be difficult to control, exceeding 6000 cm⁻¹. 2 When the bond strength with the concrete structure is reduced to / g, the bond strength may decrease.

[0117] Furthermore, in this invention, the shrinkage-reducing agent can be prepared by mixing calcium aluminum sulfonate with gypsum in a weight ratio of 4–9:1–6, and its dosage in the binder is preferably 3%–20%. If the content is less than 3% by weight, it is difficult to control cracks caused by initial shrinkage and expansion; if it exceeds 20% by weight, it is difficult to ensure working time due to rapid reaction and may lead to abnormal expansion. In this invention, the gypsum can be selected from anhydrous phosphate gypsum or hydrofluoric anhydride gypsum.

[0118] Furthermore, in this invention, the polymer resin, before hardening of the mortar composition for single-sided repair and reinforcement of concrete structures, can increase fluidity, improve workability, and after hardening, increase surface adhesion, cohesion, flexural strength, bending resistance, and waterproofing. In this invention, the polymer resin can be any one or a mixture of two or more selected from vinyl vinyl acetate (EVA), NR (Natural Rubber), NBR (Natural Rubber-Butadien Rubber), SBR (Styrene-Butadien Rubber), and polyethylene glycol (PEG) resins.

[0119] In this invention, the polymer resin should be included in the binder at a ratio of 0.5 to 1.5% by weight. When the content of the polymer resin is less than 0.5% by weight, it is difficult to achieve the effect of enhanced surface adhesion; when it exceeds 1.5% by weight, it will hinder the formation of hydration products during the hydration reaction, resulting in a decrease in strength.

[0120] Furthermore, in this invention, the fibers not only improve torsional strength and tensile strength, but also reduce surface cracks during curing, effectively improving the initial construction stability of the mortar and enhancing initial dispersibility. The fibers used in this invention are preferably composed of 20-50% by weight of polypropylene fibers, 20-50% by weight of nylon fibers, and 30-60% by weight of Arbocell fibers. The Arbocell fibers, more specifically, natural Arbocell fibers, as hydrophilic fibers, prevent surface cracking and enhance strength. When mixed with polypropylene and nylon fibers, they maximize the advantages of each fiber, achieving enhanced strength and reduced backlash. In this invention, the fibers should be included in the binder in the range of 0.2-2% by weight. If the content is below 0.2% by weight, it will not improve tensile and torsional strength; if it exceeds 2% by weight, the increased water usage will lead to poor workability and reduced economy.

[0121] In this invention, the wollastonite is a nearly perfectly spherical particle composed of particles with an average particle size of about 0.1 to 0.5 mm. It is an amorphous active wollastonite that reacts with calcium hydroxide and transforms into hydrated calcium silicate at room temperature, exhibiting superazolean properties.

[0122] 3CaOSiO2 + H2O → CSH (cement gel) + Ca(OH)2

[0123] In this invention, the silica fume cement is added to the binder because the ball bearing effect of the spherical particles improves the dispersibility and water reduction effect, the filling effect between the silica fume cement particles improves the water tightness and high strength, and the adhesion of the short stones is improved. This has the effects of reducing the amount of base material, inhibiting the alkali-silica fume reaction, and improving chemical resistance.

[0124] Furthermore, in this invention, the clinker is composed of calcium aluminum silicate, white stone, and fine stone. The clinker promotes the mixing of the binder and water. The clinker should preferably comprise 0.5 to 5% by weight of the binder; if the clinker content is below 0.5% by weight, it is difficult to mix with the binder water, and if it exceeds 5% by weight, there is a problem of decreased strength.

[0125] Furthermore, in this invention, the plastic (plaster) serves to facilitate the mixing of the components in the binder with water. The slurry should preferably comprise 0.5 to 5% by weight of the binder. Therefore, if the slurry content is below 0.5% by weight, there is a problem that the various components in the binder are difficult to mix easily with water; if it exceeds 5% by weight, there are problems such as a decrease in strength and chemical resistance.

[0126] Furthermore, in this invention, the α-type hemihydrate gypsum is obtained by heating the hydrous gypsum at a temperature of approximately 75–100°C for more than 1 hour under a reduced pressure of -600 torr or higher. The α-type hemihydrate gypsum, produced by reduced pressure heating, has an almost zero shrinkage-expansion rate and effectively inhibits shrinkage-expansion cracks. More specifically, gypsum is generally classified into natural gypsum and chemical gypsum, with purity typically determined by the SO3 content. It is further classified into dihydrate gypsum, hemihydrate gypsum, and anhydrous gypsum based on the content of water of crystallization. The hydrous gypsum transforms into α-type, β-type, or anhydrous gypsum depending on the dehydration conditions. It transforms into β-type during dehydration in a dry state and into α-type during dehydration in a wet state. α-type hemihydrate gypsum has a strength more than 10 times higher than β-type hemihydrate gypsum, a shorter initial hardening time, and effectively inhibits shrinkage-expansion cracks. In addition, α-type hemihydrate gypsum, together with the CSA-based expansive agent described later, enhances high strength, rapid setting and expansiveness, thus compensating for the shortcomings of the CSA-based expansive agent.

[0127] In this invention, the α-type hemihydrate gypsum should preferably be included in the binder in the range of 0.5 to 5% by weight. When the content of the α-type hemihydrate gypsum is less than 0.5% by weight, its crack resistance decreases. When it exceeds 10% by weight, the reaction rate accelerates, the sand addition time is shortened, and there is a problem of poor workability.

[0128] Furthermore, in this invention, fly ash refers to the residue remaining in the form of oxides after coal combustion in facilities such as coal-fired power plants, becoming micro-dust containing silicon dioxide (SiO2) or aluminum oxide (Al2O3). The use of this fly ash in a mixture not only improves workability and reduces the heat of hardening, but also enhances long-term strength and water tightness, making it economical. The fly ash content in the binder is preferably in the range of 0.01 to 5% by weight. When the fly ash content is below 0.01% by weight, the adhesion performance of the water-retaining agent decreases; when it exceeds 5% by weight, there is a problem of decreased chemical resistance.

[0129] Furthermore, the calcinated pozzolana described in this invention is mainly prepared by adding calcium to natural water-soluble soil composed of fine-grained red volcanic soil, and has the function of improving the waterproofing of the conservative reinforcing agent of this invention. Specifically, the calcinated pozzolana is preferably prepared by calcining a mixture of 100 parts by weight of natural pozzolana and 1-20 parts by weight of calcium at 1000-1200°C for 0.5-1 hour, and then pulverizing it into an average particle size of 10-20 μm. When the calcinated pozzolana treated in this way is applied to mortar, it has the function of improving the density of the structure, increasing waterproofing and strength. The calcinated pozzolana is preferably in the range of 0.01 to 5% in the bonding material. When the content of calcinated pozzolana is less than 0.01% by weight, the waterproofing of the water-retaining agent will decrease; when it exceeds 5%, the strength of the water-retaining agent will decrease.

[0130] Furthermore, in this invention, the microcrystalline silica refers to silica particles with a particle size of 10 to 200 micrometers, which improves the strength and chemical resistance of the water-retaining agent used in this invention. The microcrystalline silica is preferably included in the bonding material in the range of 0.01 to 5% by weight. If the microcrystalline silica content is less than 0.01% by weight, the strength and fire resistance of the water-retaining agent will decrease; if it exceeds 5% by weight, the adhesion performance of the water-retaining agent will decrease.

[0131] In addition, for the repair and reinforcement of underwater concrete structures, an underwater non-separating agent ranging from 0.1% to 3% by weight can be added to the binder. This underwater non-separating agent is added to improve the viscosity of the mortar composition in water and prevent its decomposition, such as methylcellulose (e.g., methylcellulose, hydroxymethylcellulose, carboxymethylcellulose); ethylcellulose (e.g., ethylcellulose, hydroxyethylcellulose, carboxyethylcellulose); or cellulose-based thickeners selected from propylcellulose such as hydroxypropylcellulose. Its content in the binder is preferably 0.1% to 3% by weight, exhibiting appropriate viscosity. If necessary, to further increase viscosity in water, more water-soluble acrylic resin powder can be added. The water-soluble acrylic resin powder is preferably used as 1% to 30% by weight of the underwater non-separating agent.

[0132] In addition, as needed, the binder 100 may also include one or more additives selected from 0.1 to 10 parts by weight of dispersant, 0.01 to 3 parts by weight of encapsulating agent, and 0.01 to 10 parts by weight of delaying agent.

[0133] The dispersant adsorbs onto the surface of mortar particles, applying a charge to the particle surface and generating mutual reaction forces between the particles, thereby dispersing the aggregated particles, increasing flowability, and making it possible to enhance water reduction and strength. The dispersant can be a common water-reducing agent, such as lignin sulfonylimide, polynaphthalene sulfonylimide, polymelamine sulfonylimide, or a mixture of polycarboxylate-based water-reducing agents, used alone or in combination with two or more. The content of the dispersant, for 100 parts by weight of the binder, should preferably be 0.1 to 10 parts by weight.

[0134] The defoamer is used to remove large pores in the mortar to improve its strength and appearance. Defoamers include mineral oil-based defoamers such as kerosene and flowing paraffin; oil-based defoamers such as animal and vegetable oils, sesame oil, castor oil, and their alkoxy derivatives; fatty acid-based defoamers such as oleic acid, stearic acid, and their alkoxy derivatives; fatty acid ester-based defoamers such as glyceryl mononosinolate, alkenyl succinic acid fluid, rosin mononosinolate, rosin triol ester, and natural waxes; polyoxyethylene, (poly)oxyalkylene ether, acetylene ether, and (poly)oxyalkylene fatty acid ester alcohol-based defoamers such as octanol, hexanediol, propanol, and alcohols; amide-based defoamers such as acrylate polyamine; phosphate ester-based defoamers such as tributyl phosphate and disodium phosphate; metal soap-based defoamers such as aluminosilicate and calcium oleate; and silicone-based defoamers such as dimethyl silicone oil, silica gel, silicone emulsion, organically modified polysilicic acid (polysiloxanes such as dimethyl polysilicic acid), and fluorosilicone oil. The defoamer should be used at a concentration of 0.01 to 3 parts by weight of the binder 100.

[0135] The retarder can be added by adjusting the hydration rate of the binder to ensure workability for a certain period of time. As a retarder, boric acid and borax, sodium borate, potassium borate, and other borates; gluconic acid, citric acid, talc, glucoheptanoic acid, arabinic acid, malic acid, or citric acid, and their sodium, potassium, calcium, magnesium, ammonium, triethanolamine, and other inorganic or organic salts containing hydroxycarboxylic acid; glucose, galactose, galactose, saccharin, xylose, avitosaccharide, rifuose, amphoteric sugars, and other monosaccharides, or disaccharides, trisaccharides, and other oligosaccharides, or dexamethasone, or other oligosaccharides. Polysaccharides such as dexamethasone, including their molasses and other sugars; sugar alcohols such as turpentine; magnesium silicophosphate and its salts or borate esters; carbamic acid and its salts; alkali-soluble proteins, tannins, phenol, glycerol, and other polyvalent alcohols; carbamates (methanesulfonic acid), 1-hydroxyethyl-1,1-diphosphonic acid, ethylenediaminetetraacetic acid (methanesulfonic acid), diethylenetriaminepentanoic acid (methanesulfonic acid), and their alkali metal salts, alkaline earth metal salts, etc., phosphonic acids and their derivatives may be used. The content is based on 100 parts by weight of the binder, and it is advisable to add 0.01 to 10 parts by weight.

[0136] This invention involves processing waste glass fibers collected from insulation boards, mixing silica sand and a metal salt-based thickener into a binder composed of powder, shrinkage-reducing agent, polymer resin, fiber, silica fume, clinker, plasma, α-type hemihydrate gypsum, Flyash, Hazollana, and microcrystalline silicon, to prepare a dry mortar premix composition. Small-crystal water is then added to this premix to form a mortar composition. In this invention, the mortar is preferably mixed in a ratio of 100 parts by weight of binder, 0.5 to 5 parts by weight of metal salt-based thickener, and 20 to 200 parts by weight of silica sand. Furthermore, the amount of water used may range from 10 to 100 parts by weight, but this can be varied depending on the application.

[0137] In this invention, the silica sand is not particularly limited, but it can be prepared by mixing medium sand with an average particle size of 10-20 mm and fine sand with an average particle size of 0.1-1.0 mm in a ratio of 1:4 to 2:3. If the average particle size and content of the silica sand are within the range described above, the fluidity and density of the mortar composition can be improved.

[0138] In this invention, the metal salt-based thickener is used to increase the solidification rate, thereby enabling early strength to be achieved.

[0139] For these metal salt-based thickeners, one or more selected from calcium formate, calcium chloride, calcium hydroxide, calcium nitrate, magnesium chloride, magnesium sulfate, lithium carbonate, lithium hydroxide, and lithium sulfate can be used. The present invention suggests that the metal salt-based thickener be included in the composition in the range of about 0.5 to 5 by weight.

[0140] The obtained mortar composition is applied to the surface of the work object to repair and reinforce the cross-section of the concrete structure. If the application is repeated more than once, the surface is roughened by grinding to improve adhesion to the work object. The application is preferably carried out by spraying or applying a paste with a thickness of 5-15 mm for the first pour, 20-50 mm for the second and third pours, and 5-15 mm for the final pour. The thickness can be changed according to the different pouring thicknesses.

[0141] 4. Surface coating agent application

[0142] The mortar composition is applied to the broken part of the concrete, smoothly finished and dried, and then a thin surface coating agent specified in this invention is applied to the surface to reinforce the repaired surface from external conditions.

[0143] The surface coating agent used in this invention can be a water-based epoxy coating.

[0144] In this invention, the waterborne epoxy coating is preferably a waterborne epoxy coating composed of an epoxy base, an amine curing agent, and water, but is not limited thereto.

[0145] Specifically, the waterborne epoxy coating is a waterborne epoxy coating composed of an epoxy base agent, an amine curing agent, and water. The epoxy coating includes 20-40 parts by weight of liquid epoxy resin, 5-10 parts by weight of hydrogen-containing polyester resin, 0.2-2.0 parts by weight of vanadate metal salt, 10-30 parts by weight of water, 0.5-2.0 parts by weight of dispersant, 0.2-1.0 parts by weight of defoamer, 0.2-2.0 parts by weight of tackifier, 20-2.0 parts by weight of pigment, and a lubricant. The coating consists of 2.0 parts by weight of a wetting agent, 20 to 2.0 parts by weight of an amine compound, 20 to 2.0 parts by weight of an amine compound, 20 to 40 parts by weight of water, 0.2 to 2.0 parts by weight of a defoamer, and 0.2 to 3.0 parts by weight of a tackifier. The mixing ratio of the epoxy base to the amine curing agent is 10:3 to 10 by weight. For 100 parts by weight of the obtained mixture of the epoxy base and the amine curing agent, 100 to 500 parts by weight of water can be added later to obtain a coating.

[0146] First, the epoxy main component includes 20-40 parts by weight of liquid epoxy resin, 5-10 parts by weight of hydrogen-containing polyester resin, 0.2-2.0 parts by weight of vanadate metal salt, 10-30 parts by weight of water, 0.5-2.0 parts by weight of dispersant, 0.2-1.0 parts by weight of defoamer, 0.2-2.0 parts by weight of tackifier, 5-20 parts by weight of extender pigment, and 0.2-2.0 parts by weight of wetting agent.

[0147] The liquid epoxy resin may be a bisphenol A-based liquid epoxy resin, which has the effect of improving adhesion and bonding strength.

[0148] The hydroxyl-containing polyester resin can be a hydroxyl-containing polyester resin or a modified resin thereof, specifically a polymer of polyols and polybasic acids. In this case, the polyol can be selected from ethanol, diethylene glycol, polyethylene glycol, glycerol, dipropylene glycol, polypropylene glycol, tetrapentanediol, 1,2-butanediol, 1,3-butanediol, polyvinyl chloride polyol, glycerol, rosin alcohol, etc., and the polybasic acid can be selected from malonic acid, glutaric acid, succinic acid, succinic acid, succinic acid, succinic acid, adipic acid, succinic acid, cyclohexane-1,4-dicarboxylic acid, etc.

[0149] In addition, modified resins containing the aforementioned hydroxyl groups include polyurethane-modified polyester resins, epoxy-modified polyester resins, acrylic-modified polyester resins, and silicone-modified polyester resins.

[0150] The hydroxyl-containing polyester resin or its modified resin preferably has an average molecular weight of 3000-5000 and a glass transfer temperature of 20-100℃.

[0151] The vanadate metal salt improves the corrosion resistance of coatings and is characterized by being water-soluble. Specific examples include calcium vanadate and potassium vanadate.

[0152] When used in subject mixing, the dispersant disperses extender pigments in the liquid phase, ensuring color uniformity. These dispersants can be selected from nonionic or anionic types.

[0153] The defoamer is used to suppress bubbles in the main material and form a uniform coating film. Non-ionic or silicone-based defoamers can be used.

[0154] The thickener is used to prevent the pigment from settling and improve workability. Specifically, it can be selected from phenytoin-based, polyurethane-based, and acrylic-based thickeners.

[0155] The extender pigment described herein enhances coating strength, creates an uneven surface, and improves adhesion to the coating, thereby improving moisture resistance and water resistance. The extender pigment used in this invention can be selected from calcium carbonate, barium sulfate, mud, tucker, micaceous iron, and silicate.

[0156] In this invention, the role of the wetting agent is to impart hydrophilicity to the material, so that the coating film of the water-soluble epoxy resin can be formed smoothly. Specifically, hydroxyethyl cellulose-based wetting agents can be used.

[0157] The amine-based curing agent promotes the curing of the epoxy water agent components.

[0158] The specific components of the amine-based curing agent include 30-60 parts by weight of amine compound, 20-40 parts by weight of water, 0.2-2.0 parts by weight of defoamer, and 0.2-3.0 parts by weight of tackifier.

[0159] The amine compound may be selected from aliphatic, aromatic, and alicyclic amine compounds, with an amine equivalent of 100–320 g / eq and a viscosity at room temperature of 30–4000 cps being preferred.

[0160] The defoamer, thickener, and other components may be the same as or different from the epoxy main component.

[0161] In this invention, in order to form the waterborne epoxy coating, it is recommended to mix the epoxy substrate and the amine curing agent in a weight ratio of 10:3 to 10, and to obtain a coating, water is added in the form of 100 parts by weight of the obtained mixture of epoxy substrate and amine curing agent.

[0162] Next, after the waterborne epoxy coating has cured and been maintained, a waterborne polyurethane coating can be applied to the surface coated with the waterborne epoxy coating.

[0163] The waterborne polyurethane coating is preferably applied using a waterborne polyurethane coating composed of water-dispersible acrylic resin, extender pigment, and yucca.

[0164] Specifically, the waterborne polyurethane coating may consist of 50-80 parts by weight of water-dispersible acrylate resin, 0.2-2.0 parts by weight of dispersant, 0.5-2.0 parts by weight of tackifier, 5-20 parts by weight of extender pigment, 0.2-2.0 parts by weight of defoamer, 0.2-2.0 parts by weight of yucca resin, and 0.2-5.0 parts by weight of additives.

[0165] The water-dispersible acrylic polyurethane resin can be synthesized into a polyurethane emulsion by adding any acrylate monomer selected from 2-hydroxyethyl methacrylate (2-HEMA), methyl methacrylate (MMA), n-butyl acrylate (n-BA), and acrylic acid (AAc), as well as anionic or nonionic emulsifiers and initiators. The water-dispersible acrylic polyurethane resin dries quickly and exhibits excellent weather resistance, durability, and UV stability under external exposure conditions. It is water-soluble and environmentally friendly.

[0166] The dispersant is used to uniformly disperse extender pigments in the liquid phase during the mixing of water-soluble polyurethane coatings, forming a uniformly colored coating film. In this invention, any one of nonionic polyoxyethylene surfactants or anionic polycarbonate surfactants can be used.

[0167] The thickener is used to prevent pigment sedimentation and improve workability during coating. In this invention, any of the following can be selected: phenytoin-based, polyurethane-based, or acrylic-based thickeners.

[0168] The extender pigment is used to represent the color of water-soluble polyurethane coatings, and any one of red iron oxide, titanium dioxide, yellow iron oxide, or carbon black can be used.

[0169] The defoamer is used to suppress air bubbles in water-soluble polyurethane coatings to form a uniform coating film. This invention can use either non-ionic or silicone-based defoamers.

[0170] The silane is used to enhance adhesion and improve the water resistance and durability of the coating. Any one of the following can be selected from diethyl malonate, γ-methoxypropane, γ-propylpropane, γ-aminopropane, and vinyltrimethylpropane.

[0171] The co-solvent is used to improve the solvent's dissolving power and facilitate the coating film shape; any one of tetrachlorophenol, butyl acetate, or butanediol can be used.

[0172] The surface coating applied using the above method employs the aforementioned environmentally friendly coating composition, exhibiting excellent adhesion and durability to the mortar surface, as well as superior physical properties such as adhesion strength and compressive strength. In particular, it demonstrates excellent waterproofing, salt resistance, and fire resistance, resulting in superior surface reinforcement of concrete structures. Furthermore, as a water-soluble material, it does not leach organic solvents or heavy metals, making it environmentally friendly and extending the coating's lifespan. Therefore, it provides long-term maintenance of the structural surface reinforcement effect.

[0173] The invention will now be described in more detail with reference to implementation examples. However, the scope of the invention is not limited to the following embodiments.

[0174] [Implementation Example]

[0175] (Manufacturing Process 1) Mortar Composition Manufacturing

[0176] Cement and blast furnace slag powder were fed into an un-crushed equipment (cement:blast furnace slag = 65:35). Waste glass fiber (RGF) collected from the insulation board was also fed into the un-crushed equipment. The fed components were crushed and the powder was collected. The collected powder had a specific surface area of ​​3000 to 6000 cm2 / g. The collected powder was mixed with ordinary Portland cement at a weight ratio of 25.

[0177] The following components were synthesized: 65 parts by weight of the obtained powder (processed powder), 5 parts by weight of a shrinkage reducing agent (a mixture of calcium sulfonate and anhydrous gypsum phosphate in a 7:3 weight ratio), 1.0 part by weight of polymer resin (EVA resin), 1.0 part by weight of fiber (a mixture of 30 parts by weight of polypropylene, 40 parts by weight of nylon and 30 parts by weight of Arvocell fiber), 2.0 part by weight of silicone, 2 parts by weight of beaker, 1 part by weight of plasma, α semi-solid rubber, 3.5 parts by weight of aluminum hydroxide, and silicone.

[0178] In the binder 100 parts by weight, a mortar composition was prepared by mixing silica sand 80 parts by weight (containing medium filaments with an average particle size of 10-20 mm and fine filaments with an average particle size of 0.1-1.0 mm in a 2:3 ratio), a metal salt-based thickener (calcium phosphate), and water 30 parts by weight.

[0179] (Comparative Manufacturing Example 1) Mortar Composition Manufacturing

[0180] Portland cement was used as the binding material.

[0181] In the Portland cement binder 100 parts by weight, 80 parts by weight of silica sand (mixed in a 2:3 ratio of medium sand with an average particle size of 10 to 20 mm and fine sand with an average particle size of 0.1 to 1.0 mm) and 30 parts by weight of water were mixed to prepare a mortar composition.

[0182] (Comparative Manufacturing Example 2) Mortar Composition Manufacturing

[0183] A binder was prepared by mixing 65 parts by weight of Portland cement, 20 parts by weight of blast furnace slag powder, 5 parts by weight of shrinkage and emission reduction agent (a mixture of calcium sulfonate and anhydrous gypsum phosphate in a 7:3 weight ratio), 1.0 part by weight of polymer resin (EVA resin), 1.0 part by weight of cellulose fiber, and 0.5 parts by weight of sodium bicarbonate.

[0184] In the binder 100 parts by weight, 80 parts by weight of silica sand and 30 parts by weight of water were mixed in a 2:3 ratio of medium filaments with an average particle size of 10 to 20 mm and fine filaments with an average particle size of 0.1 to 1.0 mm to prepare a mortar composition.

[0185] (Comparative Manufacturing Example 3) Mortar Composition Manufacturing

[0186] An admixture was prepared by adding 65 parts by weight of Portland cement, 20 parts by weight of blast furnace slag powder, 5 parts by weight of shrinkage and emission reduction agent (a mixture of calcium sulfonate aluminum and anhydrous gypsum phosphate in a 7:3 weight ratio), 1.0 part by weight of polymer resin (EVA resin), 1.0 part by weight of cellulose fiber, 0.5 part by weight of sodium bicarbonate, 0.5 part by weight of water-resistant non-separating agent (methylcellulose), 0.5 part by weight of dispersant (PC-based), 0.2 part by weight of agent, and 0.2 part by weight of retarder (methylcellulose).

[0187] In the binder 100 parts by weight, 80 parts by weight of silica sand and 30 parts by weight of water were mixed in a 2:3 ratio of medium filaments with an average particle size of 10 to 20 mm and fine filaments with an average particle size of 0.1 to 1.0 mm to prepare a mortar composition.

[0188] (Manufacturing Example 2) Manufacturing of Surface Coating Agent

[0189] As a waterborne epoxy coating, 30 parts by weight of bisphenol A type epoxy resin, 8.5 parts by weight of epoxy modified polyester resin (average molecular weight about 20,000, glass transition temperature about 80°C), 1.0 part by weight of calcium vanadate, 20 parts by weight of water, 1.0 part by weight of dispersant, 0.5 part by weight of defoamer, 0.5 part by weight of thickener, 10 parts by weight of sieved pigment, and 0.8 parts by weight of wetting agent are mixed to obtain the main component. 0.5 parts by weight of styrene agent, 0.8 parts by weight of weight-weighting agent, and 0.8 parts by weight of weight-weighting agent are then mixed to obtain a mixed component ratio of 10.30, 0.8, 0.8, and 0.8 by weight. Approximately 300 parts by weight of water are added to 100 parts by weight of the obtained mixture of the main component and curing agent to prepare the coating.

[0190] As a waterborne polyurethane coating, a coating is prepared by mixing 60 parts by weight of water-dispersible acrylate resin, 1.0 part by weight of dispersant, 0.9 part by weight of thickener, 15 parts by weight of extender pigment, 0.9 part by weight of encapsulating agent, 1.5 part by weight of yucca and 2.5 parts by weight of cosolvent.

[0191] [Implementation Example 1]

[0192] The damaged concrete structure's cross-section was repaired and broken. After removing the internal rusted reinforcing steel, the base was sprayed and dried. The mortar composition prepared in process 1 was smoothly sprayed onto the structural surface and then cured. On the hardened mortar surface, a water-based epoxy coating with a total thickness of 200 hectares was applied to the surface coating agent prepared in process 2, following the sequence of water-based epoxy coating and water-based polyurethane coating. Then, it was cured and dried, completing the repair and reinforcement work.

[0193] [Comparison Example 1]

[0194] Similar to Example 1, but in practice, the mortar prepared in Comparative Preparation Example 1 was sprayed, and the surface was coated differently using the surface coating agent prepared in Preparation Example 2.

[0195] [Comparison Example 2]

[0196] Similar to Example 1, but in practice, the mortar manufactured in Comparative Manufacturing Example 2 was sprayed and the surface was coated differently using the surface coating agent manufactured in Manufacturing Example 2.

[0197] [Comparison Example 3]

[0198] Similar to Example 1, but in practice, the mortar manufactured in Comparative Manufacturing Example 3 was sprayed and the surface was coated differently using the surface coating agent manufactured in Manufacturing Example 2.

[0199] Performance evaluation

[0200] 1. Physical properties of mortar compositions

[0201] Test specimens were prepared using the mortars prepared in Preparation Example 1 and Comparative Preparation Examples 1 to 3, and their physical properties were determined using the next phase test method.

[0202] 1) Setting time: KSF2436

[0203] 2) Torsional strength: KS F2476 "Test Method for Strength of Polymer Cement Mortar"

[0204] 3) Compressive strength: KSF2405

[0205] 4) Adhesion strength: KS F4716 "Test Method for Strength of Polymer Cement Mortar"

[0206] 5) Length change rate: The length change rate was determined according to the KS F2424 test method for mortar and concrete. The value is 0 for the initial construction body, - indicates shrinkage rate, and + indicates expansion rate.

[0207] 6) Procedure: Implemented according to KS L5220

[0208] The results are shown in Table 1 below. Figures 13 to 16 middle.

[0209] Table 1

[0210]

[0211]

[0212] As shown in Table 1 above, the mortar composition according to the present invention has significantly superior physical properties compared to mortar compositions using conventional Portland cement as a binder or without the use of waste glass fiber powder.

[0213] 2. Evaluation of hearing resistance, adhesion strength, acid resistance, flexural strength, and water resistance.

[0214] According to Example 1 and Comparative Examples 1 to 3, the sound insulation, adhesion strength, acid resistance, flexural strength and water resistance of the formed surfaces were evaluated, and the results are shown in Table 2.

[0215] Table 2

[0216]

[0217] As can be seen from the results in Table 2 above, the mortar and coating agent manufactured by this invention have excellent adhesion strength and other physical properties when used for repair work.

[0218] 3. Evaluation of flame retardancy, weather resistance, chloride ion penetration resistance, and impact resistance.

[0219] The flame retardancy, weather resistance, chloride ion penetration resistance, and impact resistance of the mortars and coatings formed in Example 1 and Comparative Examples 1 to 3 were evaluated (flame retardancy was evaluated using the UL94 method, and other physical properties were evaluated using the KS F4929 (2010) method).

[0220] The evaluation results showed that all samples exhibited self-digestion in terms of flame retardancy, and all samples showed suitable or normal results in other physical properties.

[0221] The experimental results above confirm that when using the mortar and surface coating agent specified in this invention for surface reinforcement of concrete structures, it exhibits excellent mechanical and chemical properties.

[0222] As a reference example, the following Table 3 and Figure 17 The results show the results of mortar using only Portland cement as a binder and mortar of sample 1 with an RGF weight ratio of 1-16 for 100 parts of cement.

[0223] Table 3

[0224] project Sample 1 Sample 2 <![CDATA[Torsion strength (N / mm 2 )]]> 10 14 Compressive strength (N / mm2) 51 62

[0225] As shown in Table 3 above and Figure 17 As shown, in the case of RGF-admixed mortar compositions, it can be confirmed that their physical properties are significantly better than those of compositions using conventional Portland cement as a binder.

[0226] Furthermore, when comparing the physical properties of mortar with a weight ratio of 17-32 and that of sample 4 (with a weight ratio of 33-50) as sample 5, compared to sample 2 with ordinary Portland cement by weight 100, the results are shown in Table 4 below. Figure 18 middle.

[0227] Table 4

[0228] project Sample 2 Sample 3 Sample 3 Torsional strength (N / mm2) 21 25 23 Compressive strength (N / mm2) 70 78 75

[0229] As shown in Table 4 and Figure 18 As shown, sample 3 exhibits the best compressive strength and torsional strength. In the case of sample 4, although the RGF weight ratio is the highest, the presence of [unclear text - possibly a typo] indicates a problem. Figure 8The same phenomenon of reunion occurs, but the material properties seem to decrease.

[0230] Therefore, when preparing the composition using the proportions of Sample 3, the optimal physical properties were confirmed.

[0231] As described above, the preferred embodiments of the invention have been introduced in this list and drawings. Although certain terminology has been used, it is only for the purpose of illustrating the technical content of the invention and aiding in understanding the invention in a general sense, and is not intended to limit the scope of the invention. Other variations based on the technical concept of the invention may be implemented in addition to the embodiments introduced herein, which will be self-evident to those skilled in the art to which this invention pertains.

Claims

1. A process for structural repair and reinforcement using an environmentally friendly mortar composition, characterized in that, The process for structural repair and reinforcement using environmentally friendly mortar composition includes the following steps: (1) Chipping the sections of the concrete structure that need repair until undamaged sections are visible; (2) Apply primer to the polished concrete section; (3) Spraying a mortar composition for section repair onto the section surface on which the primer is sprayed; and (4) Spray a surface protectant onto the surface of the mortar composition for section repair. The single-sided repair mortar composition is for powders with a fineness of 3000-6000 cm⁻¹. 2 The waste glass fibers collected from the insulation board are processed to obtain a 100-part complex consisting of 50-80% by weight powder, 3-20% by weight shrinkage reducer, 0.5-1.5% by weight polymer resin, 0.2-2% by weight fiber, 1-5% by weight silica fume, 0.5-5.0% by weight clinker, 0.5-5.0% by weight plastic, 0.5-5% by weight α-type hemihydrate gypsum, 0.01-5% by weight fly ash, 0.01-5% by weight microsilica, 20-200 parts by weight silica sand, 0.5-5 parts by weight metal salt thickener, and water.

2. The structural repair and reinforcement process using an environmentally friendly mortar composition according to claim 1, characterized in that, The method for processing the waste glass fiber powder collected from the heat insulation board to obtain powder includes the following steps: (a) Prepare powders of cement, blast furnace slag powder or a combination thereof, and feed them into a powdering equipment; (b) The recycled glass fiber (RGF) collected by the insulation board is fed into the un-crushed equipment in (a); (c) Crush the ingredients fed into the un-crushed equipment; (d) Collect the powder obtained in (c) above; and (e) The powder obtained in (d) is mixed with ordinary Portland cement in a ratio of 100 parts by weight to 1 to 50 parts by weight.

3. The structural repair and reinforcement process using environmentally friendly mortar composition according to claim 2, characterized in that, The un-pulverized equipment in (b) is a pin mill, fine impact mill, ball mill, or vertical mill.

4. The structural repair and reinforcement process using environmentally friendly mortar composition according to claim 2, characterized in that, The waste glass fiber used in the un-crushed equipment in (b) weighs no more than 0.1 to 50% of the powder, including the cement and blast furnace slag powder, compared to 100% by weight.

5. The structural repair and reinforcement process using an environmentally friendly mortar composition according to claim 1, characterized in that, The polymer resin is selected from one or more of the following resins: Ethylene Vinyl Acetate (EVA), NR (Natural Rubber), NBR (Natural Rubber-Butadien Rubber), SBR (Styrene-Butadien Rubber), and Polyvinyl Acetate.

6. The structural repair and reinforcement process using an environmentally friendly mortar composition according to claim 1, characterized in that, The metal salt-based thickener is selected from one or more of the following: calcium phosphate, calcium chloride, calcium hydroxide, calcium nitrate, magnesium chloride, magnesium sulfate, lithium carbonate, lithium hydroxide, and lithium sulfate.

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