Regenerated runway stone surface strengthening method suitable for indoor decorative plate and construction method

Abstract

The invention discloses a regenerated runway stone surface strengthening method suitable for an indoor decorative plate and a construction method. The method comprises the steps that the front face of a regenerated runway stone specification plate is coated with glue to fill holes, sand holes and gaps in the stone surface; the hole filling glue used for coating the glue comprises oxide micro powder; the volume ratio of the oxide micro powder in the pore filling glue is 30-50%; and polishing the paved regenerated runway stone by using an acidic polishing solution, and the like. The oxide micro powder with good wear resistance is added into the filling glue of the stone pores, and the regenerated decorative plate is polished with the acid polishing solution after being mounted, so that the oxide content of the filling surface of the regenerated runway stone is further increased, the wear resistance and acid resistance of the surface of the regenerated runway stone are improved, and meanwhile, the polishing glossiness is ensured; therefore, the regenerated runway stone meets the use requirement of an indoor decorative plate.

Description

Technical Field

[0001] This invention relates to the field of racetrack stone recycling technology, and more specifically, to a method and construction method for surface strengthening of recycled racetrack stone suitable for interior decorative panels. Background Technology

[0002] Airport runway stones primarily originate from the demolition processes of the flight area and apron during airport reconstruction, including discarded concrete pavement, asphalt pavement, shoulders, and runway debris. If this waste concrete is disposed of as construction waste, it not only occupies land resources but also causes secondary pollution. In fact, although airport runway stones become more brittle after years of high-frequency use, they still possess excellent hardness, modulus, and other physical properties, giving them high reuse value.

[0003] Through scientific classification, collection, and secondary processing, some waste airport runway stones can be transformed into various building materials such as concrete decorative panels, imitation stone curb stones, prefabricated pavements, and recycled fillers, which can be directly applied in airport reconstruction or expansion projects. Concrete decorative panels, as interior decoration materials, require high gloss levels and need to be polished after installation. However, airport runway stones, being recycled concrete, have numerous surface pores and high water absorption rates. During processing, pore-filling adhesives are typically added to reduce water absorption. However, commercially available pore-filling adhesives are usually organic substances such as epoxy resin or polyurethane. The filling process not only reduces the wear resistance and acid resistance of the runway stone surface, but also results in recycled runway stone decorative panels that do not meet the requirements for interior decoration materials in terms of wear resistance and acid resistance. This problem limits the large-scale application of recycled airport runway stone decorative panels. Summary of the Invention

[0004] To address the aforementioned deficiencies in existing technologies, this invention provides a method and construction method for surface strengthening of recycled racetrack stone suitable for interior decorative panels. By adding oxide micro-powder to the pore-filling adhesive and polishing with an acidic polishing liquid after installation of the recycled decorative panel, the oxide content on the surface of the recycled racetrack stone is further increased, thereby improving the wear resistance and acid resistance of the recycled racetrack stone surface while ensuring polishing gloss, enabling the recycled racetrack stone to meet the usage requirements of interior decorative panels.

[0005] To achieve the above objectives, on the one hand, the present invention provides a method for surface strengthening of recycled racetrack stone suitable for interior decorative panels. The recycled racetrack stone standard panel is coated with adhesive to fill the holes, sand holes and gaps on the stone surface; the filling adhesive used for coating includes oxide micro powder; the volume ratio of the oxide micro powder in the filling adhesive is 30~40%; the recycled racetrack stone after laying is polished with acid polishing liquid; after polishing, the water absorption rate of the recycled racetrack stone is less than 1.5%, the acid resistance is higher than 97%, and the average Mohs hardness is not less than 6.

[0006] This invention uses a pore-filling adhesive comprising oxide micropowder to fill pores on the surface of recycled racetrack stone. This reduces the surface porosity and water absorption of the stone. Furthermore, the volume percentage of the oxide micropowder in the pore-filling adhesive is 30-40%. Too low a volume percentage results in insufficient wear and acid resistance for the filler material, while too high a percentage makes it difficult for the filler material to disperse evenly in the matrix, reducing the bonding strength between the adhesive and the stone. Polishing the stone surface with an acidic polishing solution increases the oxide content on the stone surface, further improving the wear and acid resistance of the recycled racetrack stone surface.

[0007] Furthermore, the oxide micropowder is at least one of silica micropowder and alumina micropowder, with a particle size of 0.5~2μm. Oxide micropowder with this particle size can be better and more uniformly dispersed in the colloidal matrix.

[0008] Furthermore, the pore-filling adhesive includes commercially available epoxy resin-based pore-filling adhesive and oxide micropowder.

[0009] Furthermore, the pore-filling adhesive comprises commercially available polyurethane-based pore-filling adhesive and oxide micropowder.

[0010] Furthermore, the acidic polishing solution comprises citric acid, abrasive powder, and water, with a pH value of 2-3. Citric acid exhibits higher corrosiveness to epoxy resin or polyurethane at grinding temperatures than oxide micropowder, and the grinding process further increases the proportion of oxides on the polished surface.

[0011] On the other hand, the present invention provides a construction method for recycled racetrack stone suitable for interior decorative panels, comprising the following steps:

[0012] Step S1: Cut and slab the rough stones for the racetrack to obtain slabs of the required specifications;

[0013] Step S2: Apply adhesive to the front of the racetrack stone slab to fill the holes, sand holes, and gaps on the stone surface, resulting in a recycled racetrack stone decorative slab; the filling adhesive used for the adhesive application includes oxide micro powder; the volume percentage of the oxide micro powder in the filling adhesive is 30-40%;

[0014] Step S3: According to the decorative panel layout requirements, cement mortar is used to lay the recycled decorative panels of the racetrack stone on site, leaving expansion joints.

[0015] Step S4, Opening and Filling the Joints: Use a stone cutting machine to reopen and clean the expansion joints between the recycled track stone decorative panels, ensuring the joint width is uniform; fill the expansion joints with grout.

[0016] Step S5: Polish the laid track stone recycled decorative panels with acid polishing liquid to complete the construction.

[0017] Furthermore, the step of laying the recycled runway stone decorative panels in step S3 includes:

[0018] Step S31: Cleaning and leveling the concrete base layer;

[0019] Step S32, Marking lines: Mark the cross control lines on the concrete base and extend them to the bottom of the wall. Then, find the surface elevation based on the +0.5m horizontal control line of the wall and mark the horizontal elevation line on the wall.

[0020] Step S33, Apply cement slurry and lay mortar bonding layer: Sprinkle water to moisten the concrete base layer, apply a layer of neat cement slurry; draw cross control lines, and lay a leveling layer with dry hard cement mortar of 1:2 to 1:3; control the thickness so that it is 3 to 4 mm higher than the surface level line when the track stone blocks are placed.

[0021] Step S34: First, pre-wet the recycled track stone decorative panels with water. After the surface is air-dried and free of standing water, begin installation from the intersection of the control lines. Perform a trial installation by aligning the recycled track stone decorative panels with the control lines and placing them on the leveled layer. Tap the wooden pads on the recycled track stone decorative panels to compact the mortar to the installation height. Then, lift the recycled track stone decorative panels and move them aside to check if the mortar surface matches the recycled track stone decorative panels. If any hollow areas are found, fill them with mortar. Next, perform the formal installation by applying a layer of cement slurry to the back of the recycled track stone decorative panels, then laying the panels, ensuring all four corners are lowered simultaneously. Gently tap the wooden pads on the recycled track stone decorative panels with a rubber or wooden mallet to level them according to the horizontal line. After laying the first panel, continue laying the recycled track stone decorative panels sequentially to the sides and backwards.

[0022] Furthermore, the oxide powder is at least one of silica powder and alumina powder, with a particle size of 0.5~2μm.

[0023] Furthermore, the acidic polishing solution in step S5 comprises citric acid, abrasive powder, and water, with a pH value of 2-3.

[0024] Furthermore, after the surface of the recycled racetrack stone decorative panel is completely dry, a second adhesive coating is applied to the recycled racetrack stone decorative panel before mechanical grinding, which can further fill the surface depressions caused by solvent evaporation during the first adhesive coating.

[0025] Compared with the prior art, the present invention has the following technical effects:

[0026] (1) The present invention applies adhesive to the pores of the recycled track stone to strengthen the surface of the recycled track stone; by adding oxide micro powder to the pore filling adhesive and polishing the recycled track stone with acid polishing liquid after installation, the oxide content of the surface of the recycled track stone is further increased, thereby improving the wear resistance and acid resistance of the surface of the recycled track stone, while ensuring the polishing gloss, so that the water absorption rate of the recycled track stone is less than 1.5%, the acid resistance is higher than 97%, and the average Mohs hardness is not less than 6, which meets the requirements for use of indoor decorative panels.

[0027] (2) The filling adhesive used in this invention can be prepared by commercial pore filling adhesive and commercially available oxide micro powder. The acidic polishing liquid used can also be obtained by general market customization. The preparation process is relatively simple and will not significantly increase the cost.

[0028] (3) The large-area paving process of ground stone has high requirements for the layout and line setting of the recycled decorative slabs for the runway stone. The accuracy of the line setting and the paving sequence have a great impact on the construction effect. The present invention uses cross control line marking, trial paving and formal paving combined with the paving sequence from the central axis outward to ensure the construction effect. Attached Figure Description

[0029] Figure 1 This is a flowchart of a construction method for recycled racetrack stone applicable to interior decorative panels according to an embodiment of the present invention.

[0030] Figure 2 This is a cross-sectional view of a racetrack stone recycled decorative panel paving structure in one embodiment of the present invention. Detailed Implementation

[0031] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, but these are not intended to limit the scope of the invention.

[0032] The synthesis apparatus, monomer compounds, grinding powders, wetting agents, thickeners, and solvents involved in the following examples are all commercially available.

[0033] The detection instruments and reagents used in the following examples are all commercially available, and the detection methods used are existing technologies that can be found online.

[0034] Furthermore, the order of actions, steps, etc., in the apparatus and methods shown in the claims, specification, and drawings may be implemented in any order, unless otherwise expressly specified, and provided that the output of a preceding process is not used in a subsequent process. The term "comprising" and any variations thereof are intended to cover non-exclusive inclusion. For example, a process, method, product, or apparatus that includes a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to these processes, methods, products, or apparatuses.

[0035] Example

[0036] Airport runway stone is a type of high-grade concrete. During its disposal, it is recycled for environmental reasons as an indoor flooring finish. However, recycled runway stone as an indoor flooring finish still faces problems such as excessive water absorption, insufficient gloss, and inadequate acid resistance. This embodiment provides a construction method for recycled runway stone suitable for indoor decorative panels, regenerating airport runway stone into terminal building floor decorative panels. The total area of ​​the decorative panels is approximately 3000 square meters. 2 See Figure 1 The specific construction process includes the following steps:

[0037] Step S1: Cutting and slab-cutting of the track stone slabs to obtain the required specifications. Specifically, firstly, a track-mounted rock saw is used at the designated location in the North Second Finger Corridor to divide the concrete into large slabs. Secondly, the track stone slabs are cut: the raw stone blocks are placed on a circular saw and cut to a thickness of 40mm. Because the track stone is made of concrete, the saw blade is easily coated with mud during cutting, causing significant damage. Therefore, the mortar needs to be analyzed, and automatic compensation based on the type is implemented to prevent processing steps from forming on the slab surface during frequent sawing and exiting, ensuring the flatness of the slabs. Next, the finished slabs are cut: an infrared electronic bridge cutter is used to cut the track stone slabs to the required length and width dimensions to obtain the desired specifications.

[0038] Step S2: Apply adhesive to the front of the racetrack stone standard panel to fill the holes, sand holes and gaps on the stone surface to obtain a racetrack stone recycled decorative panel; the filling adhesive used for the adhesive application includes oxide micro powder; the volume ratio of the oxide micro powder in the filling adhesive is 30~40%.

[0039] As a preferred example, the pore-filling adhesive is prepared by mixing 50% by volume of a commercial epoxy resin-based pore-filling adhesive, 40% by volume of oxide micropowder, and 10% by volume of epoxy resin-based pore-filling adhesive solvent. The oxide micropowder is at least one of silica micropowder and alumina micropowder, with a particle size ranging from 0.5 to 2 μm. This particle size of oxide micropowder allows for better and more uniform dispersion within the pore-filling adhesive matrix.

[0040] As another example, the pore-filling adhesive is obtained by mixing 55% by volume of a commercial polyurethane-based pore-filling adhesive, 30% by volume of oxide micropowder, and 15% by volume of a solvent in the polyurethane-based pore-filling adhesive. The oxide micropowder is at least one of silica micropowder and alumina micropowder, with a particle size ranging from 0.5 to 2 μm.

[0041] The volume percentage of oxide micro powder in the pore-filling adhesive should not exceed 40%. Otherwise, the oxide micro powder will be difficult to disperse evenly, the adhesive will have poor fluidity, the penetration depth into the pores will decrease, and the bonding force between the adhesive and the stone will also decrease.

[0042] Step S3: According to the layout requirements of the decorative panels, cement mortar is used to lay the recycled decorative panels of the racetrack stone on site, leaving expansion joints.

[0043] More specifically, see Figure 2 The step S3, which involves laying recycled track stone decorative panels, includes:

[0044] Step S31: Clean and level the concrete substrate (e.g., concrete slab or concrete subbase).

[0045] Step S32, Marking lines: Mark the cross control lines on the concrete base and extend them to the bottom of the wall. Then, find the surface elevation based on the +0.5m horizontal control line of the wall and mark the horizontal elevation line on the wall.

[0046] Step S33, Apply cement slurry and lay mortar bonding layer: Sprinkle water to moisten the concrete base layer, apply a layer of neat cement slurry; draw cross control lines, and lay a leveling layer with dry hard cement mortar of 1:2 to 1:3; control the thickness so that it is 3 to 4 mm higher than the surface level line when the track stone blocks are placed.

[0047] Step S34: Set up a north-south control line on site. Due to the large north-south span, the cumulative error of the stone is also relatively large. To ensure the alignment of the stone joints in the north-south direction, the stone must be laid strictly according to the north-south control line. The east-west direction uses the axis as the control line. The east-west expansion joints coincide with the axis. When laying the stone, start laying 4mm north and south of the axis to ensure the straightness of the east-west expansion joints and to ensure an 8mm expansion joint. Start laying from the intersection of the central axis. Before laying the recycled track stone decorative panels, soak them in water and allow them to air dry until no standing water remains. Begin installation from the intersection of the control lines. First, perform a trial installation by aligning the recycled track stone decorative panels with the control lines and placing them on the leveled layer. Tap the wooden pads on the panels to compact the mortar to the desired height. Then, lift the panels and move them aside to check for a proper fit between the mortar surface and the panels. If any hollow areas are found, fill them with mortar. Next, perform the formal installation by applying a layer of cement slurry to the back of each panel, then laying the panels with all four corners lowered simultaneously. Gently tap the wooden pads on the panels with a rubber or wooden mallet to level them according to the horizontal line. After laying the first panel along the central axis, continue laying the panels sequentially to the sides and backwards.

[0048] Step S4, Joint Opening and Sealing: Due to the high surface roughness of the recycled racetrack stone decorative panels, a stone cutting machine is used to reopen and clean the expansion joints between the panels, ensuring uniform joint width. The expansion joints are then filled with sealant. The sealant is preferably a foam strip with good elasticity combined with silicone sealant. Copper strips are preferably used to cover the expansion joints.

[0049] Step S5: Polish the paved recycled track stone decorative panels with acidic polishing liquid to complete the construction: First, clean the surface of the recycled track stone decorative panels, then use grinding pads for pre-rough grinding to obtain a smooth surface, and then use an acidic polishing liquid with citric acid-abrasive powder system and a soft polishing pad for polishing.

[0050] More specifically, after the recycled stone decorative panels to be laid are cleaned and completely dried, stone grinding machinery with diamond grinding discs is used to pre-grind the stone surface through multiple processes, from coarse to fine, using discs of 50#, 150#, 300#, and 500#, to make the stone surface smooth and flat. The acidic polishing solution of the citric acid-grinding powder system mainly includes 1~3wt% citric acid and 5~8wt% silica micropowder (particle size 1~3μm), with water as the grinding solvent, and the pH value of the polishing solution is controlled at 2~3. Citric acid has a higher corrosiveness to epoxy resin or polyurethane than oxide micropowder at the grinding temperature, and the grinding process can further increase the proportion of oxides on the grinding surface.

[0051] Depending on the polishing effect and the consumption of the polishing slurry, ethylene glycol can be added to the polishing slurry as a thickener to increase the viscosity of the polishing slurry, enhance the adhesion of the abrasive particles, and improve the mechanical action. Alternatively, surfactants can be added to the polishing slurry as wetting agents to improve the spreading effect of the polishing slurry on the polished surface.

[0052] Even better, after the recycled track stone decorative panel is completely dry, it can be coated with adhesive a second time, and then ground and polished with acid polishing liquid.

[0053] The installed recycled runway stone decorative panels meet the technical specifications in Table 1.

[0054] Table 1 Technical Specifications of Terminal Building Floor Paving Materials

[0055] 1 compressive strength 100Mpa and above 2 Water absorption rate Less than 1.5% 3 Anti-slip coefficient Reaching Level 3 or above 4 Average Mohs hardness 6 5 Acid resistance Greater than 97.5% 6 High impermeability higher

[0056] As described above, steps S2 and S5 are also a method for surface strengthening of recycled racetrack stone. The processing and construction method for recycled racetrack stone decorative panels in this embodiment can significantly improve the construction quality of the recycled racetrack stone decorative panels without increasing processing and construction procedures, and largely avoids rework and problems such as insufficient water absorption, wear resistance, and acid resistance.

[0057] Those skilled in the art should understand that variations can be implemented by combining existing technology with the above embodiments, which will not be elaborated here. Such variations do not affect the essence of the present invention, and will not be elaborated here either.

[0058] The preferred embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, and the devices and structures not described in detail should be understood as being implemented in a conventional manner in the art. Any person skilled in the art can make many possible variations and modifications to the technical solutions of the present invention using the methods and techniques disclosed above, or modify them into equivalent embodiments with equivalent changes, without departing from the scope of the present invention. This does not affect the essential content of the present invention. Therefore, any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of the present invention without departing from the content of the present invention's technical solutions still fall within the protection scope of the present invention.

Claims

1. A method for surface strengthening of recycled racetrack stone suitable for interior decorative panels, characterized in that, The recycled track stone standard slabs are coated with adhesive to fill the holes, sand holes and gaps on the stone surface; the filling adhesive used for coating includes oxide micro powder; the volume ratio of the oxide micro powder in the filling adhesive is 30~40%; the recycled track stone is polished with acid polishing liquid after installation; after polishing, the water absorption rate of the recycled track stone is less than 1.5%, the acid resistance is higher than 97%, and the average Mohs hardness is not less than 6.

2. The method for surface strengthening of recycled racetrack stone suitable for interior decorative panels according to claim 1, characterized in that, The oxide micro powder is at least one of silica micro powder and alumina micro powder, with a particle size of 0.5~2μm.

3. The method for surface strengthening of recycled racetrack stone suitable for interior decorative panels according to claim 1 or 2, characterized in that, The pore-filling adhesive includes commercially available epoxy resin-based pore-filling adhesive and oxide micro powder.

4. The method for surface strengthening of recycled racetrack stone suitable for interior decorative panels according to claim 1 or 2, characterized in that, The pore-filling adhesive includes commercially available polyurethane-based pore-filling adhesive and oxide micropowder.

5. The method for surface strengthening of recycled racetrack stone suitable for interior decorative panels according to claim 1 or 2, characterized in that, The acidic polishing solution consists of citric acid, abrasive powder, and water, with a pH value of 2-3.

6. A construction method for recycled racetrack stone suitable for interior decorative panels, characterized in that, Includes the following steps: Step S1: Cut and slab the rough stones for the racetrack to obtain slabs of the required specifications; Step S2: Apply adhesive to the front of the racetrack stone slab to fill the holes, sand holes, and gaps on the stone surface, resulting in a recycled racetrack stone decorative slab; the filling adhesive used for the adhesive application includes oxide micro powder; the volume percentage of the oxide micro powder in the filling adhesive is 30-40%; Step S3: According to the decorative panel layout requirements, cement mortar is used to lay the recycled decorative panels of the racetrack stone on site, leaving expansion joints. Step S4, Opening and Filling the Joints: Use a stone cutting machine to reopen and clean the expansion joints between the recycled track stone decorative panels, ensuring the joint width is uniform; fill the expansion joints with grout. Step S5: Polish the laid track stone recycled decorative panels with acid polishing liquid to complete the construction.

7. The construction method of recycled racetrack stone suitable for interior decorative panels according to claim 6, characterized in that, The step of laying the recycled track stone decorative panels in step S3 includes: Step S31: Cleaning and leveling the concrete base layer; Step S32, Marking lines: Mark the cross control lines on the concrete base and extend them to the bottom of the wall. Then, find the surface elevation based on the +0.5m horizontal control line of the wall and mark the horizontal elevation line on the wall. Step S33, Apply cement slurry and lay mortar bonding layer: Sprinkle water to moisten the concrete base layer, apply a layer of neat cement slurry; draw cross control lines, and lay a leveling layer with dry hard cement mortar of 1:2 to 1:3; control the thickness so that it is 3 to 4 mm higher than the surface level line when the track stone blocks are placed. Step S34: First, pre-wet the recycled track stone decorative panels with water. After the surface is air-dried and free of standing water, begin installation from the intersection of the control lines. Perform a trial installation by aligning the recycled track stone decorative panels with the control lines and placing them on the leveled layer. Tap the wooden pads on the recycled track stone decorative panels to compact the mortar to the installation height. Then, lift the recycled track stone decorative panels and move them aside to check if the mortar surface matches the recycled track stone decorative panels. If any hollow areas are found, fill them with mortar. Next, perform the formal installation by applying a layer of cement slurry to the back of the recycled track stone decorative panels, then laying the panels, lowering all four corners simultaneously. Gently tap the wooden pads on the recycled track stone decorative panels with a rubber or wooden mallet to level them according to the horizontal line. After laying the first panel, continue laying the recycled track stone decorative panels sequentially to the sides and backwards.

8. The construction method of recycled racetrack stone suitable for interior decorative panels according to claim 6, characterized in that, The oxide micro powder is at least one of silica micro powder and alumina micro powder, with a particle size of 0.5~2μm.

9. The construction method of recycled racetrack stone suitable for interior decorative panels according to claim 6, characterized in that, The acidic polishing solution in step S5 consists of citric acid, abrasive powder, and water, with a pH value of 2-3.

10. The construction method of recycled racetrack stone suitable for interior decorative panels according to claim 5, characterized in that, After the surface of the recycled track stone decorative panel has completely dried, a second layer of adhesive is applied to the recycled track stone decorative panel before mechanical grinding.

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