Self-repairing type single-component polymer waterproof mortar as well as preparation method and application thereof

Abstract

The invention relates to the technical field of building materials, and provides self-repairable single-component polymer waterproof mortar as well as a preparation method and application thereof. The self-repairing type single-component polymer waterproof mortar is prepared from the following raw materials in parts by weight: 40 to 50 parts of Portland cement, 45 to 55 parts of quartz sand, 1 to 3 parts of redispersible latex powder, 0.5 to 1.5 parts of dispersible asphalt rubber powder, 0.1 to 0.3 part of silane modified polypropylene fiber, 0.1 to 0.3 part of a water reducing agent, 0.1 to 0.3 part of a de-foaming agent, 2 to 5 parts of slow-release type crystalline active particles, 0.1 to 0.3 part of an early strength agent and 1 to 3 parts of an expanding agent. According to the technical scheme, the problems of insufficient impermeability, mechanical strength and adhesive property caused by no self-repairing capability of the waterproof mortar in the prior art are solved.

Description

Technical Field

[0001] This invention relates to the field of building materials technology, specifically to a self-healing single-component polymer waterproof mortar, its preparation method, and its application. Background Technology

[0002] Polymer waterproof mortar can be divided into single-component and two-component waterproof mortars based on its composition. Two-component mortar consists of two components: liquid and powder. However, during construction, the liquid and powder components must be mixed evenly at a fixed weight ratio. Inaccurate measurement during use can easily lead to differences in mortar performance, making the construction quality control of two-component mortar more difficult. Single-component mortar is made by mixing materials such as sand, cement, and dispersible adhesive powder. It is more convenient to construct and is widely used due to its ease of construction.

[0003] Polymer waterproof mortar, as a waterproofing material, is prone to cracking and requires a relatively thick design, so it is rarely used for large-area waterproofing and is only used for localized base layer repairs. However, with the implementation of waterproofing standards, higher requirements have been placed on the waterproofing performance of residential exterior walls in some areas, making polymer waterproof mortar an indispensable product for building exterior wall waterproofing. However, traditional waterproof mortar lacks self-healing ability. When new cracks appear in the mortar under the action of external forces such as temperature changes and structural settlement, moisture can easily seep into the interior through the cracks, making it impossible for the cracks to close on their own, resulting in insufficient waterproof mortar in terms of impermeability.

[0004] When the waterproof mortar has insufficient impermeability, water will penetrate into the mortar and damage the stability of the cement hydration products, leading to the decomposition of calcium silicate hydrate gel, reducing the mechanical strength and bonding performance of the mortar, causing the mortar layer to bulge and fall off. Long-term water infiltration will cause dampness and mold inside the building, affecting the comfort of the living environment, and increasing the cost of later maintenance and reinforcement.

[0005] Therefore, it is essential to develop a self-healing single-component polymer waterproof mortar to improve its impermeability, mechanical strength, and bonding properties. Summary of the Invention

[0006] This invention proposes a self-healing single-component polymer waterproof mortar, its preparation method, and its application, which solves the problems of insufficient impermeability, mechanical strength, and bonding performance caused by the lack of self-healing ability in related technologies.

[0007] The technical solution of the present invention is as follows: The present invention proposes a self-healing single-component polymer waterproof mortar, comprising the following raw materials in parts by weight: 40-50 parts of silicate cement, 45-55 parts of quartz sand, 1-3 parts of redispersible latex powder, 0.5-1.5 parts of dispersible asphalt powder, 0.1-0.3 parts of silane-modified polypropylene fiber, 0.1-0.3 parts of water-reducing agent, 0.1-0.3 parts of defoamer, 2-5 parts of slow-release crystalline active particles, 0.1-0.3 parts of early-strength agent, and 1-3 parts of expansion agent.

[0008] As a further technical solution, the preparation method of the sustained-release crystalline active particles includes the following steps: S1. Dissolve the permeation crystallization active masterbatch in water, add porous mineral particles, soak, filter and dry to obtain pretreated porous mineral particles. S2. The emulsion is applied to the surface of the pretreated porous mineral particles and cured to obtain the slow-release crystalline active particles. The emulsion comprises the following raw materials in parts by weight: 30-35 parts epoxy resin, 10-15 parts epoxy diluent, 40-45 parts ketimine latent curing epoxy curing agent, 0.5-1 part silane coupling agent KH-560, 0.3-0.5 parts emulsifier, and 3-5 parts water.

[0009] As a further technical solution, the mass ratio of the permeation crystallization active masterbatch to water is 1:4.

[0010] As a further technical solution, the mass ratio of the permeation crystallization active masterbatch to the porous mineral particles is 3:7.

[0011] As a further technical solution, the quartz sand is composed of first quartz sand and second quartz sand with different particle sizes. The particle size of the first quartz sand is 40~80 mesh, and the particle size of the second quartz sand is 80~120 mesh. The mass ratio of the first quartz sand to the second quartz sand is 5~6:4~5.

[0012] As a further technical solution, the preparation method of the silane-modified polypropylene fiber includes the following steps: dispersing silane coupling agent KH-560 in anhydrous ethanol, adding polypropylene fiber, mixing, filtering, and drying to obtain the silane-modified polypropylene fiber.

[0013] As a further technical solution, the mass ratio of the silane coupling agent to the polypropylene fiber is 2~2.5:100.

[0014] As a further technical solution, the mass ratio of the anhydrous ethanol to the polypropylene fiber is 5:1.

[0015] As a further technical solution, the mixing time is 20-30 minutes, for example, it can be 20 minutes, 22 minutes, 24 minutes, 25 minutes, 26 minutes, 28 minutes, or 30 minutes, preferably 25 minutes.

[0016] As a further technical solution, the water-reducing agent includes one or two of polycarboxylate water-reducing agents and naphthalene-based water-reducing agents, preferably polycarboxylate water-reducing agents.

[0017] As a further technical solution, the defoamer includes one or more of silicone defoamers, polyether defoamers, and mineral oil defoamers, preferably polyether defoamers.

[0018] As a further technical solution, the early strength agent is calcium formate.

[0019] As a further technical solution, the expanding agent includes one or more of calcium sulfoaluminate expanding agent, magnesium oxide expanding agent, and calcium oxide expanding agent, preferably calcium sulfoaluminate expanding agent.

[0020] As a further technical solution, the porous mineral particles have a particle size of 20-40 mesh, and the porous mineral particles include one or more of talc, bentonite, and diatomaceous earth, preferably bentonite.

[0021] As a further technical solution, the epoxy diluent includes one or two of allyl glycidyl ether and butyl glycidyl ether, preferably allyl glycidyl ether.

[0022] As a further technical solution, the emulsifier includes one or two of octylphenol polyoxyethylene ether and fatty alcohol polyoxyethylene ether, preferably fatty alcohol polyoxyethylene ether.

[0023] As a further technical solution, the curing temperature is 180~185℃.

[0024] The present invention also proposes a method for preparing a self-healing single-component polymer waterproof mortar, which includes the following steps: mixing the weight parts of the component raw materials evenly to obtain the self-healing single-component polymer waterproof mortar.

[0025] The present invention also proposes the application of a self-healing single-component polymer waterproof mortar or the self-healing single-component polymer waterproof mortar prepared by the aforementioned preparation method in building exterior walls.

[0026] The working principle and beneficial effects of this invention are as follows: In this invention, a self-healing single-component polymer waterproof mortar contains slow-release crystalline active particles that release active substances after cracking and immersion in water, promoting the rehydration reaction of the cement mortar to form whiskers, thus possessing crack repair capabilities. Silane-modified polypropylene fibers can have a good bond with cement mortar, enhancing the mortar's flexural strength and preventing the formation of microcracks. The addition of an expansion agent can ensure the dimensional stability of the mortar, reduce the generation of internal stress, and maintain the stability of the mortar's bonding performance. Detailed Implementation

[0027] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0028] In the following examples and comparative examples: Silicate cement: Ordinary Silicate cement 42.5; First type of quartz sand: particle size is 40~80 mesh; Second type of quartz sand: particle size is 80~120 mesh; Redispersible latex powder: Ethylene / vinyl laurate / vinyl chloride terpolymer powder, model number Wacker 8034H; Dispersible bitumen powder: purchased from Jiangsu Ouxidun Waterproof Materials Co., Ltd.; Polypropylene fiber: 6~8mm in length; Water-reducing agent: Polycarboxylate superplasticizer SC-11; Defoamer: Model 362; Talc powder: particle size 30 mesh; Epoxy resin: Model E-51; Ketoimine latent curing epoxy curing agent: Model DA-134; Fatty alcohol polyoxyethylene ether: AEO-9.

[0029] Example 1 A self-healing, single-component polymer waterproof mortar comprises the following raw materials in parts by weight: 40 parts silicate cement, 55 parts quartz sand, 1.5 parts redispersible latex powder, 1.5 parts dispersible bitumen powder, 0.1 parts silane-modified polypropylene fiber, 0.1 parts water-reducing agent, 0.1 parts defoamer, 4 parts slow-release crystalline active particles, 0.1 parts calcium formate, and 0.1 parts calcium sulfoaluminate expanding agent; the quartz sand is composed of first quartz sand and second quartz sand in a mass ratio of 5:4. The preparation method of sustained-release crystalline active particles includes the following steps: S1. Dissolve the permeation crystallization active masterbatch in water, add porous mineral particles, soak, filter and dry to obtain pretreated porous mineral particles; the mass ratio of permeation crystallization active masterbatch to water is 1:4; the mass ratio of permeation crystallization active masterbatch to porous mineral particles is 3:7. S2. The emulsion is dipped onto the surface of pretreated porous mineral particles with a coating thickness of 0.1 mm. After curing, slow-release crystalline active particles are obtained. The emulsion comprises the following raw materials in parts by weight: 30 parts epoxy resin, 10 parts allyl glycidyl ether, 40 parts ketimide latent curing epoxy curing agent, 0.5 parts silane coupling agent KH-560, 0.3 parts fatty alcohol polyoxyethylene ether, and 3 parts water; The preparation method of silane-modified polypropylene fiber includes the following steps: dispersing silane coupling agent KH-560 in anhydrous ethanol, adding polypropylene fiber, mixing for 25 min, filtering and drying to obtain silane-modified polypropylene fiber; the mass ratio of silane coupling agent to polypropylene fiber is 2:100; the mass ratio of anhydrous ethanol to polypropylene fiber is 5:1. A method for preparing a self-healing single-component polymer waterproof mortar includes the following steps: mixing raw materials evenly to obtain a self-healing single-component polymer waterproof mortar.

[0030] Example 2 A self-healing, single-component polymer waterproof mortar comprises the following raw materials in parts by weight: 45 parts silicate cement, 46 parts quartz sand, 2 parts redispersible latex powder, 1 part dispersible asphalt powder, 0.3 parts silane-modified polypropylene fiber, 0.1 parts water-reducing agent, 0.2 parts defoamer, 5 parts slow-release crystalline active particles, 0.1 parts calcium formate, and 2 parts calcium sulfoaluminate expanding agent; the quartz sand is composed of first quartz sand and second quartz sand in a mass ratio of 5:4. The preparation method of sustained-release crystalline active particles includes the following steps: S1. Dissolve the permeation crystallization active masterbatch in water, add porous mineral particles, soak, filter and dry to obtain pretreated porous mineral particles; the mass ratio of permeation crystallization active masterbatch to water is 1:4; the mass ratio of permeation crystallization active masterbatch to porous mineral particles is 3:7. S2. The emulsion is dipped onto the surface of pretreated porous mineral particles with a coating thickness of 0.1 mm. After curing, slow-release crystalline active particles are obtained. The emulsion comprises the following raw materials in parts by weight: 32 parts epoxy resin, 12 parts allyl glycidyl ether, 42 parts ketimide latent curing epoxy curing agent, 0.8 parts silane coupling agent KH-560, 0.4 parts fatty alcohol polyoxyethylene ether, and 4 parts water; The preparation method of silane-modified polypropylene fiber includes the following steps: dispersing silane coupling agent KH-560 in anhydrous ethanol, adding polypropylene fiber, mixing for 25 min, filtering and drying to obtain silane-modified polypropylene fiber; the mass ratio of silane coupling agent to polypropylene fiber is 2:100; the mass ratio of anhydrous ethanol to polypropylene fiber is 5:1. A method for preparing a self-healing single-component polymer waterproof mortar includes the following steps: mixing raw materials evenly to obtain a self-healing single-component polymer waterproof mortar.

[0031] Example 3 A self-healing, single-component polymer waterproof mortar comprises the following raw materials in parts by weight: 50 parts silicate cement, 45 parts quartz sand, 2.5 parts redispersible latex powder, 0.5 parts dispersible bitumen powder, 0.3 parts silane-modified polypropylene fiber, 0.3 parts water-reducing agent, 0.3 parts defoamer, 1 part slow-release crystalline active particles, 0.3 parts calcium formate, and 3 parts calcium sulfoaluminate expanding agent; the quartz sand is composed of first quartz sand and second quartz sand in a mass ratio of 6:5. The preparation method of sustained-release crystalline active particles includes the following steps: S1. Dissolve the permeation crystallization active masterbatch in water, add porous mineral particles, soak, filter and dry to obtain pretreated porous mineral particles; the mass ratio of permeation crystallization active masterbatch to water is 1:4; the mass ratio of permeation crystallization active masterbatch to porous mineral particles is 3:7. S2. The emulsion is dipped onto the surface of pretreated porous mineral particles with a coating thickness of 0.1 mm. After curing, slow-release crystalline active particles are obtained. The emulsion comprises the following raw materials in parts by weight: 35 parts epoxy resin, 15 parts allyl glycidyl ether, 45 parts ketimine latent curing epoxy curing agent, 1 part silane coupling agent KH-560, 0.5 parts fatty alcohol polyoxyethylene ether, and 5 parts water. The preparation method of silane-modified polypropylene fiber includes the following steps: dispersing silane coupling agent KH-560 in anhydrous ethanol, adding polypropylene fiber, mixing for 25 min, filtering and drying to obtain silane-modified polypropylene fiber; the mass ratio of silane coupling agent to polypropylene fiber is 2.5:100; the mass ratio of anhydrous ethanol to polypropylene fiber is 5:1. A method for preparing a self-healing single-component polymer waterproof mortar includes the following steps: mixing raw materials evenly to obtain a self-healing single-component polymer waterproof mortar.

[0032] Example 4 Compared with Example 2, Example 4 differs in that the ketimine latent curing epoxy curing agent in step S2 is replaced with an equal amount of conventional curing agent, model NX8101.

[0033] Comparative Example 1 Compared with Example 2, Comparative Example 1 differs in that the slow-release crystalline active particles were replaced with an equal amount of penetrating crystalline active masterbatch, and no subsequent preparation process was performed.

[0034] Comparative Example 2 Compared with Example 2, Comparative Example 2 differs in that no sustained-release crystalline active particles were added.

[0035] Comparative Example 3 Compared with Example 2, Comparative Example 3 differs in that no silane-modified polypropylene fiber and calcium sulfoaluminate expanding agent were added.

[0036] Comparative Example 4 The difference between Comparative Example 4 and Example 2 is that the silane-modified polypropylene fibers were replaced with an equal amount of polypropylene fibers.

[0037] Comparative Example 5 Compared with Example 2, Comparative Example 5 differs in that no calcium sulfoaluminate expanding agent was added.

[0038] Experimental Example 1 The performance of the self-healing single-component polymer waterproof mortars prepared in Examples 1-4 and Comparative Examples 1-5 was tested according to the following test methods.

[0039] 1. Compressive strength: The compressive strength of the specimen shall be tested in accordance with the test method specified in 7.6 of JC / T 984-2011; 2. Flexural strength: The flexural strength of the specimen shall be tested in accordance with the test method specified in 7.6 of JC / T 984-2011; 3. Bond strength: Prepare specimens according to the method specified in 7.8.1 of JC / T 984-2011, cure them according to the method in 7.1.1, and conduct tests according to 5.4.3 of JC / T 907-2002 to test the bond strength; 4. Permeability pressure: The permeability pressure of the coated specimens and mortar specimens shall be tested according to the test method specified in 7.5 of JC / T 984-2011; 5. Shrinkage rate: The ingredients are prepared according to 7.3 of JC / T 984-2011, and the molding, curing and testing are carried out according to JC / T 603 to test the shrinkage rate.

[0040] The test results are shown in Table 1: Table 1 Performance test results of Examples 1-4 and Comparative Examples 1-5

[0041] As shown in Table 1, in Examples 1 to 3, the amount of soluble adhesive powder added was 3 parts, which consisted of two types of adhesive powder: polymer adhesive powder and asphalt dispersion adhesive powder. As the proportion of polymer adhesive powder increased, the proportion of asphalt dispersion adhesive powder decreased, which had a negative impact on the bonding strength of the waterproof mortar, but a positive effect on the flexural strength.

[0042] Compared to Example 2, Comparative Example 3 added unmodified silane-modified polypropylene fibers and an expanding agent, Comparative Example 4 added unmodified polypropylene fibers, and Comparative Example 5 did not add an expanding agent. The results showed that the performance of Comparative Examples 3-5 was lower than that of Example 2. This is because the polypropylene fibers can play a traction role in the mortar, and the modified polypropylene fibers bond better with the inorganic materials, exhibiting higher flexural strength. The expanding agent mainly compensates for the volume shrinkage caused by the hydration reaction during the mortar curing process. Therefore, the synergistic effect of the expanding agent and silane-modified polypropylene fibers results in polymer mortar with better flexural strength and shrinkage rate.

[0043] Compared with Example 2, Comparative Example 1 directly added the penetrating crystallizing active masterbatch without coating, and Comparative Example 2 did not add slow-release crystallizing active particles. As a result, the initial anti-permeability pressure of Comparative Example 1 was higher, but the secondary pressure was still lower. The main active substances were released during the specimen preparation process. The anti-permeability pressure of Comparative Example 2, which did not add slow-release crystallizing active particles, was significantly lower. It can be seen that slow-release crystallizing active particles have long-term repair function and can repair micro-cracks in mortar and improve anti-permeability performance.

[0044] Compared to Example 2, Example 4 used a conventional curing agent. As a result, the performance of Example 4 was lower than that of Example 2. The latent curing epoxy resin curing agent used in Example 2 can form a capsule at room temperature and cure at high temperature. At the same time, as the temperature increases, the gas volatilization in the coating and the gas expansion in the porous mineral material cause the coating to form microporous channels, which can slowly release active substances. The conventional curing agent used in Example 4 can cure at room temperature within a certain time. The resulting coating completely seals the capsule core and loses the function of slowly releasing active substances.

[0045] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A self-healing, single-component polymer waterproof mortar, characterized in that, The raw materials include the following components by weight: 40-50 parts silicate cement, 45-55 parts quartz sand, 1-3 parts redispersible latex powder, 0.5-1.5 parts dispersible asphalt powder, 0.1-0.3 parts silane-modified polypropylene fiber, 0.1-0.3 parts water-reducing agent, 0.1-0.3 parts defoamer, 2-5 parts slow-release crystalline active particles, 0.1-0.3 parts early-strength agent, and 1-3 parts expansion agent.

2. The self-healing single-component polymer waterproof mortar according to claim 1, characterized in that, The method for preparing the sustained-release crystalline active particles includes the following steps: S1. Dissolve the permeation crystallization active masterbatch in water, add porous mineral particles, soak, filter and dry to obtain pretreated porous mineral particles. S2. The emulsion is applied to the surface of the pretreated porous mineral particles and cured to obtain the slow-release crystalline active particles. The emulsion comprises the following raw materials in parts by weight: 30-35 parts epoxy resin, 10-15 parts epoxy diluent, 40-45 parts ketimine latent curing epoxy curing agent, 0.5-1 part silane coupling agent KH-560, 0.3-0.5 parts emulsifier, and 3-5 parts water.

3. The self-healing single-component polymer waterproof mortar according to claim 1, characterized in that, The quartz sand is composed of first quartz sand and second quartz sand with different particle sizes. The particle size of the first quartz sand is 40-80 mesh, and the particle size of the second quartz sand is 80-120 mesh. The mass ratio of the first quartz sand to the second quartz sand is 5-6:4-5.

4. The self-healing single-component polymer waterproof mortar according to claim 1, characterized in that, The preparation method of the silane-modified polypropylene fiber includes the following steps: dispersing silane coupling agent KH-560 in anhydrous ethanol, adding polypropylene fiber, mixing, filtering, and drying to obtain the silane-modified polypropylene fiber.

5. The self-healing single-component polymer waterproof mortar according to claim 1, characterized in that, The water-reducing agent includes one or two of polycarboxylate water-reducing agents and naphthalene-based water-reducing agents; The defoamer includes one or more of the following: silicone defoamer, polyether defoamer, and mineral oil defoamer; The early-strength agent is calcium formate; The expanding agent includes one or more of calcium sulfoaluminate expanding agent, magnesium oxide expanding agent, and calcium oxide expanding agent.

6. The self-healing single-component polymer waterproof mortar according to claim 2, characterized in that, The porous mineral particles have a particle size of 20-40 mesh, and the porous mineral particles include one or more of talc, bentonite, and diatomaceous earth.

7. The self-healing single-component polymer waterproof mortar according to claim 2, characterized in that, The epoxy diluent includes one or both of allyl glycidyl ether and butyl glycidyl ether; The emulsifier includes one or both of octylphenol polyoxyethylene ether and fatty alcohol polyoxyethylene ether.

8. The self-healing single-component polymer waterproof mortar according to claim 2, characterized in that, The curing temperature is 180~185℃.

9. A method for preparing a self-healing single-component polymer waterproof mortar, used to prepare the self-healing single-component polymer waterproof mortar according to any one of claims 1 to 8, characterized in that, The process includes the following steps: mixing the raw materials by weight parts evenly to obtain the self-healing single-component polymer waterproof mortar.

10. The application of a self-healing single-component polymer waterproof mortar according to any one of claims 1 to 8 or the self-healing single-component polymer waterproof mortar prepared by the preparation method according to claim 9 in the exterior walls of buildings.

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