Double-layer dry-sprinkling type recycled stone-like composite material and construction process

Abstract

This application relates to the field of concrete technology, specifically disclosing a double-layer dry-spreading recycled imitation stone composite material and its construction process. It consists of a bottom layer of crack-resistant imitation stone dry-spreading substrate and a top layer of imitation stone dry-spreading fabric. The bottom layer of crack-resistant imitation stone dry-spreading substrate is made from the following raw materials: recycled stone aggregate, pigments, ordinary silicate cement, crack-resistant fast-setting and fast-hardening sulfoaluminate cement, crack-resistant admixtures, wetting and dispersing agents, crack-resistant long fibers, and water-reducing agents. The top layer of imitation stone dry-spreading fabric is made from the following raw materials: recycled stone aggregate, pigments, cement, crack-resistant admixtures, crack-resistant short fibers, wetting and dispersing agents, and water-reducing agents. The preparation method is as follows: S1, base layer pouring; S2, dry-spreading of the substrate; S3, dry-spreading of the fabric; S4, curing and post-treatment. This composite material can be used in the field of floor decoration, and it has the advantages of natural and realistic decorative effect, good crack resistance, good integration with the base layer, green and environmentally friendly, cost-effective, and convenient and efficient construction.

Description

Technical Field

[0001] This application relates to the field of concrete technology, and more specifically, to a two-layer dry-spreading recycled stone-like composite material and its construction process. Background Technology

[0002] Concrete is the most widely used and consumed building material in modern civil engineering, with a wide range of applications. Its advantages lie in the fact that after cementitious materials, aggregates, and water are scientifically proportioned and set, they can form extremely high compressive strength and good durability, enough to withstand physical wear and chemical erosion for decades or even hundreds of years. At the same time, fresh concrete has excellent plasticity and can be cast into any complex curved shape and ultra-large volume structure with the help of formwork, meeting the dual demands of modern architecture for aesthetics and function. In addition, compared with steel and wood, concrete raw materials are widely available and relatively inexpensive. Its excellent heat storage capacity and complementary mechanism with steel reinforcement further enable reinforced concrete structures to have both rigid load-bearing and flexible earthquake resistance.

[0003] The concrete is decorated by applying a colored coating or pasting a finishing material to the surface. However, this surface treatment has different physical properties from the concrete base. Under temperature changes or loads, it is prone to peeling and cracking, which leads to insufficient durability of the decorative layer, increased maintenance costs and affects the overall structural performance. Summary of the Invention

[0004] To address the issues of insufficient durability of decorative layers, increased maintenance costs, and impact on overall structural performance caused by applying dyed coatings or adhesive finishing materials to the surface of concrete, this application provides a double-layer dry-spreading recycled stone-like composite material and its construction process.

[0005] In the first aspect, this application provides a double-layer dry-spreading recycled stone-like composite material, which adopts the following technical solution:

[0006] A double-layer dry-spreading recycled stone-like composite material comprises a bottom layer of crack-resistant dry-spreading base material and a top layer of crack-resistant dry-spreading surface material. The bottom layer of crack-resistant dry-spreading base material is made from the following raw materials in parts by weight: 60-80 parts of recycled stone aggregate with a particle size of 1-8 mm, 12-20 parts of ordinary silicate cement, 2-5 parts of crack-resistant, fast-setting, and fast-hardening sulfoaluminate cement, 0.1-2 parts of pigment, 1-3 parts of crack-resistant admixture, 0.2-0.8 parts of fiber, 1-3 parts of wetting and dispersing agent, and a reducing agent. The water-based agent is 0.05-0.1 parts; while the surface layer of imitation stone dry-spreading material is made of raw materials containing the following parts by weight: 30-60 parts of recycled stone aggregate with a particle size of 0.2-5mm, 12-20 parts of ordinary silicate cement, 2-5 parts of crack-resistant fast-setting and fast-hardening sulfoaluminate cement, 0.1-2 parts of pigment, 0.2-1 parts of crack-resistant admixture and 0.05-0.1 parts of water-reducing agent; the recycled stone aggregate is obtained by crushing and screening stone scraps from stone mining or road recycled stone.

[0007] By adopting the above technical solution, due to the use of a dual-layer functional material system, the bottom layer aggregate has a larger particle size, which can effectively embed into the concrete base layer and reduce the thickness of the surface paste layer. The addition of crack-resistant, fast-setting, and fast-hardening sulfoaluminate cement further enhances the strength in the early stage of concrete hydration to reduce plastic shrinkage cracks. Combined with crack-resistant fibers and admixtures, the crack resistance and structural stability are synergistically improved from both physical and chemical aspects, providing solid support for the surface layer. The surface layer uses finer-particle aggregate with continuous gradation and is paired with special pigments to restore the delicate texture and color of natural stone. Both layers use recycled stone aggregate as the core raw material, realizing the recycling of resources. Therefore, a dual-layer composite material with a strong structure, crack resistance, decorative effect, and environmental friendliness is obtained.

[0008] Preferably, the recycled stone aggregate in the bottom anti-crack dry-spreading substrate includes gravel aggregate with a particle size of 3-8mm, and the recycled stone aggregate in the surface imitation stone dry-spreading material adopts a continuous real stone aggregate gradation with a particle size of 0.1-5mm.

[0009] By adopting the above technical solution, the use of gravel aggregate in the bottom layer further increases the aggregate particle size, which can more effectively improve the cracking problem caused by the excessive thickness of the surface paste layer in traditional processes, and enhance the physical bonding force with the base concrete. The addition of crack-resistant, fast-setting, and fast-hardening sulfoaluminate cement further enhances the strength of the concrete in the early stage of hydration, thereby reducing plastic shrinkage cracks. The surface layer ensures a reasonable combination of aggregates of different particle sizes, making the aggregate packing more compact and the color distribution more uniform, thus mimicking the natural texture and granular feel of natural stones such as marble and granite. Therefore, a better crack-resistant base and a more realistic stone-like decorative effect are obtained.

[0010] Preferably, the fibers in the base material are polypropylene fibers or steel fibers; the crack-resistant additive is a mortar water-retaining agent; the fibers in the fabric are polypropylene fibers; and the crack-resistant additive is a mortar water-retaining agent.

[0011] By adopting the above technical solutions, the use of polypropylene fibers or steel fibers allows these fibers to form a three-dimensional network support in the composite material, effectively suppressing the generation and propagation of microcracks during plastic shrinkage and drying shrinkage. The crack-resistant, fast-setting, and fast-hardening sulfoaluminate cement itself has minimal shrinkage and enables the decorative layer to develop strength early, achieving early suppression of surface cracking in the overall structure. The addition of concrete water-retaining agents can further reduce drying shrinkage. The cement is dyed with high-temperature resistant and colorfast inorganic mineral pigments, ensuring that the surface color remains stable under long-term outdoor conditions such as sunlight and wind and rain, without fading. Therefore, a composite material with stronger durability and long-lasting, vibrant colors is obtained.

[0012] Preferably, in the recycled stone aggregate, the large-diameter aggregate has a particle size of 5-8mm, and the fine-diameter aggregate does not contain impurities or organic pollutants.

[0013] By adopting the above technical solution, the particle size of recycled aggregate is controlled, and the large-particle aggregate mainly provides skeletal support; at the same time, the fine-particle aggregate is required to be clean and free of impurities and organic pollutants. This ensures that a strong and pure interface transition zone can be formed between the aggregate and the cement paste, avoiding impurities from affecting the bonding strength and the color purity of the final finish. Therefore, a composite material with more stable performance and a higher visual effect is obtained.

[0014] Secondly, this application provides a construction process for a double-layer dry-spreading recycled stone-like composite material, employing the following technical solution:

[0015] A construction process for a double-layer dry-spreading recycled stone-like composite material includes the following steps:

[0016] S1. Base layer pouring: On-site pouring of concrete base layer, followed by vibration and preliminary leveling.

[0017] S2. Dry spreading of base material: Before the concrete base surface initially sets, the bottom anti-cracking dry spreading base material is evenly spread on the base surface, moistened and then lightly pressed flat and compacted.

[0018] S3. Dry spreading of the fabric: On the surface of the base material that has been smoothed, the surface layer of imitation stone dry spreading fabric is evenly spread, compacted and flattened, and then polished.

[0019] S4. Curing and post-treatment: Curing is carried out on the completed imitation stone concrete. After the design strength is reached, the entire surface layer is cleaned, ground, polished or acid-washed to form an integrated imitation stone finish.

[0020] By adopting the above technical solution, the process of simultaneously spreading two layers of material before the initial setting of the cast-in-place concrete base layer allows the base material and the surface material to bond sequentially with the not-fully-cured base layer, forming a whole through chemical and physical interactions, thus achieving structural integration and avoiding the risks of delamination and hollow areas. This process supports on-site casting and shaping, and can adapt to complex spaces such as zigzag lines and curves, without requiring extensive cutting of natural stone, resulting in minimal material waste. Subsequent grinding and polishing processes can enhance the texture of the aggregate, forming a large-panel structure. Therefore, an integrated stone-like finish with excellent structural integrity, high load-bearing capacity, adaptability to complex terrain, and high construction efficiency is achieved.

[0021] Preferably, in step S2, the dry spreading amount of the bottom anti-crack dry spreading material is 4-6 kg per square meter, and the spreading thickness is 2-3 mm.

[0022] By adopting the above technical solution, the amount of dry spreading of the bottom layer is controlled at 4-6 kg per square meter and the spreading thickness is 2-3 mm. This parameter can ensure that the base material completely covers the surface of the concrete base layer, forming a moderately thick and uniform reinforcement layer. This thickness can provide sufficient crack resistance and support for the surface layer, while avoiding the increased cost and potential cracking risk caused by excessive material thickness. It is a balance point between crack resistance and economy.

[0023] Preferably, in step S3, the dry spreading amount of the surface layer imitation stone dry spreading fabric is 4-6 kg per square meter, and the spreading thickness is 2-3 mm; the total spreading thickness of the bottom layer and the surface layer is controlled at 4-6 mm.

[0024] By adopting the above technical solution, since the surface layer is also dry-spread at a rate of 4-5 kg ​​per square meter, a decorative layer of 2-3 mm is formed. This thickness is sufficient to accommodate the continuously graded imitation stone aggregate, showcasing color and texture. By controlling the total thickness of the bottom and surface layers within the range of 4-6 mm, this parameter design ensures that the double-layer system provides the necessary functions while maintaining the thinnest overall thickness, effectively controlling material usage and structural weight, and further reducing the possibility of cracking due to the moderate thickness.

[0025] Preferably, in step S4, when used outdoors, an anti-slip cover layer is applied to the surface of the polished surface.

[0026] By adopting the above technical solution, in outdoor application scenarios, the step of adding an anti-slip coating to the final finished stone-like surface can effectively improve the anti-slip performance of the floor surface, enhance wear resistance and stain resistance, and provide additional protection for the underlying dyeing layer to cope with complex outdoor weather and usage conditions; thus, a more durable, safer, and suitable stone-like floor for outdoor pedestrian traffic areas is obtained.

[0027] Preferably, in step S4, the grinding and polishing process can create a surface finish that resembles stone, such as a smooth, cut, or bush-hammered surface.

[0028] By adopting the above technical solution, after the curing reaches the required strength, the integrated stone-like surface layer is subjected to differentiated post-treatments such as cleaning, grinding, and polishing. By controlling the grinding particle size and process, the surface can be treated to achieve various textures such as smooth, cut, or bush-hammered surfaces. This step can expose different cross-sections of the aggregate, enhancing the realism and decorativeness of the stone-like surface, and meeting the diverse design needs of different projects for visual and tactile aspects.

[0029] Preferably, both the bottom anti-crack dry-spread base material and the surface imitation stone dry-spread material are prepared using a dry powder mortar mixer before construction. The order of feeding is as follows: first, one-third of the recycled stone aggregate and all the pigments are added and mixed; then, all the additives and fibers are added; next, half of the cement is added; then, all the remaining recycled stone aggregate is added; and finally, all the remaining cement is added and mixed evenly.

[0030] By adopting the above technical solution, and by using a specific dry powder mixing and feeding sequence, firstly, a portion of the aggregate is premixed with all the pigments to ensure that the pigments are fully dispersed in the dry powder system and to avoid clumping; then, admixtures and fibers are added to ensure that they are evenly distributed in the dry powder; cement is added in two batches and thoroughly mixed with all the aggregates. This sequence ensures that cement particles effectively coat each aggregate particle, while simultaneously ensuring that fibers and admixtures are evenly dispersed throughout the mixture. Therefore, a dry-spread composite material with highly uniform distribution of components, consistent color, and stable performance is obtained, laying the foundation for the uniformity of subsequent construction quality.

[0031] In summary, this application has the following beneficial effects:

[0032] 1. This application adopts a composite material system with differentiated functions of the bottom layer and the top layer. The bottom layer is composed of coarser recycled aggregate and crack-resistant components to form a supporting structure, while the top layer is composed of finer aggregate and pigments to form a decorative surface. The two layers of materials are combined with the concrete base layer in the same way during construction to form an integral whole, thus achieving the effects of improved crack resistance of the floor surface, enhanced structural integrity and high decorative effect.

[0033] 2. In this application, a gradient gradation design of coarse aggregate in the bottom layer and fine aggregate in the top layer is adopted. The bottom aggregate disperses stress and provides a stable foundation for the top layer. The continuous gradation of the aggregate in the top layer ensures uniform texture and color. The two gradations work together to achieve the effect of improving performance from structural crack resistance to surface decoration.

[0034] 3. The method of this application involves adding fibers and crack-resistant additives to the material. The fibers form a three-dimensional network in the material to block crack propagation, while the crack-resistant additives reduce material shrinkage and increase density. The two work together from the aspects of physical crack prevention and chemical shrinkage reduction, thus achieving the effect of enhancing the crack resistance and durability of the material.

[0035] 4. In this application, the recycled aggregate is controlled to originate from industrial waste and its cleanliness is ensured. This allows an interface to be formed between the aggregate and the cement paste, avoiding the interference of impurities on strength and color. The raw material quality control is coordinated with subsequent gradation and processes, thus achieving the effect of ensuring the mechanical properties and decorative effect of the product while realizing resource recycling.

[0036] 5. The construction process of this application achieves simultaneous bonding by dry spreading of composite materials before the initial setting of the base concrete, followed by subsequent curing and surface treatment, thus achieving a stable bond between the finish and the base, adaptability to complex shapes, and the formation of a high-performance overall structure. Attached Figure Description

[0037] Figure 1 This is a flowchart illustrating the construction process of a double-layer dry-spreading recycled stone-like composite material proposed in this application. Detailed Implementation

[0038] The present application will be further described in detail below with reference to the accompanying drawings and embodiments.

[0039] Technical concept:

[0040] The concrete is decorated by applying a colored coating or pasting a finishing material to the surface. However, this surface treatment has different physical properties from the concrete base. Under temperature changes or loads, it is prone to peeling and cracking, which leads to insufficient durability of the decorative layer, increased maintenance costs and affects the overall structural performance.

[0041] This application discloses a double-layer dry-spreading recycled stone-like composite material and its construction process. It consists of a bottom layer of crack-resistant dry-spreading stone-like base material and a top layer of dry-spreading stone-like surface material. The bottom layer of crack-resistant dry-spreading stone-like base material is made from the following raw materials: recycled stone aggregate, pigments, ordinary silicate cement, crack-resistant fast-setting and fast-hardening sulfoaluminate cement, crack-resistant admixtures, wetting and dispersing agents, crack-resistant long fibers, and water-reducing agents. The top layer of dry-spreading stone-like surface material is made from the following raw materials: recycled stone aggregate, pigments, cement, crack-resistant admixtures, crack-resistant short fibers, wetting and dispersing agents, and water-reducing agents. The preparation method is as follows: S1, base layer pouring; S2, dry-spreading of the base material; S3, dry-spreading of the surface material; S4, curing and post-layer treatment.

[0042] This application adopts a composite material system with differentiated functions of the base layer and the surface layer. The base layer consists of coarser recycled aggregate combined with crack-resistant components to form a supporting structure, while the surface layer consists of finer aggregate and pigments to form a decorative surface layer. During construction, the two layers of materials are combined with the concrete base layer to form an integral whole, thus achieving the effects of improved crack resistance, enhanced structural integrity, and high decorative effect of the floor surface.

[0043] Example 1: This example provides a double-layer dry-spreading recycled stone-like composite material, consisting of a bottom layer of crack-resistant dry-spreading substrate and a top layer of stone-like dry-spreading fabric. The bottom layer of crack-resistant dry-spreading substrate is made from the following raw materials in parts by weight: 60 parts of recycled stone aggregate with a particle size of 1-8mm, 12 parts of ordinary silicate cement, 2 parts of crack-resistant fast-setting and fast-hardening sulfoaluminate cement, 0.1 parts of pigment, 1 part of crack-resistant admixture, 0.2 parts of fiber, 1 part of wetting and dispersing agent, and 0.05 parts of water-reducing agent. The top layer of stone-like dry-spreading fabric is made from the following raw materials in parts by weight: 30 parts of recycled stone aggregate with a particle size of 0.2-5mm, 12 parts of ordinary silicate cement, 2 parts of crack-resistant fast-setting and fast-hardening sulfoaluminate cement, 0.1 parts of pigment, 0.2 parts of crack-resistant admixture, and 0.05 parts of water-reducing agent.

[0044] The recycled stone aggregate in the bottom anti-crack dry-spread base material includes gravel aggregate with a particle size of 3-8mm, and the recycled stone aggregate in the surface imitation stone dry-spread material adopts a continuous real stone aggregate gradation with a particle size of 0.1-5mm.

[0045] The base material contains polypropylene fibers; the crack-resistant additive is a mortar water-retaining agent; and the fabric contains a crack-resistant additive and a mortar water-retaining agent.

[0046] Among them, the large-diameter aggregates in the recycled stone aggregates have a particle size of 5-8mm, and the fine-diameter aggregates do not contain impurities or organic pollutants.

[0047] The construction process of the above-mentioned double-layer dry-spreading recycled stone-like composite material includes the following steps:

[0048] S1. Base layer pouring: On-site pouring of concrete base layer, followed by vibration and preliminary leveling.

[0049] S2. Dry spreading of base material: Before the concrete base surface has initially set, evenly spread the bottom anti-cracking dry spreading base material on the base surface, moisten it, and then lightly press it flat and compacted.

[0050] The dry-spreading amount of the bottom anti-cracking dry-spreading material is 4 kg per square meter, and the paving thickness is 2 mm.

[0051] S3. Dry spreading of fabric: On the surface of the base material that has been smoothed, spread the surface layer of imitation stone dry spreading fabric evenly, press it flat and then perform a finishing process.

[0052] The surface layer of imitation stone dry-spread fabric has a dry-spreading amount of 4 kg per square meter and a paving thickness of 2 mm; the total paving thickness of the base layer and the surface layer is controlled at 4 mm.

[0053] S4. Curing and post-treatment: Curing is carried out on the completed imitation stone concrete. After the design strength is reached, the entire surface layer is cleaned, ground, polished or acid-washed to form an integrated imitation stone finish.

[0054] For outdoor applications, this also includes coating the surface of the polished surface with an anti-slip cover.

[0055] Among them, grinding and polishing can create a surface finish that resembles stone, such as a smooth, cut, or bush-hammered surface.

[0056] The bottom layer of crack-resistant dry-spread base material and the top layer of imitation stone dry-spread fabric are both prepared using a dry powder mortar mixer before construction. The order of feeding materials is as follows: first, one-third of the recycled stone aggregate and all the pigments are added and mixed, then all the admixtures and fibers are added, then half of the cement is added, then the remaining recycled stone aggregate is added, and finally the remaining cement is added and mixed evenly.

[0057] Example 2: This example provides a double-layer dry-spreading recycled stone-like composite material, consisting of a bottom layer of crack-resistant dry-spreading substrate and a top layer of stone-like dry-spreading fabric. The bottom layer of crack-resistant dry-spreading substrate is made from the following raw materials in parts by weight: 70 parts of recycled stone aggregate with a particle size of 1-8mm, 16 parts of ordinary silicate cement, 3.5 parts of crack-resistant, fast-setting, and fast-hardening sulfoaluminate cement, 1.0 part of pigment, 2 parts of crack-resistant admixture, 0.5 parts of fiber, 2 parts of wetting and dispersing agent, and 0.075 parts of water-reducing agent. The top layer of stone-like dry-spreading fabric is made from the following raw materials in parts by weight: 45 parts of recycled stone aggregate with a particle size of 0.2-5mm, 16 parts of ordinary silicate cement, 3.5 parts of crack-resistant, fast-setting, and fast-hardening sulfoaluminate cement, 1.0 part of pigment, 0.6 parts of crack-resistant admixture, and 0.075 parts of water-reducing agent.

[0058] The recycled stone aggregate in the bottom anti-crack dry-spread base material includes gravel aggregate with a particle size of 3-8mm, and the recycled stone aggregate in the surface imitation stone dry-spread material adopts a continuous real stone aggregate gradation with a particle size of 0.1-5mm.

[0059] The base material contains steel fibers; the crack-resistant additive is a mortar water-retaining agent; and the fabric contains a crack-resistant additive and a mortar water-retaining agent.

[0060] Among them, the large-diameter aggregates in the recycled stone aggregates have a particle size of 5-8mm, and the fine-diameter aggregates do not contain impurities or organic pollutants.

[0061] The construction process of the above-mentioned double-layer dry-spreading recycled stone-like composite material includes the following steps:

[0062] S1. Base layer pouring: On-site pouring of concrete base layer, followed by vibration and preliminary leveling.

[0063] S2. Dry spreading of base material: Before the concrete base surface has initially set, evenly spread the bottom anti-cracking dry spreading base material on the base surface, moisten it, and then lightly press it flat and compacted.

[0064] The dry-spreading amount of the bottom anti-cracking dry-spreading material is 5 kg per square meter, and the spreading thickness is 2.5 mm.

[0065] S3. Dry spreading of fabric: On the surface of the base material that has been smoothed, spread the surface layer of imitation stone dry spreading fabric evenly, press it flat and then perform a finishing process.

[0066] The surface layer of imitation stone dry-spread fabric has a dry-spreading amount of 5 kg per square meter and a paving thickness of 2.5 mm; the total paving thickness of the base layer and the surface layer is controlled at 5 mm.

[0067] S4. Curing and post-treatment: Curing is carried out on the completed imitation stone concrete. After the design strength is reached, the entire surface layer is cleaned, ground, polished or acid-washed to form an integrated imitation stone finish.

[0068] For outdoor applications, this also includes coating the surface of the polished surface with an anti-slip cover.

[0069] Among them, grinding and polishing can create a surface finish that resembles stone, such as a smooth, cut, or bush-hammered surface.

[0070] The bottom layer of crack-resistant dry-spread base material and the top layer of imitation stone dry-spread fabric are both prepared using a dry powder mortar mixer before construction. The order of feeding materials is as follows: first, one-third of the recycled stone aggregate and all the pigments are added and mixed, then all the admixtures and fibers are added, then half of the cement is added, then the remaining recycled stone aggregate is added, and finally the remaining cement is added and mixed evenly.

[0071] Example 3: This example provides a double-layer dry-spreading recycled stone-like composite material, consisting of a bottom layer of crack-resistant dry-spreading substrate and a top layer of stone-like dry-spreading fabric. The bottom layer of crack-resistant dry-spreading substrate is made from the following raw materials in parts by weight: 80 parts of recycled stone aggregate with a particle size of 1-8mm, 20 parts of ordinary silicate cement, 5 parts of crack-resistant fast-setting and fast-hardening sulfoaluminate cement, 2 parts of pigment, 3 parts of crack-resistant admixture, 0.8 parts of fiber, 3 parts of wetting and dispersing agent, and 0.1 parts of water-reducing agent. The top layer of stone-like dry-spreading fabric is made from the following raw materials in parts by weight: 60 parts of recycled stone aggregate with a particle size of 0.2-5mm, 20 parts of ordinary silicate cement, 5 parts of crack-resistant fast-setting and fast-hardening sulfoaluminate cement, 2 parts of pigment, 1 part of crack-resistant admixture, and 0.1 parts of water-reducing agent.

[0072] The recycled stone aggregate in the bottom anti-crack dry-spread base material includes gravel aggregate with a particle size of 3-8mm, and the recycled stone aggregate in the surface imitation stone dry-spread material adopts a continuous real stone aggregate gradation with a particle size of 0.1-5mm.

[0073] The base material contains polypropylene fibers; the crack-resistant additive is a mortar water-retaining agent; and the fabric contains a crack-resistant additive and a mortar water-retaining agent.

[0074] Among them, the large-diameter aggregates in the recycled stone aggregates have a particle size of 5-8mm, and the fine-diameter aggregates do not contain impurities or organic pollutants.

[0075] The construction process of the above-mentioned double-layer dry-spreading recycled stone-like composite material includes the following steps:

[0076] S1. Base layer pouring: On-site pouring of concrete base layer, followed by vibration and preliminary leveling.

[0077] S2. Dry spreading of base material: Before the concrete base surface has initially set, evenly spread the bottom anti-cracking dry spreading base material on the base surface, moisten it, and then lightly press it flat and compacted.

[0078] The dry-spreading amount of the bottom anti-cracking dry-spreading material is 6 kg per square meter, and the paving thickness is 3 mm.

[0079] S3. Dry spreading of fabric: On the surface of the base material that has been smoothed, spread the surface layer of imitation stone dry spreading fabric evenly, press it flat and then perform a finishing process.

[0080] The surface layer of imitation stone dry-spread fabric has a dry-spreading amount of 6 kg per square meter and a paving thickness of 3 mm; the total paving thickness of the base layer and the surface layer is controlled at 6 mm.

[0081] S4. Curing and post-treatment: Curing is carried out on the completed imitation stone concrete. After the design strength is reached, the entire surface layer is cleaned, ground, polished or acid-washed to form an integrated imitation stone finish.

[0082] For outdoor applications, this also includes coating the surface of the polished surface with an anti-slip cover.

[0083] Among them, grinding and polishing can create a surface finish that resembles stone, such as a smooth, cut, or bush-hammered surface.

[0084] The bottom layer of crack-resistant dry-spread base material and the top layer of imitation stone dry-spread fabric are both prepared using a dry powder mortar mixer before construction. The order of feeding materials is as follows: first, one-third of the recycled stone aggregate and all the pigments are added and mixed, then all the admixtures and fibers are added, then half of the cement is added, then the remaining recycled stone aggregate is added, and finally the remaining cement is added and mixed evenly.

[0085] Comparative Example 1: This comparative example refers to the content of Example 1, except that the recycled stone aggregate in the bottom anti-crack dry-spread base material uses only a single-size aggregate with a particle size of 8mm, and does not use a gradation of 1mm and 8mm. The rest of the content is the same as Example 1.

[0086] Comparative Example 2: This comparative example refers to the content of Example 1, except that the amount of recycled stone aggregate in the bottom anti-crack dry-spread base material is 90 parts, the pigment is removed, and the amount and proportion of the remaining components remain unchanged. The rest of the content is the same as Example 1.

[0087] Comparative Example 3: This comparative example refers to the content of Example 1, except that the fiber component is removed, while the amount and proportion of the remaining components remain unchanged, and the rest of the content is the same as in Example 1.

[0088] Comparative Example 4: This comparative example refers to the content of Example 1, except that the amount of crack-resistant admixture is changed to 0.1 parts, while the amount and proportion of the other components remain unchanged. The rest of the content is the same as that of Example 1.

[0089] Comparative Example 5: This comparative example refers to the content of Example 1, except that the dry spreading amount of the bottom anti-crack dry spreading base material is changed to 2 kg per square meter, the dry spreading amount of the surface imitation stone dry spreading fabric is changed to 2 kg per square meter, and the total spreading thickness is about 2 mm. The rest of the content is the same as Example 1.

[0090] Comparative Example 6: This comparative example refers to the content of Example 1, except that the timing of dry spreading of the base material and the surface material is changed to after the concrete base layer has finally hardened, and the synchronous bonding with the base layer is cancelled. The other process parameters are the same as those in Example 1.

[0091] Performance testing

[0092] Sample preparation: Based on the raw material ratios, aggregate gradations, and construction processes described in Examples 1 to 3 and Comparative Examples 1 to 6, standard performance test specimens were prepared. The preparation process simulated on-site construction: first, a concrete base layer was poured, and before its initial setting, the bottom anti-crack dry-spread base material and the surface imitation stone dry-spread material were evenly spread in sequence according to the dry-spreading amount and spreading thickness specified in each example. After light pressing and finishing, the specimens were cured under standard curing conditions to the specified age. Some specimens were ground and polished according to the process requirements to finally obtain composite material decorative specimens for various performance tests.

[0093] Crack resistance test: The prepared composite material slurry is poured into a specified flat thin-plate mold, vibrated and smoothed; the specimen is placed in a specific dry environment with controlled wind speed, temperature and humidity. The occurrence time, length and width of all cracks within the specified area are observed and recorded at regular intervals, and the total cracked area per unit area is calculated; the test standard for this performance parameter is the early crack resistance test method in GB / T 50082 "Standard for Test Methods of Long-Term Performance and Durability of Ordinary Concrete".

[0094] Bond strength test: On the composite specimen surface layer cured to the specified age, a standard pull-out head is attached using high-strength adhesive; after the adhesive has cured, a special pull-out instrument is used to apply a uniform tensile force perpendicular to the surface layer until failure occurs between the surface layer and the base layer or inside the material. The maximum tensile force value at failure is recorded, and the bond strength is calculated. The test standard for this performance parameter is JGJ / T 110 "Standard for Testing Bond Strength of Facing Bricks in Building Engineering".

[0095] Abrasion resistance test: Cut a test block of specified size from the polished surface material and fix it on the horizontal turntable of the abrasion testing machine; under a specified load, make the specified abrasive contact the surface of the test piece and rotate it for a certain number of revolutions; after the test, measure the length of the pit formed on the surface of the test piece and calculate the amount of wear; the test standard for this performance parameter is GB / T 12988 "Test Method for Abrasion Resistance of Inorganic Flooring Materials".

[0096] Compressive strength test: Using the same layered dry spreading method as the construction process, standard cubic test blocks are formed in the mold and cured to the specified age according to standard. Using a pressure testing machine, continuous and uniform pressure is applied to the test blocks at the specified loading rate until the test blocks are broken. The maximum pressure value at the time of failure is recorded, and the compressive strength is calculated. The test standard for this performance parameter is GB / T 17671 "Test Method for Strength of Cement Mortar (ISO Method)".

[0097] Table 1: Comparison of Composite Material Performance Testing

[0098] Group <![CDATA[Total cracking area per unit area (mm 2 / m 2 )]]> Bond strength (MPa) <![CDATA[Wear amount (mm 2 / 500r)]]> Compressive strength (MPa) Example 1 100 8.0 300 60 Example 2 120 7.5 280 65 Example 3 110 7.8 290 63 Comparative Example 1 160 7.2 350 55 Comparative Example 2 140 4.5 380 40 Comparative Example 3 180 6.0 400 45 Comparative Example 4 150 7.0 360 55 Comparative Example 5 130 7.5 500 58 Comparative Example 6 190 3.2 450 50

[0099] Example Conclusion:

[0100] As can be seen from Examples 1-3 and Comparative Example 1, and Table 1, using recycled aggregate with a reasonable gradation can more effectively fill internal voids and optimize particle packing structure compared to using aggregate with a single particle size, thereby improving the density and structural integrity of the composite material, and thus obtaining better crack resistance, wear resistance and compressive strength.

[0101] As can be seen from Examples 1-3 and Comparative Example 2, and Table 1, controlling the appropriate ratio between recycled aggregate and cementitious material has an impact. When the aggregate ratio is too high and the cementitious material is too low, the slurry cannot fully coat and bind the aggregate particles, resulting in a loose internal structure and weak interface, which damages the mechanical properties of the material such as bonding strength and compressive strength.

[0102] As can be seen from Examples 1-3 and Comparative Example 3, and Table 1, the addition of fibers forms a three-dimensional support network inside the composite material, which can effectively block the propagation of cracks and dissipate stress, thereby improving the crack resistance and toughness of the material. The lack of fiber components will reduce the crack resistance of the material and consequently affect its wear resistance and overall strength.

[0103] As can be seen from Examples 1-3 and Comparative Example 4, and Table 1, a sufficient amount of anti-cracking admixture can effectively reduce material shrinkage and improve density through chemical action; when the amount is insufficient, the material's ability to resist drying shrinkage stress is weakened, internal microcracks are more likely to be generated and develop, resulting in a decrease in crack resistance and durability.

[0104] As can be seen from Examples 1-3 and Comparative Example 5, and Table 1, ensuring that the base layer and the top layer have sufficient paving thickness is the basis for ensuring the performance of the finishing layer; if the thickness is too thin, the surface aggregate will be easy to peel off and the wear-resistant layer will be insufficient, thereby causing its wear resistance to deteriorate sharply and failing to meet the durability requirements for long-term use.

[0105] As can be seen from Examples 1-3 and Comparative Example 6, and Table 1, dry spreading before the initial setting of the concrete base layer is a key process. This timing allows the finishing layer material to chemically bond and mechanically interlock with the base layer slurry, achieving true integration. If this timing is missed, the two will only be physically bonded, resulting in insufficient bonding strength and weakening the crack resistance of the overall structure.

[0106] This specific embodiment is merely an explanation of this application and is not intended to limit it. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they fall within the scope of the claims of this application.

Claims

1. A double-layer dry-spreading recycled stone-like composite material, characterized in that, It consists of a base layer of imitation stone crack-resistant dry-spreading material and a surface layer of imitation stone dry-spreading material; wherein the base layer of crack-resistant dry-spreading material is made of raw materials containing the following parts by weight: 60-80 parts of recycled stone aggregate with a particle size of 1-8mm, 12-20 parts of ordinary Portland cement, 2-5 parts of crack-resistant fast-setting and fast-hardening sulfoaluminate cement, 0.1-2 parts of pigment, 1-3 parts of crack-resistant admixture, 0.2-0.8 parts of fiber, 1-3 parts of wetting and dispersing agent, and 0.05-0.5 parts of water-reducing agent. 0.1 parts; and the surface layer of imitation stone dry-spreading material is made of raw materials comprising the following parts by weight: 30-60 parts of recycled stone aggregate with a particle size of 0.2-5mm, 12-20 parts of ordinary silicate cement, 2-5 parts of crack-resistant fast-setting and fast-hardening sulfoaluminate cement, 0.1-2 parts of pigment, 0.2-1 parts of crack-resistant admixture and 0.05-0.1 parts of water-reducing agent; the recycled stone aggregate is obtained by crushing and screening stone scraps from stone mining or road recycled stone.

2. The double-layer dry-spreading recycled stone-like composite material according to claim 1, characterized in that, The recycled stone aggregate in the bottom anti-crack dry-spreading base material includes gravel aggregate with a particle size of 3-8mm, and the recycled stone aggregate in the surface imitation stone dry-spreading material adopts a continuous real stone aggregate gradation with a particle size of 0.1-5mm.

3. The double-layer dry-spreading recycled stone-like composite material according to claim 1, characterized in that, The base material contains polypropylene fibers or steel fibers; the crack-resistant additive is a mortar water-retaining agent; the fabric contains polypropylene fibers; the crack-resistant additive is a mortar water-retaining agent.

4. The double-layer dry-spreading recycled stone-like composite material according to claim 1, characterized in that, The recycled stone aggregate contains large-diameter aggregates with a particle size of 5-8mm, and fine-diameter aggregates that do not contain impurities or organic pollutants.

5. A construction process for a double-layer dry-spreading recycled stone-like composite material, characterized in that, The method for using a double-layer dry-spreading recycled stone-like composite material according to any one of claims 1-4 includes the following steps: S1. Base layer pouring: On-site pouring of concrete base layer, followed by vibration and preliminary leveling. S2. Dry spreading of base material: Before the concrete base surface initially sets, the bottom anti-cracking dry spreading base material is evenly spread on the base surface, moistened and then lightly pressed flat and compacted. S3. Dry spreading of the fabric: On the surface of the base material that has been smoothed, the surface layer of imitation stone dry spreading fabric is evenly spread, compacted and flattened, and then polished. S4. Curing and post-treatment: Curing is carried out on the completed imitation stone concrete. After the design strength is reached, the entire surface layer is cleaned, ground, polished or acid-washed to form an integrated imitation stone finish.

6. The construction process of a double-layer dry-spreading recycled stone-like composite material according to claim 5, characterized in that, In step S2, the dry spreading amount of the bottom anti-cracking dry spreading material is 4-6 kg per square meter, and the spreading thickness is 2-3 mm.

7. The construction process of a double-layer dry-spreading recycled stone-like composite material according to claim 5, characterized in that, In step S3, the dry spreading amount of the surface layer imitation stone dry spreading fabric is 4-6 kg per square meter, and the spreading thickness is 2-3 mm; the total spreading thickness of the bottom layer and the surface layer is controlled at 4-6 mm.

8. The construction process of a double-layer dry-spreading recycled stone-like composite material according to claim 5, characterized in that, In step S4, for outdoor applications, an anti-slip cover layer is also applied to the polished surface of the top layer.

9. The construction process of a double-layer dry-spreading recycled stone-like composite material according to claim 5, characterized in that, In step S4, the grinding and polishing process can create a surface finish that mimics stone, such as a smooth, cut, or bush-hammered finish.

10. The construction process of a double-layer dry-spreading recycled stone-like composite material according to claim 5, characterized in that, Both the bottom anti-crack dry-spread base material and the surface imitation stone dry-spread material are prepared using a dry powder mortar mixer before construction. The order of feeding is as follows: first, add one-third of the recycled stone aggregate and all the pigments and mix them; then add all the additives and fibers; next, add half of the cement; then add the remaining recycled stone aggregate; and finally add the remaining cement and mix them evenly.

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