Floor forming method

Abstract

To provide a floor forming method capable of reducing a construction period and processing finishing material such as floor painting material and tiles even while substrate material and a self-smooth mortar hardened body have high bonding strength.SOLUTION: A floor forming method comprises: a substrate material and self-smooth mortar consecutive construction process of installing a substrate material, carrying out a surface roughening treatment over the whole surface of the substrate material before the substrate material is cured, and installing self-smooth mortar after the surface roughening treatment; and a finishing process of carrying out a floor finishing treatment on the surface of the self-smooth mortar hardened body after the substrate material and the self-smooth mortar hardened body are cured.SELECTED DRAWING: None

Description

[Technical field]

[0001] The present invention relates to a method for forming a bed. [Background technology]

[0002] If you want to ensure smoothness after pouring concrete, you can pour self-smoothing mortar (self-leveling material). Self-smoothing mortar is a slurry-like mixture made by adding water to a mixture of various admixtures, with cement and fine aggregate as the base material, and using the high fluidity characteristic of this slurry to form a smooth floor surface.

[0003] Furthermore, when forming a floor surface, a coating floor material is applied or a finishing material such as tiles or stone slabs is applied to the surface to give it a beautiful appearance, water resistance, abrasion resistance, etc. Organic resins such as epoxy resins and urethane resins are generally used as coating floor materials.

[0004] For example, Patent Document 1 describes a method for constructing a concrete floor structure, which comprises providing a primer layer for self-leveling material mortar on the top surface of a concrete floor of a building, pouring and hardening a slurry prepared by mixing a self-leveling material containing alumina cement and resin powder with water on the top surface of the primer layer, providing a primer layer for a coated floor material on the top surface of the hardened self-leveling material slurry layer, and applying and hardening a base coat for a coated floor material on the top surface of the primer layer. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2008-190315 A Summary of the Invention [Problem to be solved by the invention]

[0006] Although smoothness can be ensured by pouring self-smoothing mortar into the base concrete, the increased number of processes results in a longer construction period. Also, if the adhesive strength at the interface between the base concrete and the hardened self-smoothing mortar is not sufficiently ensured, there is a risk of peeling due to impact, etc. Therefore, a construction method that can be constructed in a short period of time, ensures smoothness, and provides high adhesive strength is required.

[0007] Therefore, an object of the present invention is to provide a floor formation method that can shorten the construction period, and can process finishing materials such as floor coating materials and tiles while maintaining high adhesion strength between the base material and the self-smoothing mortar hardened body. [Means for solving the problem]

[0008] As a result of extensive research into the above-mentioned problems, the inventors have discovered that by applying the base material and self-smoothing mortar in succession and then carrying out the finishing process, it is possible to create a floor formation method in which the entire floor structure, consisting of the base material, hardened self-smoothing mortar body, and floor finishing layer, has high adhesion strength in a short period of time.

[0009] That is, the present invention is as follows. [1] A method for forming a floor comprising the steps of: a continuous application process of a base material and a self-smoothing mortar, in which the base material is poured, the entire surface of the base material is roughened before the base material is laid, and the self-smoothing mortar is poured after the roughening process; and a finishing process of performing a floor finishing process on the hardened surface of the self-smoothing mortar after the base material and the self-smoothing mortar have hardened. [2] The floor forming method described in [1], wherein the floor finishing treatment is the application of a synthetic resin-based floor coating material or the attachment of tile material. [3] A method for forming a floor according to [1] or [2], in which in the finishing step, the surface of the hardened self-smoothing mortar is polished before the floor finishing treatment. [4] A method for forming a floor according to [1] or [2], wherein the roughening treatment is brushing and / or removal of a fragile layer. [5] A method for forming a floor as described in [1] or [2], in which the roughening is dense. [6] The method for forming a floor according to [1] or [2], wherein the self-smoothing mortar comprises cement, a water-reducing agent, a viscosity improver, fine aggregate and water. [7] The method for forming a floor according to [1] or [2], wherein the self-leveling mortar has a flow value of 230 to 290 mm as specified in the Architectural Institute of Japan standard "Quality Standard for Self-Leveling Materials" JASS 15M-103:2019 when measured at the construction site, and a flow time of 10 to 30 seconds using a J10 funnel as measured in accordance with the Japan Society of Civil Engineers standard "Test Method for Fluidity of PC Grout (Draft)" JSCE-F531:2018. Effect of the Invention

[0010] According to the present invention, a floor formation method can be provided that can shorten the construction period, and can process finishing materials such as floor coating materials and tiles while the base material and the self-smoothing mortar hardened body have high adhesion strength. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Hereinafter, one embodiment of the present invention will be described in detail.

[0012] [Bed formation method] The floor formation method of this embodiment comprises a continuous construction process of the base material and self-smoothing mortar, in which the base material is poured, the entire surface of the base material is roughened before the base material is finished, and the self-smoothing mortar is poured after the roughening process, and a finishing process in which a floor finishing process is performed on the hardened surface of the self-smoothing mortar after the base material and self-smoothing mortar have hardened.

[0013] (Continuous construction process) The base material is not particularly limited, and can be ordinary concrete, mortar, etc. After the base material is poured, the subsequent steps are carried out before the base material is completely poured. In this specification, "before the base material is completed" refers to the time from the start to the end of the setting of the base material. The method of determining setting is not particularly limited, and may be determined by, for example, a Proctor penetration resistance test in accordance with JIS A 1147:2019 "Test method for setting time of concrete", or by a penetration value by an N-type penetration test in which a rod used in JIS A 1101:2020 "Test method for slump of concrete" is dropped from a certain height to measure the penetration depth, or by dropping a ball or the like from a certain height to determine the depression depth of the base material or the amount of base material attached to the ball. As a suitable timing for roughening work before the base material is completed, for example, when measured at the construction site, the penetration value by the N-type penetration test is preferably 1 to 40 mm, more preferably 5 to 35 mm, and even more preferably 10 to 30 mm. If the penetration value is within the above range, the base material is easy to roughen, and the base material and the self-smoothing mortar hardened body are integrated to further improve adhesion. In addition, by measuring the penetration value at the construction site, construction management can be performed more accurately than the elapsed time from casting, which changes depending on the temperature. In this specification, the "penetration value by the N-type penetration test" refers to the penetration depth when a rod used in JIS A 1101:2020 "Concrete Slump Test Method" is dropped from a height of 750 mm.

[0014] After pouring the base material, perform roughening treatment on the base material at the timing confirmed by the above method. If bleeding water is generated from the base material before roughening, the water may be removed using a rag or sponge. Removing the bleeding water makes the self-smoothing mortar less likely to separate into materials.

[0015] Roughening refers to making the surface of a base material finely uneven. The unevenness refers to a state in which a relatively flat base material is made into lines, scratches, pinholes, etc. by brushing with a broom or brush. There are no particular limitations on the means of roughening, and examples include brushing with a broom, brush, or dragonfly, and removing a fragile layer using a polisher, etc. Roughening is performed on the entire surface of the base material, and it is preferable that the density of the unevenness is dense. 2 This refers to a state in which there is at least one or more irregularities within a 1 cm 2 Preferably, there are 5 or more projections and recesses in the surface, more preferably 10 or more projections and recesses, and even more preferably 15 or more projections and recesses. The width of the projections and recesses is not particularly limited, but is preferably 0.1 mm or more, and more preferably 0.5 mm or more and 3.0 mm or less. The depth of the projections and recesses is also not particularly limited, but is preferably 0.2 mm or more, and more preferably 0.5 mm or more and 4.0 mm or less. Roughening the surface strengthens the adhesion between the base material and the hardened self-smoothing mortar, and the denser the roughening, the stronger the adhesion tends to be. To roughen the surface densely, methods include brushing the entire surface with a broom or brush that has dense tips, removing the brittle layer on the entire surface with a polisher, or repeatedly roughening the entire surface.

[0016] After the roughening treatment and before the base material is applied, the self-smoothing mortar is poured. The thickness of the self-smoothing mortar layer when hardened is preferably 1 to 50 mm, more preferably 1.5 to 40 mm, and even more preferably 2 to 30 mm. If the thickness of the hardened self-smoothing mortar is within the above range, it is easy to ensure smoothness and the durability tends to be excellent.

[0017] The self-smoothing mortar is not particularly limited as long as it is a material having self-leveling properties. Examples of the self-smoothing mortar include those containing cement, a water reducing agent, a thickening agent, fine aggregate, and water.

[0018] Various types of cement can be used, including, for example, various Portland cements such as ordinary, early strength, extra early strength, low heat and moderate heat, ecocement, rapid hardening cement, fly ash cement, etc. One type of cement may be used alone, or two or more types may be used in combination.

[0019] The content of cement is preferably 20 to 45 parts by mass, more preferably 25 to 40 parts by mass, and even more preferably 27 to 38 parts by mass, relative to 100 parts by mass of the powder component of the self-smoothing mortar. If the content of cement is within the above range, it is easy to ensure sufficient fluidity and various strength expression properties as a self-leveling material. The powder component refers to the entire powder constituting the self-smoothing mortar, including aggregates such as fine aggregates.

[0020] The water reducing agent includes a high-performance water reducing agent, a high-performance AE water reducing agent, an AE water reducing agent, and a superplasticizer. Examples of such water reducing agents include those specified in JIS A 6204:2011 "Chemical admixtures for concrete". Examples of the water reducing agent include polycarboxylic acid water reducing agents, naphthalene sulfonic acid water reducing agents, lignin sulfonic acid water reducing agents, and melamine water reducing agents. Among these, polycarboxylic acid water reducing agents are preferred. The water reducing agents may be used alone or in combination of two or more types.

[0021] The content of the water reducing agent is preferably 0.1 to 5 parts by mass, more preferably 0.3 to 3 parts by mass, and most preferably 0.4 to 1.5 parts by mass, in terms of solid content, relative to 100 parts by mass of cement. If the content of the water reducing agent is within the above range, better fluidity is easily obtained when the mortar is made, and the compressive strength is also easily improved.

[0022] The type of thickener is not particularly limited, and examples thereof include cellulose-based thickeners, acrylic thickeners, and guar gum thickeners. As the thickener, cellulose-based thickeners are preferred. As the cellulose-based thickener, examples thereof include methylcellulose-based thickeners such as carboxymethylcellulose, methylcellulose, and hydroxypropylmethylcellulose, hydroxyethylcellulose, and hydroxypropylcellulose. The thickener may be used alone or in combination of two or more.

[0023] The content of the thickener is preferably 0.01 to 1 part by mass, more preferably 0.03 to 0.8 parts by mass, and even more preferably 0.05 to 0.5 parts by mass, calculated as solid content relative to 100 parts by mass of cement. If the content of the thickener is within the above range, it is easy to exhibit an appropriate effect of suppressing aggregate separation.

[0024] Examples of fine aggregate include river sand, silica sand, crushed sand, kansui stone, limestone sand, slag aggregate, etc. Among these, it is preferable to use aggregate such as silica sand or limestone adjusted to a grain size that does not contain fine powder or coarse aggregate as the fine aggregate. One type of fine aggregate may be used alone, or two or more types may be used in combination. It is preferable to use fine aggregate with a grain size of 1.2 mm or less (passing through a 1.2 mm sieve), which is commonly used.

[0025] The particle size of the fine aggregate is not particularly limited, and can be adjusted within the required particle size range of the fine aggregate. The particle size of the fine aggregate can be considered from the coarse particle ratio defined by JIS A 1102:2014 "Sieving test method for aggregates". From the viewpoint of easily obtaining better fluidity and easily suppressing bleeding, the coarse particle ratio of the fine aggregate is preferably 1 to 3, more preferably 1.5 to 2.8, and even more preferably 1.8 to 2.4.

[0026] The content of the fine aggregate is preferably 100 to 300 parts by mass, more preferably 120 to 250 parts by mass, and even more preferably 140 to 200 parts by mass, relative to 100 parts by mass of cement. If the content of the fine aggregate is within the above range, it is easy to ensure sufficient fluidity and compressive strength as a self-leveling material.

[0027] The water content is preferably 60 to 100 parts by mass, more preferably 65 to 95 parts by mass, and even more preferably 70 to 90 parts by mass, relative to 100 parts by mass of cement. When the amount of water is within the above range, good fluidity is easily obtained.

[0028] Various admixtures (materials) may be blended into the self-smoothing mortar as long as the effects of the present invention are not impaired. Examples of the admixtures (materials) include expansion agents, antifoaming agents, waterproofing agents, rust inhibitors, shrinkage reducing agents, water retention agents, pigments, water repellents, and efflorescence inhibitors.

[0029] The self-smoothing mortar preferably has a flow value of 230 to 290 mm, more preferably 240 to 280 mm, and even more preferably 250 to 275 mm, as specified in the Architectural Institute of Japan standard "Quality Standard for Self-Leveling Materials" JASS 15M-103:2019. If the flow value is within the above range, the self-leveling property is further improved, and even when the self-smoothing mortar is applied to an unfinished base material, it tends to be possible to apply the mortar without material separation.

[0030] The self-smoothing mortar preferably has a flow time of 10 to 30 seconds, more preferably 12 to 25 seconds, and even more preferably 14 to 20 seconds, in a J10 funnel measured in accordance with the Japan Society of Civil Engineers standard "PC Grout Fluidity Test Method (Draft)" JSCE-F531:2018. If the flow time is within the above range, the self-leveling property is even better, and even when the self-smoothing mortar is applied to an unfinished base material, it tends to be possible to apply the mortar without material separation. The flow value and flow time of the self-smoothing mortar are preferably measured at the application site before the mortar is poured. By having the properties of the self-smoothing mortar at the application site within the above ranges, continuous application can be controlled regardless of the environmental temperature.

[0031] The preparation of the self-smoothing mortar can be carried out using a kneading tool similar to that used for general mortar, etc., and is not particularly limited. Examples of the kneading tool include a mortar mixer, a hand mixer, a tilting mixer, and a twin-shaft mixer.

[0032] In the continuous construction process, the steps from pouring the base material to pouring the self-smoothing mortar are carried out continuously, whereas in the past the base material was poured after it had completely hardened, and the time required for the base material to harden can be omitted, thereby shortening the construction period and reducing costs. In addition, the base material and the self-smoothing mortar are integrated by the continuous construction, improving their adhesion strength. In the continuous construction according to this embodiment, the primer coating process that is usually required when pouring the self-smoothing mortar is not required, and not only can the construction period be shortened and costs be reduced, but also the generation of bubbles after pouring the self-smoothing mortar, which is thought to be caused by the primer, can be reduced.

[0033] (Finishing process) In the above-mentioned continuous construction process, the base material and the self-smoothing mortar are continuously poured, and then cured until they harden. When hardening is complete, a floor finishing process is performed on the hardened surface of the self-smoothing mortar. The completion of hardening can be confirmed by standing on the hardened finishing material and checking whether there are any dents or footprints. It can also be confirmed by checking whether the measuring needle of a spring hardness tester moves.

[0034] Examples of floor finishing treatments include the application of floor coating materials, the application of tiles or stone slabs, and the application of floor covering materials such as vinyl chloride sheets or flooring materials. As floor coating materials, synthetic resin-based floor coating materials such as epoxy resin-based, urethane resin-based, methyl methacrylate (MMA) resin-based, acrylic resin-based, vinyl ester resin-based, polyester resin-based, and water-based hard urethane resin-based are preferred. When using synthetic resin-based floor coating materials, a primer may be applied to the surface of the self-smoothing mortar hardened body in advance, and floor coating materials may be applied multiple times to improve durability such as abrasion resistance and impact resistance.

[0035] In the finishing step, before carrying out the floor finishing treatment, the surface of the hardened self-smoothing mortar may be polished with a polisher, etc. Polishing allows the hardened self-smoothing mortar to adhere more firmly to floor finishing materials such as floor coating materials and tiles, and further improves the peel resistance, abrasion resistance, impact resistance, etc. of the floor structure.

[0036] According to the floor forming method of this embodiment, the base material and the self-smoothing mortar can be applied continuously, which not only shortens the construction period and reduces costs, but also improves the adhesive strength, so that a base with smoothness and strong adhesive strength for floor finishing can be formed in a short period of time. Therefore, the floor forming method of this embodiment can be suitably used for floor formation in situations where short-term construction or high durability is required. EXAMPLES

[0037] The present invention will be described in detail below with reference to examples, but the present invention is not limited thereto.

[0038] [material] Self-smoothing mortar A and B Cement: Ordinary Portland cement (commercially available) Water reducing agent: Polycarboxylic acid water reducing agent (commercially available) Thickener: Methylcellulose-based thickener (commercially available) Fine aggregate: silica sand mixture, coarse grain ratio 0.4 The materials were mixed in the proportions shown in Table 1 and mixed for 90 seconds with a hand mixer (rotation speed: 1000 rpm) to prepare self-smoothing mortars A and B. Finishing materials Floor coating material A (commercially available, epoxy resin type) Primer for floor coating material A (commercially available, epoxy resin type) Paint B (commercially available, urethane resin type) Primer for floor coating material B (commercially available, urethane resin type)

[0039] [Table 1]

[0040] [Bed formation method] The construction area for each test was 4.5m x 3.0m, the thickness of the base concrete was 100mm, and the thickness of the self-smoothing mortar hardened body was 10mm. The environmental temperature was 20℃. Example 1 The concrete base was poured in a 4.5m x 3.0m section. 4.5 hours after pouring the concrete base (penetration value of 30mm in the N-type penetration test), the bleeding water was removed and the entire surface of the concrete base was roughened by brushing with a broom. The unevenness formed by the roughening process was 1cm 2 After roughening, self-smoothing mortar A was poured continuously and cured at room temperature for 35 days. After curing, the hardened surface of the self-smoothing mortar was polished and a primer for floor coating material A was applied, and then floor coating material A was applied in two coats to complete the floor finishing process. Example 2 The concrete base was poured in a 4.5m x 3.0m section. Five hours after pouring the concrete base (penetration value of 18mm in the N-type penetration test), the bleeding water was removed and the entire surface of the concrete base was roughened by brushing with a broom. The unevenness formed by the roughening process was 1cm. 2 After roughening, self-smoothing mortar A was poured continuously and cured at room temperature for 35 days. After curing, the hardened surface of the self-smoothing mortar was polished, a primer for floor coating material B was applied, and then floor coating material B was applied in two coats to complete the floor finishing process. Example 3 Continuous construction and floor finishing treatment were carried out in the same manner as in Example 1, except that self-smoothing mortar B was used. Example 4 Continuous construction and floor finishing treatment were carried out in the same manner as in Example 3, except that the surface of the hardened self-smoothing mortar was not polished in the floor finishing treatment step. Comparative Example 1 The base concrete was poured and cured at room temperature for 7 days. After curing, a self-smoothing mortar primer (commercially available, epoxy resin type) was applied to the base concrete, and then self-smoothing mortar B was poured and cured at room temperature for 27 days. After curing, the hardened surface of the self-smoothing mortar was polished and a primer for floor coating material A was applied, and then floor coating material A was applied in two coats to complete the floor finishing process.

[0041] The evaluation results are shown in Table 2. [Evaluation method] Fluidity (flow test, flow down test) The flow value was measured in accordance with JASS-15M-103 (quality standard for self-leveling materials) of the Architectural Institute of Japan. The flow time is based on the Japan Society of Civil Engineers standard "PC Grout Fluidity Test Method (Draft)" JSCE-F531:2018. 10 The measurements were made using a funnel tester. The measurements were carried out at ambient temperature (20°C) 0 hours after mixing the self-smoothing mortar. ·Substrate adhesion strength In accordance with JASS-15M-103:2019 (quality standard for self-leveling materials) of the Architectural Institute of Japan, the adhesive strength was measured 13 days after the mortar was poured. The test was performed using a "Construction Research Institute type adhesive strength tester using a hydraulic jack." ·Self-smoothing mortar surface aesthetics The surface of the self-smoothing mortar hardened body was visually inspected, and those with almost no bubbles or those with only bubbles that did not affect the finishing treatment were rated as ◯, and those with many bubbles were rated as ×. Forced peeling test An electric cutter was used to make a 5cm square cut, a scraper was placed on the interface between the self-smoothing mortar hardened body and the floor coating layer, and the rear of the scraper was struck with a hammer to observe the peeling pattern.

[0042] [Table 2] TIFF2025007908000003.tif40170

[0043] The floor forming method of the embodiment can shorten the construction time because the base concrete and the self-smoothing mortar can be applied continuously, and the self-smoothing mortar hardened body has a high tensile strength, so the base concrete and the self-smoothing mortar hardened body are more firmly attached. In addition, the floor forming method of the embodiment can also produce a more beautiful floor finish because the self-smoothing mortar hardened body has fewer air bubbles. In particular, in the embodiments 1 to 3 in which the self-smoothing mortar hardened body was polished, no peeling was observed at the interface of the coating floor material layer. On the other hand, in the floor forming method of the comparative example, the adhesion between the base concrete and the hardened self-smoothing mortar was weak, and air bubbles were generated when the self-smoothing mortar hardened.

Claims

1. A continuous construction process of a base material and a self-smoothing mortar, which comprises pouring a base material, roughening the entire surface of the base material before the base material is finished, and pouring a self-smoothing mortar after the roughening process; A floor forming method comprising a finishing process of performing a floor finishing treatment on the hardened surface of the self-smooth mortar after the base material and the self-smooth mortar have hardened.

2. The floor forming method according to claim 1, wherein the floor finishing treatment is the application of a synthetic resin-based floor coating material or the attachment of a tile material.

3. The floor forming method according to claim 1 or 2, wherein in the finishing step, the surface of the hardened self-smoothing mortar is polished before the floor finishing treatment.

4. The floor forming method according to claim 1 or 2, wherein the roughening treatment is a brushing and / or removal of a fragile layer.

5. 3. The method of claim 1 or 2, wherein the roughening is dense.

6. 3. The method of claim 1 or 2, wherein the self-smoothing mortar comprises cement, a water reducing agent, a viscosity improver, fine aggregate and water.

7. The self-smoothing mortar has a flow value of 230 to 290 mm as defined in the Architectural Institute of Japan standard "Quality Standard for Self-Leveling Materials" JASS 15M-103:2019 when measured at the construction site, and a J10 funnel flow time of 10 to 30 seconds as measured in accordance with the Civil Engineering Society standard "PC Grout Fluidity Test Method (Draft)" JSCE-F531:2018.

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