Road repair materials

Abstract

In a road surface repair material that uses an acrylic resin emulsion liquid as the liquid material and a container containing a cement-containing powder material is used as a container for mixing the liquid material and powder material and squeezing it onto the object to be repaired, the mixture of the liquid material and powder material has an appropriate viscosity and is easy to apply to the object to be repaired. [Solution] The road surface repair material comprises a first container containing a powder material and a second container containing a liquid material. The first or second container functions as a container for mixing the powder material and the liquid material and squeezing the mixture onto the area to be repaired. The powder material contains 5-35% by mass of cement, 19-85% by mass of aggregate, 7-30% by mass of fine powder, and 1-8% by mass of re-emulsified powdered resin. The liquid material is an acrylic resin emulsion liquid, and the liquid material contains 0.5-8.0 parts by mass of acrylic resin per 100 parts by mass of powder material contained in the first container.

Description

Technical Field

[0001] The present invention relates to a road surface repair material.

Background Art

[0002] As in Patent Document 1 below, there is known a method of mixing a cement composition using two containers, cutting a part of a bag to form an opening, and squeezing out the cement composition onto a construction part using the bag. In this method, one bag contains a cement material obtained by mixing 1 part by mass of ordinary Portland cement and 2 parts by mass of dry sand, and the other bag contains an aqueous solution obtained by mixing 1 part by mass of a styrene-butadiene latex cement admixture and 1 part by mass of water. Immediately before use, the aqueous solution is poured into the bag containing the cement material, and the contents are kneaded by hand to mix them. It is said that the tip of the protrusion of the bag containing the cement material is cut so that the discharge hole becomes 8 mm, and the mixture is extruded into the V-cut having a width of 10 mm.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] When the inventors of the present invention studied, instead of an aqueous solution containing a styrene-butadiene latex cement admixture, an acrylic resin emulsion solution was used, and a liquid material and a powder material containing cement were mixed in a bag-shaped container, and the bag was used as a bag for squeezing out the mixture onto a construction body and applied to a construction site. However, there was a problem that the cement composition had little viscosity and the cement composition could not be applied to the construction site as intended.

[0005] The present invention provides a road surface repair material that utilizes an acrylic resin emulsion liquid as the liquid material and uses a container containing a cement-containing powder material as the container for mixing the liquid material and powder material and squeezing it onto the object to be repaired. The objective is to provide a road surface repair material in which the mixture of liquid material and powder material has an appropriate viscosity and is easy to apply to the object to be repaired. [Means for solving the problem]

[0006] The road surface repair material comprises a first container containing a powder material and a second container containing a liquid material. The first or second container functions as a container for mixing the powder material and the liquid material and squeezing the mixture onto the area to be repaired. The powder material contains 5-35% by mass of cement, 19-85% by mass of aggregate, 7-30% by mass of fine powder, and 1-8% by mass of re-emulsified powdered resin. The liquid material is an acrylic resin emulsion liquid, and the liquid material contains 0.5-8.0 parts by mass of acrylic resin per 100 parts by mass of powder material contained in the first container. This road surface repair material solves the above problems.

[0007] In the aforementioned road surface repair material, the powder material contains lithium carbonate as a hardening accelerator in a quantity of 1 × 10⁻⁶ units. -3 It may contain approximately 0.1% by mass.

[0008] In the aforementioned road surface repair material, the powder material may contain 0.01 to 0.2% by mass of organic fibers for the purpose of preventing cracking of the hardened body.

[0009] In the aforementioned road surface repair material, the liquid material may contain 11 to 20 parts by mass of water relative to 100 parts by mass of powder material contained in the first container.

[0010] In the aforementioned road surface repair material, the powder material may contain 0.05 to 1.0% by mass of an expansive agent. [Effects of the Invention]

[0011] According to the present invention, a road surface repair material is provided that utilizes an acrylic resin emulsion liquid as the liquid material and a container containing a cement-containing powder material as the container for mixing the liquid material and powder material and squeezing it onto the object to be repaired. The mixture of the liquid material and powder material has good fluidity when squeezed out of the container, and the mixture of the liquid material and powder material has an appropriate viscosity, making it easy to apply to the object to be repaired. [Brief explanation of the drawing]

[0012] [Figure 1] This is an explanatory diagram showing the mixing process of the powder material stored in the first container and the liquid material stored in the second container. [Figure 2] This is an explanatory diagram showing the state in which a nozzle is attached to the second container containing the mixture. [Modes for carrying out the invention]

[0013] Figures 1 and 2 show an example of a road surface repair material. The road surface repair material 1 shown in Figures 1 and 2 is a set comprising a first container 11 containing powder material 3 and a second container 12 containing liquid material. The first container 11 functions as a container for mixing the powder material 3 and liquid material 4 and squeezing the mixture of powder material and liquid material onto the area to be repaired. Alternatively, instead of the first container, the second container 12 containing the liquid material may be used to mix the powder material 3 and liquid material 4 and squeeze the mixture of powder material and liquid material onto the area to be repaired.

[0014] The first container 11 or the second container 12 may be made of a suitable material. The first container 11 or the second container 12 is made of a transparent plastic film bag that allows the contents stored inside to be visually inspected and can be easily deformed when external force is applied to squeeze out the contents. The bag can be made of a material such as PET, polypropylene, or polyethylene.

[0015] In particular, the container for squeezing out the mixture of powder and liquid is preferably a bag that can be easily deformed when external force is applied to squeeze out the contents. The second container for the liquid may be a container that retains its shape if the first container containing the powder is used as the container for squeezing out the mixture 6. By giving the second container shape retention, it is possible to prevent the second container from unintentionally deforming and leaking its contents when external force is applied to it.

[0016] The first container 11 and the second container 12 are provided with cylindrical portions 111 and 121 having openings. Preferably, one cylindrical portion is configured to have a larger diameter than the other cylindrical portion, allowing the other cylindrical portion to be inserted into it. In the example shown in Figure 1, the cylindrical portion 111 of the first container 11, which is a container for squeezing out the mixture 6, is configured to allow the insertion of the cylindrical portion 121 of the second container 12. By configuring it as described above, the contents of one container can be easily transferred into the other container without spilling.

[0017] The container used to squeeze out the mixture is used as a container for mixing the powder and the liquid. The powder and liquid may be mixed by shaking the container, or, if the container is made of a material that can be easily deformed, the powder and liquid can be mixed by kneading the container. When mixing the powder and the liquid, it is preferable to cover the opening provided in the cylindrical part of the container.

[0018] After mixing the powder and liquid materials in the container, the mixture is squeezed onto the workpiece, such as a road surface, for application. Attaching the nozzle 5 shown in Figure 2 to the cylindrical portion of the container facilitates application of the mixture to the workpiece. The nozzle 5 has a female threaded portion at its base end that screws into a male threaded portion on the outer circumference of the cylindrical portion 111. The circumferential surface of the nozzle body has a deformable portion with alternating annular convex and annular concave sections. The deformable portion allows the nozzle to bend easily, making it possible to easily change the orientation of the nozzle tip.

[0019] Depending on the location where the mixture is to be applied, the nozzle may be omitted, and the mixture may be directly applied to the application site from the rounded head of the first container or the second container, or from an opening provided by cutting a part of the first container or the second container. The inner diameter of the nozzle, the rounded head, or the opening can be, for example, 20 to 25 mm. The inner diameter of the opening refers to the inner diameter when the opening is at its smallest.

[0020] The first container containing the powder material and the second container containing the liquid material are stored in a packaging material such as a box or a bag and provided as a set, that is, a pair.

[0021] The powder material contains 5 to 35% by mass of cement, 19 to 85% by mass of aggregate, 7 to 30% by mass of fine powder, and 1 to 8% by mass of re-emulsified powdered resin.

[0022] As the cement, known hydraulic cement powder can be used. For example, as the cement, alumina cement; Portland cement such as ordinary Portland cement and early-strength Portland cement; or BF cement mixed with blast furnace slag fine powder (BF) can be mentioned. In addition, alumina cement with an alumina content of 50 to 92% by mass can be used. The particle size range of the cement is not particularly limited, but for example, it is 1 μm or more and less than 40 μm.

[0023] As the aggregate, those generally used in manufacturing concrete structures can be used. The aggregate is used for the purpose of volume increase, suppression of the shrinkage amount in the hardened body, prevention of crack generation in the hardened body, improvement of the strength of the hardened body, and improvement of the abrasion resistance of the hardened body. As the aggregate, inorganic aggregates can be used. For example, sand such as chamotte, alumina, silica sand, mullite, silicon carbide, and river sand, gravel such as river gravel and mountain gravel, crushed stone, or a mixture thereof can be used. The particle size range of the aggregate is not particularly limited, but for example, it is 0.5 mm or more and less than 10 mm. Based on the mass of the powder material, the content of the aggregate may be 50 to 72% by mass.

[0024] Fine powder can be any type commonly used in the manufacture of concrete structures. Fine powder is used for purposes such as increasing bulk, suppressing shrinkage in the hardened body, preventing crack formation in the hardened body, improving the strength of the hardened body, and improving the wear resistance of the hardened body. Inorganic materials can be used as fine powder. For example, chamotte, alumina, silica sand, mullite, silicon carbide, river sand, gravel such as river gravel or mountain gravel, crushed stone, or mixtures thereof can be used. The particle size range of the fine powder is not particularly limited, but for example, it is 8 μm or larger and less than 0.5 mm.

[0025] The re-emulsified powder resin can be a commercially available product commonly used in the manufacture of polymer cement. For example, the re-emulsified powder resin can contain at least one elastic resin selected from the group consisting of vinyl acetate-ethylene copolymer, vinyl acetate-acrylic monomer copolymer, and styrene-acrylic monomer copolymer. The re-emulsified powder resin is produced, for example, by spray-drying an emulsion obtained by copolymerizing multiple monomers, such as ethylene and vinyl acetate. The particle size range of the re-emulsified powder resin is not particularly limited, but is, for example, 8 μm or more and less than 600 μm. The re-emulsified powder resin may contain fillers such as calcium carbonate and clay minerals such as kaolin, but it is preferable to use one with a synthetic resin content of 90 to 100% by mass.

[0026] The liquid material is an acrylic resin emulsion, and the liquid material contains 0.5 to 8.0 parts by mass of acrylic resin per 100 parts by mass of powder material contained in the first container. Alternatively, the liquid material is an acrylic resin emulsion, and it is preferable that the liquid material contains 11 to 20 parts by mass of water per 100 parts by mass of powder material contained in the first container. The acrylic resin emulsion is preferably composed of 3 to 38% by mass of acrylic resin. In this case, the concentration of acrylic resin may be changed by adding water to a commercially available acrylic resin emulsion.

[0027] Acrylic resin emulsion liquids commercially available for civil engineering and cement admixture can be suitably used. Among these, acrylic resin emulsion liquids containing cations can be suitably used. The substrate at the application site is often negatively charged. By including cations, the adhesive strength of the road surface repair material is improved.

[0028] The aforementioned powder material preferably contains an expander. The expander content is preferably 0.05 to 1.0% by mass, based on the mass of the powder material.

[0029] The expansive material used is one that, after being mixed with cement and water, generates ettringite through a hydration reaction, thereby forming concrete. For example, a material called hauyne, containing calcium sulfoaluminate (3CaO·3Al2O3·CaSO4), lime (CaO), and anhydrous gypsum (CaSO4), can be used as the expansive material. The particle size range of the expansive material is not particularly limited, but is, for example, 1 μm to 1.8 mm, or 8 μm to 1.2 mm. The ettringite produced by adding water to the precursor expansive material grows needle-shaped crystals in the construction material, reducing long-term curing shrinkage and crack formation.

[0030] The aforementioned powder material preferably contains lithium carbonate as a curing accelerator. The lithium carbonate content is determined by the mass of the powder material, with a lithium carbonate content of 1 × 10⁻⁶. -3 It is preferable that it contains approximately 0.1% by mass.

[0031] The aforementioned powder material preferably contains organic fibers for the purpose of preventing cracking. The organic fiber content is preferably 0.01 to 0.2% by mass, based on the mass of the powder material. The organic fibers can be carbon fibers, aramid fibers, polyolefin fibers such as polypropylene and polyethylene, or vinylon fibers, which are used to reinforce concrete. As organic fibers, for example, those with a fineness of 0.1 to 5 dtex and a fiber length of 2 to 10 mm can be used. A fineness of 0.2 to 4.5 dtex is preferred, and a fiber length of 2.5 to 9 mm is more preferred.

[0032] The particle size range of the powder material is not particularly limited, but for example, it is between 1 μm and less than 10 mm. [Examples]

[0033] The following describes one embodiment of the road surface repair material of the present invention. The embodiment shown below is merely a limited example of the present invention, and the technical scope of the present invention is not limited to the embodiment shown.

[0034] Powder materials and liquid materials according to Examples 1 to 9 and comparative examples 1 to 4 were prepared using the compositions described in Tables 1 to 3.

[0035] In each example and comparative example, the following raw materials were used. As the re-emulsified powder resin, a powder of a re-emulsified elastic resin was used, which was obtained by copolymerizing vinyl acetate monomer and ethylene monomer to produce a powdered emulsion. The particle size of the re-emulsified powder resin was 20 μm or more and 300 μm or less. As aggregate, silica sand was used. The particle size of the aggregate was 0.5 mm or more and less than 10 mm. As fine powder, pulverized silica sand was used, with silica as the main component. The particle size of the fine powder was 8 μm or more and less than 0.5 mm. For cement, alumina cement, high alumina cement, ordinary Portland cement, rapid-hardening Portland cement, and Type B BF cement, which is ordinary Portland cement mixed with blast furnace slag fine powder (BF), which are commonly used in construction work, were used. Alumina cement contains 50% by mass or more and less than 60% by mass of alumina. High alumina cement contains 65% by mass or more and less than 75% by mass of alumina.

[0036] The expansive material used was a commonly used expansive material for concrete admixture. The particle size was 1 μm or larger and 1.2 mm or smaller. The expansive material used contained hauyne, a calcium sulfoaluminate (3CaO·3Al2O3·CaSO4), lime (CaO), and anhydrous gypsum (CaSO4), and produced ettringite upon addition of water. As organic fibers, polypropylene fibers with a fiber length of 2-10 mm and 2.2 dtex were used. Lithium carbonate, a white powdered pure substance, was used as a hardening accelerator.

[0037] The above raw materials were mixed in the proportions shown in Tables 1 to 3 to obtain the powder material.

[0038] A liquid material was prepared by mixing a cation-containing aqueous acrylic resin emulsion liquid, which is sold for civil engineering and cement admixture, with water as shown in Tables 1 to 3. In Examples 1 to 9, the liquid material contained 11 to 20 parts by mass of water per 100 parts by mass of the powder material contained in the first container. Note that the notation "Water: 18.5" in the "Acrylic resin emulsion + water (parts by mass)" column in Comparative Example 4 of Table 2 indicates that 18.5 parts by mass of water was used as the liquid material instead of the mixed liquid material of acrylic resin emulsion liquid and water.

[0039] The powder materials of each of the above embodiments and comparative examples were placed into a first container having the same configuration as shown in Figure 1, and the powder materials of each of the above embodiments and comparative examples were placed into a second container having the same configuration as shown in Figure 1, thereby producing a road surface repair material consisting of a set of first and second containers.

[0040] The road surface repair materials of each of the above examples and comparative examples were evaluated for viscosity, workability, free flow, application time, curing properties, and flexural strength using the following method. When applying the road surface repair material, the opening of the second container was placed inside the opening of the cylindrical part of the first container, and the entire contents of the liquid material in the second container were transferred into the first container. The powder material and liquid material in the first container were then thoroughly mixed by hand. The first and second containers are made of polypropylene film material. Subsequently, the mixture from the cylindrical part of the first container was filled into the recessed holes, which were used to represent the repair areas, as described below. The inner diameter of the cylindrical part is 22 mm.

[0041] ·viscosity The mixture from the first container was dispensed from the tip of the nozzle into a recessed hole measuring 300 mm wide, 200 mm long, and 25 mm deep, which was intended to simulate a repair area. The viscosity during application was evaluated according to the following criteria. About viscosity ○ The mixture has a suitable viscosity. △ The mixture can be applied even if its viscosity is high or low. × The viscosity of the mixture is too high or too low, causing problems during application.

[0042] Regarding workability The mixture from the first container was dispensed from the tip of the nozzle into the recessed hole, which was intended to represent the repair area. The viscosity during application was evaluated according to the following criteria. ○ Allows for smooth filling of repair areas. △ With enough time, the mixture can be filled into the repair area. × It is difficult to complete the work of filling the repair area.

[0043] • Regarding available construction hours This indicates the time it takes to squeeze the mixture out of the first container by hand. Note that a "-" in Table 1 indicates that the time is slightly less than the indicated time, for example, slightly less than 3 hours.

[0044] hardenability The mixture from the first container was dispensed from the tip of the nozzle into the recessed hole, which was intended to represent the repair area. The viscosity during application was evaluated according to the following criteria. ○ After 24 hours, it has hardened to a degree that poses no practical problems. △ It solidifies after 24 hours. × It has not solidified after 24 hours.

[0045] • Free flow test Based on the method specified in JIS R 2521:1995, the mixtures of each example and comparative example, mixed in the first container, were filled from a nozzle into a bottomless container called a flow cone. After removing the flow cone, the extent to which the mixture spread one minute after the container was removed was measured. The initial value of the inner diameter of the flow cone, i.e., the diameter of the mixture, was 100 mm. Tables 1 to 3 show the diameter of the mixture after one minute.

[0046] ·Available construction time For each of the above-described examples and comparative examples, the time it took to squeeze the mixture from the nozzle of the first container and fill the area to be worked on was measured. This time is the time from immediately after mixing the powder and liquid materials until the mixture loses its fluidity. Loss of fluidity means that the mixture can no longer be squeezed out by hand from the nozzle of the first container.

[0047] • Bending strength Based on JIS R 2553:2005, the bending strength of test specimens prepared using the road surface repair materials of each example and comparative example was measured by the following method and is shown in Tables 1 to 3.

[0048] The powder materials for each example and comparative example were placed in a bowl, the corresponding liquid materials for each example and comparative example were added, and the mixture was kneaded by hand with a spoon before being poured into a mold. After curing in the room for 24 hours, the mold was removed to obtain the sample. The dimensions of the test specimen were 40 mm × 40 mm × 160 mm.

[0049] The maximum load on the test specimen was determined by applying a uniform load of 49.03 to 68.05 N / sec to the center of the side surface of the test specimen, which was supported by two support rolls during molding. The bending strength Tr (MPa) of the test specimen was calculated using the following formula and rounded to one decimal place according to JIS Z 8401. Tr = 3Wl ÷ 2bd 2 However, W: maximum load (N), l: center distance of support rolls (mm) = 100 mm, b: width of test specimen (mm), d: thickness of test specimen (mm).

[0050] ·Shear adhesive strength A mold with internal dimensions of 50 mm in length, 50 mm in width, and 10 mm in height was fixed to the flat surface of the recess of an L-shaped chamotte brick in a side view. The mixture of liquid and powder materials from Examples 3 to 5 and Comparative Examples 3 and 4 was filled into this fixed mold. After filling was completed, it was allowed to cure for 24 hours, and then heated at 110°C for 24 hours to prepare the test specimen.

[0051] The shear bond strength was determined by applying a uniform load of 49.03 to 68.05 N / sec to the joint between an L-shaped brick and a molded mixture, using the following formula. The area of ​​the bonding surface between the brick and the molded body was 50 mm × 50 mm. The load was applied parallel to the bonding surface. Tr = W ÷ bd However, W is the maximum load (N), b is the width of the test specimen (mm), and the product of d and d is the area of ​​the adhesive surface (50 mm × 50 mm).

[0052] [Table 1]

[0053] [Table 2]

[0054] [Table 3]

[0055] As shown in Table 1, in Example 1, although the viscosity of the mixture was slightly low, the mixture could be smoothly filled into the recessed holes representing the repair areas. In Example 2, although the viscosity of the mixture was slightly high, the mixture could be smoothly filled into the recessed holes representing the repair areas. On the other hand, in Comparative Example 1, the viscosity of the mixture was excessively high, requiring time and effort to squeeze the mixture out of the nozzle, and it took a long time to complete the work of filling the recessed holes representing the repair areas. In Comparative Example 2, although the viscosity was excessively low and it could be quickly filled into the repair areas, the solid and liquid components separated slightly, and the mixture could not be fixed into the recessed holes representing the repair areas.

[0056] As shown in Table 2, in the road surface repair material of Example 4, both the viscosity of the mixture and the fluidity when the mixture was discharged from the nozzle were good, and the mixture could be smoothly filled into the recessed holes representing the repair areas. In the road surface repair material of Example 4, although the viscosity of the mixture was slightly high, the mixture could be smoothly filled into the recessed holes representing the repair areas. In the road surface repair material of Example 5, the viscosity of the mixture was high, and the fluidity when the mixed part was discharged from the nozzle was not good, but it was possible to fill the repair area with the mixture if time was taken. On the other hand, in the road surface repair material of Comparative Example 3, the viscosity of the mixture was excessively high, requiring time and effort to squeeze the mixture out of the nozzle, and the work of filling the recessed holes representing the repair areas could not be completed. In the road surface repair material of Comparative Example 4, the viscosity was excessively low, and the solid and liquid components separated slightly, making it impossible to fix the mixture in the recessed holes representing the repair areas, and the work of filling the mixture could not be completed. Furthermore, the road surface repair materials of Examples 3 to 5 exhibited higher shear adhesive strength values ​​compared to Comparative Example 4, which used water as the liquid material. This resulted in stronger adhesion to the application site and reduced likelihood of peeling.

[0057] As shown in Table 3, the road repair material of Example 7 exhibited good viscosity and fluidity when discharged from the nozzle, allowing for smooth filling of the recessed holes representing the repair areas. In the road repair materials of Examples 6, 8, and 9, although the viscosity of the mixture was slightly higher, the mixture could still be smoothly filled into the recessed holes representing the repair areas.

[0058] As in Comparative Example 4, reducing the amount of acrylic resin in the liquid material improves workability when dispensing the mixture from the nozzle tip, but the viscosity of the mixture decreases, making it more prone to separation on the workpiece, and preventing the mixture from settling into the recessed holes representing the repair area. On the other hand, as in Comparative Example 3, increasing the amount of acrylic resin in the liquid material increases the viscosity of the mixture, resulting in poor workability. [Explanation of Symbols]

[0059] 11 1st container 12 Container 2 1. Road repair materials

Claims

1. A road surface repair material comprising a first container containing powder material and a second container containing liquid material, The first or second container functions as a container for mixing the powder material and the liquid material and squeezing the mixture of the powder material and the liquid material onto the area to be worked on. The powder material contains 5-35% by mass of cement, 19-85% by mass of aggregate, 7-30% by mass of fine powder, and 1-8% by mass of re-emulsified powdered resin. The liquid material is an acrylic resin emulsion liquid. A road surface repair material comprising 100 parts by mass of powder material contained in the first container, with the liquid material containing 0.5 to 8.0 parts by mass of acrylic resin.

2. The aforementioned powder material contains lithium carbonate as a hardening accelerator in a 1 × 10 －３ The road surface repair material according to claim 1, containing up to 0.1% by mass.

3. The road surface repair material according to claim 1 or 2, wherein the powder material contains 0.01 to 0.2% by mass of organic fibers.

4. The road surface repair material according to claim 1 or 2, wherein the liquid material contains 11 to 20 parts by mass of water with respect to 100 parts by mass of powder material contained in the first container.

5. The road surface repair material according to claim 1 or 2, wherein the powder material contains 0.05 to 1.0% by mass of an expansive material.

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