Waterproofing structures and waterproofing methods

Abstract

To provide a waterproof structure having a laminated structure including an FRP layer as a waterproof layer, in which the intermediate coating layer contains an anti-slip material, thereby effectively preventing appearance defects such as pinholes and repellency on the surface of the intermediate coating layer. [Solution] A waterproof structure in which a primer layer, a fiber-reinforced resin layer which is a waterproof layer, an intermediate coating layer and a topcoat layer are laminated in this order on a substrate, characterized in that the intermediate coating layer contains an anti-slip material.

Description

[Technical Field]

[0001] The present invention relates to a waterproof structure and waterproofing method applicable to structures such as balconies and verandas, and more specifically, to a waterproof structure and waterproofing method that effectively prevents appearance defects such as pinholes and repellency on the surface of the intermediate coating layer. [Background technology]

[0002] Traditionally, waterproofing methods involving the lamination of waterproofing layers have been applied to structures such as building rooftops, balconies, and verandas to provide waterproofing. In particular, recently, because fiber-reinforced plastics (hereinafter sometimes referred to as "FRP (abbreviation for Fiber Reinforced Plastics)") are lightweight, strong, and also have excellent heat resistance and corrosion resistance, waterproofing methods using FRP for the waterproofing layer have become widely used (see Patent Documents 1 and 2).

[0003] In the case where an intermediate coating layer containing toner or the like is provided between the waterproof layer using FRP and the topcoat, appearance defects such as pinholes and repellency sometimes occur in the intermediate coating layer. While these appearance defects can be repaired by applying a topcoat to the intermediate coating layer, the need for this repair work prevents continuous topcoat coating, resulting in an inefficient work process and limiting the cost reduction of the waterproofing method. [Prior art documents] [Patent Documents]

[0004] [Patent Document 1] Japanese Patent Publication No. 2002-331632 [Patent Document 2] Japanese Patent Publication No. 2017-008575 [Overview of the Initiative] [Problems that the invention aims to solve]

[0005] The object of the present invention has been made in view of these circumstances, and is to provide a waterproof structure having a laminated structure including an FRP layer as a waterproof layer, in which the intermediate coating layer contains an anti-slip material, thereby effectively preventing appearance defects such as pinholes and repellency on the surface of the intermediate coating layer. Another object of the present invention is to provide a waterproofing method for realizing the aforementioned waterproof structure. [Means for solving the problem]

[0006] The present invention provides a waterproof structure in which a primer layer, a fiber-reinforced resin layer which is a waterproof layer, an intermediate coating layer and a topcoat layer are laminated in this order on a substrate, characterized in that the intermediate coating layer contains an anti-slip material.

[0007] It is preferable that the intermediate coating layer in the waterproof structure contains 1 to 20% by mass of an anti-slip material.

[0008] Preferably, the intermediate coating layer in the waterproof structure further contains toner.

[0009] Preferably, the fiber-reinforced resin layer in the waterproof structure is a layer in which a fiber-reinforced material is impregnated with vinyl ester resin.

[0010] Furthermore, the present invention provides a waterproofing method in which a primer layer, a fiber-reinforced resin layer which is a waterproofing layer, an intermediate coating layer and a topcoat layer are laminated in this order on a substrate, characterized in that the fiber-reinforced resin layer is a layer in which a fiber-reinforcement material is impregnated with vinyl ester resin, and the intermediate coating layer contains an anti-slip material.

[0011] In the aforementioned waterproofing method, it is preferable that the intermediate coating layer contains 1 to 20% by mass of an anti-slip material.

[0012] Preferably, the intermediate coating layer in the waterproofing method further contains toner. [Effects of the Invention]

[0013] According to the present invention, there are provided a waterproof structure and a waterproof construction method in which appearance defects such as pinholes and repellency on the surface of the intermediate coating layer are effectively prevented.

Brief Description of the Drawings

[0014] [Figure 1] It is a figure which shows the laminated structure of the waterproof structure 100 in Embodiment 1 of this invention. [Figure 2] It is a figure which shows the laminated structure of the waterproof structure 200 in Embodiment 2 of this invention. [Figure 3] Shows the appearance after forming the intermediate coating layer 4 in Example 1. [Figure 4] The upper half of FIG. 3 shows the appearance after forming the top coat layer 5. [Figure 5] Shows the appearance after forming the intermediate coating layer 4 in Comparative Example 1.

Modes for Carrying Out the Invention

[0015] FIG. 1 is a diagram showing the laminated structure of the waterproof structure 100 in Embodiment 1 of the present invention. The waterproof structure 100 is obtained by laminating a primer layer 2, a fiber reinforced resin layer 3 (hereinafter sometimes referred to as an FRP layer 3), an intermediate coating layer 4, and a top coat 5 in this order on a lower ground surface 1. The intermediate coating layer 4 contains an anti-slip material 6, which is an important feature.

[0016] Examples of the lower ground surface 1 include the roofs, eaves, open corridors, balconies, verandas, factory floors, etc. of buildings. Examples of the material of the lower ground surface 1 include concrete, mortar, asphalt, asbestos slate, plastic, wood, metal, etc.

[0017] When a primer is applied to the substrate 1 and allowed to harden, a primer layer 2 is formed. The primer layer 2 plays a role in improving the adhesion between the FRP layer 3 (described later) and the substrate 1. Suitable primers include those commonly used in FRP waterproofing methods, such as polyurethane resins, epoxy resins, vinyl ester resins, unsaturated polyester resins, and acrylic resins, but polyurethane resins are preferred. The amount of primer to apply is 0.1 to 1.0 kg / m². 2 It is preferable.

[0018] A waterproof FRP layer 3 is provided on top of the primer layer 2. The FRP layer 3 is obtained by impregnating a fiber-reinforced material with a thermosetting resin and curing the thermosetting resin. Examples of the thermosetting resin include vinyl ester resin, epoxy resin, unsaturated polyester resin, and phenolic resin, but vinyl ester resin is preferred. Vinyl ester resin is a synthetic resin obtained by diluting and dissolving a polymer produced by the addition reaction of epoxy resin and (meth)acrylic acid, mainly with styrene monomer, and known vinyl ester resins can be used. Furthermore, it is preferable that the vinyl ester resin contains polyurethane resin. By including polyurethane resin, elasticity can be imparted to the vinyl ester resin.

[0019] As the fiber reinforcement material, one or more types of glass fibers, metal fibers, ceramic fibers, carbon fibers, etc., can be used. The fiber reinforcement material is processed into one or more types of shapes, such as chopped strand mat, cloth (woven fabric), nonwoven fabric, three-dimensional woven fabric, etc., and used to form the FRP layer. The amount of fiber reinforcement material used is generally 8 to 80% by mass of the entire FRP layer 3, and preferably 10 to 60% by mass.

[0020] The thickness of the FRP layer 3 is determined appropriately depending on the application environment of the present invention and the degree of waterproofing, but it is generally preferable to set it to 2 to 3 mm.

[0021] Known additives may be added to the FRP layer 3 as needed. Examples of known additives include thickeners, fillers, curing agents, curing accelerators, shrinkage reducers, and colorants.

[0022] Figure 2 shows the laminated structure of the waterproof structure 200 in Embodiment 2. As shown in the waterproof structure 200, the FRP layer may be made into a multi-layer structure of two or more layers by adding an FRP layer 3', which is a waterproof layer, to the FRP layer 3. In this case, the multi-layer structure may be made of FRP layers using the same fiber reinforcement material and thermosetting resin, or it may be made of FRP layers using different fiber reinforcement materials and thermosetting resins. Figure 2 has the same laminated structure as Figure 1 except that it includes FRP layer 3'.

[0023] An intermediate coating material is applied to the FRP layer 3 and cured to form an intermediate coating layer 4. The intermediate coating material consists of a thermosetting resin before curing and contains an anti-slip agent. As the thermosetting resin, the one disclosed for the FRP layer 3 can be used, but it is preferable to use the same thermosetting resin as the one used for the FRP layer 3 because it has excellent adhesion.

[0024] The intermediate layer 4 is used to cover pinholes and other imperfections on the upper surface of the FRP layer 3 and to improve the finish. It does not necessarily need to contain toner, but it may contain toner from the viewpoint of improving the aesthetic appearance of the waterproof structure of the present invention. This is because if toner is contained in the topcoat 5, unevenness in the thickness of the topcoat 5 will result in differences in appearance between thin and thick areas. Furthermore, if a topcoat is applied to repair this difference, partial unevenness in the thickness of the topcoat 5 will occur, and hardening shrinkage in the thicker areas may cause cracks and fissures in the topcoat 5, potentially making it impossible to protect the waterproof structure of the present invention from deterioration due to rainwater and sunlight. Therefore, if toner is to be added, it is preferable to add it to the intermediate layer 4 rather than the topcoat 5. Here, the toner is a resin powder or paste mixed with a coloring agent such as a pigment, and known toners that are commonly used in the art of the present invention for the purpose of improving aesthetic appearance can be used.

[0025] As explained above, when the intermediate coating layer 4 contains toner, defects such as pinholes and repellency occur, and these areas become uncolored or lightly colored, making the appearance defects easily recognizable by visual inspection, which poses a significant problem. However, in the present invention, the intermediate coating layer 4 contains an anti-slip material 6, which effectively prevents the aforementioned appearance defects.

[0026] Here, pinholes occur when the intermediate coating layer 4 contains air bubbles before curing, and these bubbles burst during curing, creating holes on the surface of the intermediate coating layer 4. Repulsion occurs when the surface tension of the intermediate coating layer 4 is uneven before curing, causing depressions on a part of the surface of the intermediate coating layer 4, exposing the fiber-reinforced resin layer, or even if not exposed, creating noticeable irregularities in appearance. Both are caused by the unevenness of the components of the intermediate coating material used in the intermediate coating layer 4. However, in the present invention, it is believed that the unevenness is improved by including an anti-slip agent in the intermediate coating material, thereby effectively preventing the aforementioned appearance defects.

[0027] Examples of the anti-slip material 6 include natural silica, synthetic silica, calcium carbonate, magnesium carbonate, fly ash, dewatered sludge, kaolin, clay, calcium oxide, magnesium oxide, titanium oxide, zinc oxide, barium sulfate, calcium hydroxide, aluminum hydroxide, alumina, magnesium hydroxide, talc, mica, hydrotalcite, aluminum silicate, magnesium silicate, calcium silicate, calcined talc, wollastonite, potassium titanate, magnesium sulfate, calcium sulfate, magnesium phosphate, sepiolite, zonolite, aluminum borate, silica balloons, glass flakes, glass balloons, silica, and steelmaking slag. Examples include magnetic powders such as copper, iron, iron oxide, Sendust, Alnico magnets, and various ferrites, cement, glass powder, diatomaceous earth, antimony trioxide, magnesium oxysulfate, hydrated aluminum, hydrated gypsum, alum, and inorganic pigments (alumina white, zinc oxide, lead white, white carbon, molybdenum white, Lissage, Lithopon, Barite, cadmium red, cadmium mercury red, red iron oxide, molybdenum red, red lead, yellow lead, cadmium yellow, barium yellow, strontium yellow, titanium yellow, titanium black, chromium oxide green, cobalt oxide, cobalt green, cobalt-chromium green, ultramarine, Prussian blue, cobalt blue, cerulean blue, manganese purple, cobalt purple, etc.). The anti-slip material 6 may be used alone or in combination of two or more types.

[0028] If the intermediate coating layer 4 does not contain toner, it is preferable to use a colorless and transparent natural silica, synthetic silica, or the like as the anti-slip material 6. Furthermore, by using an inorganic pigment as the anti-slip material 6, the aesthetic appearance of the waterproof structure of the present invention can be improved without using toner.

[0029] Furthermore, if the intermediate coating layer 4 contains toner, the aesthetic appeal of the waterproof structure of the present invention can be further improved by using an inorganic pigment in combination as the anti-slip material 6. Also, when utilizing the design created with toner, it is preferable to use colorless and transparent natural silica, synthetic silica, etc., as the anti-slip material 6.

[0030] The volume-average particle size of the anti-slip material 6 is preferably 10 to 300 μm, more preferably 20 to 250 μm, and particularly preferably 30 to 200 μm. If the volume-average particle size is smaller than 10 μm, the number of fine particles increases, and the viscosity of the intermediate coating material increases, which can worsen the applicability of the intermediate coating material and may not effectively prevent appearance defects such as pinholes and repellency. If it exceeds 300 μm, sedimentation of the anti-slip material may occur, which may not effectively prevent appearance defects such as pinholes and repellency. In addition, the applicability of the intermediate coating material may worsen.

[0031] The intermediate coating layer 4 of the present invention preferably contains 1 to 20% by mass of the anti-slip material 6. In this case, the content of the anti-slip material 6 should be 1 to 20% by mass when the total mass of the intermediate coating material is 100% by mass. The content of the anti-slip material 6 in the intermediate coating layer 4 is more preferably 2 to 15% by mass, and particularly preferably 3 to 10% by mass. If the content is less than 1% by mass, it may not be possible to effectively prevent appearance defects such as pinholes and repellency, and if it exceeds 20% by mass, the applicability of the intermediate coating material may deteriorate.

[0032] The application rate for the intermediate coat layer 4 is 0.1 to 0.5 kg / m². 2 This is preferable. The application amount is 0.1 kg / m². 2 If the amount is less than 0.5 kg / m², it may become impossible to uniformly cover the FRP layer 3 with the intermediate coat layer 4. 2 If this limit is exceeded, cracks or fissures may occur in the intermediate coating layer 4 due to curing shrinkage.

[0033] After confirming that the intermediate coat layer 4 has hardened, a topcoat is applied to the intermediate coat layer 4 and hardened to form a topcoat layer 5. The topcoat layer 5 is a layer provided for the purpose of providing transparency and weather resistance, and is formed by applying a conventionally known topcoat to the intermediate coat layer 4. Conventionally known topcoats include, for example, vinyl ester resin, unsaturated polyester resin, acrylic urethane resin, etc. The topcoat layer may further be given anti-slip properties by scattering aggregate, colored by adding toner, or have mortar or the like applied to the surface to enhance its non-flammability.

[0034] The amount of topcoat to apply is 0.1 to 0.5 kg / m². 2 This is preferable. The application amount is 0.1 kg / m². 2 If the amount is less than 0.5 kg / m, it may become impossible to uniformly cover the intermediate layer 4 with the topcoat layer, and there is also a risk that the intermediate layer 4 and FRP layer 3 may become exposed over time due to friction and wear from users walking on the surface. 2 If the temperature exceeds a certain point, the coating may crack due to curing shrinkage, potentially failing to protect the intermediate coating layer 4 and the FRP layer 3 from deterioration caused by rainwater and sunlight, which in turn can lead to deterioration of the waterproof structure of the present invention on balconies and the like.

[0035] In the waterproof structure of the present invention, additional layers may be provided as needed, provided that the effects of the present invention are not impaired. As an example of additional layers, an insulating layer containing a known insulating material may be laminated between the substrate 1 and the primer layer 2. Furthermore, the insulating layer may be covered with a known resin sheet to avoid deformation of the insulating layer, and a known protective layer may be laminated on top of the insulating layer.

[0036] (Waterproofing method) The construction method for providing a waterproof structure with the above-mentioned characteristics is as follows: First, a primer layer 2 is formed on the substrate 1, such as a balcony, by applying a primer with a brush or roller. An FRP layer 3 is then placed on top of the resulting primer layer 2. One method for forming the FRP layer 3 is to prepare a fiber reinforcement material of the desired shape, apply a thermosetting resin, place the material on top of it, apply another layer of thermosetting resin, remove air bubbles with a de-aerating roller, and then cure the layer. The thermosetting resin can be applied, for example, by brush or roller. If the FRP layer consists of two or more layers, the application of thermosetting resin and the placement of the fiber reinforcement material can be repeated alternately, followed by removal of air bubbles and curing. In this case, if the same thermosetting resin is used, multiple fiber reinforcement materials can be laminated, then the thermosetting resin can be applied and air bubbles removed, and multiple FRP layers can be cured simultaneously.

[0037] Another method for forming the FRP layer 3 involves impregnating a fiber reinforcement material with a thermosetting resin by hand lay-up or the like, then placing the resulting thermosetting resin-impregnated fiber reinforcement material in a designated location and allowing it to harden.

[0038] The thermosetting resin may be pre-mixed with known additives such as curing agents. It is particularly preferable to mix the additives immediately before coating or impregnation.

[0039] As a method for forming an intermediate coating layer 4 on top of the FRP layer 3, an intermediate coating material can be prepared by pre-mixing a thermosetting resin such as vinyl ester resin and an anti-slip material, along with toner and hardener as needed, and then applying this intermediate coating material onto the FRP layer 3. Application is generally done using a brush or roller. Here, it is preferable to use the same thermosetting resin used for the intermediate coating layer 4 as the one used for the FRP layer 3, as this provides high adhesion to the FRP layer 3.

[0040] As a method of forming the top coat layer 5 on the intermediate coat layer 4, after confirming that the intermediate coat layer 4 has hardened, the top coat is applied on the intermediate coat layer 4 with a brush or a roller. Before application, it is preferable to adjust the surface of the intermediate coat layer 4 with a polisher or the like, clean it, and wipe it with a cloth soaked with acetone. Thus, the waterproof structure of the present invention in which appearance defects such as pinholes and repellency on the surface of the intermediate coat layer 4 are effectively prevented can be obtained.

Example

[0041] Hereinafter, the present invention will be further described with reference to examples and comparative examples. The technical scope of the present invention is not limited by these.

[0042] <Example 1> Using ordinary plywood as a base, on the lower ground surface 1 which is the upper surface of the ordinary plywood, a primer (manufactured by Mitsui Chemicals Co., Ltd., trade name: Reprotec Neo FP-550N) is applied at 0.2 kg / m 2 to form a primer layer 2. After that, a mixed solution obtained by adding 1.5 parts by mass of cumyl hydroperoxide curing agent (manufactured by Kayaku Nouryon Co., Ltd., trade name: Curing Agent 328E) to 100 parts by mass of vinyl ester resin (manufactured by Mitsui Chemicals Co., Ltd., trade name: Reprotec Neo NS) is impregnated into one glass mat (manufactured by Mitsui Chemicals Co., Ltd., trade name: Remaster Mat #450) having a mass of 450 g / m 2 at an amount of 1.5 kg / m 2 and then cured to form an FRP layer 3. Further, on the FRP layer 3, an intermediate coating material obtained by adding 1.5 parts by mass of cumyl hydroperoxide curing agent (manufactured by Kayaku Nouryon Co., Ltd., trade name: Curing Agent 328E) to 100 parts by mass of vinyl ester resin (manufactured by Mitsui Chemicals Co., Ltd., trade name: Reprotec Neo NS) as an intermediate coating material, and further adding silica (manufactured by Mitani Paint Co., Ltd., trade name: AS Nonce) as an anti-slip material and mixing them is applied at an amount of 0.4 kg / m 2 and dried to form an intermediate coat layer 4. Then, a mixture obtained by mixing an acrylic urethane resin top coat (manufactured by Mitsui Chemicals Co., Ltd., trade name: Reprotec Neo Stop NS) at a mixing ratio of the main agent and the curing agent of 6:4 is applied at 0.15 kg / m2 The required amount was applied and allowed to dry to form the top coat layer 5. Here, the silica content in the intermediate coating material was 5.0% by mass relative to 100% by mass of the intermediate coating material. Figure 3 shows the appearance after the intermediate coating layer 4 is formed in Example 1. Figure 4 shows the appearance after the top coat layer 5 is formed on the upper half of Figure 3. In Example 1, no appearance defects such as pinholes or blemishes were observed in the intermediate coating layer 4 and the top coat layer 5 by visual inspection.

[0043] <Comparative Example 1> The test was conducted under the same conditions as in Example 1, except that silica as an anti-slip agent was not mixed into the intermediate coating material used to form the intermediate coating layer 4 described above. Figure 5 shows the appearance after the formation of the intermediate coating layer 4 in Comparative Example 1. In Comparative Example 1, it was confirmed that the intermediate coating layer 4 showed visible signs of repulsion, indicating a defect in appearance. [Explanation of symbols]

[0044] 1 Base surface 2. Primer layer 3 FRP layers 4. Intermediate coat layer 5. Top coat layer 6 Anti-slip material 100 Waterproof structure in Example 1 200 Waterproof structure in Example 2

Claims

1. A waterproof structure comprising a primer layer, a fiber-reinforced resin layer which is a waterproof layer, an intermediate coating layer and a topcoat layer laminated in this order on a substrate, characterized in that the intermediate coating layer contains an anti-slip material.

2. The waterproof structure according to claim 1, wherein the intermediate coating layer contains 1 to 20% by mass of an anti-slip material.

3. The waterproof structure according to claim 1 or 2, wherein the intermediate coating layer further contains toner.

4. The waterproof structure according to claim 1 or 2, wherein the fiber-reinforced resin layer is a layer obtained by impregnating a fiber-reinforced material with vinyl ester resin.

5. A waterproofing method comprising layering a primer layer, a fiber-reinforced resin layer which serves as a waterproofing layer, an intermediate coating layer, and a topcoat layer in that order on a substrate, wherein the fiber-reinforced resin layer is a layer in which a fiber-reinforcement material is impregnated with vinyl ester resin, and the intermediate coating layer contains an anti-slip material.

6. The waterproofing method according to claim 5, wherein the intermediate coating layer contains 1 to 20% by mass of an anti-slip material.

7. The waterproofing method according to claim 5 or 6, wherein the intermediate coating layer further contains toner.

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