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INVENTION
Russian Federation Patent RU2163578

Self-leveling mortar

Self-leveling mortar

Name of the inventor: Zakharov SA
The name of the patentee: Closed Joint Stock Company "Spetsstroysmesi"
Address for correspondence: 107066, Moscow, ul. Novoryazanskaya 26 p / w "Wings of Motherland", LLC "Grandpatent" Prozorovsky AY
Starting date of the patent:

Use: in construction, mainly for screeds and flooring. Self-leveling mortar contains filler particle size of 0.5 mm, a filler having a specific surface of 500-5000 cm 2 / g and magnesia cement as a binder, which includes a component comprising an active magnesium oxide, for instance a caustic or caustic magnesite, dolomite, salt and component comprising hydrated or an aqueous solution of at least one salt of a strong acid and a bi- trivalent metal such as magnesium chloride, ferric chloride, magnesium sulfate, or mixtures thereof. Furthermore, the mixture contains a stabilizing additive, pigment and builders. The amount of ingredients in the mixture is determined from the relationship between the content of active magnesium oxide, salt composition and component concentration of dust particles in the filler. The technical result - to provide an inexpensive and simple to manufacture self-leveling concrete having optimal performance and aesthetic properties.

DESCRIPTION OF THE INVENTION

The invention relates to construction materials and more particularly to high-mobility mixtures capable of a solution spontaneously spread over the surface and equalize local irregularities, and intended primarily for the production of screeds and floor coverings as well and can be used for the masonry fixing tiles, production of decorative coatings.

Known self-leveling mortar containing gypsum binder, filler, sulfate-yeast mash as a modifying agent and water [1].

The disadvantages of this mixture are the high costs, poor durability, distension during solidification, the complexity of use in connection with the fact that it quickly loses fluidity and self-leveling properties (10-15 min), the impossibility of simultaneous floor devices over a large area.

Known and leveling mortar containing Portland cement as a binder, filler, excipient, stabilizing and modifying additives (lignosulphonates) and water [2].

The disadvantages of it are the high cost, lack of strength, water-holding capacity and durability (ie, fast abrasion) obtained building structures, and therefore they require additional protective coating.

Known and self-leveling mortar containing magnesia cement as a binder, filler and glass fiber [3].

The disadvantage of this mortar is a narrow range of applications as a self-leveling mix due to the presence in its composition of the filler, the specific surface of which can be indefinitely large, rapid abrasion and brittleness of the products obtained, which prevents fabrication of thin coatings, but also due to the established therein relationships ingredients, does not allow to implement the necessary mobility of the mixture and the optimal duration of the self-regulation process and the complexity of the production process of manufacturing multilayer building constructions using soundproofing devices.

The object of the invention to provide an inexpensive and simple to manufacture self-leveling mortar having optimal performance and aesthetic properties and self-leveling and extending the arsenal of compounds.

The technical result that provides a solution to this problem lies in the same time ensuring optimal mobility in the period necessary for the distribution of the mixture on a large area, high water-holding capacity and low peelability, high bond strength to concrete, simplifying and speeding up the application process and subsequent hardening, dimensional stability, dustless obtained articles having high impact resistance and abradability, expansion of the raw materials used, with minimal or no use of the most expensive components of the polymer.

The invention consists in that the leveling mortar contains particulate filler, at least one stabilizing and water-retaining additive prevents delamination mixture, an inert filler with a specific surface of 500 - 5000 cm 2 / g, and magnesia cement (as a binder) which includes a component containing active magnesium oxide and a salt component comprising at least one salt of a strong acid and a metal with a valence of two to three, at the following ratio amounts of these components:



where A - weight component comprising an active magnesium oxide (MgO);

C - weight of the salt component;

n - the number of components (salt) comprising the salt component;

m i - mass fraction of one of the salts in the component;

M i - the molecular weight of the salt (in dimensionless units), defined as the sum of the atomic weights of the elements included in the chemical formula of salt, according to the periodic table of elements (periodic table);

K 1 = 200-350 (proportionality factor);

K 2 - mass fraction of active magnesium oxide component comprising an active magnesium oxide,

and the following ratio of amounts of filler and filler component comprising an active magnesium oxide:

H i M 3 (0,85-1,85K 3) -A, (2)

where H - the weight of a filler;

K 3 - mass fraction of dust particles in the aggregate;

M 3 - weight of aggregate,

the content of the water-retaining and stabilizing additives in the mixture is 0,025-5 wt%.

Mass fraction of substance in the component (as well as the mass fraction of dust particles in the aggregate) shows what part of the mass of the substance by weight of component, if the latter is taken as a unit, and is a dimensionless quantity, weight has a corresponding dimension - ton, kilogram, and so on. d.

As the filler mixture may contain limestone, dolomite, granite or quartz sand or sand from slags, preferably of size not more than 0.5 mm.

The filler may comprise a mixture of quartz powder and / or limestone, and as a component containing an active magnesium oxide, - caustic magnesite with a mass fraction of active magnesium oxide, from 0.75 to 0.95.

As component comprising an active magnesium oxide, and the mixture may contain caustic dolomite with a mass fraction of active magnesium oxide, from 0.15 to 0.21.

The mixture may contain salt component in solid crystalline form with at least one of the following salts of strong acids and two or trivalent metal: magnesium chloride MgCl 2, ferric chloride FeCl 3, magnesium sulfate MgSO 4.

For strong acids are acids which are completely dissociated in aqueous solutions. In this case, the component contains, as salts of strong acid salts of hydrochloric and / or sulfuric acid, bivalent metal magnesium and / or ferric metal.

The mixture may contain salt component in the form of an aqueous solution density of 1.1 - 1.35 kg / l of at least one of the following salts: magnesium chloride, ferric chloride, magnesium sulphate.

The mixture may further contain a pigment in an amount of 0.5 - 3 wt% and as water-retaining and stabilizing additives - at least one of the following additives:. Methylcellulose, polyoxyethylene, hydrolyzed polyacrylonitrile (in an amount of 0.02 - 0.5 wt%. ), bentonite clay (0.5 - 5 wt%), sulfonated naftalinoformaldegidnuyu resin (0.01 - 0.3 wt%), and in addition, as modifiers - at least one of the following additives:.. sodium salt sulfonated melamine-formaldehyde resin (0.1 -. 1%), gypsum (0,2 -. 5%), polymer dispersion (PVA) - PVA (up to 3 wt.%), antifoam (0.05 - 0.3 wt.%), phosphoric acid and its salts, and as components containing active amorphous silica (3 wt.% based on active amorphous silica SiO 2).

When implementing these (generic for a wide range of starting materials), the content ratios of components is provided to obtain the desired technical result, the nature of molecular interaction salt (s), the magnesium oxide and other ingredients, and required concentration of dust particles in the solution at a predetermined surface area.

Said filler with a specific surface area contributes to the stabilization and plasticizing ordered mixture. In the case of caustic dolomite amount of filler should be minimized, since dolomite limestone contains partially replacing filler.

Stabilizing and water-retaining additive prevents delamination solution, and the loss of water from the solution in the concrete base. Peelability mortars produced according to the present invention does not exceed 10% and the water retention capacity of 90-93%, which is not achieved in the prior art mixtures. Application naftalinoformaldegidnoy sulfonated resin used in contrast to the known mixtures as stabilizing additives leads to a small air entrapment in the mixture, which increases the stability of the solution and reduces shrink stresses.

Use of components comprising an active amorphous silica (TPP entrainment zone, metallurgical slag, ground), and phosphoric acid and its salts, and enhances the water resistance of the articles of the mixture.

The use of gypsum as a builder in the mixture additionally provides increased ductility and toughness of the solidified material. Can primenyatmsya like anhydrite (CaSO 4) and semi-aquatic (CaSO 4× 0,5H 2 O) and dihydrate (CaSO 4× 2H 2 O) gypsum.

The pigments (ocher, ocher, chalk, blue, etc.) attach decorative products obtained.

Introduction PVA type polymer dispersions material serves to impart special properties (increased adhesion to smooth surfaces, water resistance, water-repellent (hydrophobic) properties.

The rate of the mobility solution, estimated by using a face breaking Suttarda viscometer, of not less than 23 cm.

The dry mixture comprising salt components in crystalline form, such as MgCl 2 (0-6) H 2 O, is supplied to produce the finished solution in packages (bags or packages), containing all the ingredients. A mixture containing the salt component in the form of an aqueous solution similarly supplied with a separate container for that component.

Self-leveling mortar is prepared as follows.

Based on the desired properties and another batch of a mixture of nomenclature available starting materials selected value of the proportionality factor K 1 and determined by said relationships (1), (2) the required quantities of ingredients.

If the amount of the filler is not specified, it is usually, calculation is conducted on 1000 kg of dry blend components, ie:

1000 = A + H + M 3 (3)

Calculated amounts of the ingredients for the next batch of the solution was charged into a special container with adding appropriate amount of water and thoroughly mixed to obtain a homogeneous mass. Mass fraction of the salt solution component in the mixture is usually not less than 0.25, a water content - not more than 22% pure magnesium chloride - less than 4% (see examples.).

Dosage ingredients can be cyclically or continuously. Dosing error shall not exceed for cementitious materials, water and additives 1% to 2% of aggregate.

The result is ready-to-use solution.

From each batch of the solution composition is taken 4 - 6 spot samples, which are combined in the overall sample, the weight of which should be sufficient for the determination of the monitored parameters.

The prepared solution should be used within one hour as it subsequently falls sharply mobility.

Test samples should be taken to begin the period of conservation normalized mobility.

Production of the floor or other structures produced by pouring the solution on the surface of the suitably prepared, with the open filling valve without anticorrosion coating is allowed.

Self-leveling mortar occurs spontaneously under the influence of gravitational forces.

In the presence of large defects (cracks, bumps, etc.), we recommend a quick stripping solution on the surface of the comb squeegee, leaving little fast leveling "scallops".

During the first day it reached 30 - 50% of the strength of the structure, which allows to move freely on the surface. Fully normalized strength and quality indicators of the hardened solution is achieved after 28 days. Thus the adhesion strength with the concrete may exceed the tensile strength of the concrete.

example 1

The composition of the self-leveling mortar.

For preparing the mixture batch charge 342 kg salt component (C = 342) is an aqueous solution of metal salts of two (n = 2) a density of 1.205 kg / l, with a mass fraction (content) of magnesium chloride, 1 part of m = 0.15 and mass concentration of ferric chloride, component 2 = 0.05 m. The molecular weight of the magnesium chloride 1 M = 95.2, the molecular weight of ferric chloride M 2 = 164.2.

Proceeding from the required compressive strength of 25 MPa and a predetermined thickness of the product (couplers) 3.10 mm is chosen value K 1 = 260.

As component comprising an active magnesium oxide used caustic magnesite with a mass fraction of active magnesium oxide K 2 = 0.83.

By substituting the equation (1) indicated values of design parameters K 1,2, C, m 1,2, M 1,2 ( n = 2), after performing arithmetic operations on the needs of caustic magnesite mass A = 208 kg.

As the filler used quartz sand with grain size up to 0.5 mm, and a mass fraction of fines 3 K = 0.017, and as filler - silica dust with a specific surface of 2000 cm 2 / g.

The amount of filler (in this case, it is not set), and the amount of filler are determined by solving a system consisting of the relations (2) and (3), resulting in solutions which in this case is the aggregate weight of M = 3 536.8 kg, the mass of filler H = 247,2 kg.

As additives taken methylcellulose 1.49 kg, 5.96 kg of plasticizer, antifoam 1.79 kg (fish oil).

Mass fraction of salt component in this embodiment, the composition of the mixture is 0.289, a water content - 21.4%, content of pure magnesium chloride - 4%.

The following are examples 2, 3, 4 of the mixture as defined in Example 1.

example 2

For making the party mix take 287.5 kg of 15% magnesium chloride solution -protsentnogo density of 1,149 kg / l, 209.1 kg of caustic magnesite with a mass fraction 0.83 magnesium oxide, 522.6 kg of quartz sand grain size 0,1 - 0, 5 mm, 261.3 kg of silica dust with a specific surface area of 500 - 5000 cm 2 / g, 1 kg naftalinoformaldegidnoy sulfonated resin 5 kg superplasticizer (sodium salt of sulfonated melamine-formaldehyde resin) and 1 kg of antifoam (fish oil). Mass fraction of salt component of the solution is 0.287, the water content - 19% pure magnesium chloride - 3.3%.

This mixture is considered to be the base and has a hardness of 25 MPa after 7 days from the beginning of solidification.

example 3

For making the party mix take 292.8 kg of 15% magnesium chloride solution -protsentnogo, 213.0 kg of caustic magnesite with a mass fraction 0.83 magnesium oxide, 21.3 kg of plaster, 510.1 kg of quartz sand, quartz 239.6 kg dust, 1 kg naftalinoformaldegidnoy sulfonated resin 5 kg superplasticizer (sodium salt of sulfonated melamine-formaldehyde resin) and 1 kg of antifoam (fish oil). Mass fraction of salt component of the solution is 0.293, the water content - 19% pure magnesium chloride - 3.4%.

This mixture has a higher elasticity and the same strength characteristics of Example 1.

example 4

For making the party mix take 351.1 kg of 15% magnesium chloride solution -protsentnogo, 780.3 kg of caustic dolomite with a mass fraction 0.21 magnesium oxide, 200.2 kg of quartz sand (grain size up to 1.5 mm), 3.5 kg quartz dust, 1 kg naftalinoformaldegidnoy sulfonated resin 5 kg superplasticizer (sodium salt of sulfonated melamine-formaldehyde resin), 1 kg of antifoam (fish oil) and 20 kg of the pigment (ocher). Mass fraction of the salt component of the solution is 0.334, a water content - 22% pure magnesium chloride - 4%.

This mixture is both decorative and economical, as a component containing an active magnesium oxide, dolomite used caustic, and has a hardness of 15 MPa after 7 days from the beginning of solidification.

Only in the presence of the totality of the necessary features of the present invention simultaneously provides optimum mobility for the period necessary for the distribution of the solution on a large area, high water-holding capacity and low peelability solution mixture, high strength of its adhesion to the concrete, to simplify and accelerate the process of its application and subsequent hardening , dimensional stability, free from dust produced articles having high impact resistance and abradability with minimal or no use of the most expensive components of the polymer.

Reducing the cost of the latter significantly exceeds the increase in the cost of magnesia binder, compared with Portland cement.

We have now been developed and tested in practice various embodiments of a self-leveling mortar performance.

The test results confirmed the receipt of the above-mentioned technical result of the invention and willingness to industrial production.

INFORMATION SOURCES

1. SU N 1231177, 1986.

2. SU N 1470713, 1989.

3. WO N 98/55419, 1998 (prototype).

CLAIM

1. Self-leveling mortar containing particulate filler, an inert filler having a specific surface area of 500 - 5000 cm 2 / g and at least one water-retaining and stabilizing additive mixture prevents delamination, and a magnesia cement, which includes a component containing active oxide magnesium, and a salt component comprising at least one salt of a strong acid and a metal with a valence of two to three, at the following ratio amounts of these components



where A - weight component comprising an active magnesium oxide;

C - weight of the salt component;

n - the number of components (salt) comprising the salt component;

m i - mass fraction of one of the salts in the component;

M i - molecular weight of the salt;

K 1 = 200 - 350;

K 2 - mass fraction of active magnesium oxide component comprising an active magnesium oxide,

in the following ratio and amount of aggregate, filler and a component containing an active magnesium oxide

H i M 3 (0,85 - 1,85 K 3) - A

where H - the mass of filler;

K 3 - mass fraction of dust particles in the aggregate;

M 3 - weight of aggregate,

the content of the water-retaining and stabilizing additives in the mixture is 0.025 - 5 wt.%.

2. A mixture according to claim 1, characterized in that it comprises as filler quartz, limestone, dolomite or granite sand or slag sand grain size of not more than 0.5 mm.

3. A mixture according to claim 1 or 2, characterized in that it comprises as filler quartz powder and / or limestone, and as a component containing an active magnesium oxide, - caustic magnesite with a mass fraction of the active magnesium oxide of 0, 75 to 0.95.

4. A mixture according to claim 1 or 2, characterized in that the component containing an active magnesium oxide, dolomite, caustic it contains a mass fraction of active magnesium oxide, from 0.15 to 0.21.

5. A mixture according to claim 3 or 4, characterized in that it comprises a salt component in solid crystalline form with at least one of the following salts, magnesium chloride, ferric chloride, magnesium sulphate.

6. A mixture according to any one of claims 1 - 4, characterized in that it comprises a salt component in an aqueous solution density of 1.1 - 1.35 kg / l of at least one of the following salts: magnesium chloride, ferric chloride, sulfate magnesium.

7. A mixture according to any one of claims 1 - 6, characterized in that it further comprises a pigment in an amount of 0.5 - 3 wt%, wherein as water-retaining and stabilizing additive it contains at least one of the following additives:. Methylcellulose polyoxyethylene, hydrolyzed polyacrylonitrile, bentonite clay, sulfonated naftalinoformaldegidnuyu resin, and as modifying additives at least one of the following additives: sodium salt of sulfonated melamine-formaldehyde resins, gypsum, polymer dispersion (PVA) - PVA, defoamer, phosphoric acid and its salts, and and components comprising the active silica.

print version
Publication date 06.04.2007gg