【発明の詳細な説明】[Detailed description of the invention]
本発明は耐摩耗性、防じん性及び耐候性に優れ
たセメント系の耐摩耗性の塗床仕上材組成物、及
びその製造法に関する。
一般に建築物の床材料として、セメントコンク
リートもしくはセメントモルタルが多く用いられ
ているが、とりわけ超重量物の搬出入や、車輌、
歩行者の頻繁に往来する道路及び床面に上記通常
のコンクリート施工する場合比較的短期間に表面
のヒビワレ、破損、骨材の露出、粉じんの発生を
もたらし、建造物の保安及び衛生上の重大な欠陥
が指摘されている。例を挙げれば、重量物の搬出
入倉庫や工場、往来の激しい車輌道路、駅のプラ
ツトホーム、航空機の滑走路、学校、ビル等の公
共建造物の床面等頻繁かつ高負荷荷重のかかる一
般床面等が、この問題の対象になつている。
この様な障害を解決するため高密度、高強度の
特殊な骨材を用いるいわゆる高強度コンクリート
を利用する方法もあるが、著しく高価になるの
で、一般的目的にはコンクリートの施工表面に数
ミリないし数センチの特殊な耐摩耗性の床材を塗
布密着させる方法が採られている。
本発明の目的は、従来品に比し耐衝撃、耐摩耗
性、防じん性、耐候性において大幅に改良され、
かつ安価で施工法に優れた耐摩耗性床材の製造法
を提供することにある。
かような耐摩耗性床材としては、セメント及ぼ
特殊な骨材より成る主材に適宜、改質剤、充填
剤、色材等を添加配合してなる組成物が一般に使
用されているのが床材としての機能を発揮させる
上で骨材の選択がもつとも重要であり、床材の性
能を大きく左右する。
従来の耐摩耗床材にもつとも多く利用されてい
る骨材として鉄鋼片、鉄粉、鉱物粒、シリカ系硬
質骨材、炭化ケイ素等、金属系とシリカを主体と
した鉱物系に大別することができる。これらの
内、鉄金属を骨材として用いるものは機械強度が
高く、一般に高荷重の摩耗に耐えるものであるが
化学的に不安定である欠点がある。特に摩耗によ
つて露出した鉄の表面が外界の空気や水分に曝さ
れ、容易に酸化鉄や水酸化鉄を生じ、いわゆる錆
の原因となり、外観を著しく損ね耐久性に問題が
生じる。一方天然の鉱物粒子や、シリカ系の合成
骨材は一般に密度が低く機械強度が低いので高荷
重用床材の骨材としては不適である。
本発明者らは従来の耐摩耗性床材にみられる諸
欠点を改善すべく検討した結果骨材としてリンと
鉄の合金を使用することによつて化学的に容易に
変質せず機械強度の高い汎用目的に供し得る耐摩
耗床材を製造しうることを見出した。一般にフエ
ロホスホルとして知られるリン鉄は快削鋼や鋳鉄
用の添加剤として製鋼業界で広く利用されている
ものであり、製リン電気炉より副生物として排出
するものが市販されているが、本発明ではこれに
限定されず他の方法によつて製造されるリン−鉄
の合金をも対象としうる。
本発明の骨材として使用しうるリン鉄の組成
は、日本工業規格でFP1の記号で規定されている
リン含量が20〜28重量％のものが適当である。
本発明は骨材としてのリン鉄及び結合材として
のセメントを配合して成る組成物が不可欠の要件
であるが、この主組成物に適宜、品質改良剤、増
量剤、色材等を添加混入させることができる。か
ようにして得られる組成物完成品の中に含有せし
めるリン鉄の量は、その粒形や粒度分布によつて
多少変動するが50〜80重量％の範囲が適当であ
る。50％より低い範囲では耐摩耗性、強度ともに
低下し目的とする効果が充分得られず、又80％よ
り高い範囲では必然的に結合剤としてのセメント
量が減少するので結着力、及び基材との接着力の
低下をもたらし骨材粒が表面に露出するので、外
観および施工性を損う。
耐摩耗床材に使用される骨材は一般のセメント
コンクリートと異り基礎コンクリートスラブ表面
に数ミリないし数センチの薄層で塗床仕上げされ
る場合が多いのでこの塗床厚より著しく大きい寸
法の粒子は不要である。この観点で本目的に使用
するリン鉄粒子最大寸法は塗床幅の３倍〜1/2の
範囲に抑へるのが適当である。又骨材としての粒
径分布は特に制限はないが一般の耐摩耗目的に使
用する場合は、0.15ｍ／ｍ以下の微粒子を除き、
なるべく空隙率が低くなるような粒度分布に調整
するのが強度及び耐摩耗性の点で望ましい。又必
要に応じて従来の鉱物質骨材等をも併用添可しう
る。
本組成物に使用しうるセメントは各種のポルト
ランドセメント、アルミナセメント、高炉セメン
ト、フライアツシユセメント等、通常の土木、建
築素材として使用されるあらゆるセメントに亘
り、骨材としてのリン鉄は化学的に極めて安定な
物質であるので特にアルカリ度の高いセメントよ
り溶出するアルカリ分や他の腐食性物質によつ
て、酸化溶解など変質することがない。完成品の
中のセメントの適正配合割合は、使用するセメン
トの種類や骨材の粒度分布、施工目的等によつて
幾分変動するが、通常20〜50重量％の範囲が望ま
しい。
上記の如く、不可欠的に配合された骨材とセメ
ントより成る主材に対し必要に応じて通常のコン
クリートに使用される混和材料としてAE剤、分
散剤、着色剤、凝結促進もしくは遅延剤、増量材
等が挙げられるが本目的に於いてはとりわけ着色
剤、AE剤、及び分散剤が重要である。
一般に耐摩耗床材はコンクリート基礎面に対す
る化粧仕上げの目的を兼ねさせることが多く、又
危険作業を伴う工場に施工されることが多いので
安全色に着色した床面が望まれる。この目的で緑
色系の酸化クロム、赤色系のベンガラ等を適宜配
合しうる。薄幅の塗床仕上げの場合、床面の耐久
性や、ワーカビリチーが好適な施工面の成否に大
きな影響を与える。ワーカビリチーを向上させる
のにAE剤を又ワーカビリチーとともに強度向上
を期待して、減水作用を有する分散剤をも添加可
能であり、いずれも一般に市販されているもので
充分目的を達しうる。
本発明に係る耐摩耗床材は従来知られている各
種方法によつて施工しうるがとりわけ塗床仕上げ
に供する場合、モノリチツク工法として知られる
打設直後のコンクリートスラブ面へ直接塗床する
方法、又トツピング工法として知られるモルタル
打設と同時に塗床する方法等いずれによつてもよ
く、施工時に必要な練り混ぜ水の量や塗床厚み等
はそれぞれ使用目的、気候条件等に応じ適宜加減
できる。本組成物で施工された床面には耐久性、
強度、耐摩耗性、接着性、耐候性等の点で数多く
の特徴がみられる。即ちJIS A1108によつて圧縮
強度を測定したところ最高740Kg／cm2、
JIS A1453による耐摩耗性試験においては摩耗
指数６×10-3mg／mm2と従来品にみられない強度と
耐摩耗性が観察された。又、塩水浸漬下における
腐食試験においても、鉄鋼を骨材とするものにみ
られる発錆現象は全くみられない。
本材を用いた実際の施工現場における長期荷重
試験では粉じんの発生は全くなく終始美麗な表面
を保ち優れた耐油水、耐薬品性を示すことが確認
された。
以下実施例によつて具体的データを示す。
実施例
Γ試料の作製
表の実施例および比較例の各No.に示す配合組成
（部）になるように結合材、骨材、及び助剤を配
合、リボンミキサーを用いて１時間混和しNo.に示
す各組成の混合物を１Kgづつ作製した。
Γ試験方法
(1) JIS A1453による摩耗試験
ポルトランドセメント（１部）豊浦標準砂
（３部）水（0.7部）よりなるモルタルを径100
mmの円筒枠内に打設、厚さ４mm円盤状となし表
面水が引た後、上記試料をふりかけ、トツピン
グ工法によつて該基礎モルタル層の上にさらに
２mmの耐摩耗層を形成させた。48時間後型枠よ
り取り出し水中養生48時間後17日間に気乾養生
したものをJIS A1453記載の方法で摩耗減量を
測定した。
(2) 圧縮強さ試験
上記試料100部と水20部を混合し得られたコ
ンクリート床材を21×21×35mmの型枠で成型し
24時間で除枠、27日間気乾養生後圧縮強さを測
定した。
(3) 落球試験
長さ300mm幅300mm高さ90mmのコンクリートス
ラブ上面にモノリチツク工法により上記試料を
厚さ３mmの耐摩耗層を形成させ、28日間気乾養
生後に重量3.9Kg鉄球（径98mm）を2.85ｍの高
さより該塗床面に自然落下させ、衝撃によつて
生じた凹みの径を測定した。
(4) 塩水試験
摩耗指数を測定した後の試片を３％食塩水溶
液に72時間浸漬後24時間空中に放置し、表面の
腐食、発錆状態及び食塩水の汚染状態を観察し
た。
上記(1)〜(4)の試験の結果を表に一括して示す。
これらの結果より本発明の方法によつて得られ
た試片は従来法によるものに比較し耐摩耗性、強
度、耐食性ともに格段に優れていることが判明し
た。
The present invention relates to a cement-based abrasion-resistant floor finishing composition having excellent abrasion resistance, dust resistance, and weather resistance, and a method for producing the same. Generally, cement concrete or cement mortar is often used as a floor material for buildings, but it is especially used for carrying in and out of extremely heavy objects, vehicles,
When the above-mentioned ordinary concrete construction is performed on roads and floors that are frequently visited by pedestrians, cracks and damage to the surface, exposure of aggregate, and dust generation occur in a relatively short period of time, which is a serious problem for the security and hygiene of buildings. defects have been pointed out. Examples include warehouses and factories carrying heavy goods, roads with heavy traffic, station platforms, aircraft runways, schools, floors of public buildings such as buildings, and other general floors that are subject to frequent and high loads. This problem has become a target for many areas. In order to solve this problem, there is a method of using so-called high-strength concrete that uses a special aggregate with high density and high strength, but it is extremely expensive, so for general purposes it is recommended to use only a few millimeters of concrete on the construction surface. The method used is to apply a special wear-resistant flooring material that is several centimeters thick. The purpose of the present invention is to significantly improve impact resistance, abrasion resistance, dust resistance, and weather resistance compared to conventional products.
Another object of the present invention is to provide a manufacturing method for a wear-resistant flooring material that is inexpensive and has an excellent construction method. Generally used as such wear-resistant flooring materials are compositions made by adding modifiers, fillers, coloring materials, etc. as appropriate to the main material consisting of cement and special aggregates. The selection of aggregate is extremely important in achieving its functionality as a flooring material, and greatly influences the performance of the flooring material. Aggregates that are commonly used in conventional wear-resistant flooring materials include iron and steel pieces, iron powder, mineral grains, silica-based hard aggregates, and silicon carbide, and can be roughly divided into metal-based materials and mineral-based materials that mainly contain silica. Can be done. Among these, those using ferrous metal as aggregate have high mechanical strength and can generally withstand wear under high loads, but have the disadvantage of being chemically unstable. In particular, the exposed iron surface due to wear is exposed to outside air and moisture, easily producing iron oxide and iron hydroxide, which causes so-called rust, which significantly impairs the appearance and causes problems in durability. On the other hand, natural mineral particles and silica-based synthetic aggregates generally have low density and low mechanical strength, so they are unsuitable as aggregates for high-load flooring materials. The inventors of the present invention investigated ways to improve the various drawbacks of conventional wear-resistant flooring materials, and found that by using an alloy of phosphorus and iron as aggregate, the material does not change easily chemically and has improved mechanical strength. It has been found that it is possible to produce a wear-resistant flooring material that can be used for highly versatile purposes. Iron phosphorus, commonly known as ferrophosphor, is widely used in the steelmaking industry as an additive for free-cutting steel and cast iron, and products that are discharged as a byproduct from electric phosphorus furnaces are commercially available, but the present invention However, the present invention is not limited thereto, and may also be applied to phosphorus-iron alloys produced by other methods. The suitable composition of the iron phosphorus that can be used as the aggregate of the present invention is one having a phosphorus content of 20 to 28% by weight as defined by the symbol FP1 in the Japanese Industrial Standards. The essential requirement of the present invention is a composition containing iron phosphorus as an aggregate and cement as a binder, but quality improvers, fillers, colorants, etc. are added to this main composition as appropriate. can be done. The amount of iron phosphorus contained in the finished composition thus obtained varies somewhat depending on its particle shape and particle size distribution, but is suitably in the range of 50 to 80% by weight. If the range is lower than 50%, both abrasion resistance and strength will decrease, and the desired effect will not be achieved sufficiently, and if the range is higher than 80%, the amount of cement as a binder will inevitably decrease, so the binding force and the base material will decrease. This results in a decrease in adhesion with the aggregate and exposes the aggregate particles to the surface, impairing the appearance and workability. Unlike general cement concrete, the aggregate used for wear-resistant flooring is often coated on the surface of the foundation concrete slab in a thin layer of several millimeters to several centimeters, so the aggregate used for wear-resistant flooring is often coated with a thin layer of several millimeters to several centimeters, so the aggregate used for wear-resistant flooring is No particles are required. From this point of view, it is appropriate that the maximum size of the iron phosphorous particles used for this purpose be within the range of 3 to 1/2 times the width of the coated floor. There is no particular restriction on the particle size distribution as aggregate, but when used for general wear resistance purposes, excluding fine particles of 0.15 m/m or less,
In terms of strength and wear resistance, it is desirable to adjust the particle size distribution so that the porosity is as low as possible. Further, conventional mineral aggregates and the like may also be added as needed. The cements that can be used in this composition include various types of Portland cement, alumina cement, blast furnace cement, and fly ash cement, all of which are commonly used as civil engineering and construction materials. Since it is an extremely stable substance, it will not undergo oxidation, dissolution, or other deterioration due to alkalinity or other corrosive substances that are leached from cement, which has a particularly high alkalinity. The appropriate blending ratio of cement in the finished product varies somewhat depending on the type of cement used, the particle size distribution of the aggregate, the purpose of construction, etc., but it is usually desirable to be in the range of 20 to 50% by weight. As mentioned above, in addition to the main material consisting of aggregate and cement, which are essentially blended, admixtures such as AE agents, dispersants, colorants, setting accelerators or retarders, and additives used in ordinary concrete are added as necessary. Colorants, AE agents, and dispersants are particularly important for this purpose. In general, abrasion-resistant flooring materials often serve the purpose of decorative finishing on concrete foundation surfaces, and are often constructed in factories that involve dangerous work, so a floor surface colored in a safe color is desired. For this purpose, green chromium oxide, red red iron oxide, etc. may be appropriately blended. In the case of thin-width painted floors, the durability and workability of the floor surface have a major impact on the success or failure of suitable construction surfaces. It is possible to add an AE agent to improve workability, and also a dispersant with a water-reducing effect in the hope of improving workability and strength, and any of these agents, which are generally commercially available, may be sufficient to achieve the purpose. The wear-resistant flooring material according to the present invention can be constructed by various conventionally known methods, but in particular, when it is to be used for floor coating finishing, there is a method known as the monolith construction method in which the flooring is directly coated on the surface of a concrete slab immediately after pouring; Alternatively, any method such as the topping method, in which the floor is coated at the same time as mortar is poured, may be used, and the amount of mixing water required during construction, the thickness of the coated floor, etc. can be adjusted as appropriate depending on the purpose of use, climate conditions, etc. . Floors constructed with this composition have excellent durability and
It has many characteristics in terms of strength, abrasion resistance, adhesion, weather resistance, etc. In other words, the maximum compressive strength measured according to JIS A1108 was 740 Kg/cm 2 , and the abrasion index was 6 × 10 -3 mg/mm 2 in the abrasion resistance test according to JIS A1453, which shows strength and abrasion resistance not found in conventional products. was observed. In addition, even in a corrosion test under salt water immersion, no rusting phenomenon that is observed in steel aggregates was observed. In long-term load tests using this material at actual construction sites, it was confirmed that no dust was generated, the surface remained beautiful from start to finish, and it exhibited excellent oil, water, and chemical resistance. Specific data will be shown below using Examples. Preparation of Example Γ Sample Blend the binder, aggregate, and auxiliary agent to the composition (parts) shown in each No. of the Example and Comparative Example in the table, and mix for 1 hour using a ribbon mixer. 1 kg of each mixture with the composition shown in . was prepared. Γ test method (1) Abrasion test according to JIS A1453 A mortar made of Portland cement (1 part), Toyoura standard sand (3 parts), and water (0.7 parts) with a diameter of 100
It was poured into a 4 mm thick cylindrical frame, and after the surface water had subsided, the above sample was sprinkled on it and an additional 2 mm wear-resistant layer was formed on top of the basic mortar layer using the topping method. . After 48 hours, the pieces were removed from the formwork, cured in water for 48 hours, and then air-dried for 17 days.The abrasion loss was measured using the method described in JIS A1453. (2) Compressive strength test The concrete floor material obtained by mixing 100 parts of the above sample and 20 parts of water was molded in a 21 x 21 x 35 mm formwork.
The frame was removed for 24 hours, and the compressive strength was measured after air-drying for 27 days. (3) Falling ball test A wear-resistant layer with a thickness of 3 mm was formed using the above sample using the monolith construction method on the top of a concrete slab with a length of 300 mm, a width of 300 mm, and a height of 90 mm, and after air-drying for 28 days, a 3.9 kg iron ball (98 mm diameter) was allowed to fall naturally onto the coated floor surface from a height of 2.85 m, and the diameter of the dent caused by the impact was measured. (4) Salt water test After measuring the abrasion index, the specimens were immersed in a 3% saline solution for 72 hours and then left in the air for 24 hours to observe surface corrosion, rusting, and salt water contamination. The results of the tests (1) to (4) above are collectively shown in the table. These results revealed that the specimens obtained by the method of the present invention were significantly superior in wear resistance, strength, and corrosion resistance compared to specimens obtained by the conventional method.
【表】【table】
【表】【table】