Note: Descriptions are shown in the official language in which they were submitted.
- Z~ 4~32
The present invention relates to the reconstruction of sur~aces
found in civil engineering, in particular damaged road surfaces,
roofing surfaces, and surfaces such as terraces, in the
residential area.
The most varied methods have been used in order to rehabilitate
road surfaces, primarily in garages. In practice, this has been
done by grinding of~ the damaged areas of the surface with
subsequent reapplication of bonding coats which, because of their
mechanical properties, must be applied at a minimum thickness o~
several centimeters. Insofar as sufficient load bearing capacity
is provided, poured asphalt is applied, this being done without
any loss of thickness caused by grinding. The disadvantages of
this are the plastic deformability under constant load and
vulnerability to crude oil derivatives. In the case of damage
that does not ~xtend deep into the substance, these can be
recoated to a thickness of a ~ew centimeters with a binary bonded
plastic mortar. The disadvantages of this are impermeability to
gas and the danger of slipping or skidding, particularly when the
surfaoe is wet. Common to all of these systems, however, is the
disadvantage, which can be attributed to mechanical
circumstances, that cracks cannot be filled without breaking the
coating. ; -
The profile damage done in multi-storey parking garages is
characterized, in particular, by damages to the road surfaces and
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by cracks in the supporting structure, which can result in damage
being done to the finish of vehicles parked within the structure,
because rain water can leach salts out of the concrete and after
evaporation these can remain on the painted surface of the
vehicles as residues, insoluble in water, after evaporation.
One is confronted by similar problems when reconstructing
surfaces in the residential area, in particular during
reconstruction of roof surfaces and terraces. In practice, it
has been found that in special flat roof surfaces there will be
leaks in hidden places. These are caused by aging, mechanical
damage, or defective installation; very frequently, plastic or
bitumen strips or galvanized sheet metal strips are used for such
purposes. In contrast to this, terrace reinforcements consist as
a rule, of horizontal insulation, with a cement coating or tiles
or concrete slabs laid in a thin mortar bed on the installation,
serving as wearing layers.
Up to now, in order to reconstruct damage of this sort it has
always been necessary to remove the old material; this causes not
only very high labour costs, but also means that the site is
exposed to the weather for a long period while it is unprotected.
Further disadvantages of the known hydraulically bound systems
and bitumen bound structural materials are the required minimum
coating thickness of several centimeters, the associated ~;
increased surface loads, the need to raise drains to the new `-
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level, etc. All of these measures, primarily during the
rehabilitation o~ horizontal moisture installation, require that
the surface remain unused for a certain amount of time. During
the reconstruction of travelled surEaces, as well as in the
residential area, such as in the case of flat roofs and terraces,
it would, for this reason, be desirable to have available systems
that can be reused immediately after they have been laid.
In order to solve this problem, the present invention proposes a
reconstruction system for surfaces, in particular for road
surfaces, roofing surfaces, and terraced surfaces, this havin~ an
insulating layer and a wearing layer, the insulating layer being
built up in the manner Xnown per se from an adhesive that is
permanently elasto-plastic, and the wearing layer that is applied
above this that is made up of pre-fabricated wearing panels,
these consisting of wear resistant mono-grain or mixed grain
mixture that is bonded with a weather resistant, water-vapour
permeable bonding agent, and which is free of fine particles of
less than 0.3 mm.
According to one embodiment of the reconstruction system
according to the present invention, the wear resistant mono-grain
is only imbedded in part in a bed of weather resistant bonding
agent, whereas the part of the useful surface of the wearing
panel that is free of binding agent, forms the useful surface of
the wearing panel, for example, a traffic surface.
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The reconstruction system according to the present invention can,
in practice, be used as follows:
In a first step, after the usual cleaning of the sub-surface, for
example by high pressure water jets or sand blasting, an
insulating layer which, after hardening in the useful temperature
range of ~80C to -40C, and thus under all temperature
conditions encountered in practice, will remain permanently ~ `
elastoplastic and fill in cracks, is applied. The re~uired
permeability to water vapour is provided as a consequence of the
special structure of the insulating layer, in particular of the
ratio of plastic to hydraulic bonding agent.
In a second step, finished panels with a specially configured
surface are laid in this insulating layer that is impermeable to
water and which bridges cracks. These pre-fabricated wearing
panels consist, according to one embodiment of the present
invention, of aggregates, grain on grain, the bonding of which is ;
only affected up to a part of the grain diameter, for example, up ~;-
to approximately 60% of the diameter, using a weather resistant
bonding agent of binary synthetic resin or thermoplasts.
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The surface that has been reconstructed, for example a traffic
surface, can be used immediately after the pre-fabricated wearing
panel has been imbedded. The required non-skid properties are
ensured since the travelled surface consists exclusively of grain
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on grain, without any bonding agent. In addition, water
permeability can be controlled to the desired extent by the
structure of the bonding agent and by the small thickness of the
wearing layer.
In contrast to formerly known, purely hydraulically hardened
systems, which cannot be disturbed by pressure or vibration
during hydration, the reconstruction process according to the
present invention is entirely unaffected in this regard.
According to a further embodiment of the present invention, the
pre-fabricated wearing panel is formed from a wear resistant
grain mixture that is free of fine fractions of less than 0.3 mm
and is bonded by a weather resistant, water permeable binding
agent. The grain in these wearing panels is enclosed by the
binding agent system. Wearing panels of this type are especially
suitable, for example, for reconstructing terraces and balconies
in residential accommodation.
The present invention will be described in greater detail below
on the basis of the examples that follow.
EXAMPLE l:
The sub-surface is 15 year-old concrete, grade B 400, that has
been removed so as to form grooves, to a depth of 1 cm by tire
2~0~
studsand additionally damaged in the form of plate-sized shell-
like spalling caused by frost.
In a first stage of the process, the surface is cleaned with a
high pressure water jet without any damage being done to the
structure of the concrete. In a second step, the areas of the
plate-sized spalling are filled with filling mortar modified with
conventional plastic dispersion. Once this filling mortar
hardens cement and 1 part by weight plastic dispersion, with a
gamma value o~ 1.6 at a thickness of 2 mm is applied as a
horizontal moisture installation. In order to increase
elongation at break, an alkaline-resistant textile mat of 300 ~;
gr/m2 is installed. The plastic dispersion that is used has ;
elasto-plastic properties, is permanently adhesive, and has a
T~AX~ determined according to DIN 53.445, of -40C. ;
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The hardened mixture, with a weight ratio of 1:1 consisting of
cement and dispersion remains permanently elastoplastic over a
wide temperature range, even at -20C, and is permanently
adhesive. Because of the high proportion of plastic--the
dispersion is 60% with regard to the solid content--the adhesive
properties are always reactivated under dynamic pulsating
loading.
In the final stage of the process, the pre-fabricated wearing
panels (see below) are installed. The bond is effected by
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adhesion and is so great that in shear tests, separation occurred
in the old concrete by the uppermost concrete layer shearing off.
The residual elastoplasticity of the insulating layer equalized
crack movements of the sub-structure, even at low temperakures,
as a function of the overall thickness of the adhesive at 2 mm
thick by 0.4 mm, without the wearing panel suffering any damage.
The pre-fabricated wearing panels used in the above example were
produced in the following manner:
A glass lattice fabric, with a mesh size of 4 mm, was spread with
diabase chips at a grain size of 3/5 mm. This resulted in the
required surface, grain on grain.
After this preparation, which brought about a positive
orientation of the aggregate, the binding agent, an intrinsically
plasticitized binary synthetic resin system based on an epoxy
resin was so applied that the aggregate was imbedded in the
binding agent only to approximately 70% of the grain diameter.
In the gel state, which is to say before the binding agent
hardened, the resin was punctured as far as the grain using a
needle plate, which made penetration by water possible. After
hardening, the panels were cut to a size of 50 x 50 cm.
2~
EX~MPLE 2:
The concrete of a freely weathered terrace corresponds to a
concrete quality of B 225, and this was weathered to a depth of
mm by frost and, as a consequence of elasto-plastic deformations,
contained cracks across the whole width between the ~upporting
columns. The cracks are between 0.5 and 0.2 mm wide.
:
The insulating layer was applied after pretreatment, as described
in Example 1, although without any filling of the rough
structure. In contrast to Example 1, the mixing ratio of the
insulating layer amounts to 1 part-wt of cement, 1 part-wt of
pure acrylate dispersion, with the same characteristics as in
Example 1, and 1 part by weight sand, with a grain size of 0.1 to
3 mm. ~he inert filler was so selected in order to fill the
holes; in addition, the mechanical properties, namely a reduced
shear strength because of the use of the sand, were adequate for
the intended purpose, which was to make the terrace suitable for
pedestrian traffic.
It is true that the insulating layer is significantly harder than
that in Example 1, but it can still be bent over the bar at -20C
and first fractures at 60 at a test temperature of -20C.
Including the cavity filling, the thickness over the tips was
still 2 mm, and a textile mat was only installed in the area of
the cracks, with an overlap of 20 cm on both sides.
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Before the hydraulic reaction, whic,h is to say within 2 hours,
the pre-fabricated wearing panels w~ere pressed into place with a
joint width of 3 mm; the joints remain unfilled.
The following wearing panels were used in this example:
Using the same methods as described in Example 1, the aggregates
were oriented, although here with a modified maximum grain,
namely an aggregate of 1/3 mm (mesh width of the textile, 2 mm).
The bonding agent consists of cement and water-emulsified binary
synthetic based on epoxy resin, in a weight ratio of 1:1, and
dried guartz sand with a grain size of 0.1/3 mm was used as a
filler. As a consequence of the hydraulic components, the
bonding agent layer remains permeable to water.
The imbedding of the aggregate in the bonding agent was effected
to approximately 70% of the grain diameter.
Further production of the panels took place as in Example 1.
EXAMPLE 3:
The exposed and weathered parking area on the top storey.
The travelled surface has been mechanically destroyed because of
great deformation under load and widely spaced supporting
columns, particularly in the area of the gaps; the gap,
originally 2 cm wide, had grown to 4 to 5 cm wide because of 45
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spalling; numerous cracks could be seen on the surface. During
rain, water ran through gaps and crzlcks into the next floor down.
The surface is prepared by sand blasting. All of the joints were
ground out to a width of 10 cm and to a depth of 1 cm. The moist
insulation is then sprayed on to a thickness of 3 mm, and
reinforcement was installed in this. The reinforcing mat is laid
along the ground out trough with a loop that falls downwards into
the actual joint, so that continuous insulation was formed. This
means that three-dimensional deformations do not lead to the
destruction of the insulation in the joints.
After a hardening period of approximately 24 hours, the same
mixture of cement and plastic dispersion (ratio 1:1) was mixed
with 2% colloidal silicic acid: this resulted in thixotropy. The `~ -
insulating layer is applied with a notched spatula (dimension 4
mm) and the pre-fabricated wearing panels were pressed into
place. By pressing in at a 4-mm notch height, after pressing the
insulating layer was 2 mm thick. The wearing panel was displaced
by 4 mm to the ground-out joint trough, the height of th2
finished panel amounts to approximately 5 mm, grain on grain,
diabase stone chips 3 to 5 mm.
The step in the area of the joints, is approximately 11 mm high
and 9 cm wide, allowing for the continuous insulating layer. A
pre-fabricated wearing panel, based on the same principle of
4~3
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grain on grain, although with a grain size of 8 to 12 mm, 8 cm
wide and approximately 12 mm high and 1 m long was pressed into
the mould case. This was done to achieve a high level of
mechanical stability because of the great thicXness and because
of the narrow joint width to the two [adjoining surfaces], and
relatively easy removal in the event of damage to the joint
insulation area, which could occur if the concrete panels shift
because of temperature and deformation under load, to the point
that they come into contact with each other.
The pre-fabricated wearing panels were produced analogously by
the same method as set out in Example 1. With the same
orientation of the aggregate of diabase chips, the binder
consists of a binary synthetic resin on a polyurethane base, with
the addition of filler of 0/1 mm in a weight ratio of 1:1. No
punturing was carried out in this case.
The wearing panel for filling the ground-out trough consist of ~-~
diabase grain 8/12 mm. In this case, because of the grain size, -
orientation of the aggregate could be achieved on a level;panel
with no problems. A thixotropic elastic polyester resin, which
was, however, brittle after hardening, was used at a weight ratio ~-
of 1 part-wt binding agent and 2 parts-wt of filler with a grain
size of 0.1/3 mm was used as the binding agent.
EXAMPLE 4:
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A flat roof, the concrete is of B 300 quality and which had been
insulated against moisture 10 years previously using welded
bitumen strips. Concrete stepping stones led to the individual
skylights and these were supported on their edges on rubber
pedestals measuring approximately 10 x 10 cm. Oxidation had
caused the bitumen strips to crack and become non-elastic. The
edges of the stepping stones had become stuck in the edges and
had in part broken away. Once the finish panels had been cleared
away, the bitumen strip insulation was left in place.
In order to fix the dust, 1 part-wt of cement : 1 part-wt plastic
dispersion were mixed with 3 parts-wt water and brushed on. The
moisture insulation layer was then applied in two stages when, in
each instance, an alkali resistant reinforcing mat of 450 gr/m2
weight was imbedded. The overall thickness amounts, on average,
to 5 mm.
After hardening for 24 hours at 18C, the foot paths were laid
using pre-fabricated wearing panels, set in an adhesive bed of
the same material.
In order to form the pre-fabricated wearing panels, aggregate
with a grain size of 5/8 mm was spread in one layer, when the the ;
grain was preventecl from rolling off by means of a frame
measuring 4 x 4 m.
2 0106~9~
Thixotropic, elastic binary synthetic resin based on a
methacrylate was used as the binding agent. The degree of
filling amounts to 1 part-wt binderr 0.5 parts-wt sand with a
grain size of 0.1 mm, and 3 parts-wt colloidal silicic acid. The
aggregate was imbedded into the bonding agent to approximately
70% of the grain diameter.
Once the binding agent had hardened, the panels were cut into
pieces measuring 50 x 50 cm.
EXAMPLE 5:
Parking area of a weathered installation, concrete quality B 450,
14 years old. -~
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The entrancs rsads to the parking places are as rough as sand
paper and weathered to a depth of 3 mm; the parking areas
themselves are almost undamaged on the surface. In contrast to
this, the concrete structure displays continuous cracks, like
spiderwebs, with a crack width between 0.5 and 1 mm.
, . ~ ~''
The insulating layer was applied after cleaning by means of high
pressure water jets. This layer consists of 1 part-wt cement, 1
part-wt butadiene styrol, at a weight ratio of 80:20, with a
dynamic shear modulus of -60C. This was used at 5 kg/m2, which
corresponds to a layer thickness of approximately 3.2 mm after
thorough drying.
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The pre-fabricated wearing panels were installed without
reinforcement by textile insert, and were produced in the
following manner:
Single grain diabase aggreqate with a grain size of 3/5 mm was
spread in a single layer and mixed with intrinsically elastified
binary synthetic resin based on an epoxy resin, in excess. The
bonding agent itself is so thixotropized with colloidal silicic
acid that before hardening the resin flows to the base. Applied
at 1.75 kg/m2 of binding agent after hardening one achievPd
imbedding o~ the diabase aggregate to a thickness of 60%. The
grain on grain wearing panel has on its surface a coating of
synthetic resin film of 20 to 25 ~m, which is rapidly abraded by
tra~fic. -
EXAMPLE 6:
Production of pre-fabricated wearing panels:
Wear rasistant sand with a grain size of 0.3 to 1.7 mm is mixed
with thixotropic binary synthetic resin. The binding agent
accounts for 7.5%-wt. This single grain concrete, with a
residual fraction of less than 0.25 mm of at most 6%-wt is shaken
into a steel mould to produce a layer thickness of 7 mm, with
vertical plates. After unmoulding and the removal of the plates
from the frame one obtained wearing panels measuring 40 x 40 cm,
7 mm thick; no subsequent cutting was required.
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EXAMPLE 7:
Production of pre-fabricated wearing panels:
A grain misture (40%-wt smaller than 0.5 mm, 60%-wt greater than
5 mm, no grain fraction smaller than 0.25 mm) is mixed with
thixotropic binary synthetic resin. The bonding agent
requirement is approximately 9%-wt. As in Example 6, the mixture
was shaken into a steel mould with vertical divider plates. -
Because of the lack of a grain fraction of less than 0.25%, one
obtained a panel that was permeable by water vapour. This type `~;
of production produces smooth panel surfaces; the grain is `
enclosed by the adhesive system. This type of panel is
particularly well suited for reinforcing terraces.
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