Accelerating agent, spraying material and spraying method employing it

Abstract: An accelerating agent which comprises calcium aluminosilicate glass and aluminum sulfate as effective components.

Description: The present invention relates to an accelerating agent, a spraying material and a spraying method employing it. Particularly, it relates to an accelerating agent which improves the quick setting property and adhesion of cement concrete sprayed to a ceiling or wall of a tunnel or pit, a spraying material comprising such an accelerating agent, and a spraying method for cement concrete employing such a spraying material. For the purpose of the present invention, cement concrete is a general term which covers a cement paste, mortar and concrete. Heretofore, it has been common that during excavation of a tunnel, concrete is sprayed on the excavated surface for lining to prevent falling of the excavated surface or collapse due to spring water. Further, it is common to incorporate an accelerating agent to such concrete to impart a quick setting property. In tunneling work, it has been common to adopt a method in which primary spraying is followed by secondary lining. However, there is a recent trend to widely employ a single shell system whereby the work is completed by the primary spraying only. Spraying methods for cement concrete are generally classified into two types of dry system and wet system. The dry system spraying method is a method wherein a dry mixed mixture of cement, aggregate and an accelerating agent is transported by compressed air and during the transportation, water is added and mixed, followed by spraying from a nozzle to the surface to be treated. The wet system spraying method is a method in which concrete kneaded with water is transported, and during the transportation, an accelerating agent is added and mixed, followed by spraying from a nozzle to the surface to be treated. As the accelerating agent to be used for the spraying method, a composition comprising calcium aluminate and an alkali metal carbonate or aluminate, a composition comprising calcined alunite, lime or an alkali metal carbonate, or a composition comprising an alkali metal carbonate and aluminate, has been proposed (e.g. JP-B-56-27457 or JP-A-60-260452). These accelerating agents usually contain an alkali metal component such as sodium or potassium in the form of a hydroxide, a carbonate, a silicate or an aluminate, in order to attain quick setting. Such an alkali metal component is strongly alkaline, and when incorporated in cement concrete, it may cause an alkali-aggregate reaction depending upon the type of aggregate used. Thus, it has been pointed out heretofore that it sometimes adversely affects a concrete structure. Further, such a strongly alkaline substance is soluble in water, and if it directly contacts the skin of a worker, it causes a serious damage to the skin, whereby the working environment at the excavation site will be substantially deteriorated. Further, there has been a problem that it is likely to dissolve in soil water, thus leading to environmental pollution of the surrounding area. To solve such a problem, a setting accelerator comprising calcium aluminate, calcium sulfoaluminate and a basic aluminum salt, was proposed as an accelerator for spraying which contains substantially no or little alkali metal component (JP-A-8-48553). However, such an accelerating agent had problems such that the quick setting property was inadequate, and rebound of the sprayed cement concrete was substantial, the loss of material was accordingly substantial, and dust was likely to be formed. The present inventors have conducted an extensive study to solve such problems and as a result, have found that by using a certain specific accelerating agent, it is possible to obtain a spraying concrete which provides excellent adhesion and quick setting property without deteriorating the working environment or the surrounding environment. The present invention has been accomplished on the basis of this discovery. That is, the present invention provides an accelerating agent which comprises calcium aluminosilicate glass and aluminum sulfate as effective components as defined by claim 1, a spraying material which comprises cement and such an accelerating agent as effective components, a spraying concrete which contains such a spraying material, and a spraying method for cement concrete which comprises using such a spraying material. Now, the present invention will be described in detail with reference to the preferred embodiments. The calcium aluminosilicate glass (hereinafter referred to as CAS glass) to be used in the present invention, is necessary to impart a quick setting property, and is usually the one vitrified by rapidly cooling a melt formed at a high temperature of e.g. from 1,200 to 1,700°C by e.g. an electric furnace using CaO material, Al 2 O 3 material and SiO 2 material. The CaO material may, for example, be quick lime, slaked lime, limestone or calcium carbonate. The Al 2 O 3 material may, for example, be alumina, bauxite, diaspore, feldspar or clay. The SiO 2 material may, for example, be silica sand, clay, diatomaceous earth or silicon oxide. It is preferred to use calcium carbonate, alumina or silicon oxide which does not substantially contain an alkali metal component. The composition of CAS glass preferably comprises from 40 to 50 wt% of CaO, from 40 to 50 wt% of Al 2 O 3 and from 10 to 20 wt% of SiO 2 . If CaO or Al 2 O 3 is outside such a range, no adequate quick setting property may sometimes be obtained. If SiO 2 is less than 10 wt%, good strength may not last for a long period of time, and if it exceeds 20 wt%, the initial strength may sometimes be low. For the purpose of the present invention, glass is meant for "one having a glass transition point" as commonly used in the field of glass, and it is not necessarily entirely glass and may be one having a vitrification ratio of at least 60%. As a method for measuring the vitrification ratio, a method may be employed wherein a sample is heated at 1,000°C for 2 hours and then gradually cooled at a cooling rate of 5°C/min, whereby area S 0 of the main peak of crystal mineral is obtained by a powder X-ray diffraction method, and the vitrification ratio is obtained by using the formula of glass vitrification ratio = (l-S/So)×100, from this So and the main peak area S of the crystal in the sample. The particle size of CAS glass of the present invention is not particularly limited, but it is preferably at a level with a Blaine value of from 3,000 to 9,000 cm 2 /g. Aluminum sulfate is used preferably in an amount of from 20 to 50 parts by weight, more preferably from 30 to 40 parts by weight, per 100 parts by weight of CAS glass. If the amount of aluminum sulfate is outside this range, no adequate quick setting property may sometimes be obtained. The accelerating agent of the present invention comprises CAS glass and aluminum sulfate as effective components, and it may contain alkali metal components such as sodium and potassium. The total amount of such alkali metal components is preferably at most 0.05 wt% as calculated as sodium oxide (Na 2 O). The particle size of the accelerating agent varies depending upon the purpose or manner of use but it is at a level with a Blaine value of from 3,000 to 9,000 cm 2 /g. If the Blaine value is less than 3,000 cm 2 /g, the quick setting property may sometimes deteriorate, and even if it exceeds 9,000 cm 2 /g, no additional effects can be expected. The accelerating agent is used preferably in an amount of from 3 to 15 parts by weight, more preferably from 4 to 10 parts by weight, in 100 parts by weight of the spraying material comprising cement and the accelerating agent. If the amount of the accelerating agent is less than 3 parts by weight, the quick setting property tends to be inadequate, and even if it exceeds 15 parts by weight, no additional effects will be obtained. Here, the cement to be used in the present invention is not particularly limited and may, for example, be various Portland cements such as normal, high early strength, ultra-high early strength and moderate heat Portland cements, various mixed cements having blast furnace slag or fly ash mixed to such Portland cements, expansive cements having an expanding agent mixed to such Portland cements, and special cements such as alumina cements such as alumina cement, white cement and colloidal cement. Further, various other additives may be incorporated to the accelerating agent or the spraying material of the present invention. For example, it is possible to incorporate one or more additives selected from setting adjusting agents, aggregates such as silica sand, natural sand and gravel, fiber materials such as glass fibers, carbon fibers and steel fibers, underwater non-separable admixtures such as polymer emulsions (latexes), colorants (pigments), AE agents, water-reducing agents, AE water-reducing agents, fluidizing agents, rust-proofing agents and methylcellulose, thickeners, blowing agents, foaming agents, calcium compounds such as calcium hydroxide, and anti-freezing agent, within a range not to impair the purpose of the present invention. To prepare the accelerating agent for the spraying material of the present invention, a conventional mixing and stirring apparatus such as an inclined barrel mixer, an omni mixer, a twin-cylinder mixer, a Henshel mixer or a Naughter mixer, may be used. The mixing may be carried out in such a manner that the respective materials are mixed at the time of application, or some or all of such materials may be mixed beforehand. Further, the aging method is not particularly limited, and a commonly employed aging method may be used. For the spraying operation of the spraying material of the present invention, either a dry spraying method or a wet spraying method may be employed. Now, the present invention will be described in further detail with reference to Examples. In Examples, "%" means "wt%". EXAMPLE 1 CaO material, Al 2 O 3 material and SiO 2 materiel were mixed and melted in an electric furnace at 1,600°C. The melt thereby obtained was quenched by a high pressure air method, followed by pulverization to obtain CAS glass having a Blaine value of 5,000 ± 200 cm 2 /g as identified in Table 1. 100 parts by weight of the prepared CAS glass and 35 parts by weight of aluminum sulfate α were mixed to obtain an accelerating agent. The alkali metal components in this accelerating agent were analyzed, whereby Na 2 O eq. i.e. the total amount of alkali metal components, was not more than 0.05%. This accelerating agent was mixed with cement to obtain a spraying material, whereby the amount of the accelerating agent was 7 parts by weight in 100 parts by weight of the spraying material comprising cement A and the accelerating agent. 700 g of the obtained spraying material and 2,100 g of fine aggregate were blended and dry-mixed for 30 seconds at a low speed by means of a small size table top type mortar mixer. Then, 350 g of water was added thereto, and the mixture was kneaded for 10 seconds at a high speed to obtain cement mortar, whereupon the setting property of the cement mortar was evaluated by a proctor penetration resistance. The results are shown in Table 2. For the purpose of comparison, an experiment was carried out in the same manner as above by using a commercially available accelerating agent instead of the accelerating agent of the present invention. The results are shown also in Table 2. Materials used CaO material: Calcium carbonate, first grade reagent Al 2 O 3 material: Aluminum oxide, first grade reagent SiO 2 material: Silicon oxide, first grade reagent Aluminum sulfate α: Anhydride, first grade reagent, Na 2 O eq. 0.04% Commercially available accelerating agent: Main component: calcium aluminate, Na 2 O eq. 15.8% Cement A: Normal Portland cement, Blaine value: 3,300 cm 2 /g, Na 2 O eq. 0.48% Fine aggregate:River sand produced in Himekawa, Niigata-ken, Japan, specific gravity: 2.62 Water: City water Measuring methods Alkali metal analysis: By means of atomic absorption spectroscopy, in addition to sodium, other alkali metal components were also calculated as Na 2 O, and the total amount of alkali metal components was represented by Na 2 O eq. Proctor penetration resistance: The mixture was kneaded in a constant temperature chamber of 20°C, and then it was immediately divided into two layers in formworks and quickly packed while pushing the mortar by a pushing rod, whereupon the proctor penetration resistance was measured every a predetermined period of time after introducing water, by means of a needle having a needle head area of 1/40 in - 2 in accordance with ASTM C 403-65 T. CAS glass symbol CaO (%) Al 2 O 3 (%) SiO 2 (%) Vitrification ratio (%) a 60 35 5 65 b 60 30 10 75 c 50 45 5 91 d 50 40 10 92 e 50 30 20 95 f 45 45 10 95 g 45 40 15 97 h 40 55 5 92 i 40 50 10 93 j 40 45 15 96 k 40 40 20 96 l 40 30 30 96 m 30 60 10 68 n 30 50 20 75 o 30 40 30 73 Test No. CAS glass Proctor penetration resistance (psi) Notes 1 min 2 min 3 min 5 min 10 min 1-1 - 100 100 200 300 800 Comparative 1-2 a 600 1000 2200 3000 4000 Invention 1-3 b 500 1100 2600 3200 4200 Invention 1-4 c 600 1200 2500 3000 4100 Invention 1-5 d 900 1200 2500 4000 - Invention 1-6 e 700 1300 2600 3200 4400 Invention 1-7 f 800 1500 2800 4100 - Invention 1-8 g 900 1500 3000 4100 - Invention 1-9 h 600 1000 2500 3200 4000 Invention 1-10 i 900 1300 2900 4100 - Invention 1-11 j 900 1600 2900 4200 - Invention 1-12 k 700 1200 3000 4300 - Invention 1-13 l 500 1000 2100 3200 4200 Invention 1-14 m 600 1000 2500 3500 4300 Invention 1-15 n 800 1500 2800 3700 4300 Invention 1-16 o 600 1500 3000 3500 4200 Invention 1-17 *l 700 900 1500 2100 4600 Comparative *l in the column for "CAS glass" indicates that the commercially available accelerating agent was used. Symbol "-" for the proctor penetration resistance indicates that no measurement was made. EXAMPLE 2 An accelerating agent was prepared in the same manner as in Example 1 using CAS glass g and aluminum sulfate β. Na 2 O eq. in the prepared accelerating agent was 0.04%. The test was carried out in the same manner as in Example 1 except that this accelerating agent was used. The results are shown in Table 3. Further, for the purpose of comparison, the test was carried out in the same manner as above except that gypsum was used instead of aluminum sulfate. The results are shown also in Table 3. Materials used Aluminum sulfate β: 14 to 18 hydrate, first grade reagent, Na 2 O eq. 0.04% Gypsum: II-type anhydrous gypsum, Blaine value: 5,900 cm 2 /g Test No. Aluminum sulfate Proctor penetration resistance (psi) Notes 1 min 2 min 3 min 5 min 10 min 1-8 α 35 900 1500 3000 4100 - Invention 2-1 β 35 700 1400 3100 4000 - Invention 2-2 *135 200 400 500 500 800 Comparative "Aluminum sulfate" represents parts by weight per 100 parts by weight of CAS glass. *l indicates that gypsum was used instead of aluminum sulfate. Symbol "-" for the proctor penetration resistance indicates that no measurement was made. EXAMPLE 3 An accelerating agent was prepared in the same manner as in Example 1 using CAS glass g and aluminum sulfate α as identified in Table 4. Na 2 O eq. in the prepared accelerating agent was 0.04%. The test was carried out in the same manner as in Example 1 except that this accelerating agent was used. The results are shown also in Table 4. Test No. Aluminum sulfate Proctor penetration resistance (psi) Notes 1 min 2 min 3 min 5 min 10 min 3-1 0 400 500 900 1000 1200 Comparative 3-2 20 500 1100 2600 3300 4500 Invention 3-3 30 800 1200 2900 4000 - Invention 1-8 35 900 1500 3000 4100 - Invention 3-4 40 1000 1700 3300 4100 - Invention 3-5 50 1200 2000 2700 3200 4200 Invention "Aluminum sulfate" represents parts by weight per 100 parts by weight of CAS glass. Symbol "-" for the proctor penetration resistance indicates that no measurement was made. EXAMPLE 4 An accelerating agent was prepared in the same manner as in Example 1 using CAS glass g and aluminum sulfate α. Na 2 O eq. in the prepared accelerating agent was 0.04%. The test was carried out in the same manner as in Example 1 except that this accelerating agent and cement as identified in Table 5 were used. The results are shown also in Table 5. Materials used Cement B: Moderate heat Portland cement, Blaine value: 3,100 cm 2 /g, Na 2 O eq. 0.46% Cement C: High early strength Portland cement, Blaine value: 4,400 cm 2 /g, Na 2 O eq. 0.43% Test No. Cement Proctor penetration resistance (psi) 1 min 2 min 3 min 5 min 10 min 1-8 A 900 1500 3000 4100 - 4-1 B 700 1200 2600 3200 4400 4-2 C 1000 1900 2700 4000 - Symbol "-" for the proctor penetration resistance indicates that no measurement was made. EXAMPLE 5 An accelerating agent was prepared in the same manner as in Example 1 using CAS glass g and aluminum sulfate α. Na 2 O eq. in the prepared accelerating agent was 0.04%. The test was carried out in the same manner as in Example 1 except that this accelerating was used in an amount shown by parts by weight in Table 6 in 100 parts by weight of the spraying material. The results are shown also in Table 6. Test No. Accelerating agent Proctor penetration resistance (psi) 1 min 2 min 3 min 5 min 10 min 5-1 3 600 1100 2400 3000 4500 5-2 4 700 1200 2600 3200 - 1-8 7 900 1500 3000 4100 - 5-3 10 1100 1800 3200 4500 - 5-4 15 1300 2200 3400 4600 - Symbol "-" for the proctor penetration resistance indicates that no measurement was made. EXAMPLE 6 Using unit amounts of materials being 360 kg/m 3 of cement A, 1,130 kg/m 3 of fine aggregate, 756 kg/m 3 of coarse aggregate and 162 kg/m 3 of water, an accelerating agent containing not more than 0.05% of Na 2 O eq. as shown in Table 7 was mixed in an amount of 7 parts by weight in 100 parts by weight of the spraying material, to obtain concrete wherein the maximum aggregate size is 10 mm and the fine aggregate proportion is 60%. This concrete was sprayed to a simulated tunnel having a height of 3.5 m and a width of 3 m by means of a dry spraying machine and a wet spraying machine, whereupon the amount of the concrete fallen in the tunnel was measured, and the rebound ratio was calculated. The results are shown also in Table 7. Material used Coarse aggregate: River gravel produced in Himekawa, Niigata-ken, Japan, specific gravity: 2.66 Measuring method Rebound ratio: The ratio of the rebound amount at the time of spraying of the concrete which fell off without attaching to the simulated tunnel to the amount of the concrete used for spraying. As described in the foregoing, the accelerating agent of the present invention is substantially free from alkali metal components, whereby there will be no adverse effects to the working environment or the surrounding environment, and it presents an excellent quick setting property.

Claims: An accelerating agent having a Blaine value of from 3,000 to 9,000 cm 2 /g, which comprises calcium aluminosilicate glass and aluminum sulfate as effective components. A spraying material which comprises cement and the accelerating agent as defined in Claim 1 as effective components. A spraying concrete which contains the spraying material as defined in claim 2. A spraying method for cement concrete which comprises using the spraying material as defined in claim 2.

Inventors: ISHIDA ATSUMU, MIHARA TOSHIO, YANAGIHARA TSUYOSHI, ISHIDA, ATSUMU, MIHARA, TOSHIO, YANAGIHARA, TSUYOSHI, Ishida, Atsumu, Denki Kagaku Kogyo K.K., Mihara, Toshio, Denki Kagaku Kogyo K.K., Yanagihara, Tsuyoshi, Denki Kagaku Kogyo K.K.
Applicants: DENKI KAGAKU KOGYO KK, DENKI KAGAKU KOGYO KABUSHIKI KAISHA
Application year: 1997
Main classification: C04B28
IPC codes: E21D11, C04B40, C04B28, C04B22