Two-component mortar compound and use thereof

Abstract

A two-component mortar compound contains at least one resin component (A), which, as the curable ingredient, contains at least one epoxy-base resin that can be polymerized by addition reaction; and a hardener component (B), which contains a hardening agent for the resin of the resin component (A), wherein at least one of the components contains at least one siloxane, which has at least one functional moiety that is capable of addition reaction with an epoxide but does not have any hydrolyzable group bound to a silicon atom, especially no alkoxy moieties.

Claims

1. A two-component mortar composition, comprising: at least one resin component (A), which contains at least one epoxy-base resin as a curable ingredient that can be polymerized by addition reaction; and a hardener component (B), which contains a hardening agent for the resin of the resin component (A), wherein at least one of the components contains at least one siloxane which has at least one functional moiety that is capable of addition reaction with an epoxide but does not have any hydrolyzable group bound to a silicon atom.

2. The two-component mortar composition according to claim 1, wherein the functional moiety capable of addition reaction with epoxy groups is a terminal moiety.

3. The two-component mortar composition according to claim 2, wherein the functional moiety is selected from the group consisting of hydroxy, carboxy, amino, sec-amino, mercapto, isocyanato, alkenyl, (meth)acryloyl, anhydrido and epoxy moieties.

4. The two-component mortar composition according to claim 1, wherein the siloxane has the structure R.sub.3Si[OSi(R.sup.1).sub.2]n-OSiR.sub.3, where n stands for 0 or a whole number from 1 to 1000 inclusive, R and R.sup.1, independently of one another, respectively stand for a C.sub.1-C.sub.20 alkyl moiety or aralkyl moiety that optionally contains a hetero atom and optionally has at least one moiety capable of addition reaction with an epoxy group.

5. The two-component mortar composition according to claim 1, wherein the siloxane has two or more identical or different terminal functional moieties capable of addition reaction with an epoxy group.

6. The two-component mortar composition according to claim 1, wherein the siloxane is selected from the group consisting of 1,3-bis(2-aminoethylaminoethyl)tetramethyldisiloxane, 1,3-bis(glycidoxypropyl)tetramethyl-disiloxane, tris(glycidoxypropyldimethylsiloxy)phenylsilane, 3-methacryloxy-propylpentamethyldisiloxane, poly(acryloxypropylmethyl)siloxane, 1,3-bis(acryloxypropylmethyl)siloxane, 1,3-bis(3-methacryloxypropyl)tetrakis-(trimethylsiloxy)disiloxane, 1,3-bis(3-methacryloxypropyl)tetramethyldisiloxane, monomethacryloxypropyl-terminated polydimethylsiloxane, poly[dimethylsiloxane-co-(3-(monomethacryloxy)propyl)methylsiloxane], 1,3-bis(4-methacryloxybutyl)-tetramethyldisiloxane, (methacryloxypropyl)methylsiloxane/dimethylsiloxane copolymer, dodecamethylpentasiloxane, 1,1,1,3,5,7,7,7-octamethyl-3,5-bis(trimethylsilanyloxy)tetrasiloxane, trimethylsilyl-terminated poly(methylhydrosiloxane), bis(hydroxyalkyl)-terminated poly(dimethylsiloxane), poly[di-methylsiloxane-co-(2-(3,4-epoxycyclohexyl)ethyl)methylsiloxane], diglycidylether-terminated poly(dimethylsiloxane), poly[dimethylsiloxane-co-[3-(2-(3-hydroxy-ethoxy)ethoxy)propyl]methylsiloxane] and monoglycidylether-terminated poly(di-methylsiloxane).

7. The two-component mortar composition according to claim 1, wherein a proportion of the siloxane is 0.5 to 20 wt %, relative to the total weight of the two-component composition.

8. The two-component mortar composition according to claim 1, wherein the resin component (A) and/or the hardener component (B) contains at least one thixotropic agent as a further ingredient.

9. The two-component mortar composition according to claim 1, wherein the resin component (A) and/or the hardener component (B) contains at least one inorganic filler as a further ingredient.

10. The two-component mortar composition according to claim 1, wherein the composition is present in a casing, a cartridge or a foil bag, wherein the resin component (A) and the hardener component (B) are disposed in chambers separated from one another.

11. A method for chemical fastening of a structural part which is present in a mineral substrate, said method comprising: applying the composition of claim 1 to the mineral substrate and/or the structural part; wherein said structural part is selected from the group consisting of a threaded anchor rod, a rebar, a threaded sleeve and a screw in a drilled hole.

Description

EXAMPLES OF PRODUCTION

Examples 1 to 5

(1) The resin component (A) is prepared first by mixing the ingredients indicated in Table 1, wherein the ingredients are first prestirred manually and then mixed in a speed mixer for 10 seconds at 1000 rpm, then for 20 seconds at 2500 rpm and then for 15 seconds at 1500 rpm.

(2) For production of the hardener component (B), the ingredients indicated in Table 2 are mixed together, prestirred manually and then mixed in a speed mixer for 10 seconds at 1000 rpm, then for 20 seconds at 2500 rpm and then for 15 seconds at 1500 rpm.

(3) Then the resin component (A) and the hardener component (B) are united in the calculated ratio, prestirred manually and them mixed in the speed mixer for 10 seconds at 1500 rpm. The mixing ratio of components (A) and (B) in examples 1 to 5 was approximately 3:1 (w/w).

(4) A composition commercially available under the designation Epilox M884 (LEUNA-Harze GmbH) was used as the epoxy resin in Examples 1 to 5. The amine hardener is available under the designation Beckopox SEH 2627 from the Allnex Co. of Belgium.

(5) The abbreviations contained in Tables 1 and 2 for the siloxanes that were used have the following meanings: EPSilox1: 1,3-bis(glycidoxypropyl)tetramethyldisiloxane EPSilox2: Tris(glycidoxypropyldimethylsiloxy)phenylsilane Amsilox: 1,3-bis(3-aminopropyl)tetramethyldisiloxane

(6) TABLE-US-00001 TABLE 1 Resin component (A) Example 1 (comparison) Example 2 Example 3 Example 4 Example 5 [wt %] [wt %] [wt %] [wt %] [wt %] Epoxy 61.3 61.3 57.0 57.0 57.1 resin Quartz 35.7 35.7 35.9 35.9 35.9 flour Fumed 3.0 3.0 3.0 3.0 3.0 silica EPSilox1 4.1 4.1 EPSilox2 4.0 Total 100 100 100 100 100

(7) TABLE-US-00002 TABLE 2 Hardener component (B) Example 1 (comparison) Example 2 Example 3 Example 4 Example 5 [wt %] [wt %] [wt %] [wt %] [wt %] Amine 62.4 53.0 58.5 62.4 62.4 hardener Amsilox 10.3 4.2 Fumed 4.0 4.0 4.0 4.0 4.0 silica Quartz 13.6 13.2 13.5 13.6 13.6 flour Alumina 20.0 19.5 19.8 20.0 20.0 cement Total 100 100 100 100 100

Examples 6 to 10

(8) The resin component (A) is prepared first by mixing the ingredients indicated in Table 3, wherein the ingredients are first prestirred manually and then mixed in a speed mixer for 10 seconds at 1000 rpm, then for 20 seconds at 2500 rpm and then for 15 seconds at 1500 rpm.

(9) For production of the hardener component (B), the ingredients indicated in Table 4 are mixed together, prestirred manually and then mixed in a speed mixer for 10 seconds at 1000 rpm, then for 20 seconds at 2500 rpm and then for 15 seconds at 1500 rpm.

(10) Then the resin component (A) and the hardener component (B) are united in the calculated ratio, prestirred manually and them mixed in the speed mixer for 10 seconds at 1500 rpm. The mixing ratio of components (A) and (B) in examples 6 to 10 was approximately 3:1 (w/w).

(11) A composition commercially available under the designation Araldite BY 20157 (Huntsman Advanced Materials) was used as the epoxy resin in Examples 6 to 10. The amine hardener is available under the designation Aradur 30446 of Huntsman Advanced Materials.

(12) The abbreviations contained in Tables 3 and 4 for the silicon compounds that were used have the following meanings: Dynasilan: (3-Glycidyloxypropyl)trimethoxysilane EPSilox1: 1,3-bis(glycidoxypropyl)tetramethyldisiloxane EPSilox2: Tris(glycidoxypropyldimethylsiloxy)phenylsilane Amsilox: 1,3-bis(3-aminopropyl)tetramethyldisiloxane

(13) TABLE-US-00003 TABLE 3 Resin component (A) Example 6 Example (comparison) Example 7 Example 8 Example 9 10 [wt %] [wt %] [wt %] [wt %] [wt %] Epoxy 61.4 61.4 57.4 57.4 57.4 resin Quartz 35.8 35.8 35.8 35.8 35.8 flour Fumed 2.8 2.8 2.8 2.8 2.8 silica EPSilox1 4.0 4.0 EPSilox2 4.0 Total 100 100 100 100 100

(14) TABLE-US-00004 TABLE 4 Hardener component (B) Example 6 Exam- Example (comparison) Example 7 Example 8 ple 9 10 [wt %] [wt %] [wt %] [wt %] [wt %] Amine 60.7 50.7 56.7 60.7 60.7 hardener Amsilox 10.0 4.0 Fumed silica 4.3 4.3 4.3 4.3 4.3 Quartz flour 19.5 19.5 19.5 19.5 19.5 Alumina 13.0 13.0 13.0 13.0 13.0 cement Accelerator 2.5 2.5 2.5 2.5 2.5 Total 100 100 100 100 100

Example 11

(15) Check of the Internal Strength by Pull-Off Test

(16) Diamond-sawed concrete C20/25, respectively in wet and dry condition, was used as the substrate. Round metal plates having a ring of double-sided adhesive tape as spacer are fastened to the substrate to be bonded and are filled with the mortar compound. After curing at room temperature (20 C., 1 day), the adhesive strength is measured with an adhesion-testing machine (DYNA Z, manufactured by proceq).

(17) The results are presented in Table 5 below:

(18) TABLE-US-00005 TABLE 5 Adhesive strength in the pull-off test Dry concrete Wet concrete Pull-off diameter Change Pull-off diameter Change Examples [N/mm2] [%] [N/mm2] [%] 1 3.7 0 0.7 0 (comparison) 2 5.3 43.2 2.3 228 3 5.1 37.8 2.5 257 4 5.1 37.8 2.7 285 5 4.6 12.4 2.3 2282 6 3.9 0 0.9 0 (comparison) 7 4.7 20.5 1.9 11.1 8 4.0 2.5 2.2 44.4 9 5.0 28.2 2.1 33.3 10 4.9 25.6 2.5 77.7

(19) As is apparent from the test results, the adhesive strength of the inventive mortar compounds is improved on dry and especially water-saturated concrete and at the same time the formation of undesired VOCs is prevented by the use of epoxy-functional or amino-functional siloxanes without silicon-bonded hydrolyzable groups compared with the comparison compounds without epoxy-functional or amino-functional siloxanes (Examples 1 and 6).

Example 12

(20) Determination of the Load Ratings in Wet Concrete

(21) For determination of the load ratings achieved with two-component mortar compounds according to Examples 6 to 10, a high-strength M12 threaded anchor bar is used in the form of a dowel held by the inventive two-component mortar compound in a drilled hole having a diameter of 14 mm and a drilled-hole depth of 72 mm. After a predesignated curing time at room temperature, the mean failure load is measured by pulling the threaded anchor bar out centrally against closely positioned bracing means, and the mean failure load of five anchors is determined.

(22) The investigated drilled holes were prepared using a diamond drill and the drilled hole was cleaned two times with compressed air (6 bar), brushed and then blown out again twice with compressed air.

(23) To measure the load ratings in wet concrete, the drilled holes were filled with water, after which the water was left to act for one day. Then the water was sucked out and the anchor bars were set using the mortar compound. The mortar compound was cured at room temperature (212 C.) for 24 hours.

(24) The load ratings determined for Examples 6 to 10 are reported in Table 6 below.

(25) TABLE-US-00006 TABLE 6 Load ratings in wet concrete Failure load Change Examples [N/mm.sup.2] [%] 6 27.9 0 (comparison) 7 32.5 16.5 8 32.7 17.2 9 33.3 19.3 10 33.3 19.3

(26) The test results show a distinct improvement of the mortar performance under critical drilled-hole conditions for the inventive mortar compounds. Further tests reveal that the improvement of the load ratings under the indicated conditions is also achieved for mortar compounds that contain between 1.5 percent by weight and 4 percent by weight of siloxanes without silicon-bound hydrolyzable groups.