Coating system having high surface roughness

Abstract

A coating system including at least one reactive resin system RH, at least one thixotropic assistant TH selected from the group consisting of urea preparations HZ and fibers FS and at least one inorganic aggregate AZ having a particle size in the range from 0.2 to 3.0 mm. The coating system has a viscosity as measured with a shear rate of 1 s.sup.−1 of 9000-100,000 Pas and a viscosity as measured with a shear rate of 100 s.sup.−1 of 400-15,000 Pas. The coating system is notable for high surface roughness and for reliable and long-term bonding of the aggregates to the coating with no need for sealing. There is also no need for the coating to be subsequently strewn with aggregates such as sand, for example.

Claims

1. A coating system comprising: at least one reactive resin system RH; at least one thixotropic assistant TH selected from the group consisting of urea preparations HZ and fibers FS; at least one inorganic aggregate AZ having a particle size in the range from 0.2 to 3.0 mm; wherein the coating system 3 min after the mixing of all the components of the coating system apart from the at least one inorganic aggregate AZ has a viscosity as measured at 23° C. using a rheometer with heatable plate (Rheotec MRC300) (0.5 mm gap, measurement plate diameter: 50 mm (plate/plate)) with a shear rate of 1 s-1 of 9000-100,000 Pas and a viscosity as measured at a shear rate of 100 s-1 of 400-15,000 Pas.

2. The coating system as claimed in claim 1, wherein the inorganic aggregate AZ has a grading curve in the range from 0.3 to 2.0 mm.

3. The coating system as claimed in claim 1, wherein the inorganic aggregate AZ has a particle size in the range from 0.3 to 2.0 mm.

4. The coating system as claimed in claim 1, wherein the fibers FS are glass fibers, carbon fibers or polymeric fibers.

5. The coating system as claimed in claim 1, wherein the urea preparation HZ is a solution of a urea urethane, in an aprotic solvent.

6. The coating system as claimed in claim 5, wherein the urea urethane is synthesized from a monofunctional C4 to C22 alkyl alcohol or cycloalkyl alcohol, a diisocyanate, and a diamine.

7. The coating system as claimed in claim 1, wherein the coating system has a viscosity as measured at 23° C. using a rheometer with heatable plate (Rheotec MRC300) (0.5 mm gap, measurement plate diameter: 50 mm (plate/plate)) with a shear rate of 1 s-1 of 10,000-80,000 Pas, and a viscosity as measured at 23° C. using a rheometer with heatable plate (Rheotec MRC300) (0.5 mm gap, measurement plate diameter: 50 mm (plate/plate)) with a shear rate of 100 s-1 of 400-12,000 Pas.

8. The coating system as claimed in claim 1, wherein the reactive resin of the reactive resin system RH is selected from the group consisting of epoxy resins, polyurethanes, polyureas, mixtures of polyurethanes and polyureas, polymethacrylates, and polyacrylates.

9. The coating system as claimed in claim 8, wherein the reactive resin of the reactive resin system RH is selected from the group consisting of epoxy resins and polyurethanes.

10. A cured composition obtained from a coating system as claimed in claim 1, after the mixing of the components and their curing.

11. The use of A coating formed from a coating system as claimed in claim 1.

12. A floor coating system, comprising optionally a primer and/or an undercoat and/or a repair compound or leveling compound, at least one layer of the coating system described in claim 1, optionally a seal.

13. The floor coating system as claimed in claim 12, applied to an industrial floor, a bridge, or a parking deck.

14. A method for producing a coating with a coating system as claimed in claim 1, the method comprising the following method steps: a) mixing reactive resin system RH, thixotropic assistant TH, and inorganic aggregates AZ as in claim 1 to give a coating system as claimed in claim 1, b) applying the resulting coating system to a substrate, c) machining the applied coating system, and d) curing the applied coating system.

Description

EXAMPLES

(1) Given below are working examples which are intended to further elucidate the invention described. Of course, the invention is not confined to these working examples described.

(2) Commercial Substances Used: Sikafloor®-161 Two-component epoxy resin coating, Sika AG Sikafloor®-32 Pronto Three-component polymethyl methacrylate coating, Sika AG Sikafloor®-377 Two-component polyurethane coating, Sika AG Stellmittel T Stellmittel T, thixotropic agent, polyethylene fibers, fiber length: <0.3 mm, fiber thickness: around 0.1 μm, Sika AG BYK 410 Bentone Urea urethane with a small amount of lithium chloride in a 1-methyl-2-pyrrolidone solvent, BYK Chemie BENTONE SD-2, organic derivative of bentonite, Elementis Specialties Silica sand Grading curve=0.6-1.2 mm, particle size=0.6-1.2 mm, Gebrüder Dorfner GmbH & Co., Germany

(3) Production and Application of the Mixed Coating Systems, and Methods of Testing:

(4) The components of the relevant reactive resin system (reactive resin system RH and thixotropic assistant TH) are mixed with a paddle stirrer in the stated mixing ratio and after thorough mixing (around 1 minute) the thixotropic assistant TH is added continuously in accordance with the quantities specified in Table 1, and mixing continues for around 1 minute.

(5) Immediately thereafter the silica sand was added, in an amount of 125 wt %, based on the total weight of the sum total of mixed reactive resin system and added thixotropic assistant TH. Mixing was continued for one minute.

(6) Without delay, the viscosities of the mixed compositions Z1-Z12 (before the addition of the silica sand) and their slump were tested, and respectively these compositions were applied as follows:

(7) The sample plates (30 cm×100 cm) were primed (400-600 g/m.sup.2) with Sikafloor-161. Thereafter the mixed compositions Z1-Z12 were poured out on the sample plate and spread over the area with a smoothing trowel. After a waiting time of around 2 minutes, a perforated foam roll (Rollo-Schaum, coarse structured roll (roll width 25 cm, roll diameter 80 mm) from Friess-Techno-Profi Gmbh, Germany) was rolled over the area. The layer thickness was around 3 mm.

(8) The viscosity was measured at 23° C. using a rheometer with a heatable plate (Rheotec MRC300) (0.5 mm gap, measurement plate diameter: 50 mm (plate/plate)).

(9) The slump was determined in accordance with EN-12350-5 using a flow table at 23° C. Immediately after the mixing of the components, 500 ml of the respective mixture was introduced up to the upper edge of the cone, and poured out on a glass plate. The sample was thereafter spread on the flow table with 15 jolts. The mean diameter of the spread composition was measured after 5 minutes.

(10) The surface roughness is determined by the user, who compares the surface roughnesses obtained with values from the prior art. Serving as the reference is a system which, as known in the prior art, has been sanded off with silica sand. A system of this kind was accorded the value of “rough”.

(11) The processing qualities are determined by the user during application. Critical here is the resistance with which the coating can be spread. The aim of application is to be able to apply a layer 3 mm thick with appropriate force and in an appropriate time using a notched coater. The self-leveling coating systems that are on the market, and their application properties, serve as a reference. A reference system of this kind was accorded the value of “+”=good. The value “∘” denotes “adequate”, and “-” denotes “unsatisfactory”.

(12) Surprisingly it was found that only urea preparations and fibers within the viscosities according to the invention lead to high surface roughness in conjunction with assured processing qualities. The use of bentones, in contrast, does not lead to such characteristics.

(13) TABLE-US-00001 TABLE 1 Thixotropic assistant Reactive (wt % based on total coating Surface Processing resin Experiment system weight) D = 1 s−1 D = 5 s−1 D = 10 s−1 D = 100 s−1 Slump roughness qualities SR-161 Z1 — 2100 1340 1200 1050 n.d. smooth + SR-161 Z2 2 wt % Stellmittel T 32 600   13 900   10 300   4220 189 mm very rough + SR-32 Z3 — 1110  621  546  468 n.d. smooth + SR-32 Z4 3 wt % Stellmittel T 16 300   6070 4530 1980 191 mm very rough + SR-377 Z5 — 2550 2590 2710 2900 n.d. smooth + SR-377 Z6 0.1 wt % BYK 410 2710 2640 2730 2830 n.d. smooth + SR-377 Z7 1 wt % BYK 410 8270 4690 4090 3230 n.d. very slight + roughness SR-377 Z8 5 wt % BYK 410 69 300   23 200   16 000   6810 195 mm rough ∘ SR-377 Z9 0.5 wt % Stellmittel T 5040 4760 4790 4490 n.d. smooth + SR-377 Z10 1 wt % Stellmittel T 8330 7000 6470 5300 n.d. very slight + roughness SR-377 Z11 2 wt % Stellmittel T 27 800   15 800   13 300   8150 200 mm rough ∘ SR-377 Z12 5 wt % Bentone 16 400   15 500   16 600   17 700   n.d. smooth − n.d. = not determined