Orthogonal optimization mix ratio of fiber polymer repair protect mortar and its comprehensive performance realization mechanism
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摘要: 双碳节约型经济大背景下，亟待开发面向复杂服役环境下基础设施修补用高性能修补防护砂浆。本文结合正交试验手段，综合探讨钢纤维(SF)掺量、EVA乳胶粉掺量、高贝利特硫酸盐水泥和普通硅酸盐水泥比例对相应复配而成的纤维聚合物修补防护砂浆(SCPRM)的工作性能、力学性能、界面粘结性能和防水/抗渗耐久性能的影响规律。最优配比SCPRM的流动扩展度、凝结时间、抗折强度(ft)、抗压强度(fc)、14 d粘结强度(fb14d)、90 d干燥收缩率、3 d吸水率、接触角和氯离子渗透系数分别达226.0 mm、41 min/63 min(初凝/终凝时间)、5.2/17.1 MPa(ft1 d/ft28 d)、16.7/73.2 MPa(fc1 d/fc28 d)、3.61 MPa(fb14 d)、16.44×10−5、0.16%、70.04°和0.9486×10−12 m2·s−1。相应宏/微观结构显示SF分散均匀、EVA聚合物膜在水化产物中交替分布；FTIR揭示了复合胶凝体系水化特点与EVA对其水化影响机制。最终，制备出了一种综合性能优异，能够适应复杂服役环境的高性能修补防护砂浆。Abstract: Under background of carbon peaking and carbon neutrality economic savings, it is urgent to develop high performance repair protect mortar for infrastructure repairing and protecting in complex service environment. In this paper, the effects of steel fiber (SF) dosing, EVA emulsion powder dosing, and the proportion of high-belite sulfate cement and ordinary Portland cement on the workability, mechanical properties, interfacial bonding performance and waterproofing/ impermeability durability of the fiber reinforced polymer repair protect mortar (SCPRM) were investigated by Taguchi orthogonal method. Results reveal that the flowability, setting time, flexural strength (ft), compressive strength (fc), bond strength at 14 d (fb14d), drying shrinkage at 90 d, water absorption after 3 d soaking, surface contact angle and chlorine ion permeability coefficient are 226.0 mm, 41 min/63 min (initial/final setting time), 5.2/17.1 MPa (ft1d/ft28d), 16.7/73.2 MPa (fc1d/fc28d), 3.61 MPa (fb14d), 16.44×10−5, 0.16%, 70.04°, and 0.9486×10−12 m2·s−1, respectively. The corresponding macroscopic/microscopic structures show that SFs are uniformly dispersed in the hydration products and the EVA polymer film was netlike distributed. FTIR reveals the hydration feature of compound cementitious system, and the corresponding influence mechanism of its hydration of EVA dosing. Finally, a high-performance repair protect mortar with excellent comprehensive performance and adaptability to complex service environment are successively prepared.
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图 2 SCPRM的14天粘结强度(fb14 d)试验试件与试验过程(①拉拔金属头，②环氧树脂，③修补防护砂浆，④钢垫片，⑤旧混凝土基层)
Figure 2. Bond strength at 14 d (fb14 d) test specimens and procedure (① Pulling hook, ② Epoxy resin, ③ Repair mortar, ④ Steel spacer, ⑤ Old concrete substrate)
图 3 不同组别SCPRM的流动扩展度均值、偏差及不同因素对流动扩展度的影响
Figure 3. Mean & deviation of flowability of varied groups SCPRM and the effect of OPC/HBSAC, wEVA and VSF on flowability
图 4 不同组别SCPRM的凝结时间均值及不同因素对凝结时间的影响
Figure 4. Mean of setting time of varied groups SCPRM and the effect of OPC/HBSAC, wEVA and VSF on setting time
图 5 不同组别SCPRM的抗折强度(ft)、抗压强度(fc)均值及不同因素对 ft、fc的影响
Figure 5. Mean of ft, fc of varied groups SCPRM and the effect of OPC/HBSAC, wEVA and VSF on ft, fc
图 6 不同组别SCPRM的fb14 d均值、偏差及不同因素对fb14 d的影响
Figure 6. Mean & deviation of fb14 d of varied groups SCPRM and the effect of OPC/HBSAC, wEVA and VSF on fb14 d
图 7 不同组别SCPRM的干燥收缩均值及不同因素对干燥收缩的影响
Figure 7. Mean of drying shrinkage of varied groups SCPRM and the effect of OPC/HBSAC, wEVA and VSF on drying shrinkage
图 8 不同组别SCPRM的吸水率均值及不同因素对吸水率的影响
Figure 8. Mean of water absorption of varied groups SCPRM and the effect of OPC/HBSAC, wEVA and VSF on water absorption
图 9 不同组别SCPRM的接触角均值、偏差及不同因素对接触角的影响
Figure 9. Mean & deviation of contact angle of varied groups SCPRM and the effect of OPC/HBSAC, wEVA and VSF on contact angle
图 10 不同组别SCPRM的迁移系数(λ)均值、偏差及不同因素对λ的影响
Figure 10. Mean & deviation of transport coefficient (λ) of varied groups SCPRM and the effect of OPC/HBSAC, wEVA and VSF on λ
图 11 通过喷涂AgNO3溶液显色法评价修补防护砂浆试件的氯离子侵蚀深度
Figure 11. Depth of chloride ion attack of varied groups repair mortar specimens through color comparison after spraying AgNO3 solution
图 13 EVA和不同龄期时的修补防护砂浆的FTIR图谱(①-CPRM1；②-CPRM2；③-CPRM3)
Figure 13. FTIR spectrum of EVA and repair mortars with different proportions at different curing ages (①-CPRM1; ②-CPRM2; ③-CPRM3)
表 1 普通硅酸盐水泥(OPC)与抗裂快凝快硬高贝利特硫铝酸盐水泥(HBSAC)的主要化学成分(wt%)
Table 1. Main chemical composition of ordinary silicate cement (OPC) and high-belite sulfate aluminate cement (HBSAC) (wt%)
Cement type CaO SiO2 Al2O3 SO3 Fe2O3 MgO R2O P·O 42.5 51.42 24.99 8.26 2.51 4.03 3.71 1.73 HBSAC 52.5 41.97 18.33 16.63 14.97 1.00 5.34 0.78 
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表 2 乙烯-醋酸乙烯共聚物(EVA)可再分散乳胶粉的主要理化特性
Table 2. Main physical and chemical properties of ethylene-vinyl acetate copolymer (EVA) re-dispersible emulsion powder
Model of EVA Appearance Solid content/
wt%Ash content/
wt%Glass transition
temperature /℃Particle
size /mmStabilization
systemWacker 5044 N White powder 99±1 10±2 0 0.4 Polyvinyl alcohol
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表 3 钢纤维(SF)主要性能指标
Table 3. Main performance indicators of steel fiber (SF)
Length /mm Diameter /mm Density (g·cm−3) Tensile strength /MPa Appearance 12-14 0.18-0.23 7.85 ≥3000 Golden/Glossy
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表 4 SF改性聚合物修补防护砂浆(SCPRM)正交试验因素与因素水平
Table 4. Factors and factor levels of orthogonal test for SF modified polymer repair protect mortar (SCPRM)
Test factor Level of the factors Item No. OPC∶HBSAC 1∶0 A1 0.7∶0.3 A2 0.5∶0.5 A3 EVA dosing wEVA/wt% 0 B1 8 B2 15 B3 SF dosing VSF/vol% 0 C1 1 C2 2 C3
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表 5 9组SCPRM正交试验材料配比(kg/m3)
Table 5. Orthogonal mix ratio of 9 groups of SCPRM (kg/m3)
Group No. (C + EVA + FA) : W OPC HBSAC S FA EVA SF W Sup DA SCPRM1 0.25 900 0 1125 112.5 0 0 253.1 4.1 4 SCPRM2 72 156 271.1 4.3 SCPRM3 135 78 286.9 4.6 SCPRM4 630 270 0 156 253.1 4.1 SCPRM5 72 78 271.1 4.3 SCPRM6 135 0 286.9 4.6 SCPRM7 450 450 0 78 253.1 4.1 SCPRM8 72 0 271.1 4.3 SCPRM9 135 156 286.9 4.6 Notes: C—Cement; FA—Fly ash; S—Quartz sand; W—Water; Sup—Superplasticizer; DA—Defoamer.
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表 6 傅里叶变换红外光谱(FTIR)试验中3组修补砂浆的材料配比(kg/m3)
Table 6. Mix ratio of 3 groups repair mortar for fourier transform infrared spectrum (FTIR) test (kg/m3)
Group No. (C + EVA + FA)∶W OPC HBSAC S FA EVA W Sup DA CPRM1 0.25 900 0 1125 112.5 0 253.1 4.1 4 CPRM2 630 270 0 253.1 4.1 CPRM3 630 270 72 271.1 4.3
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表 7 SCPRM流动扩展度极差分析结果
Table 7. Range analysis results of flowability of SCPRM
Analysis result OPC/HBSAC EVA SF Optimal level R*/mm 60 141.6 35.7 Degree of influence B(wEVA)>A(OPC∶HBSAC)>C(VSF) *Note: R in Table 7 is the range of flowability, and R in the range analysis tables below are the range of the corresponding performance respectively.
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表 8 SCPRM初凝时间极差分析结果
Table 8. Range analysis results of initial setting time of SCPRM
Analysis result OPC/HBSAC EVA SF Optimal level A3 B1 C1 R/min 1243 1083 483 Degree of influence A(OPC∶HBSAC)>B(wEVA)>C(VSF)
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表 9 SCPRM终凝时间极差分析结果
Table 9. Range analysis results of final setting time of SCPRM
Analysis result OPC/HBSAC EVA SF Optimal level A3 B1 C1 R/min 1786 1638 864 Degree of influence A(OPC∶HBSAC)>B(wEVA)>C(VSF)
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表 10 SCPRM的1 d抗折强度(ft1 d)极差分析结果
Table 10. Range analysis results of flexural strength at 1 d (ft1 d) of SCPRM
Analysis result OPC/HBSAC EVA SF Optimal level A3 B1 C3 R/MPa 14.4 12.0 3.8 Degree of influence A(OPC∶HBSAC)>B(wEVA)>C(VSF)
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表 11 SCPRM的1 d抗压强度(fc1 d)极差分析结果
Table 11. Range analysis results of compressive strength at 1 d (fc1 d) of SCPRM
Analysis result OPC/HBSAC EVA SF Optimal level A3 B1 C3 R/MPa 42.2 49.6 3.8 Degree of influence B(wEVA)>A(OPC:HBSAC)>C(VSF)
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表 12 SCPRM的28 d抗折强度ft28 d极差分析结果
Table 12. Range analysis results of flexural strength at 28 d (ft28 d) of SCPRM
Analysis result OPC/HBSAC EVA SF Optimal level A2 B3 C3 R/MPa 3.8 8.9 3.8 Degree of influence B(wEVA)>A(OPC∶HBSAC)>C(VSF)
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表 13 SCPRM的28 d抗压强度(fc28 d)极差分析结果
Table 13. Range analysis results of compressive strength at 28 d (fc28 d) of SCPRM
Analysis result OPC/HBSAC EVA SF Optimal level A2 B1 C2 R/MPa 22.4 84.5 24.7 Degree of influence B(wEVA)>C(VSF)>A(OPC∶HBSAC)
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表 14 SCPRM在14 d龄期时的fb14 d极差分析结果
Table 14. Range analysis results of fb14 d of SCPRM
Analysis result OPC/HBSAC EVA SF Optimal level A2 B2 C2 R/MPa 1.03 2.48 0.93 Degree of influence B(wEVA)>A(OPC∶HBSAC)>C(VSF)
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表 15 SCPRM的90 d干燥收缩极差分析结果
Table 15. Range analysis results of drying shrinkage at 90 d of SCPRM
Analysis result OPC/HBSAC EVA SF Optimal level A2 B2 C1 R/×10−5 60.65 33.96 21.78 Degree of influence A(OPC∶HBSAC)>B(wEVA)>C(VSF)
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表 16 SCPRM的72 h吸水率极差分析结果
Table 16. Range analysis results of water absorption rate at 72 h of SCPRM
Analysis result OPC/HBSAC EVA SF Optimal level A2 B3 C2 R/% 0.69 1.44 0.24 Degree of influence B(wEVA)>A(OPC∶HBSAC)>C(VSF)
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表 17 SCPRM的接触角极差分析结果
Table 17. Range analysis results of contact angle of SCPRM
Analysis result OPC/HBSAC EVA SF Optimal level A2 B3 C2 R/° 8.49 75.06 7.68 Degree of influence B(wEVA)>A(OPC∶HBSAC)>C(VSF)
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表 18 SCPRM的λ极差分析结果
Table 18. Range analysis results of λ of SCPRM
Analysis result OPC/HBSAC EVA SF Optimal level A3 B2 C1 R/ m2·s−1 5.2003×10−12 2.9155×10−12 2.0152×10−12 Degree of influence A(OPC∶HBSAC)>B(wEVA)>C(VSF)
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表 19 SCPRM不同性能对应的最佳配比
Table 19. Optimal ratios corresponding to different properties of SCPRM
Property Setting time ft1 d fc1 d ft28 d fc28 d fb14 d Drying
shrinkageWater absorption
rateContact
angleλ Optimal ratio A3B1C1 A3B1C3 A3B1C3 A2B3C3 A2B1C2 A2B2C2 A2B2C1 A2B3C2 A2B3C2 A3B2C1
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表 20 不同类型修补防护砂浆综合性能对比分析
Table 20. Comparison of the comprehensive performances of different types repair protect mortars
Type of repair protect mortar Flowability
/mmSetting time
/minft1 d/ft28 d
/MPafc1 d/fc28 d
/MPafb 14 d
/MPaDrying shrinkage
/10−5Water absorption rate
/%λ
/10−12 m2·s−1SCPRM5 226 63 5.2/17.1 16.7/73.2 3.61 16.44 0.16 0.9486 Basalt fiber reinforced geopolymer repair protect mortar [59] 220 23 5.2/10.5 27.0/59.2 1.3 550 - Polypropylene fiber reinforced geopolymer repair protect mortar [59] 190 29 4.8/9.6 22.0/56.4 1.4 510 Acrylic polymer repair protect mortar [60] - 12.0 (3 d)
/17.043.4 (3 d)
/62.32.8 7.0 - 5.25 MPCRM [61] - 13 40.0/35 2.8 4.0 - Ultra-early-strength MPCRM [62] 200 7 6.4 (3 h)
/9.830 (3 h)
/50.48.8 (Flexural-tensile strength) -
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表 21 图12(a)中点#1 EDS点扫描结果(at%)
Table 21. EDS point scan results for point #1 in Fig. 12(a) (at%)
Number C O Si S Ca Mo #1 12.3 57.1 2.1 8.1 15.1 2.3
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