JP7556561B2 - Floor coating method and floor coating - Google Patents

Description

The present invention relates to a coating method and a coating floor that creates a durable, highly slip-resistant floor surface in a short period of time.

Conventionally, floor surfaces such as concrete in factories and maintenance garages are not suitable for work environments because, as is, they generate dust, oil seeps in, and tools and other objects chip when dropped. To solve these problems, floor coatings have been applied to the floors.

In environments where floor surfaces are prone to becoming covered in liquids such as water or oil, for example food factories and kitchens, floor coatings made from highly slip-resistant materials can be applied, or floor coatings containing aggregate of a specified particle size can be applied to create physical irregularities on the floor surface.

In this situation, for example, the technology described in Patent Document 1 discloses a method for forming a coated floor in which an aqueous hard urethane concrete composition containing aggregate is applied to a base by troweling, the coated surface obtained by troweling is further compressed by a rolling means, and the aqueous hard urethane concrete composition is hardened to form an aqueous hard urethane concrete coated floor.

This technology is said to be capable of improving the strength, abrasion resistance, and surface appearance of water-based hard polyurethane concrete floor coatings that contain aggregate.

Furthermore, for example, the technology related to Patent Document 2 discloses a floor coating method in which a primer is applied to a base and then a floor coating material is applied on top of that, in which aggregate is spread before the primer hardens, and the primer is hardened to fix the aggregate, and then the floor coating material is applied.

This technology is said to enable low-fluidity floor coating materials to be applied evenly to a smooth base without slipping.

JP 2016-138385 A JP 2001-207631 A

The technology described in Patent Document 1 certainly has the advantage that the inclusion of aggregate can improve the strength and abrasion resistance of the coated floor, and furthermore, the proportion of the main component of the expensive coated floor material can be kept low by using the aggregate.

However, because workers cannot walk on the surface obtained by troweling before it hardens, they must either compact the area they can from unworked areas with a compaction roller, or compact from scaffolding or other means that will not affect the coated surface.

In the former case, the area that can be compacted at one time is limited, so troweling and compacting the base must be repeated multiple times, resulting in a long construction time. In the latter case, scaffolding must be set up, making the work extremely complicated, and the scaffolding can only be removed after the applied surface has hardened, resulting in a long construction time.

In addition, because this technology uses rolling compaction to cause the aggregate to settle and move downward, it is not possible to create physical irregularities on the surface with the aggregate to provide anti-slip properties.

In addition, the technology described in Patent Document 2 is indeed advantageous in that when applying a low-fluidity floor coating material to a smooth base, if the surface of the undercoat is first unevenly formed with aggregate, it is possible to prevent the floor coating material from slipping against the undercoat.

However, because workers cannot walk on the coated surface before the primer hardens, in order to spread aggregate (and compact it to help the aggregate adhere) before the primer hardens, workers must either spread (or compact) the area from an unpainted area, or compact it from scaffolding or similar that does not affect the coated surface.

In the former case, the area that can be sprayed (or compacted) at one time is limited, so the primer coat (and compaction) must be applied to the base multiple times, resulting in a long construction time. In the latter case, scaffolding must be set up, making the work extremely complicated, and the scaffolding can only be removed after the primer has hardened, resulting in a long construction time.

As such, the technology in Patent Document 2 also has the same problem as Patent Document 1 in that it takes a long time to install.

The technology described in Patent Document 2 is a technology that prevents the floor coating material from slipping during work, but since the floor coating material is simply applied on top of an undercoat, the aggregate in the floor coating material itself cannot be fixed to the undercoat, and therefore the anti-slip properties and abrasion resistance cannot be maintained for a long period of time.

This invention was made in consideration of the above circumstances, and aims to provide a coating method and a coating floor that can create a durable, highly slip-resistant floor surface in a short time.

To achieve the above objectives, the present invention provides the following technologies:

The invention of claim 1 comprises a base preparation step of preparing the base, an undercoat step of applying a basecoat material containing a first aggregate to the surface of the prepared base, a first rolling step of compacting the surface of the undercoat material, a spraying step of spraying a second aggregate onto the rolled surface of the undercoat material before the undercoat material hardens, a second rolling step of compacting the surface onto which the undercoat material has been sprayed, and a topcoat step of applying a topcoat material after the undercoat material has hardened. The invention provides a floor coating method characterized in that after the base preparation step, the base is divided into a number of adjacent work areas, and the undercoat step through the second rolling step are performed on a first work area that serves as a starting point, and then the undercoat step through the second rolling step are repeated for adjacent work areas in sequence to complete all of the work areas, and then the topcoat step is performed on all of the work areas after the undercoat material has hardened .

The invention of claim 2 aims to provide the coated floor construction method described in claim 1, characterized in that the undercoat material contains the first aggregate, forms urethane bonds and urea bonds with polyol, isocyanate, and water, and is an aqueous hard urethane concrete composition that forms concrete through a hydration reaction with cement and water.

The invention of claim 3 aims to provide the coated floor construction method described in claim 2, characterized in that the film thickness of the undercoat material is approximately 4.0 mm to approximately 7.0 mm, the film thickness of the topcoat material is approximately 0.1 mm to approximately 0.3 mm, the particle size of the first aggregate is approximately 2.0 mm to 3.0 mm, and the particle size of the second aggregate is approximately 0.5 mm to 2.0 mm.

According to the invention described in claim 1, the method includes a base preparation step for preparing the base, a base coating step for applying a base coating material containing a first aggregate to the surface of the prepared base, a first rolling step for compressing the surface of the base coating material, a spraying step for spraying a second aggregate onto the rolled surface of the base coating material before the base coating material hardens, a second rolling step for compressing the surface onto which the base coating material has been sprayed, and a top coating step for applying a top coating material after the base coating material hardens. As a result, the second aggregate can be laminated and fixed onto the first aggregate before the base coating material hardens, and the second aggregate can be used to stably form an uneven surface, allowing the construction of a durable floor surface with high anti-slip properties.

In addition, because a stable unevenness can already be formed before the topcoat process, the topcoat can be applied as a thin film, and topcoats with individual functions such as coloring to improve aesthetics, abrasion resistance, and chemical resistance can be used flexibly without compromising anti-slip properties.

Furthermore , after the surface preparation process, the base is divided into a number of adjacent work areas, and the first work area is subjected to the undercoat process through the second rolling process. The undercoat process through the second rolling process are then repeated for the adjacent work areas in sequence until all work areas are completed. After the undercoat material has hardened, the topcoat process is performed on all work areas. This allows all work areas up to the second rolling process to be completed in one go, even if the work area is large. Furthermore, once the undercoat material in the work area that has completed the final rolling process has hardened, the topcoat process can be performed on all work areas in one go, allowing work to be completed in a short amount of time.

According to the invention described in claim 2 , the undercoat material contains a first aggregate, and is an aqueous hard urethane concrete composition which forms urethane bonds and urea bonds with polyol, isocyanate, and water, and which forms concrete through a hydration reaction with cement and water. Therefore, it has excellent impact resistance and abrasion resistance, as well as heat resistance and chemical resistance, and can therefore be widely used as a floor material with excellent durability required for food factories, machine factories, and industrial floors, and the particle size and content of the first aggregate can be easily adjusted.

According to the invention described in claim 3 , the thickness of the undercoat material is approximately 4.0 mm to approximately 7.0 mm, the thickness of the topcoat material is approximately 0.1 mm to approximately 0.3 mm, the particle size of the first aggregate is approximately 2.0 mm to 3.0 mm, and the particle size of the second aggregate is approximately 0.5 mm to 2.0 mm. This makes it possible to stably layer the second aggregate on top of the first aggregate, thereby enabling the second aggregate to stably form an uneven surface, and thus enabling the construction of a floor surface with high slip resistance.

FIG. 1 is a flow diagram of a floor coating method according to an embodiment of the present invention. FIG. 11 is a plan view showing the state of the undercoat construction area of the floor coating method according to this embodiment, where (a) is before the undercoat process, (b) is a diagram of the divided work area, (c) is a diagram of the first work area after construction, (d) is a diagram of the fifth work area after construction, (e) is a diagram of the tenth work area after construction, and (f) is a diagram of the completion of the undercoat for all work areas. FIG. 2 is a simplified cross-sectional view of a coated floor constructed by the coating floor construction method according to the present embodiment.

The gist of the floor coating method according to the embodiment of the present invention is that it is characterized by comprising a base preparation step for preparing the base, an undercoat step for applying a basecoat containing a first aggregate to the surface of the prepared base, a first rolling step for compacting the surface of the undercoat, a spraying step for spraying a second aggregate onto the rolled surface of the undercoat before the undercoat hardens, a second rolling step for compacting the surface onto which the undercoat has been sprayed, and a topcoat step for applying a topcoat after the undercoat has hardened. In other words, the aim is to provide a floor coating method that constructs a floor surface with durable, highly slip-resistant properties in a short time.

As shown in Figures 1 and 2, the floor coating method according to an embodiment of the present invention includes a base preparation step S1 for preparing the base of a base G, an undercoat step S2 for applying an undercoat material 2 containing a first aggregate 1 to the surface of the prepared base G, a first rolling step S3 for compacting the surface of the undercoat material 2, a spraying step S4 for spraying a second aggregate 3 onto the compacted surface of the undercoat material 2 before the undercoat material 2 hardens, a second rolling step S5 for compacting the sprayed surface of the undercoat material 2, and a topcoat step S6 for applying a topcoat material 4 after the undercoat material 2 hardens.

After the surface preparation process S1, the base G is divided into a number of adjacent work areas, and the first work area g1, which serves as the starting point, is subjected to the undercoat process S2 through the second rolling process S5. The undercoat process S2 through the second rolling process S5 are then repeated for the adjacent work areas (g2 onwards) until all work areas have been completed, and then the topcoat process S6 is performed on all work areas after the undercoat material 2 has hardened.

The undercoat material 2 is an aqueous hard urethane concrete composition that contains the first aggregate 1, forms urethane bonds and urea bonds with polyol, isocyanate, and water, and forms concrete through a hydration reaction with cement and water.

The coated floor is formed using materials in which the thickness of the undercoat material 2 is approximately 4.0 mm, the thickness of the topcoat material 4 is approximately 0.15 mm, the particle size of the first aggregate 1 is approximately 2.5 mm, and the particle size of the second aggregate 3 is approximately 1.0 mm. However, it is possible to use materials in which the thickness of the undercoat material 2 is approximately 4.0 mm to approximately 7.0 mm, the thickness of the topcoat material 4 is approximately 0.1 mm to approximately 0.3 mm, and the particle size of the first aggregate 1 is approximately 2.0 mm to approximately 3.0 mm, and the particle size of the second aggregate 3 is approximately 0.5 mm to approximately 2.0 mm.

Furthermore, the topcoat process S6 is carried out approximately two hours after the undercoat process S2 is completed.

The floor coating method according to this embodiment is described in detail below.

The base G can be concrete, mortar, a painted floor, etc., but is not limited to this. In this embodiment, the method will be described as a painted floor method for concrete.

The construction area G described in the floor coating method according to this embodiment is an area that is approximately L-shaped in plan view and has a construction area of 49.0 ^mm2 (T1 = 5.0 m, T2 = 8.0 m, T3 = 3.0 m, T4 = 3.0 m) as shown in the plan view of Figure 2 (a), and all areas except T4 will be described as spaces surrounded by walls.

Also, as shown in Figure 2 (b), this construction area G is divided into eight work areas g1 to g15 (t1, t2, t3 = 1.0 m), and construction proceeds sequentially from the first work area g1 on the north side, which is the starting point, to the work areas g1, ..., g8 to g12 on the south side, and then to the work areas g13 to g15 on the east side .

It goes without saying that the division of the work area G can be changed as appropriate depending on the situation, such as the area to be worked on and the number of divisions, so long as the second compaction process S5 can be completed in one go.

The undercoat material 2 described in the floor coating method according to this embodiment is prepared by mixing a first liquid (Nihon Tokushu Toryo Co., Ltd.: Yutak Complete CPM Liquid A) whose main components are polyol and water, a second liquid (Nihon Tokushu Toryo Co., Ltd.: Yutak Complete CPM Liquid B) whose main component is isocyanate, and a first aggregate 1 made of cement consisting of powder with a particle size of approximately 0.1 mm to 0.3 mm and the ceramic aggregate described above.

The resin produced by the reaction between the first and second liquids exhibits flexibility, impact resistance, and abrasion resistance due to the urethane bonds, and exhibits chemical resistance, abrasion resistance, toughness, and adhesiveness due to the urea bonds. Concrete, which is made of cement and water, can improve its heat resistance, adhesiveness, and strength due to the hydration reaction.

In addition, the undercoat material 2 may be mixed with a curing accelerator or a coloring agent that acts as a pigment to accelerate curing and improve appearance.

Specifically, for the construction area G of 49.0 ^mm2 shown in Figure 2 (a), approximately 36 kg of the first liquid, approximately 36 kg of the second liquid, and approximately 324 kg of a mixture of cement and first aggregate 1 are used, and a coating film of approximately 4.0 mm thickness is formed using the primer 2 obtained by mixing and stirring these.

Next, in the base preparation process S1, after removing dust and foreign matter from the surface, any remaining laitance, efflorescence, and oils and greases are thoroughly removed, and on the flat areas, U-groove joints 10 mm wide and 10 mm deep are formed at intervals of up to 5 m, and similar U-grooves are also formed at the boundaries with the edges of walls, etc.

In addition, in the base material adjustment process S1, it is necessary that there is no floating water and that the material is sufficiently dry.

In addition, it is sufficient if the work area is large enough to allow all work areas to be completed at once for the subsequent processes, but if it is necessary to divide the work area into multiple work areas for work, it is desirable to clearly mark the work areas on the floor with masking tape or the like so that they can be identified in advance, as shown in Figure 2(b), for example.

In the undercoat process S2, the topcoat material 4 containing the first aggregate 1 is applied to the base using a trowel such as a metal trowel, and in this embodiment, this process is carried out within 15 minutes for one work area.

The first rolling step S3 is carried out immediately after the undercoating step S2. The rolling step is carried out by rolling the coated surface with a sand roller without pressing it against the coated surface. The rolling step is repeated several times until the resin portion floats up .

In this embodiment, a sand and bone roller is used for compaction, but other rollers such as a wool roller, a mastic roller, or a head cut roller may also be used, and the method is not limited to this embodiment.

The spreading process S4 is carried out immediately after the first compaction process S3. In this embodiment, the alumina aggregate with a particle size of approximately 1.0 mm is spread uniformly by hand as described above. However, when spreading by hand, the distance at which the hand can be stretched from the untreated area and the spread can be carried out stably is set to approximately 1.0 m. Therefore, in this embodiment, all the work areas g1 to g15 are divided in consideration of the length at which hand spreading is possible.

In this embodiment, alumina aggregate is used as the second aggregate 3, and in a broader sense, ceramic aggregate is also used. However, since ceramic aggregate has poor uniformity in particle size, it is preferable to use a material with a particle size in the range of approximately 0.5 mm to 2.0 mm. Silica sand (No. 4: 0.6 mm to 1.12 mm) can also be used.

In addition, in this embodiment, the spraying is done by hand, but other devices such as a lysine gun or blower may also be used, and the method is not limited to this embodiment.

In addition, for aesthetic reasons, it is desirable to use an aggregate of the same color as the undercoat material 2 for the second aggregate 3 to be scattered.

The second rolling step S5 is carried out immediately after the spreading step S4, and is carried out by rolling the sand roller gently over the application surface, without pressing it against the surface. In this case, it is necessary to use even less force than the second rolling step S5.

In this embodiment, a sand and bone roller is used for compaction, but other rollers such as a wool roller, a mastic roller, or a head cut roller may also be used, and the method is not limited to this embodiment.

The base G that has been prepared in this way is then subjected to the undercoat process S2 through the second rolling process S5. However, if the work is divided into multiple work areas, for example, as shown in Figures 2(b) through (f), the undercoat process S2 through the second rolling process S5 are performed on the first work area g1, which serves as the starting point, and then the undercoat process through the second rolling process S5 are repeated for adjacent work areas in sequence until all work areas are completed.

Once the second compaction process S5 has been completed for all work areas, the topcoat process S6 can be carried out using a roller or brush approximately two hours after the final application of the undercoat material 2.

In this embodiment, the coated surface can be walked on without being affected after more than two hours have passed since application of the above-mentioned undercoat material 2, and the topcoat process S6 can be carried out.

The topcoat material 4 used in the topcoat process S6 is not particularly limited, but in this embodiment, because stable unevenness has already been formed in the previous process, the topcoat material 4 is applied using the following material, which is thin and emphasizes anti-slip properties.

The topcoat material 4 described in the floor coating method according to this embodiment is prepared by mixing a third liquid whose main components are polyol and water (Nihon Tokushu Toryo Co., Ltd.: Yutak Complete G Liquid A), a fourth liquid whose main component is isocyanate (Nihon Tokushu Toryo Co., Ltd.: Yutak Complete G Liquid B), and cement made of powder (Nihon Tokushu Toryo Co., Ltd.: Yutak Complete T Powder).

Specifically, for the application area G of 49.0 ^mm2 shown in Figure 2 (a), approximately 2 kg of the third liquid, approximately 2 kg of the fourth liquid, and approximately 3 kg of cement are used, and these are mixed and stirred to obtain a topcoat material 4, which is used to form a coating film approximately 0.15 mm thick.

Therefore, in this embodiment, by forming the top coat material 4 on the undercoat material 2 that is approximately 4.0 mm thick, a coating floor that is approximately 4.15 mm thick is formed from the base G, and the area where the second aggregate 3 appears is approximately 5.15 mm thick at its maximum, creating a well-defined uneven surface.

In the topcoat process S6, the prepared topcoat material 4 is applied to the surface of the undercoat material 2 by a roller. In this case, the work can be done on the entire application area G in one go, and in this embodiment, it is completed within 7 minutes, forming a coating film as shown in Figure 3.

In this embodiment, a wool roller is used for the top coat, but a mastic roller, head cut roller, brush, etc. may also be used, and the method is not limited to this embodiment.

As explained above, the floor coating method according to this embodiment includes a surface preparation step S1 for preparing the base G, a base coating step S2 for applying a base coating material 2 containing a first aggregate 1 to the surface of the base coating material G that has been prepared, a first rolling step S3 for rolling the surface of the base coating material 2, a spraying step S4 for spraying a second aggregate 3 on the rolled surface of the base coating material 2 before the base coating material 2 hardens, a second rolling step S5 for rolling the surface on which the base coating material 2 has been sprayed, and a top coating step S6 for applying a top coating material 4 after the base coating material 2 hardens. Therefore, the second aggregate 3 can be laminated and fixed on the first aggregate 1 before the base coating material 2 hardens, so that the second aggregate 3 can stably form an uneven surface, and a durable floor surface with high slip resistance can be constructed.

In addition, because stable unevenness can already be formed before the topcoat step S6, the topcoat material 4 can be formed into a thin film, and topcoats with individual functions such as coloring to improve aesthetics, abrasion resistance, and chemical resistance can be used flexibly without compromising anti-slip properties.

After the surface preparation step S1, the base G is divided into a number of adjacent work areas, and the first work area g1, which serves as the starting point, is subjected to the undercoat step S2 through the second rolling step S5. The undercoat step S2 through the second rolling step S5 are then repeated for the adjacent work areas (g2 onwards) until all work areas are completed. After the undercoat material 2 has hardened, the topcoat step S6 is performed on all work areas. This allows all work areas up to the second rolling step S5 to be worked on at once, even if the work area is large. Moreover, once the undercoat material 2 in the last work area where the second rolling step S5 has been completed has hardened, the topcoat step S6 can be performed on all work areas at once, allowing work to be completed in a short time.

The undercoat material 2 contains the first aggregate 1, and is an aqueous hard urethane concrete composition that forms urethane bonds and urea bonds with polyol, isocyanate, and water, and forms concrete through a hydration reaction with cement and water. This gives the undercoat material excellent impact resistance and abrasion resistance, as well as heat resistance and chemical resistance. Not only can it be widely used as a flooring material with excellent durability required for food factories, machine factories, and industrial floors, but the particle size and content of the first aggregate 1 can also be easily adjusted.

Furthermore, by setting the thickness of the undercoat material to approximately 4.0 mm to approximately 7.0 mm, the thickness of the topcoat material to approximately 0.1 mm to approximately 0.3 mm, the particle size of the first aggregate to approximately 2.0 mm to 3.0 mm, and the particle size of the second aggregate to approximately 0.5 mm to 2.0 mm, the second aggregate 3 can be layered stably on top of the first aggregate 1, so that the second aggregate 3 can stably form an uneven surface, allowing the construction of a floor surface with high slip resistance.

Floor coating using the floor coating method of the present invention can provide a floor surface with high slip resistance.

Although the preferred embodiment of the present invention has been described above, the present invention is not limited to the specific embodiment, and various modifications and variations are possible within the scope of the gist of the present invention described in the claims.

G Base g1 Working area (first)
g2 work area g3 work area g4 work area g5 work area g6 work area g7 work area g8 work area g9 work area g10 work area g11 work area g12 work area g13 work area g14 work area g15 work area (last)
S1: Base preparation step S2: Undercoat step S3: First rolling compaction step S4: Spraying step S5: Second rolling compaction step S6: Topcoat step 1: First aggregate 2: Undercoat material 3: Second aggregate 4: Topcoat material

Claims (3)

The method comprises a surface preparation step of preparing a base, a base coating step of applying a base coating material containing a first aggregate to the surface of the base coating that has been prepared, a first rolling step of compressing the surface of the base coating material, a scattering step of scattering a second aggregate onto the surface of the base coating material that has been compressed before the base coating material hardens, a second rolling step of compressing the surface onto which the base coating material has been scattered, and a top coating step of applying a top coating material after the base coating material hardens ,
This floor coating method is characterized in that after the base preparation process, the base is divided into a number of adjacent work areas, and the undercoat process through the second rolling process are carried out on a first work area that serves as a starting point, and then the undercoat process through the second rolling process are repeated for adjacent work areas in sequence until all work areas have been completed, and then the topcoat process is carried out on all work areas after the undercoat material has hardened . The method for applying the coating to a floor according to claim 1, characterized in that the undercoat material contains the first aggregate, and is an aqueous hard urethane-based concrete composition that forms urethane bonds and urea bonds with polyol, isocyanate, and water, and forms concrete through a hydration reaction with cement and water . The coating method according to claim 2, characterized in that the thickness of the undercoat material is approximately 4.0 mm to approximately 7.0 mm, the thickness of the topcoat material is approximately 0.1 mm to approximately 0.3 mm, the particle size of the first aggregate is approximately 2.0 mm to 3.0 mm, and the particle size of the second aggregate is approximately 0.5 mm to approximately 2.0 mm .

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