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CA-3094255-C - EPOXY RESIN COMPOSITION FOR UNDERWATER GROUTING

CA3094255CCA 3094255 CCA3094255 CCA 3094255CCA-3094255-C

Abstract

Disclosed are curable epoxy resin compositions containing at least one epoxy resin having on average more than one epoxide group per molecule, at least one inorganic filler, at least one hydraulic binder, and at least one polycarboxylate ether, wherein said inorganic filler comprises silica with an amount of between 45 and 65 wt. -%, based on the total curable epoxy resin composition, and the amount of said polycarboxylate ether is between 0.01 and 0.03 wt. -%, based on the total curable epoxy resin composition. Also disclosed are multi-component systems for producing said epoxy resin compositions, cured epoxy resins, and methods for repairing or reinforcing a pile or column.

Inventors

  • Yan Shao
  • Weijie YEK
  • Lanwei WANG

Assignees

  • SIKA TECHNOLOGY AG

Dates

Publication Date
20260505
Application Date
20180321

Claims (18)

  1. Claims 1.
  2. 2.
  3. 3.
  4. 4.
  5. 5. A curable epoxy resin composition for underwater grouting, comprising at least one epoxy resin having on average more than one epoxide group per molecule, at least one inorganic filler, at least one hydraulic binder, and at least one polycarboxylate ether, wherein the epoxy resin is selected from the group consisting of diglycidyl ethers of bisphenol A, of bisphenol F, and of bisphenol A/F; the hydraulic binder is cement in an amount of between 5 and 10 wt. %, based on the total curable epoxy resin composition; said inorganic filler comprises silica in an amount of between 45 and 65 wt.-%, based on the total curable epoxy resin composition, and the at least one polycarboxyate ether is in a solid state and in an amount of between 0.01 and 0.03 wt.-%, based on the total curable epoxy resin composition. The curable epoxy resin composition according to claim 1, wherein said silica has a particle size of < 50 µm, determined by sieve analysis according to ASTM E11 using a No. 325 Mesh. The curable epoxy resin composition according to claim 1 or 2, additionally comprising at least one curing agent and/or at least one reactive diluent. The curable epoxy resin composition according to any one of claims 1 to 3, wherein the epoxy resin comprises at least one glycidyl ether, and/or the curing agent comprises at least one polyamine. The curable epoxy resin composition according to claim 4, wherein the at least one polyamine is selected from the group consisting of aliphatic, 35 cycloaliphatic or arylaliphatic primary diamines, triamines, tetramines, polyamines with more than four amine groups per molecule, secondary amine group-containing polyamines, amine/polyepoxide adducts, poly(ethylene imines), polyamidoamines, Mannich bases and amino terminated butadiene/acrylonitrile copolymers.
  6. 6.
  7. 7. The curable epoxy resin composition according to any one of claims 1 to 5, wherein the polycarboxylate ether has side chains linked to a main chain via ester, amide and/or ether groups, wherein the main chain has at least one acrylic acid moiety or a salt thereof and/or at least one methacrylic acid moiety or a salt thereof. The curable epoxy resin composition according to any one of claims 1 to 6, wherein the polycarboxylate ether is a comb polymer comprising structural units (i) of the formula II and structural units (ii) of the formula III, wherein (II) (III) 36 R1, independently of one another, represents -COOM, -SO2–OM, -O–PO(OM)2, and/or -PO(OM)2, R2 und R5, independently of one another, represent H, -CH2COOM, or an alkyl radical with 1 to 5 carbon atoms, R3 und R6, independently of one another, represent H or an alkyl radical with 1 to 5 carbon atoms, R4 und R7, independently of one another, represent H, -COOM, or an alkyl radical with 1 to 5 carbon atoms, or wherein R1 together with R4 forms an anhydride -CO-O-CO- ring, M, independently of one another, represents H+, an alkali metal ion, an alkaline earth metal ion, an ammonium cation, an organic ammonium compound, a di- or trivalent metal cation, or mixtures thereof; m = 0, 1, or 2, p = 0 or 1, X, independently of one another, represents -O-, NH-, or -NR8-, R8, independently of one another, represents a radical of the formula -[AO]n-Ra, wherein A = C2- to C4-alkylene, Ra represents H, a C1- to C20-alkyl group, -cyclohexyl group, or –alkylaryl group, and n = 2 to 250.
  8. 8.
  9. 9. The curable epoxy resin composition according to claim 7, wherein n = 10 to 200. The curable epoxy resin composition according to claim 7 or 8, wherein R1 represents -COOM, R2, R4, R5, R3, R6 and R7 represent H, M, independently of one another, represents H+, an alkali metal ion, or an alkaline earth metal ion; m = 0, p = 1, X represents –O-, 37 R8 represents a group of formula -[AO]n-Ra, wherein A = C2-alkylene, Ra represents CH3, and n = 22 to 72.
  10. 10. A multi-component system for producing a curable epoxy resin composition as defined in any one of claims 1 to 8, comprising a component K1 comprising said at least one epoxy resin, and a curing agent component K2 comprising at least one curing agent, wherein said inorganic filler, said hydraulic binder, and said polycarboxylate ether are comprised in said component K1, said component K2, or in an additional component K3.
  11. 11. The multi-component system according to claim 10, wherein said multi component system is a two-component system, comprising the component K1 comprising said at least one epoxy resin, and the curing agent component K2 comprising at least one curing agent, wherein said inorganic filler, said hydraulic binder, and said polycarboxylate ether are comprised in said component K1.
  12. 12. The two-component system according to claim 11, wherein said component K1 comprises - - - - - between 15 and 35 wt.-%, based on the total component K1, of said epoxy resin; between 0 and 5 wt.-%, based on the total component K1, of an epoxy functional diluent; between 0 and 0.1 wt.-%, based on the total component K1, of a defoamer; between 5 and 10 wt.-%, based on the total component K1, of said hydraulic binder; between 50 and 70 wt.-%, based on the total component K1, of said inorganic filler; 38 CA 3094255- between 0.015 and 0.025 wt.-%, based on the total component K1, of said polycarboxylate ether; and said component K2 comprises - between 20 and 60 wt.-%, based on the total component K2, of at least one polyamine; - - between 0 and 15 wt.-%, based on the total component K2, of an accelerator; between 0 and 50 wt.-%, based on the total component K2, of solvents; wherein all amounts of the individual ingredients in each component K1 and K2 are adjusted such that sum of all individual amounts does not exceed 100% in the respective component K1 or K2.
  13. 13. A cured epoxy resin obtained by curing the epoxy resin composition as defined in any one of claims 1 to 9 or by mixing the components and curing the multi- or two-component system as defined in any one of claims 10 to 12.
  14. 14. A method for repairing or reinforcing a pile or column, comprising the steps a) Installing a sleeve around the pile or column covering the damaged areas of the pile or column surface such that the sleeve circumvents the pile or column leaving a gap between the surface of the pile or column and the inner surface of the sleeve; b) Sealing the sleeve against the pile or column; c) Introducing the curable epoxy-resin composition as defined in any one of claims 1 to 9, or the epoxy-resin composition obtained by mixing a multi- or two-component system as defined in any one of claims 10 to 12 in the appropriate ratio into the gap between the sleeve and the pile or column; d) Curing the epoxy-resin composition. 39
  15. 15. The method according to claim 14, wherein the steps further include pretreating the pile or column by cleaning, sand- or wet blasting, priming, and/or brushing.
  16. 16. The method according to claim 14 or 15, wherein sealing the sleeve against the pile or column is at the lower opening,
  17. 17. The method according to any one of claims 14 to 16, wherein said pile or column is at least partially submerged in water.
  18. 18. The method according to any one of claims 14 to 17, wherein said pile or column is made of concrete and/or steel. 40

Description

EPOXY RESIN COMPOSITION FOR UNDERWATER GROUTING Technical field The present invention relates to curable epoxy resin compositions for underwater grouting, containing at least one epoxy resin having on average more than one epoxide group per molecule, at least one inorganic filler, at least one hydraulic binder, and at least one polycarboxylate ether. The present invention also relates to two-component systems for producing epoxy resin compositions, cured epoxy resin compositions, and methods for their application. Prior art Epoxy resins are used for a variety of applications, for example as adhesives, coatings, sealants, or molding compositions for producing moldings. Among these, compositions comprising fillers and/or hydraulic binders are commonly used in grouting applications. Such filled composition show good mechanical properties as well as chemical, environmental, and mechanical resistance and have very good adhesive properties on substrates such as natural stone, concrete, and other construction surfaces. One special field of application is the refurbishment or reinforcement of concrete foundations in water, of buildings such as piers or bridges, where concrete columns, piles, and other foundation elements are used to support platforms next to or on water bodies. Especially at the seaside, where strong elemental forces and high water movement are common, and the saline water itself has highly corrosive properties, these foundation structures often suffer from severe mechanical and chemical degradation and at some point require restorative work 1 in order to maintain their ability to support the structures built thereon. Without any restoration, such affected foundation structures show concrete failure and steel bar exposure and they ultimately collapse. One elegant and cost-efficient method for reinforcing underwater piles or columns involves the attachment of a glass-fiber sleeve around the damaged pile or column and the introduction of a grouting material between the damaged pile or column and the inner side of the glass-fiber sleeve. After curing, the grout forms a strongly adhering interlayer between pile or column and the sleeve and additionally fills cracks and holes, and the whole structure is significantly strengthened and protected against future abrasion. This method is known since the 1970s, and still is being optimized and further developed. For example, Chinese utility model CN 205205695 U or Chinese patent application CN 10586257 4 A teach this method in a recent approach. However, this method requires a highly adapted grout that is also able to properly cure underwater, since the abrasion of the concrete piles or columns takes place also in partially or completely submerged sections. Many epoxy-based grouts are not able to meet the required properties and fail to cure and/or adhere properly on the substrates when in contact with water, in particular seawater. Some special epoxy-based grouts have thus been developed that are generally suitable for this task. It was found that the use of BaSO4 as filler in epoxy-based grouts leads to good underwater curing behavior, since it renders the compositions heavy by density increase and generally provides good flowability and low oil absorption in the material, which is advantageous. However, it is often observed that BaSO4-filled compositions tend to disperse or separate when poured into water and the fillers are washed out over time, thereby reducing the overall performance of the cured grout. 2 Other commonly used fillers increase the viscosity of the compositions too much, which puts a serious burden on the workability of the compositions. In general, it is a persistent problem in this field to balance flowability and dispersity of such epoxy-based grout compositions in water. Overall, it would be desirable to provide an epoxy-based curable grout composition that is non-separable and fast curing under water, shows no shrinkage, has a low viscosity and good workability and an overall excellent performance regarding mechanical properties, chemical, mechanical, and fatigue resistance, as well as adhesion, in particular on wet or damp concrete. The object of the invention The object of the invention is to overcome the problems described above. In particular, the invention shall provide a curable epoxy-resin composition with good flowability that shows excellent underwater handling and curing behavior and outstanding mechanical properties and adhesion, in particular underwater. Furthermore, it is an object of the present invention to provide a method for repairing or reinforcing a pile or column using the inventive curable epoxy resin composition, in particular a pile or column at least partially submerged in water. Disclosure of the invention Substance names beginning with "poly" designate substances which formally contain, per molecule, two or more of the functional groups occurring in their names. For instance, a polyamine refers to a compound