CN111116165A - Double-layer modified inorganic anticorrosive coating and preparation method thereof - Google Patents
Double-layer modified inorganic anticorrosive coating and preparation method thereof Download PDFInfo
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- CN111116165A CN111116165A CN201911204017.8A CN201911204017A CN111116165A CN 111116165 A CN111116165 A CN 111116165A CN 201911204017 A CN201911204017 A CN 201911204017A CN 111116165 A CN111116165 A CN 111116165A
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/34—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing cold phosphate binders
- C04B28/344—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing cold phosphate binders the phosphate binder being present in the starting composition solely as one or more phosphates
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
- C04B2111/00482—Coating or impregnation materials
- C04B2111/00525—Coating or impregnation materials for metallic surfaces
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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Abstract
The invention discloses a double-layer modified inorganic anticorrosive coating, which is characterized in that: the composite material comprises an inner layer and an outer layer, wherein the outer layer comprises the following raw material components, by weight, 30-40 parts of inorganic phosphate, 30-50 parts of metal oxide, 5-10 parts of nano particles, 10-20 parts of inorganic filler, 1-10 parts of retarder and 1-10 parts of dispersant; the inner layer comprises the following raw material components, by weight, 30-40 parts of inorganic phosphate, 30-50 parts of metal oxide, 10-20 parts of inorganic filler, 1-10 parts of retarder and 1-10 parts of dispersant. The invention also discloses a preparation method of the double-layer modified inorganic anticorrosive coating. The double-layer modified inorganic anti-corrosion coating not only is an inorganic coating with excellent internal and external anti-corrosion and high temperature resistance, but also is a modified inorganic coating which is cured at normal temperature and is compatible with concrete and has excellent adhesion, and has excellent double protection effects.
Description
Technical Field
The invention belongs to the technical field of building materials, and particularly relates to a double-layer modified inorganic anticorrosive coating and a preparation method thereof.
Background
The reinforced concrete structure has the advantages of firmness, stability, good fireproof performance, low construction cost, strong bearing capacity and the like, so that the reinforced concrete structure is widely applied to expressways, underground tunnels, large-span bridges, harbor dams and ocean platforms. But the steel bars are corroded and damaged by environmental factors such as physical action, chemical corrosion, microbial corrosion and the like, so that the service life and the durability of the reinforced concrete structure are seriously reduced.
Chinese patent CN104418552A "preparation method of inorganic anticorrosive coating for reinforcing steel bar" describes an inorganic anticorrosive coating for reinforcing steel bar, which has good adhesion with the surface of reinforcing steel bar, good compatibility between the coating and concrete and high bonding strength. The use of a water-hardening gel compatible with cement ingredients is satisfactory for improving the bonding strength with concrete, but has the following problems: (1) the inorganic anticorrosive coating for the reinforcing steel bars introduced in the patent can only enable the bonding strength between the reinforcing steel bars and concrete to reach 1.0-2.0MPa, but the bonding strength of the inorganic coating is 5.0-10 MPa; (2) the added aggregate fine sand can increase the porosity of the coating and reduce the bonding property and the corrosion resistance of the coating.
Chinese patent CN108795128A, a double-layer compact metal anticorrosive coating formed by low-temperature sintering, a preparation method and application thereof, discloses a double-layer compact metal anticorrosive coating formed by low-temperature sintering, which is composed of an outer inorganic ceramic coating and an inner matrix oxide coating. The method is suitable for the field of metal corrosion prevention in a corrosive environment, but has the following problems: (1) the thickness of the base oxide coating of the inner layer produced by low-temperature sintering is small, and the corrosion resistance can be reduced due to the fact that the compactness of the iron rust generated on the surface of the steel bar is relatively insufficient; (2) the interface of the inner layer and the outer layer can be obviously distinguished, which shows that the fusion bonding degree between the inner layer and the outer layer is not high, the inner and outer anti-corrosion performance is different, and the similar rust product further reduces the inner anti-corrosion performance.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention provides the double-layer modified inorganic anticorrosive coating which is cured at normal temperature, has excellent anticorrosive capability and can improve the microcosmic bonding strength and the macroscopic bonding strength between the reinforcing steel bar and the concrete and the preparation method thereof.
The technical scheme adopted by the invention for solving the technical problems is as follows: a double-layer modified inorganic anticorrosive coating comprises an inner layer and an outer layer, wherein the outer layer comprises the following raw material components, by weight, 30-40 parts of inorganic phosphate, 30-50 parts of metal oxide, 5-10 parts of nano particles, 10-20 parts of inorganic filler, 1-10 parts of retarder and 1-10 parts of dispersant; the inner layer comprises the following raw material components, by weight, 30-40 parts of inorganic phosphate, 30-50 parts of metal oxide, 10-20 parts of inorganic filler, 1-10 parts of retarder and 1-10 parts of dispersant.
Preferably, the nanoparticles are one or a combination of two or more of nano calcium carbonate, nano silicon dioxide, nano titanium dioxide and nano tricalcium silicate.
After the nano particles are doped, the porosity is obviously reduced, the pore structure is greatly refined, the pore diameter is also converted from most harmful pores to secondary harmful pores, the early cement hydration process can be promoted by adding nano calcium carbonate, nano silicon dioxide and titanium dioxide into the cement, and the early cement hydration process can be promoted by adding the nano calcium carbonate, the nano silicon dioxide and the titanium dioxide into a cement hydration product Ca (OH)2Reaction to produce C-S-H gel, nano CaCO3The calcium aluminate reacts with tricalcium aluminate to generate needle-shaped hydrated calcium sulphoaluminate and hydrated calcium carbonate aluminate, the porosity is further reduced, the aperture is refined, a large amount of ultrahigh-density C-S-H gel is generated, and the cohesiveness is improved. Tricalcium silicate is added into the coating, the components of the tricalcium silicate are the same as those of concrete, hydration products such as calcium hydroxide, calcium silicate hydrate, ettringite and the like are generated with water, the cohesiveness of the concrete poured in the later period is enhanced, and the tricalcium silicate reacts with the nano particles to further improve the cohesiveness of a transition area of a steel bar-concrete interface.
Preferably, the inorganic phosphate is one or a combination of two or more of aluminum dihydrogen phosphate, sodium dihydrogen phosphate, aluminum phosphate and calcium phosphate.
Preferably, the metal oxide is one or a combination of two of magnesium oxide, sodium oxide and aluminum oxide.
Preferably, the inorganic filler is one or a combination of two or more of boehmite, montmorillonite, bauxite and borax.
Preferably, the retarder is one or a combination of two or more of borax, sodium hexametaphosphate and sodium tripolyphosphate. Borax, sodium tripolyphosphate and sodium hexametaphosphate have high solubility in water, but slow solubility, have the capability of generating soluble complex for metal ions such as calcium, magnesium and the like, prevent gel precipitation, and have corrosion resistance. The sodium tripolyphosphate can also make the calcium, aluminum and other particles better dissolved in the plasma-removing water medium to play a thickening role, and the sodium tripolyphosphate can be used together with an anticorrosive pigment to improve the anticorrosive performance of an aqueous system and a solvent system.
Preferably, the dispersant is one or a combination of two or more of sodium silicate, sodium carbonate and sodium phosphate.
The dispersing agent can quickly wet the surface of the coating, effectively improve the particle wettability, suspension stability and coating rheological property in a high-temperature melting state of the coating under the condition of low moisture content, and enable the coating to have proper viscosity so as to achieve the purpose of improving the bonding strength. The inorganic dispersant is ionized into ions and then adsorbed on the surface of the nano particles, a double electric layer structure is formed on the surface of the nano particles, so that the surface charge density of the nano particles is improved, the van der Waals attractive force among the particles is overcome through the repulsion effect of the same kind of charges on the surface, and the dispersed nano particles are uniformly distributed. After the dispersing agent is added, the dispersing agent is adsorbed on the surface of the particles, the surface of the original particles is partially or completely covered by the dispersing agent, the agglomeration of the nano particles is hindered, and the bonding strength between the coating and the concrete can be improved after the uniformly distributed nano particles react.
Preferably, the inorganic filler is sieved by a sieve with 300-500 meshes.
Preferably, the overall thickness of the coating is 200-300 microns, and the thickness ratio of the inner layer to the outer layer is 1.5-2: 1.
the invention discloses a double-layer modified inorganic anti-corrosion coating, which relates to the field of reinforced concrete structures of large-scale projects such as expressways, underground tunnels, large-span bridges, harbor dams, ocean platforms and the like.
The invention also discloses a double-layer modified inorganic anticorrosive coating, which comprises the following steps:
1) preparing an inner layer coating: weighing 30-40 parts of inorganic phosphate, 30-50 parts of metal oxide, 10-20 parts of inorganic filler, 1-10 parts of retarder and 1-10 parts of dispersant, adding plasma-removed water to adjust viscosity, heating and stirring at 100 ℃ and 200 ℃ to react for 1-2h, and standing to obtain a semitransparent inner layer component with the phosphate mass solubility of 20-50%;
2) preparing an outer layer coating: weighing 30-40 parts of inorganic phosphate, 30-50 parts of metal oxide, 5-10 parts of nano particles, 10-20 parts of inorganic filler, 1-10 parts of retarder and 1-10 parts of dispersing agent, adding plasma-removed water to adjust viscosity, heating and stirring at 100 ℃ and 200 ℃ for reaction for 1-2h, and standing to obtain a semitransparent outer layer component with the phosphate mass solubility of 20-50%;
3) coating and curing the inner layer: uniformly coating an inner layer coating on the surface of the steel bar, and drying and curing for 1-2h in the air at normal temperature;
4) coating and curing the outer layer: and uniformly coating the outer layer coating on the surface coated with the inner layer coating, and drying and curing for 1-2h in the air at normal temperature.
The invention has the beneficial effects that: (1) the outer coating is compatible with concrete, the bonding strength is high, the bonding property between the inner layer and the steel bar is optimized, the bonding strength between the ribbed steel bar of the coating and the concrete is more than 1.8 times that of a common twisted steel bar, (2) the corrosion resistance is excellent, and no obvious corrosion defect appears on the surface of the steel bar in an electrochemical accelerated corrosion test 22 d; (3) the degree of adhesion between the coating and the steel bar can reach more than 10MPa, which is superior to that of the epoxy coating steel bar; (4) the coating can be cured at normal temperature, and the influence on the steel bar is reduced.
Drawings
FIG. 1 shows a multilayer modified inorganic anticorrosive coating, an outer modified inorganic coating bonded to concrete, and an inner inorganic coating bonded to a metal substrate.
Detailed Description
In order to make the technical solutions of the present invention better understood, the technical solutions in the embodiments of the present invention will be clearly and completely described below, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Example 1
The double-layer modified inorganic anticorrosive coating comprises an inner layer and an outer layer, wherein the inner layer comprises the following raw material components in parts by weight: 185g of aluminum oxide, 110g of sodium oxide, 105g of magnesium oxide, 155g of aluminum dihydrogen phosphate, 115g of sodium dihydrogen phosphate, 80g of aluminum phosphate, 56g of boehmite, 34g of montmorillonite, 54g of bauxite, 52g of sodium silicate and 54g of sodium carbonate; the outer layer comprises the following raw material components by weight: 151g of aluminum oxide, 105g of sodium oxide, 94g of magnesium oxide, 84g of aluminum dihydrogen phosphate, 100g of sodium dihydrogen phosphate, 116g of aluminum phosphate, 50g of boehmite, 30g of montmorillonite, 70g of bauxite, 54g of sodium silicate, 52g of sodium carbonate, 50g of nano calcium carbonate, 30g of nano calcium silicate and 20g of nano silicon dioxide.
A double-layer modified inorganic anticorrosive coating comprises the following steps:
1) preparing an inner layer coating: weighing 185g of aluminum oxide, 110g of sodium oxide, 105g of magnesium oxide, 155g of aluminum dihydrogen phosphate, 115g of sodium dihydrogen phosphate, 80g of aluminum phosphate, 56g of boehmite, 34g of montmorillonite, 54g of bauxite, 52g of sodium silicate and 54g of sodium carbonate, mixing and uniformly stirring, adding 200g of plasma-removed water to adjust viscosity, heating and stirring at 120 ℃ for reaction for 1h, and standing for 24h to obtain a semitransparent inner-layer component with the phosphate mass solubility of 25%;
2) preparing an outer layer coating; weighing 151g of aluminum oxide, 105g of sodium oxide, 94g of magnesium oxide, 84g of aluminum dihydrogen phosphate, 100g of sodium dihydrogen phosphate, 116g of aluminum phosphate, 50g of boehmite, 30g of montmorillonite, 70g of bauxite, 54g of sodium silicate, 52g of sodium carbonate, 50g of nano calcium carbonate, 30g of nano calcium silicate and 20g of nano silicon dioxide, mixing, adding 200g of plasma-removed water to adjust viscosity, heating and stirring at 120 ℃ for reaction for 1h, and standing for 24h to obtain a semitransparent outer layer component with the phosphate mass solubility of 25%;
3) treating a base material: the concrete is blown or washed to remove dust and impurities on the surface, and keeps clean and dry;
4) coating and curing the inner layer, namely uniformly coating the inner layer coating on the surface of the steel bar, and drying and curing for 1.6 hours in the air at normal temperature;
5) and (3) coating and curing the outer layer, uniformly coating the outer layer coating on the surface coated with the inner layer coating, and drying and curing for 1.4h in the air at normal temperature. The coating thickness was 258um, the inner layer thickness was 165, and the outer layer thickness was 93 um.
Example 2
The double-layer modified inorganic anticorrosive coating comprises an inner layer and an outer layer, wherein the inner layer comprises the following raw material components in parts by weight: 100g of aluminum oxide, 100g of sodium oxide, 200g of magnesium oxide, 150g of aluminum dihydrogen phosphate, 100g of sodium dihydrogen phosphate, 150g of aluminum phosphate, 30g of boehmite, 70g of montmorillonite, 50g of bauxite, 30g of sodium hexametaphosphate and 20g of sodium tripolyphosphate; the outer layer comprises the following raw material components by weight: 150g of aluminum oxide, 100g of sodium oxide, 100g of magnesium oxide, 100g of aluminum dihydrogen phosphate, 100g of sodium dihydrogen phosphate, 100g of aluminum phosphate, 50g of boehmite, 30g of montmorillonite, 70g of bauxite, 30g of sodium hexametaphosphate, 20g of sodium tripolyphosphate, 50g of nano calcium carbonate, 30g of nano calcium silicate and 20g of nano silicon dioxide.
A double-layer modified inorganic anticorrosive coating comprises the following steps:
1) inner layer coating: weighing 100g of aluminum oxide, 100g of sodium oxide, 200g of magnesium oxide, 150g of aluminum dihydrogen phosphate, 100g of sodium dihydrogen phosphate, 150g of aluminum phosphate, 30g of boehmite, 70g of montmorillonite, 50g of bauxite, 30g of sodium hexametaphosphate and 20g of sodium tripolyphosphate, mixing and uniformly stirring, adding 300g of plasma-free water to adjust viscosity, heating and stirring at 150 ℃ for reaction for 1.5h, and standing for 24h to obtain a semitransparent inner-layer component with the phosphate mass solubility of 30.8%;
2) coating the outer layer; weighing 150g of aluminum oxide, 100g of sodium oxide, 100g of magnesium oxide, 100g of aluminum dihydrogen phosphate, 100g of sodium dihydrogen phosphate, 100g of aluminum phosphate, 50g of boehmite, 30g of montmorillonite, 70g of bauxite, 30g of sodium hexametaphosphate, 20g of sodium tripolyphosphate, 50g of nano calcium carbonate, 30g of nano calcium silicate and 20g of nano silicon dioxide, mixing, adding 300g of plasma-removing water to adjust viscosity, heating and stirring at 150 ℃ for reaction for 1.5h, and standing for 24h to obtain a semitransparent outer layer component with the phosphate mass solubility of 23.1%;
3) treating a base material: the concrete is blown or washed to remove dust and impurities on the surface, and keeps clean and dry;
4) coating and curing the inner layer, namely uniformly coating the inner layer coating on the surface of the steel bar, and drying and curing for 1.5 hours in the air at normal temperature;
5) coating and curing the outer layer, uniformly coating the outer layer coating on the surface coated with the inner layer coating, and drying and curing for 1.7h in the air at normal temperature; the coating thickness was 226um, the inner layer thickness was 155 um and the outer layer thickness was 71 um.
Example 3
The double-layer modified inorganic anticorrosive coating comprises an inner layer and an outer layer, wherein the inner layer comprises the following raw material components in parts by weight: 210g of aluminum oxide, 95g of sodium oxide, 85g of magnesium oxide, 102g of aluminum dihydrogen phosphate, 148g of sodium dihydrogen phosphate, 150g of aluminum phosphate, 33g of boehmite, 77g of montmorillonite, 40g of bauxite, 16g of borax, 14g of sodium hexametaphosphate and 20g of sodium tripolyphosphate; the outer layer comprises the following raw material components by weight: 150g of aluminum oxide, 100g of sodium oxide, 100g of magnesium oxide, 100g of aluminum dihydrogen phosphate, 100g of sodium dihydrogen phosphate, 150g of aluminum phosphate, 50g of boehmite, 30g of montmorillonite, 70g of bauxite, 10g of borax, 30g of sodium hexametaphosphate, 20g of sodium tripolyphosphate, 20g of nano calcium carbonate, 30g of nano calcium silicate and 50g of nano silicon dioxide.
A double-layer modified inorganic anticorrosive coating comprises the following steps:
1) inner layer coating: weighing 210g of aluminum oxide, 95g of sodium oxide, 85g of magnesium oxide, 102g of aluminum dihydrogen phosphate, 148g of sodium dihydrogen phosphate, 150g of aluminum phosphate, 33g of boehmite, 77g of montmorillonite, 40g of bauxite, 16g of borax, 14g of sodium hexametaphosphate and 20g of sodium tripolyphosphate, mixing and uniformly stirring, adding 200g of deionized water to adjust viscosity, heating and stirring at 180 ℃ for reaction for 1.5h, and standing for 24h to obtain a semitransparent inner layer component with the phosphate mass solubility of 33.3%;
2) outer layer coating: weighing 150g of aluminum oxide, 100g of sodium oxide, 100g of magnesium oxide, 100g of aluminum dihydrogen phosphate, 100g of sodium dihydrogen phosphate, 150g of aluminum phosphate, 50g of boehmite, 30g of montmorillonite, 70g of bauxite, 10g of borax, 30g of sodium hexametaphosphate, 20g of sodium tripolyphosphate, 20g of nano calcium carbonate, 30g of nano calcium silicate and 50g of nano silicon dioxide, mixing, adding 200g of plasma-removing water to adjust the viscosity, heating and stirring at 180 ℃ for reaction for 1.5h, and standing for 24h to obtain a semitransparent phosphate outer layer component with the phosphate mass solubility of 35.7%;
3) treating a base material: the concrete is blown or washed to remove dust and impurities on the surface, and keeps clean and dry;
4) coating and curing the inner layer: uniformly coating an inner layer coating on the surface of the steel bar, and drying and curing for 1.7h in the air at normal temperature;
5) coating and curing the outer layer: and uniformly coating the outer layer coating on the surface coated with the inner layer coating, drying and curing for 1.4h in the air at normal temperature, wherein the coating thickness is 226um, the inner layer thickness is 149, and the outer layer thickness is 77 um.
Example 4
The double-layer modified inorganic anticorrosive coating comprises an inner layer and an outer layer, wherein the inner layer comprises the following raw material components in parts by weight: 200g of aluminum oxide, 150g of sodium oxide, 50g of magnesium oxide, 150g of aluminum dihydrogen phosphate, 100g of sodium dihydrogen phosphate, 150g of aluminum phosphate, 50g of boehmite, 30g of montmorillonite, 70g of bauxite, 20g of sodium phosphate, 10g of sodium hexametaphosphate and 20g of sodium tripolyphosphate; the outer layer comprises the following raw material components by weight: 150g of aluminum oxide, 150g of sodium oxide, 50g of magnesium oxide, 150g of aluminum dihydrogen phosphate, 100g of sodium dihydrogen phosphate, 100g of aluminum phosphate, 50g of boehmite, 30g of montmorillonite, 70g of bauxite, 20g of sodium phosphate, 10g of sodium hexametaphosphate, 20g of sodium tripolyphosphate, 50g of nano calcium carbonate, 20g of nano calcium silicate and 30g of nano silicon dioxide.
A double-layer modified inorganic anticorrosive coating comprises the following steps:
1) inner layer coating: weighing 200g of aluminum oxide, 150g of sodium oxide, 50g of magnesium oxide, 150g of aluminum dihydrogen phosphate, 100g of sodium dihydrogen phosphate, 150g of aluminum phosphate, 50g of boehmite, 30g of montmorillonite, 70g of bauxite, 20g of sodium phosphate, 10g of sodium hexametaphosphate and 20g of sodium tripolyphosphate, mixing and uniformly stirring, adding 250g of deionized water to adjust viscosity, heating and stirring at 150 ℃ for reaction for 1h, and standing for 24h to obtain a semitransparent inner layer component with the phosphate mass solubility of 24.1%;
2) coating the outer layer; weighing 150g of aluminum oxide, 150g of sodium oxide, 50g of magnesium oxide, 150g of aluminum dihydrogen phosphate, 100g of sodium dihydrogen phosphate, 100g of aluminum phosphate, 50g of boehmite, 30g of montmorillonite, 70g of bauxite, 20g of sodium phosphate, 10g of sodium hexametaphosphate, 20g of sodium tripolyphosphate, 50g of nano calcium carbonate, 20g of nano calcium silicate and 30g of nano silicon dioxide, mixing, adding 250g of plasma-removing water to adjust viscosity, heating and stirring at 150 ℃ for reaction for 1h, and standing for 24h to obtain a semitransparent outer layer component with the phosphate mass solubility of 24.1%;
3) treating a base material: the concrete is blown or washed to remove dust and impurities on the surface, and keeps clean and dry;
4) coating and curing the inner layer: uniformly coating an inner layer coating on the surface of the steel bar, and drying and curing for 1.9h in the air at normal temperature;
5) coating and curing the outer layer: and uniformly coating the outer layer coating on the surface coated with the inner layer coating, drying and curing for 1.6h in the air at normal temperature, wherein the coating thickness is 238um, the inner layer thickness is 151, and the outer layer thickness is 87 um.
Example 5
The double-layer modified inorganic anticorrosive coating comprises an inner layer and an outer layer, wherein the inner layer comprises the following raw material components in parts by weight: 200g of aluminum oxide, 50g of sodium oxide, 100g of magnesium oxide, 100g of aluminum dihydrogen phosphate, 200g of sodium dihydrogen phosphate, 150g of aluminum phosphate, 30g of boehmite, 50g of montmorillonite, 70g of bauxite, 20g of sodium carbonate, 20g of sodium hexametaphosphate and 10g of sodium tripolyphosphate; the outer layer comprises the following raw material components by weight: 100g of aluminum oxide, 100g of sodium oxide, 150g of magnesium oxide, 100g of aluminum dihydrogen phosphate, 150g of sodium dihydrogen phosphate, 100g of aluminum phosphate, 30g of boehmite, 50g of montmorillonite, 70g of bauxite, 20g of sodium carbonate, 20g of sodium hexametaphosphate, 10g of sodium tripolyphosphate, 30g of nano calcium carbonate, 20g of nano calcium silicate and 50g of nano silicon dioxide.
A double-layer modified inorganic anticorrosive coating comprises the following steps:
1) inner layer coating: weighing 200g of aluminum oxide, 50g of sodium oxide, 100g of magnesium oxide, 100g of aluminum dihydrogen phosphate, 200g of sodium dihydrogen phosphate, 150g of aluminum phosphate, 30g of boehmite, 50g of montmorillonite, 70g of bauxite, 20g of sodium carbonate, 20g of sodium hexametaphosphate and 10g of sodium tripolyphosphate, mixing and uniformly stirring, adding 200g of deionized water to adjust viscosity, heating and stirring at 200 ℃ for reaction for 2 hours, and standing for 24 hours to obtain a semitransparent phosphate binder inner layer component with the mass solubility of 37.5%;
2) coating the outer layer; weighing 100g of aluminum oxide, 100g of sodium oxide, 150g of magnesium oxide, 100g of aluminum dihydrogen phosphate, 150g of sodium dihydrogen phosphate, 100g of aluminum phosphate, 30g of boehmite, 50g of montmorillonite, 70g of bauxite, 20g of sodium carbonate, 20g of sodium hexametaphosphate, 10g of sodium tripolyphosphate, 30g of nano calcium carbonate, 20g of nano calcium silicate and 50g of nano silicon dioxide, mixing, adding 200g of plasma-removed water to adjust viscosity, heating and stirring at 200 ℃ for reaction for 2h, and standing for 24h to obtain a translucent inner layer component of the phosphate binder with the mass solubility of 29.2%;
3) treating a base material: the concrete is blown or washed to remove dust and impurities on the surface, and keeps clean and dry;
4) coating and curing the inner layer: uniformly coating an inner layer coating on the surface of the steel bar, and drying and curing in the air at normal temperature for 1.6 h;
5) coating and curing the outer layer: the surface coated with the inner layer coating is uniformly coated with the outer layer coating, the coating is dried and cured in the air for 1.8h at normal temperature, the thickness of the coating is 271um, the thickness of the inner layer is 171, and the thickness of the outer layer is 100 um.
Example 6
The double-layer modified inorganic anticorrosive coating comprises an inner layer and an outer layer, wherein the inner layer comprises the following raw material components in parts by weight: 150g of aluminum oxide, 200g of sodium oxide, 50g of magnesium oxide, 150g of aluminum dihydrogen phosphate, 100g of sodium dihydrogen phosphate, 100g of aluminum phosphate, 30g of boehmite, 50g of montmorillonite, 70g of bauxite, 20g of sodium silicate, 20g of sodium carbonate, 10g of sodium phosphate, 10g of borax, 20g of sodium hexametaphosphate and 20g of sodium tripolyphosphate; the outer layer comprises the following raw material components by weight: 150g of aluminum oxide, 150g of sodium oxide, 50g of magnesium oxide, 100g of aluminum dihydrogen phosphate, 100g of sodium dihydrogen phosphate, 100g of aluminum phosphate, 30g of boehmite, 50g of montmorillonite, 70g of bauxite, 20g of sodium silicate, 20g of sodium carbonate, 10g of sodium phosphate, 20g of sodium hexametaphosphate, 20g of sodium tripolyphosphate, 20g of nano calcium carbonate, 50g of nano calcium silicate and 30g of nano silicon dioxide.
A double-layer modified inorganic anticorrosive coating comprises the following steps:
1) inner layer coating: weighing 150g of aluminum oxide, 200g of sodium oxide, 50g of magnesium oxide, 150g of aluminum dihydrogen phosphate, 100g of sodium dihydrogen phosphate, 100g of aluminum phosphate, 30g of boehmite, 50g of montmorillonite, 70g of bauxite, 20g of sodium silicate, 20g of sodium carbonate, 10g of sodium phosphate, 10g of borax, 20g of sodium hexametaphosphate and 20g of sodium tripolyphosphate, mixing and uniformly stirring, adding 200g of plasma-removed water to adjust viscosity, heating and stirring at 200 ℃ for reaction for 1.5h, and standing for 24h to obtain a semitransparent inner layer component with the phosphate mass solubility of 29.2%;
2) coating the outer layer; weighing 150g of aluminum oxide, 150g of sodium oxide, 50g of magnesium oxide, 100g of aluminum dihydrogen phosphate, 100g of sodium dihydrogen phosphate, 100g of aluminum phosphate, 30g of boehmite, 50g of montmorillonite, 70g of bauxite, 20g of sodium silicate, 20g of sodium carbonate, 10g of sodium phosphate, 20g of sodium hexametaphosphate, 20g of sodium tripolyphosphate, 20g of nano calcium carbonate, 50g of nano calcium silicate and 30g of nano silicon dioxide, mixing, adding 200g of plasma-removing water to adjust viscosity, heating and stirring at 200 ℃ for reaction for 2h, and standing for 24h to obtain a semitransparent outer layer component with the phosphate mass solubility of 25.2%;
3) treating a base material: the concrete is blown or washed to remove dust and impurities on the surface, and keeps clean and dry;
4) coating and curing the inner layer: uniformly coating an inner layer coating on the surface of the steel bar, and drying and curing in the air at normal temperature for 1.8 h;
5) coating and curing the outer layer: uniformly coating an outer layer coating on the surface coated with the inner layer coating, and drying and curing in the air at normal temperature for 1.3 h; the coating thickness was 282um, the inner layer thickness was 169, and the outer layer thickness was 113 um.
As seen from figure 1, the interface compatibility of the inner coating and the outer coating is strong, the porosity of the transition area of the interface of the steel bar and the concrete is small, and the interface excessive bonding strength is improved from a microscopic angle.
It can be seen that the outer modified inorganic coating can be prepared only if the material ratio of the specific nano-particles, the inorganic phosphate filler inorganic decomposer inorganic thickener and the corresponding preparation process parameters are met, and the thickness ratio of the inner inorganic coating bonded with the metal matrix is (1.5-2) to 1.
In order to verify the effects of the coating layer and coating method for preventing corrosion of reinforcing steel bars according to the present invention, the following tests were performed:
1) adhesion force
The coating adhesion effect for steel bar corrosion prevention of the invention is verified according to the standard requirements of GB/T5210 adhesion test of color paint and varnish by the pull-open method, and the average adhesion value of the coating prepared according to examples 1-6 and the steel bar is shown in Table 1.
TABLE 1 average adhesion of coating to reinforcing bars
| Example 1 | Example 2 | Example 3 | Example 4 | Example 5 | Example 6 | |
| Adhesion (MPa) | 8.2 | 9.1 | 8.5 | 10.9 | 11.4 | 10.3 |
The average adhesion force of the coating prepared according to the examples 1 to 6 and the concrete is shown in table 2, the coating is firstly coated with a plurality of layers of modified coatings on the section of the steel bar with the diameter of 50mm, then a concrete sample with the diameter of 50mm is poured on the coating surface, and the adhesion force of the coating and the concrete is obtained through a pull-off test.
TABLE 2 average values of adhesion of the coatings to concrete
| Example 1 | Example 2 | Example 3 | Example 4 | Example 5 | Example 6 | |
| Adhesion (MPa) | 0.12 | 0.10 | 0.07 | 0.09 | 0.11 | 0.09 |
As can be seen from tables 1 and 2, the adhesion between the coating and the steel bar of the invention is more than 8MPa, and the adhesion between the coating and the concrete is more than 0.07MPa, which is higher than that of a metal coating and an organic coating, and can be used for improving the bonding strength of a reinforced concrete structure.
2) Bond strength of coating and reinforced concrete
HRB400 hot-rolled ribbed steel bars with the diameter of 12mm are selected by drawing longitudinal steel bars. The outer coated steel bars prepared according to examples 1-6 were designed to have a bond length of 5 longitudinal bar diameters (length of 60mm) according to the DL/T5150-2017 hydraulic concrete test procedure. Different loading rates of 10mm/min were designed.
TABLE 3 mean values of bond strengths of coated reinforced concretes
As can be seen from table 3, the bonding strength of the coated rebar of examples 1-6 is more than 1.8 times that of the ordinary rebar. Meanwhile, almost all concrete cleavage damage occurs, which indicates that the strength limit of the concrete is reached before the bonding strength limit between the coating thread steel bar and the concrete is reached. It is thus demonstrated that the actual bond strength of the coated rebar will be 1.8 times greater than that of the conventional rebar. The nano particles greatly improve the bonding strength of the coated steel bar.
3) Corrosion resistance test of steel bars
In order to verify the corrosion resistance of the multilayer modified coating steel bar, six groups of coating steel bars prepared according to examples 1 to 6 were selected from plain round steel bars of HPB300, a control group was uncoated steel bars, three test pieces in each group were subjected to rust removal on the surface of the steel bar, placed in a 3.5% sodium chloride solution, and subjected to an accelerated corrosion test after being electrified.
TABLE 4 Corrosion time comparison of accelerated Corrosion tests on reinforcing bars (unit: min)
| Comparison group | Example 1 | Example 2 | Example 3 | Example 4 | Example 5 | Example 6 | |
| 1 | 139 | 1281 | 1339 | 1294 | 1249 | 1301 | 1342 |
| 2 | 129 | 1329 | 1273 | 1320 | 1201 | 1238 | 1317 |
| 3 | 161 | 1283 | 1193 | 1351 | 1184 | 1212 | 1382 |
| Mean value of adhesion (MPa) | 143 | 1298 | 1268 | 1322 | 1211 | 1250 | 1347 |
From table 4, it can be seen that the coated steel bars of examples 1-6 remained noncorrosive for 8.5-10 times longer than the uncoated steel bars.
The foregoing detailed description is intended to illustrate and not limit the invention, which is intended to be within the spirit and scope of the appended claims, and any changes and modifications that fall within the true spirit and scope of the invention are intended to be covered by the following claims.
Claims (10)
1. A double-layer modified inorganic anticorrosive coating is characterized in that: the composite material comprises an inner layer and an outer layer, wherein the outer layer comprises the following raw material components, by weight, 30-40 parts of inorganic phosphate, 30-50 parts of metal oxide, 5-10 parts of nano particles, 10-20 parts of inorganic filler, 1-10 parts of retarder and 1-10 parts of dispersant; the inner layer comprises the following raw material components, by weight, 30-40 parts of inorganic phosphate, 30-50 parts of metal oxide, 10-20 parts of inorganic filler, 1-10 parts of retarder and 1-10 parts of dispersant.
2. The double-layer modified inorganic anticorrosive coating according to claim 1, characterized in that: the nano particles are one or the combination of two or more of nano calcium carbonate, nano silicon dioxide, nano titanium dioxide and nano tricalcium silicate.
3. The double-layer modified inorganic anticorrosive coating according to claim 1, characterized in that: the inorganic phosphate is one or the combination of two or more of aluminum dihydrogen phosphate, sodium dihydrogen phosphate, aluminum phosphate and calcium phosphate.
4. The double-layer modified inorganic anticorrosive coating according to claim 1, characterized in that: the metal oxide is one or the combination of magnesium oxide, sodium oxide and aluminum oxide.
5. The double-layer modified inorganic anticorrosive coating according to claim 1, characterized in that: the inorganic filler is one or a combination of two or more of boehmite, montmorillonite, bauxite and borax.
6. The double-layer modified inorganic anticorrosive coating according to claim 1, characterized in that: the retarder is one or the combination of two or more of borax, sodium hexametaphosphate and sodium tripolyphosphate.
7. The double-layer modified inorganic anticorrosive coating according to claim 1, characterized in that: the dispersing agent is one or the combination of two or more of sodium silicate, sodium carbonate and sodium phosphate.
8. The double-layer modified inorganic anticorrosive coating according to claim 1, characterized in that: the inorganic filler is sieved by a sieve with 300 meshes and 500 meshes.
9. The double-layer modified inorganic anticorrosive coating according to claim 1, characterized in that: the overall thickness of the coating is 200-300 microns, and the thickness ratio of the inner layer to the outer layer is 1.5-2: 1.
10. a double-layer modified inorganic anticorrosive coating is characterized by comprising the following steps:
1) preparing an inner layer coating, weighing 30-40 parts of inorganic phosphate, 30-50 parts of metal oxide, 10-20 parts of inorganic filler, 1-10 parts of retarder and 1-10 parts of dispersing agent, adding plasma-removed water to adjust viscosity, heating and stirring at 100-200 ℃ for reaction for 1-2h, and standing to obtain a semitransparent inner layer component with the phosphate mass solubility of 20-50%;
2) preparing an outer layer coating, weighing 30-40 parts of inorganic phosphate, 30-50 parts of metal oxide, 5-10 parts of nano particles, 10-20 parts of inorganic filler, 1-10 parts of retarder and 1-10 parts of dispersant, adding plasma-removed water to adjust viscosity, heating and stirring at 100-200 ℃ for reaction for 1-2h, and standing to obtain a semitransparent outer layer component with the phosphate mass solubility of 20-50%;
3) coating and curing the inner layer, namely uniformly coating the inner layer coating on the surface of the steel bar, and drying and curing for 1-2h in the air at normal temperature;
4) and (3) coating and curing the outer layer, uniformly coating the outer layer coating on the surface coated with the inner layer coating, and drying and curing for 1-2h in the air at normal temperature.
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