CN111575630A - Concrete surface protection treatment method based on plasma thermal spraying technology - Google Patents

Concrete surface protection treatment method based on plasma thermal spraying technology Download PDF

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CN111575630A
CN111575630A CN202010317056.5A CN202010317056A CN111575630A CN 111575630 A CN111575630 A CN 111575630A CN 202010317056 A CN202010317056 A CN 202010317056A CN 111575630 A CN111575630 A CN 111575630A
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concrete
temperature
pressure air
thermal spraying
spraying
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CN111575630B (en
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石妍
李杨
李家正
韩炜
邓龙辉
李响
陈霞
吕兴栋
曹亚
李明霞
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Changjiang River Scientific Research Institute Changjiang Water Resources Commission
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Changjiang River Scientific Research Institute Changjiang Water Resources Commission
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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
    • C23C4/11—Oxides
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/4505—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application
    • C04B41/4523—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application applied from the molten state ; Thermal spraying, e.g. plasma spraying
    • C04B41/4527—Plasma spraying
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
    • C04B41/5024—Silicates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
    • C04B41/5025—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with ceramic materials
    • C04B41/5031—Alumina
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
    • C04B41/5025—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with ceramic materials
    • C04B41/5035—Silica
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
    • C04B41/5025—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with ceramic materials
    • C04B41/5037—Clay, Kaolin
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/60—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only artificial stone
    • C04B41/61—Coating or impregnation
    • C04B41/65—Coating or impregnation with inorganic materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/60—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only artificial stone
    • C04B41/61—Coating or impregnation
    • C04B41/65—Coating or impregnation with inorganic materials
    • C04B41/68—Silicic acid; Silicates
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/134—Plasma spraying

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Aftertreatments Of Artificial And Natural Stones (AREA)

Abstract

The invention provides a concrete surface protection treatment method based on a plasma thermal spraying technology. The treatment method comprises the steps of firstly, drying the surface of the concrete by utilizing high-pressure air with the temperature of 80-100 ℃; then, high-pressure air is used for wrapping particles to coarsen the surface of the concrete part; then utilizing high-pressure air with the temperature of 100-150 ℃ to wash and preheat the surface of the concrete; finally, by means of plasma thermal spraying equipment, the inorganic material protective layer is thermally sprayed on the surface of the concrete by adjusting parameters such as powder feeding speed, plasma power, airflow flow, moving speed, spraying distance and the like by using powder-shaped inorganic non-metallic material raw materials with the particle size of 20-120 microns. The invention improves the frost resistance and impermeability of concrete, overcomes the defects of poor weather resistance and short service life of the traditional organic material protective coating coated by brushing, and can be widely applied to surface protection of concrete prefabricated parts and cast-in-place concrete structures.

Description

Concrete surface protection treatment method based on plasma thermal spraying technology
Technical Field
The invention belongs to the field of hydraulic engineering, and particularly relates to a concrete surface protection treatment method based on a plasma thermal spraying technology.
Background
Concrete is a heterogeneous multi-phase composite material composed of various materials, and is subject to the infiltration of environmental water and the erosion of harmful ions in the service process, so that the performance and the structure are deteriorated, and the safe operation and the durability of the structure are influenced. Therefore, the problem of durability of concrete materials has long been the focus and difficulty of research in this field, and the key of the problem lies in the improvement of the surface compactness of concrete.
The research on the durability of concrete materials is gradually started from the last 60 years in China, and through many years of exploration, the research and design aspects of the durability of concrete materials and structures in China have made great progress, and a great deal of work has been carried out on the occurrence mechanism, the evolution process, the fission rule, the influence factors and the prevention and control measures of the durability problem; research routes combining experimental research, theoretical analysis and numerical simulation have become common consensus; research results play a great role in promoting the service life and health condition of concrete structures, a large number of concrete projects which are called as long-service life and high in durability emerge successively, but the service life of an actual concrete structure is often difficult to meet the requirement, for example, the actual service life of many concrete buildings in our country is only 20 to 30 years, and the cause of the problem is mainly related to the corrosion of harmful ions in the external environment. Therefore, retarding and insulating the attack of harmful ions is very important to improve the durability of concrete materials.
Concrete surface coating materials can be divided into organic coating materials and inorganic coating materials. The organic coating material comprises products such as epoxy coating, polyurethane coating, acrylate coating, organic silicon resin coating, fluororesin coating, polyurea coating, ethylene-vinyl acetate, rubber and the like, has the advantages of easiness in coating, adjustable color and the like, but generally has the problems of weak anti-aging capability in the atmosphere, insufficient weather resistance, easiness in yellowing of a coating film, temperature sensitivity, easiness in brittleness at low temperature, easiness in viscosity loss at high temperature and the like, and is mainly caused by inherent properties of organic materials. Meanwhile, the organic material has the problem of incongruity with the thermal property and the deformation property of the concrete matrix, and the peeling and the debonding of the organic coating are easily caused, so that the protection failure is caused.
The inorganic coating material on the concrete surface mainly refers to a permeable crystallization material, and comprises a cement-based permeable crystallization material and a silane permeable crystallization material. The permeable crystalline material can invade into cracks and pores of a concrete matrix and is precipitated, hydrated or hydrated with a concrete cementing material hydration product Ca (OH)2The reaction is further carried out, the compaction degree of the concrete matrix is improved, so that a protective layer is formed on the surface of the concrete, the permeation of external moisture and the invasion of harmful ions are prevented, and the durability of the concrete is improved. However, the penetration depth of the permeable crystalline material cannot be judged, and particularly, the effect of the permeable crystalline material is extremely limited for high-performance concrete with higher strength grade and compact surface.
The thermal spraying technique is to heat and melt a coating material, atomize the coating material into ultrafine particles by high-speed airflow, and spray the ultrafine particles onto the surface of a workpiece at a high speed to form a coating. Different material removing layers are selected according to the requirements, so that one or more performances of wear resistance, corrosion resistance, oxidation resistance, heat resistance and the like can be obtained. The patent of 'a method for improving the corrosion resistance of reinforced concrete' mentions that the method of thermally spraying zinc or zinc alloy coating can be used to improve the corrosion resistance of reinforced concrete, and the corrosion of the steel bar in reinforced concrete is reduced by connecting the zinc or zinc alloy coating with the steel bar to form a galvanic cell. Shen Lin, et al analyzed the application of thermal spray zinc coating in reinforced concrete structure of bridge, indicating that zinc coating can form anode protection for the steel bars in reinforced concrete structure. The high-temperature sapphire and the like also consider that the hot spraying of zinc or zinc alloy on the surface of reinforced concrete has better anti-corrosion effect. These studies indicate that it is feasible to form a metal coating on a concrete surface using thermal spray techniques. However, the differences between the metal coating and the concrete substrate in terms of mechanical strength, thermal properties, deformation characteristics and the like are large, so that the metal protective coating is difficult to be well matched with the concrete substrate in the natural service process.
Wangshen et al, in patent publication No. CN107858623A entitled surface thermal spray treatment method, describe a method for spray treatment of a product surface using a thermal spray base, which includes roughening the product surface by sand blasting, then wiping the product surface with alcohol cleaning to remove oil contamination completely, then preparing thermal spray powder or particles, and finally spraying the powder or particles onto the product surface by thermal spray process. Although the patent mentions that the thermal spray material is selected from metal, metal alloy or non-metal material, the patent does not indicate which products are specifically included in the patent, and the embodiment is only described for the alloy spray material for disclosing the specific process. The invention of patent publication No. CN108531849A discloses spraying alumina ceramic powder on the surface of a forged aluminum alloy wheel hub as a coating material in a plasma thermal spraying process, but those skilled in the art know that the wheel hub is metal, actually disclose that a non-metal material is sprayed on the surface of a metal piece, and the spraying process specifically comprises the steps of cleaning and drying the surface of the wheel hub by liquid, roughening the surface by a shot blasting machine, preheating by a heating furnace, and then thermally spraying.
It can be seen from the prior art that proper raw materials are selected according to the requirements of surface treatment of products, and the raw materials are sprayed on the surfaces of the products by a thermal spraying process, so as to achieve the purposes of preventing metal oxidation (such as corrosion), improving wear resistance, conductivity, light reflection, corrosion resistance (such as copper sulfate) and improving the appearance, and the like. However, the existing research shows that before the product is subjected to thermal spraying, the surface of the product needs to be cleaned, coarsened, dried and the like, and in addition, the concrete is exposed for a long time, the surface of the product has a weathered layer, and if the product is not properly treated in the spraying process, the sprayed material cannot be combined with the concrete material; in addition, the concrete material has poor thermal stability, phase transformation or decomposition can occur in the heating process, and the performance of the concrete can be influenced by improper heating and drying, so that the conventional treatment mode is not suitable for the concrete material. In the prior art, the wear resistance of the metal piece is improved by thermally spraying a non-metallic material on the surface of the metal piece, so that the service life of the metal piece is prolonged; or the outer surface of the non-metal part forms a galvanic cell by utilizing a thermal spraying metal coating to prevent the steel bar from being rusted, the thermal spraying of an inorganic non-metal material is not explored, and the research on the coordination relationship between the spraying process of the inorganic non-metal material and the performance of the concrete is lacked.
Disclosure of Invention
The invention aims to overcome the defects in the prior art, and provides a concrete surface protection treatment method based on a plasma thermal spraying technology, which utilizes the thermal spraying technology to deposit an inorganic non-metal material on the surface of concrete to form a film, can avoid the defects of poor weather resistance of an organic material and difficult immersion of a permeable crystallization material, has no risks of performance aging, brittle failure and chemical bond damage of an inorganic non-metal protective layer formed on the surface of the concrete, can overcome the problem of insufficient service life of an organic coating material, and is suitable for the protection work of the surface of the concrete in water conservancy engineering.
In order to achieve the technical purpose, the invention provides a concrete surface protection treatment method based on a plasma thermal spraying technology, which is characterized by comprising the following steps:
(1) drying the surface of the concrete by using high-pressure air at the temperature of 80-100 ℃ until the surface of the concrete is completely dried, and adjusting the distance between an air nozzle and the surface of the concrete to be 0.08-0.15 m in the drying process;
(2) carrying out coarsening treatment on the surface of the dried concrete by using high-pressure air to wrap the granular material, removing floating ash or a weakened layer on the surface, and controlling the distance between a granular material spray head and the surface of the concrete to be 0.4-0.6 m;
(3) washing and preheating the surface of the concrete by using high-pressure air at the temperature of 100-150 ℃ until no dust is on the surface of the concrete, and the preheating temperature of the surface of the concrete reaches 80-120 ℃; in the washing and preheating processes, the distance between the high-pressure air nozzle and the surface of the concrete is controlled to be 0.08-0.15 m;
(4) feeding the powder inorganic non-metallic material with the particle size of 20-120 mu m into a powder feeder, adjusting the powder feeding speed of the powder feeder to be 15-30 g/min, and melting and vertically spraying the inorganic non-metallic material on the surface of concrete by using plasma spraying equipment to form a 0.1-1.0 mm protective layer; wherein the plasma thermal spray parameters are set to: the working current of the electric arc is 600A-700A, the plasma power is 40kw-60kw, the main gas flow is 40L/h-60L/h, the spraying distance is 0.15m-0.25m, the flame temperature is more than 1000 ℃, the powder material is melted to be liquid, and the working gas is inert gas; when spraying the molten liquid powder, cooling gas is delivered towards the front end of the thermal spraying flame, so that the molten powder material instantaneously contacts the concrete surface and stabilizes to a temperature below 200 ℃.
The further technical scheme of the invention is that the inorganic non-metallic material in the step (4) is oxide containing Si and Al, and the thermal expansion coefficient of the inorganic non-metallic material is 1-15 × 10-6/K。
The invention has the following excellent technical scheme: in the step (1), high-pressure air is sprayed to the surface of the concrete through a spray head to dry the surface of the concrete, the moving speed of the high-pressure air spray head is controlled to be 0.1-0.3 m/s, and the pressure of the high-pressure air is controlled to be 0.2-0.3 MPa.
The invention has the following excellent technical scheme: and (2) adopting a sand blasting machine to perform coarsening treatment on the quartz sand with the high-pressure sprayed grain diameter of 0.5mm-1.0mm on the surface of the concrete, wherein the pressure is 0.3MPa-0.4MPa, and the moving speed of the nozzle is controlled to be 0.1m/s-0.2 m/s.
The invention has the following excellent technical scheme: and (4) spraying high-temperature and high-pressure air to the surface of the concrete through the spray nozzle in the step (3) to wash and preheat the surface of the concrete, controlling the moving speed of the high-temperature and high-pressure air spray nozzle to be 0.1-0.3 m/s, and controlling the pressure of the high-temperature and high-pressure air to be 0.2-0.3 MPa.
The invention has the following excellent technical scheme: when the molten powder material is sprayed, starting cooling gas carried by the plasma spraying equipment to spray the cooling gas to the joint of the hot spray flame and the concrete; the cooling gas is normal-temperature high-pressure air, and the conveying pressure of the cooling gas is 0.2MPa-0.3 MPa.
The invention has the following excellent technical scheme: the inert gas in the step (4) is N2Or Ar.
The invention has the following excellent technical scheme: the inorganic non-metallic material in the step (4) is selected from mullite, kaolin and industrial pure grade SiO2Industrial grade Al2O3Any one of them.
The concrete in the present invention is hardened concrete, and generally includes a formed concrete member or a concrete structure.
The drying treatment in the invention aims to remove moisture contained in the concrete surface, and the wet base surface influences the bonding effect with the coating. Because of the initial wet state and area difference of concrete, the drying process only needs to completely dry the surface, and because the formed uneven laitance, the surface layer weathering in the long-term service process and the dusting in the drying process can cause the floating ash or the weakened layer on the surface of the concrete to influence the bonding effect with the coating interface, the next roughening treatment is carried out. Due to poor thermal stability of concrete materials at high temperatures, phase transformation or decomposition can occur during heating. Research table of the inventor by using comprehensive thermal analysis technologyObviously, the concrete can lose free water in pores before 100 ℃, which is a physical desorption phenomenon; between 100 ℃ and 200 ℃ will cause the loss of chemically bound water in the cement hydration product phase, such as Calcium Silicate Hydrate (CSH), and between 400 ℃ and 450 ℃ will cause the loss of calcium hydroxide (Ca (OH) in the hydration product2) Decomposition of (3). The decomposition phenomenon of the concrete in the heating process is caused by the intrinsic properties of the materials, and is not related to the strength grade and the mix proportion design. Therefore, in order to ensure the stable performance of the concrete body in the drying process, the temperature and the drying conditions of the high-temperature and high-pressure air need to be limited. Meanwhile, considering the influence of the environmental temperature and the wind speed, when the construction is carried out in cold weather in winter with lower air temperature and higher wind speed, high-temperature and high-pressure air with higher temperature and higher pressure is selected and constructed at a slower moving speed of the spray nozzle and a shorter distance; when the construction is carried out in hot summer with high temperature and low wind speed, high-temperature and high-pressure air with low temperature and low pressure is selected and constructed at a high nozzle moving speed and a long distance. In bad weather such as overcast and rainy, cold tide, strong wind, etc., the construction should be suspended.
The high-pressure air drying, the high-temperature high-pressure air washing and the preheating in the invention can be directly operated by adopting thermal spraying equipment, the pressure and the temperature are adjusted, and the high-temperature high-pressure air can be directly sprayed without adding any substance. The normal temperature air in the present invention is air at room temperature.
When the coarsening treatment is carried out, in order to ensure the coarsening effect and clean removal of the surface weathered layer, the particle size of quartz sand, the pressure of high-pressure air, the moving speed of a spray head and the spraying distance are selected by combining the strength of concrete, the service life and the thickness of the weathered layer. When the strength grade of the concrete is higher and the service life is longer, quartz sand with larger grain diameter is used, and the roughening treatment of the surface of the concrete is carried out at a slower moving speed and a closer spraying distance under higher air pressure; when the concrete strength grade is low and the service life is short, the quartz sand with a small particle size is used, and the roughening treatment of the concrete surface is carried out at a high moving speed and a long spraying distance under low air pressure.
In the preheating process, the temperature and pressure of the high-temperature and high-pressure air, the moving speed and distance of the spray head and other parameters need to be considered according to the factors of the environment, such as the temperature, the wind speed and the like. Meanwhile, the preheating temperature of the concrete surface is selected by considering factors such as aggregate content, thermal property, internal relative humidity and the like in the concrete, so that the preheated concrete surface is still in a high-temperature state within a certain range. When the aggregate content in the concrete is high, the heat conduction capability is strong, and the internal relative humidity is high, the surface of the concrete is ensured to have high preheating temperature, so that sufficient margin is reserved for dissipation of the internal heat of the concrete, and the time is also reserved for subsequent spraying construction; and when the concrete aggregate content is less, the heat conduction capability is weaker, and the internal water content is less, the preheating temperature of the concrete surface can be reduced.
The determination of the spraying parameters comprehensively considers the performance of the concrete substrate, the type and performance of the coating material, the environmental temperature and the wind speed condition. The invention uses the SiO-containing2The material to be sprayed should be selected to have a high plasma power and a high arc operating current. When the construction is carried out in winter with lower environmental temperature and higher wind speed, the larger main airflow is preferably selected, and the powder feeding rate of the powder feeder is improved. The moving speed of the spray gun takes the relation of the distance between the spray gun and the concrete surface, the tail flame temperature, the diameter of beam spot and the thickness of a protective layer into consideration.
Because the cementing material and the sandstone aggregate of the concrete contain more silicon phases and aluminum phases, the invention selects the concrete containing SiO2And Al2O3The substance can keep better compatibility with the concrete matrix. Systematic studies by the inventors have shown that SiO is a material that is more common than other inorganic materials commonly used in the concrete field2And Al2O3Has lower melting temperature and better spraying effect, and the formed protective coating can have better cooperative deformability with concrete and can even further react with hydration products Ca (OH) of the concrete2Reaction occurs to enhance the bonding ability of the protective coating to the concrete substrate. The fineness of the spray material has an effect on the melting temperature and the layering effect after spraying. The fineness is improved to improve the spraying effect and enhance the coagulationThe protection capability of the soil against moisture penetration and ion erosion, but the corresponding economic cost is also increased; although the reduction of the fineness can improve the economical efficiency, the melting temperature is increased, the melting time is prolonged, the uneven degree of the coating is increased, and the protective capability on the performances of concrete such as impermeability and chlorine ion corrosion resistance is reduced. Moreover, the chemical composition of the spraying material also has influence on the melting process and the layering effect, but the influence of the chemical composition change on the spraying process and the effect can be weakened as much as possible by adopting a sample with industrial purity grade and controlling the fineness. After investigation and summary, the selected fineness range of the application considers most of the commercially available SiO2And Al2O3The chemical composition of (2) can ensure that the spraying process can be suitable for 95 percent of commercially available SiO2And Al2O3。
The cooling gas is mainly used for cooling the concrete surface, the powder material is sprayed to the concrete surface along with flame after being melted, the temperature of the plasma flame can even reach tens of thousands of degrees, the cooling gas is conveyed towards the front end of the flame when the powder is thermally sprayed, the length of the flame is shortened, the concrete surface is prevented from suffering from high temperature due to flame flow and coating precipitation, the burning of a matrix is avoided, the thermal spraying powder melting material instantly contacts with a test piece, and the temperature is stabilized to be below 200 ℃. The selection of the auxiliary airflow pressure is related to various factors such as the type of the powder material, the pressure of the main airflow, the spraying distance, the preheating temperature of the concrete surface and the like. The research of the inventor shows that the auxiliary airflow is too long, so that the temperature of the flame flow is too low after the flame flow reaches the surface of the concrete, and the spraying material is difficult to form a protective layer; when the auxiliary air flow is too short and the spraying distance is too long, the flame flow causes the surface temperature of the concrete to be too high, the auxiliary air flow cannot play a cooling effect, the surface performance of the concrete is damaged, and the bonding strength of the protective layer of the spraying material is influenced.
The invention has the beneficial effects that:
(1) the invention utilizes inorganic non-metallic material to form a thermal spraying protective layer on the surface of the concrete, changes the situation that metal or metal alloy is mainly used in the prior thermal spraying technology, and the capability of the inorganic non-metallic material protective layer for improving the frost resistance and the impermeability and durability of the concrete is more than 10 percent higher than that of the metal or metal alloy protective layer.
(2) The bonding strength of the inorganic non-metallic material protective layer and the concrete matrix is higher than that of the metal or metal alloy protective layer by more than 20%. The chemical element composition and content of the inorganic nonmetal protective layer are similar to those of concrete, and the inorganic nonmetal protective layer has the possibility of reacting with a concrete hydration product and has less risk of debonding and peeling.
(3) The inorganic non-metal protective layer formed on the surface of the concrete by utilizing the thermal spraying process has no risks of performance aging, brittle failure and chemical bond destruction, overcomes the problem of insufficient service life of an organic coating material, and is particularly suitable for engineering in high-altitude and strong ultraviolet radiation areas in western regions of China.
(4) According to the invention, the surface of the concrete is dried, so that the surface of the concrete can not be decomposed by heating; the concrete surface is treated in a gas-sand carrying mode, and the treatment process is more convenient; the particle materials are quartz sand which has good hardness and economy, the particle size of the quartz sand is 0.5mm-1.0mm, the roughening treatment process can remove the surface weathered layer, the bonding strength of the inorganic material coating and the concrete substrate is increased, the roughening degree is proper, the unevenness of the concrete surface cannot be increased, the use amount, the thickness and the cost of the inorganic material coating are increased, and the economy is reduced.
(5) The preheating of the invention can reduce the temperature difference in the layering process of the inorganic material, and prevent the performance from being influenced by the sudden temperature drop in the layering process of the inorganic material caused by the over-low surface temperature of the concrete, the preheating temperature of the surface of the concrete is 80-100 ℃, thereby not only ensuring the stable performance of the material, but also preventing the decomposition of substances.
(6) The invention selects the particles of the non-metallic inorganic material with special fineness, can be beneficial to improving the spraying effect under the condition of ensuring the lowest cost, ensures the uniform coating and enhances the protection capability of concrete to water penetration and ion erosion.
(7) The spraying distance and the pre-cooling treatment of the invention ensure the heating time of the spraying materialUnder the condition, the flame flow influence temperature of the concrete matrix can not be too high, the spraying quality and the coating uniformity are ensured, and the spraying material and the concrete can be sprayed
Figure BDA0002459944710000111
Tightly bonding; the moving speed of the spray gun is matched with the spraying material, the spraying distance and the spraying process, so that the beam spots are ensured to be overlapped in the moving process of the spray gun, the incomplete protective layer is avoided, meanwhile, the phenomenon that the beam spots are overlapped to a too high degree is avoided, and the problems that the preorder protective layer is melted again and damaged and the like caused by tail flames in the subsequent spraying process are avoided.
Drawings
FIG. 1 shows Al in example 12O3SEM photograph of the bonding surface of the protective layer and the concrete substrate;
FIG. 2 is an effect diagram of the precast element of example 2 after the surface is coated with a mullite protective layer;
FIG. 3 is SiO in example 32SEM photograph of the bonding surface of the protective layer and the concrete substrate.
Detailed Description
The present invention will be described in detail with reference to specific examples.
The embodiment 1 aims at the protection of the outer wall of a power station factory building of a certain hydro-junction engineering at the altitude of 3200m in the Tibet region, construction in winter is carried out, the temperature is 5 ℃, and no wind exists. The strength grade of the concrete of the outer wall of the power station plant is C35, and the surface is dry and anhydrous. The method of the invention is adopted to carry out protection treatment on the concrete outer wall, and the treatment process comprises the following steps:
(1) drying the surface of the concrete outer wall by using high-pressure air with the temperature of 100 ℃ and the pressure of 0.2MPa, controlling the moving speed of an air nozzle to be 0.1m/s and the distance between the air nozzle and the surface of the concrete outer wall to be 0.15m until the surface of the concrete is completely dried;
(2) after drying, carrying quartz sand with the particle size of 1.0mm by high-pressure air with the pressure of 0.35MPa at normal temperature to roughen the surface of the concrete outer wall, keeping the distance between a quartz sand nozzle and the surface of the concrete outer wall to be 0.4m, controlling the moving speed of the quartz sand nozzle to be 0.1m/s, and removing floating ash or a weakening layer on the surface until gravel aggregate is exposed on the surface of the concrete;
(3) after the surface roughening treatment of the concrete outer wall is finished, preheating the surface of the concrete by using high-temperature and high-pressure air with the temperature of 150 ℃ and the pressure of 0.3MPa, controlling the moving speed of an air nozzle to be 0.1m/s, and controlling the distance between the air nozzle and the surface of the concrete outer wall to be 0.08m, so as to ensure that the surface of the concrete outer wall is clean, dry and free of dust, and preheating the surface of the concrete outer wall to be more than 80 ℃;
(4) after the surface preheating of the concrete outer wall is finished, spraying inorganic non-metallic materials by adopting low-pressure plasma thermal spraying equipment, and spraying Al with the particle size of 50 mu m2O3Putting the powder into a powder feeder, adjusting the powder feeding speed of the powder feeder to be 16g/min, adjusting the arc working current to be 700A in the low-pressure plasma thermal spraying process, adjusting the plasma power to be 60kw, adjusting the main gas flow to be 60L/h, adjusting the spraying distance to be 0.15m, and adjusting the moving speed of a spray gun to be 0.8 m/s; in the spraying process, normal-temperature high-pressure air is used as auxiliary air flow, and the pressure of the air is 0.2 MPa.
The field test shows that Al2O3The thickness of the protective layer is 0.7mm, and the bonding degree with the surface of the concrete outer wall is good. Al observed by scanning electron microscope2O3The combination of the protective layer and the concrete substrate is as shown in figure 1, and the combination effect of the protective layer and the concrete substrate is good. Comparing Al by a water penetration height method2O3The results of the impermeability of the concrete before and after spraying the protective layer show that the water penetration height of the concrete sample without the protective layer is 6.8cm under the pressure of 0.8MPa for 10h, while the sprayed Al2O3The water seepage height of a concrete outer wall test piece of the protective layer is only 5.9cm under the pressure of 0.8MPa for 10 hours, and the reduction range of the water seepage height is 13%. Al tested by drawing test2O3The bonding strength of the protective layer and the concrete matrix is 2.53 MPa.
Example 2 is directed to a high performance concrete slab precast element, the size of the concrete precast element is 600mm × 600mm × 63mm, the concrete strength grade is C60, the construction environment is indoor spraying, and the specific treatment process is as follows:
(1) drying the surface of the concrete prefabricated part by using high-pressure air with the temperature of 80 ℃ and the pressure of 0.25MPa, controlling the moving speed of an air nozzle to be 0.3m/s and the distance between the air nozzle and the surface of the concrete prefabricated part to be 0.08m until the surface of the concrete is completely dried;
(2) after drying, carrying quartz sand with the particle size of 0.5mm by high-pressure air with the pressure of 0.4MPa at normal temperature to coarsen the surface of the concrete prefabricated part, keeping the distance between a quartz sand nozzle and the surface of the concrete prefabricated part to be 0.6m, controlling the moving speed of the quartz sand nozzle to be 0.2m/s, and removing floating ash or a weakening layer on the surface until gravel aggregate is exposed on the surface of the concrete;
(3) after the surface roughening treatment of the concrete prefabricated part is finished, preheating the surface of the concrete prefabricated part by using high-temperature and high-pressure air with the temperature of 100 ℃ and the pressure of 0.2MPa, controlling the moving speed of an air nozzle to be 0.2m/s, controlling the distance between the air nozzle and the surface of the concrete prefabricated part to be 0.12m, ensuring that the surface of the concrete prefabricated part is clean, dry and free of dust, and preheating the surface of the concrete prefabricated part to be more than 90 ℃;
(4) after the surface preheating of the concrete prefabricated part is finished, spraying inorganic non-metallic materials by adopting low-pressure plasma thermal spraying equipment, putting mullite with the particle size of 60 mu m into a powder feeder, adjusting the powder feeding speed of the powder feeder to be 18g/min, wherein the electric arc working current in the low-pressure plasma thermal spraying process is 650A, the plasma power is 50kw, the main gas flow is 50L/h, the spraying distance is 0.2m, and the moving speed of a spray gun is 0.9 m/s; in the spraying process, normal-temperature high-pressure air is used as auxiliary air flow, and the pressure of the air is 0.25 MPa.
The field test shows that the thickness of the mullite protective layer is 0.65mm, and the mullite protective layer has good combination degree with the surface of the concrete prefabricated member. The photo of the test piece after surface spraying is shown in fig. 2, and the bonding effect is good. The change condition of the frost resistance of the concrete prefabricated part before and after spraying of the mullite protective layer is researched by using a rapid freeze-thaw test by taking the relative mass loss as an index, the test result is shown in table 1, and after the freeze-thaw cycle test for the same times, the mass loss of the concrete prefabricated part with the mullite protective layer sprayed on the surface is 10% -13% less than that of the concrete prefabricated part without the mullite protective layer sprayed.
TABLE 1 variation of the antifreeze properties of the mullite protective layer sprayed on the surface of the prefabricated parts (relative mass loss/%)
Figure BDA0002459944710000141
Example 3 is directed to concrete faced protection of rock-fill dam for certain hydro-junction engineering at 1300m altitude in Xinjiang area, construction in summer with 35 ℃ temperature and breeze. The strength grade of the concrete of the panel is C30, and the surface is dry and anhydrous. The specific treatment process is as follows:
(1) drying the surface of the concrete panel by using high-pressure air with the temperature of 100 ℃ and the pressure of 0.3MPa, controlling the moving speed of an air nozzle to be 0.2m/s and the distance between the air nozzle and the concrete surface to be 0.12m until the concrete surface is completely dried;
(2) after drying, adopting high-pressure air with normal temperature and pressure of 0.3MPa to wrap quartz sand with the particle size of 0.8mm to coarsen the surface of the concrete panel, keeping the distance between a quartz sand nozzle and the concrete surface at 0.5m, controlling the moving speed of the quartz sand nozzle at 0.15m/s, and removing floating ash or a weakening layer on the surface until sandstone aggregate is exposed on the surface of the concrete;
(3) after the surface of the concrete panel is roughened, preheating the surface of the concrete panel by using high-temperature and high-pressure air with the temperature of 130 ℃ and the pressure of 0.2MPa, controlling the moving speed of an air nozzle to be 0.3m/s and the distance between the air nozzle and the surface of the concrete panel to be 0.15m, ensuring that the surface of the concrete panel is clean, dry and free of dust, and preheating the surface of the concrete to be not more than 100 ℃;
(4) after the surface of the concrete panel is preheated, spraying inorganic non-metallic materials by adopting low-pressure plasma thermal spraying equipment, and spraying SiO with the particle size of 50 mu m2Putting the powder into a powder feeder, adjusting the powder feeding speed of the powder feeder to be 22g/min, adjusting the arc working current to be 700A in the low-pressure plasma thermal spraying process, adjusting the plasma power to be 40kw, adjusting the main gas flow to be 40L/h, adjusting the spraying distance to be 0.25m, and adjusting the moving speed of a spray gun to be 1.0 m/s;in the spraying process, normal-temperature high-pressure air is used as auxiliary air flow, and the pressure of the air is 0.3 MPa.
The field detection shows that the SiO2The thickness of the protective layer is 1.0mm, and the bonding degree with the surface of the concrete is good. SiO observed by scanning electron microscope2The combination of the protective layer with the concrete matrix is shown in fig. 3, in which individual microcracks are caused by damage at the cut section.
In summary, the present invention is a specific embodiment, but the present invention is not limited to the above-mentioned embodiments, and any means that can achieve the technical effects of the present invention with the same or similar means should fall within the protection scope of the present invention.

Claims (8)

1. A concrete surface protection treatment method based on a plasma thermal spraying technology is characterized by comprising the following steps:
(1) drying the surface of the concrete by using high-pressure air at the temperature of 80-100 ℃ until the surface of the concrete is completely dried, and adjusting the distance between an air nozzle and the surface of the concrete to be 0.08-0.15 m in the drying process;
(2) carrying out coarsening treatment on the surface of the dried concrete by using high-pressure air to wrap the granular material, removing floating ash or a weakened layer on the surface, and controlling the distance between a granular material spray head and the surface of the concrete to be 0.4-0.6 m;
(3) washing and preheating the surface of the concrete by using high-pressure air at the temperature of 100-150 ℃ until no dust is on the surface of the concrete, and the preheating temperature of the surface of the concrete reaches 80-120 ℃; in the washing and preheating processes, the distance between the high-pressure air nozzle and the surface of the concrete is controlled to be 0.08-0.15 m;
(4) feeding the powder inorganic non-metallic material with the particle size of 20-120 mu m into a powder feeder, adjusting the powder feeding speed of the powder feeder to be 15-30 g/min, and melting and vertically spraying the inorganic non-metallic material on the surface of concrete by using plasma spraying equipment to form a 0.1-1.0 mm protective layer; wherein the plasma thermal spray parameters are set to: the working current of the electric arc is 600A-700A, the plasma power is 40kw-60kw, the main gas flow is 40L/h-60L/h, the spraying distance is 0.15m-0.25m, the flame temperature is more than 1000 ℃, the powder material is melted to be liquid, and the working gas is inert gas; when spraying the molten liquid powder, cooling gas is delivered towards the front end of the thermal spraying flame, so that the molten powder material instantaneously contacts the concrete surface and stabilizes to a temperature below 200 ℃.
2. The method for the protective treatment of the concrete surface based on the plasma thermal spraying technology as claimed in claim 1, wherein the inorganic non-metallic material in the step (4) is an oxide containing Si and Al, and the thermal expansion coefficient of the inorganic non-metallic material is 1-15 × 10-6/K。
3. The concrete surface protection treatment method based on the plasma thermal spraying technology according to claim 1 or 2, characterized in that: in the step (1), high-pressure air is sprayed to the surface of the concrete through a spray head to dry the surface of the concrete, the moving speed of the high-pressure air spray head is controlled to be 0.1-0.3 m/s, and the pressure of the high-pressure air is controlled to be 0.2-0.3 MPa.
4. The concrete surface protection treatment method based on the plasma thermal spraying technology according to claim 1 or 2, characterized in that: and (2) coarsening the quartz sand with the high-pressure sprayed grain diameter of 0.5mm-1.0mm on the surface of the concrete by using a sand blasting machine until the sandstone aggregate is exposed on the surface of the concrete, wherein the sand blasting pressure is 0.3MPa-0.4MPa, and the moving speed of a nozzle is controlled to be 0.1m/s-0.2 m/s.
5. The concrete surface protection treatment method based on the plasma thermal spraying technology according to claim 1 or 2, characterized in that: and (4) spraying high-temperature and high-pressure air to the surface of the concrete through the spray nozzle in the step (3) to wash and preheat the surface of the concrete, controlling the moving speed of the high-temperature and high-pressure air spray nozzle to be 0.1-0.3 m/s, and controlling the pressure of the high-temperature and high-pressure air to be 0.2-0.3 MPa.
6. The concrete surface protection treatment method based on the plasma thermal spraying technology according to claim 1 or 2, characterized in that: when the molten powder material is sprayed, starting cooling gas carried by the plasma spraying equipment to spray the cooling gas to the joint of the flame and the concrete; the cooling gas is normal-temperature high-pressure air, and the conveying pressure of the cooling gas is 0.2MPa-0.3 MPa.
7. The concrete surface protection treatment method based on the plasma thermal spraying technology according to claim 1 or 2, characterized in that: the inert gas in the step (4) is N2Or Ar.
8. The concrete surface protection treatment method based on the plasma thermal spraying technology as claimed in claim 2, characterized in that: the inorganic non-metallic material in the step (4) is selected from mullite, kaolin and industrial pure grade SiO2Industrial grade Al2O3Any one of them.
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JPH01119576A (en) * 1987-10-30 1989-05-11 Maeda Seikan Kk Surface treatment of concrete
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CN113372136A (en) * 2021-07-08 2021-09-10 广东博智林机器人有限公司 Inorganic artificial stone plate and preparation method thereof
CN113372136B (en) * 2021-07-08 2023-02-28 广东博智林机器人有限公司 Inorganic artificial stone plate and preparation method thereof

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