EP1027478B1 - Method for improving corrosion resistance of reinforced concrete - Google Patents

Method for improving corrosion resistance of reinforced concrete Download PDF

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Publication number
EP1027478B1
EP1027478B1 EP98951521A EP98951521A EP1027478B1 EP 1027478 B1 EP1027478 B1 EP 1027478B1 EP 98951521 A EP98951521 A EP 98951521A EP 98951521 A EP98951521 A EP 98951521A EP 1027478 B1 EP1027478 B1 EP 1027478B1
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EP
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Prior art keywords
layer
coated
zinc
spray
reinforced concrete
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EP98951521A
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German (de)
French (fr)
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EP1027478A1 (en
Inventor
Michael Knepper
Jochen Spriestersbach
Jürgen Wisniewski
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Grillo Werke AG
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Grillo Werke AG
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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
    • C23C4/18—After-treatment
    • 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
    • C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F13/00—Inhibiting corrosion of metals by anodic or cathodic protection
    • C23F13/02—Inhibiting corrosion of metals by anodic or cathodic protection cathodic; Selection of conditions, parameters or procedures for cathodic protection, e.g. of electrical conditions
    • C23F13/06—Constructional parts, or assemblies of cathodic-protection apparatus
    • C23F13/08—Electrodes specially adapted for inhibiting corrosion by cathodic protection; Manufacture thereof; Conducting electric current thereto
    • C23F13/10—Electrodes characterised by the structure
    • 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
    • C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F2201/00—Type of materials to be protected by cathodic protection
    • C23F2201/02—Concrete, e.g. reinforced

Definitions

  • the present invention relates to a method according to claim 1 for Improve the corrosion resistance by using a thermal Spray layer made of metals, especially zinc or Zinc alloys, coated reinforced concrete.
  • Thermal spray coatings made of zinc or zinc aluminum alloys are used for surface finishing of metals, plastics, Concrete, cardboard etc. used. Among other things, they improve the temperature resistance, the wear behavior and the electrical conductivity of the substrate materials.
  • EP-A-0 677 592 the adhesive strength of thermal spray coatings Metals, metal oxides or hard materials, especially of zinc, Aluminum and its alloys, the spray layers after spraying with a one-component, moisture-curing Be coated with polyurethane resin. Special meaning has achieved this procedure for steel workpieces. It is mentioned that on the polyurethane resin layer so applied usual coating systems can be applied, which are compatible with polyurethane resins. examples for this are not known. But it had already been observed that Materials such as alkyd resins, epoxy resins or PVC resins without the Polyurethane resin layer not on the metal spray layers adhere sufficiently.
  • the present invention has set itself the task Improve the corrosion resistance by using a thermal Spray layer made of metals, especially zinc or Zinc alloys, coated reinforced concrete are available too ask, if possible also the adhesive strength of the Spray layer on the concrete should be improved.
  • Spray coating with the reinforcement of the reinforced concrete electrically is connected and additionally with a polyurethane resin is coated, which as a low-viscosity solution in organic Solvents is applied.
  • the polyurethane resin layer is preferably applied so thinly that no closed film is formed, only the pores of the spray layer are closed.
  • the polyurethane resin also has an epoxy resin layer is applied.
  • This epoxy resin layer is applied that they preferably have a thickness of 200 to 400 ⁇ m.
  • Polyurethane layers are also well suited as well as layers of mixtures of epoxy resins and polyurethanes.
  • the spray layer made of zinc or zinc alloys on the concrete is generally 100 to 400 microns, preferably 150 to 300 ⁇ m. Spray layers of this type exhibit adhesive strength measurements by means of forehead deduction between 1.0 and 2.0 MPa. After the application of the polyurethane resin layer, the adhesion increases the zinc layer on the concrete surprisingly to 2.5 to 3.0 MPa. Is a after curing the polyurethane layer Epoxy resin layer are applied after they have hardened Adhesive strengths measured between 2.5 and 3.5 MPa.
  • the invention applied layer with the reinforcement of the reinforced concrete is electrically connected. To do this, it is necessary electrically conductive connection between the metal reinforcement of the Manufacture reinforced concrete and the surface of the concrete. This is a measure that has so far been carried out hesitantly, because parts of the reinforcement that are not covered with cement of the outside world and actually as flaws be viewed where there is particularly rapid corrosion of the reinforced concrete comes.
  • the method is that by coating with polyurethane resin not only the adhesive strength of the spray layer the concrete is improved, but also the lifespan of the Spray coating.
  • the self-corrosion of the zinc layer when wet Weather conditions are greatly reduced and thus the Life span of the spray layer increased.
  • Corrosion tests in the Salt spray test according to DIN 50121-SS have shown that a 100 microns 60% of the thick layer is removed after 336 hours. After the application of the polyurethane resin layer, the removal is the zinc spray coating only 13%. If an additional If the epoxy resin layer is applied, the inherent corrosion decreases the spray layer to practically 0.
  • Spraying methods are used, for example wire flame spraying or wire arc spraying. This procedure differ mainly by different process temperatures and therefore also through different order efficiencies.
  • the adhesive strengths on the concrete don't just depend on the Surface pretreatment, but also on the type of protective concrete.
  • the spray layers are depending on the thickness and Spray type more or less dense. To a sufficient To ensure corrosion protection, the thicknesses should be preferred are in the range between 150 and 300 ⁇ m.
  • Epoxy resin can be achieved, such as the paint Amerlock 400 GFR from Ameron, USA for excellent results has led.
  • This additional epoxy resin layer will especially used when it was mechanically heavily loaded Areas. Layers of are also well suited Polyurethane or mixtures of epoxy resins and polyurethanes.
  • a new structure made of reinforced concrete is prepared by means of compressed air jets up to the Sa3 degree of cleaning and an average roughness depth R z of 45 ⁇ m. Then the workpiece prepared in this way is cleaned of adhering contaminants as well as possible using compressed air, preheated to 70 to 90 ° C and provided with a 150 to 300 ⁇ m thick spray coating made of zinc.
  • the adhesive strength measurements carried out by means of forehead deduction result in values between 1.0 and 2.0 MPa.
  • the sprayed metal layer is then coated with a commercially available, low-viscosity 1-component PU coating solution using a brush so that no measurable layer build-up takes place.
  • the Polyurethane layer had hardened, part of the Additionally coated with an epoxy resin layer.
  • the Amerlock 400 GFA material was used in layers between 200 and 400 ⁇ m. After curing this second Layer, the adhesive strength was 2.5 to 3.5 MPa.
  • Example 2 The same zinc spray coating as in Example 1 was used immediately coated with the epoxy resin.
  • the adhesive strength measurement using the forehead trigger remains at 1.0 to 2.0 MPa.
  • the Adhesive strength of the epoxy layer on the zinc layer was not resistant.
  • Anchor arches in need of renovation in a seaport first externally freed from corroded concrete until the Reinforcement bars are exposed. They are welded together that they are overall electrically conductive with each other are connected. Electrical lines are also installed and isolated. Then repair mortar in applied up to 10 cm thick. After setting a 300 ⁇ m thick spray layer is applied to this as in Example 1 applied from zinc and then with the low viscosity PUR coating solution coated, but for that Care is taken to ensure that there is no electrically conductive contact between the reinforcing bars and the zinc layer. The the zinc layer applied in this way acts as a sacrificial anode. Through the subsequent coating with the PUR solution increases the mechanical stability of the coating. Then the Surface as in example 1 covered with an epoxy resin layer, which has an average thickness of 400 microns. It arises such a highly resistant to sea water and other corrosion Surface providing long-term protection of the concrete and the reinforcement bars stored in it.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Organic Chemistry (AREA)
  • Metallurgy (AREA)
  • Materials Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Laminated Bodies (AREA)
  • Prevention Of Electric Corrosion (AREA)
  • Aftertreatments Of Artificial And Natural Stones (AREA)
  • Paints Or Removers (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Manufacturing Of Tubular Articles Or Embedded Moulded Articles (AREA)

Description

Gegenstand der vorliegenden Erfindung ist ein Verfahren gemäß Anspruch 1 zur Verbesserung der Korrosionsbeständigkeit von mit einer thermischen Spritzschicht aus Metallen, insbesondere aus Zink oder Zinklegierungen, beschichtetem Stahlbeton.The present invention relates to a method according to claim 1 for Improve the corrosion resistance by using a thermal Spray layer made of metals, especially zinc or Zinc alloys, coated reinforced concrete.

Thermische Spritzschichten aus Zink oder Zinkaluminiumlegierungen werden zur Oberflächenveredelung von Metallen, Kunststoffen, Beton, Pappe etc. eingesetzt. So verbessern sie unter anderem die Temperaturbeständigkeit, das Verschleißverhalten und die elektrische Leitfähigkeit der Substratmaterialien.Thermal spray coatings made of zinc or zinc aluminum alloys are used for surface finishing of metals, plastics, Concrete, cardboard etc. used. Among other things, they improve the temperature resistance, the wear behavior and the electrical conductivity of the substrate materials.

Aus der EP-A-0 677 592 ist ein Verfahren bekannt zur Verbesserung der Haftfestigkeit von thermischen Spritzschichten aus Metallen, Metalloxiden oder Hartstoffen, insbesondere aus Zink, Aluminium und deren Legierungen, wobei die Spritzschichten nach dem Aufspritzen mit einem einkomponentigen, luftfeuchtigkeitshärtenden Polyurethanharz beschichtet werden. Besondere Bedeutung hat dieses Verfahren erlangt bei Werkstücken aus Stahl. Es wird erwähnt, daß auf die so aufgetragene Polyurethanharzschicht übliche Beschichtungssysteme aufgetragen werden können, die sich mit Polyurethanharzen vertragen. Beispiele hierfür sind nicht genannt. Es war aber bereits beobachtet worden, daß Materialien wie Alkydharze, Epoxyharze oder PVC-Harze ohne die Polyurethanharzschicht nicht auf den Spritzschichten aus Metall ausreichend haften.A method for improvement is known from EP-A-0 677 592 the adhesive strength of thermal spray coatings Metals, metal oxides or hard materials, especially of zinc, Aluminum and its alloys, the spray layers after spraying with a one-component, moisture-curing Be coated with polyurethane resin. Special meaning has achieved this procedure for steel workpieces. It is mentioned that on the polyurethane resin layer so applied usual coating systems can be applied, which are compatible with polyurethane resins. examples for this are not known. But it had already been observed that Materials such as alkyd resins, epoxy resins or PVC resins without the Polyurethane resin layer not on the metal spray layers adhere sufficiently.

Die vorliegende Erfindung hat sich die Aufgabe gestellt, die Verbesserung der Korrosionsbeständigkeit von mit einer thermischen Spritzschicht aus Metallen, insbesondere aus Zink oder Zinklegierungen, beschichtetem Stahlbeton zur Verfügung zu stellen, wobei nach Möglichkeit auch die Haftfestigkeit der Spritzschicht auf dem Beton verbessert werden soll.The present invention has set itself the task Improve the corrosion resistance by using a thermal Spray layer made of metals, especially zinc or Zinc alloys, coated reinforced concrete are available too ask, if possible also the adhesive strength of the Spray layer on the concrete should be improved.

Diese Aufgabe wird erfindungsgemäß dadurch gelöst, daß die Spritzschicht mit der Bewehrung des Stahlbetons elektrisch verschaltet wird und zusätzlich mit einem Polyurethanharz beschichtet wird, welches als niedrigviskose Lösung in organischen Lösungsmitteln aufgetragen wird.This object is achieved in that the Spray coating with the reinforcement of the reinforced concrete electrically is connected and additionally with a polyurethane resin is coated, which as a low-viscosity solution in organic Solvents is applied.

Vorzugsweise wird die Polyurethanharzschicht so dünn aufgetragen, daß sich kein geschlossener Film bildet, sondern nur die Poren der Spritzschicht verschlossen werden.The polyurethane resin layer is preferably applied so thinly that no closed film is formed, only the pores of the spray layer are closed.

Besonders gute Ergebnisse werden erzielt, wenn nach dem Aushärten des Polyurethanharzes zusätzlich eine Epoxyharzschicht aufgebracht wird. Diese Epoxyharzschicht wird so aufgetragen, daß sie nach dem Aushärten vorzugsweise eine Dicke von 200 bis 400 µm aufweist. Weiterhin gut geeignet sind Polyurethanschichten sowie Schichten aus Gemischen von Epoxyharzen und Polyurethanen.Particularly good results are achieved if after curing the polyurethane resin also has an epoxy resin layer is applied. This epoxy resin layer is applied that they preferably have a thickness of 200 to 400 µm. Polyurethane layers are also well suited as well as layers of mixtures of epoxy resins and polyurethanes.

Die Spritzschicht aus Zink oder Zinklegierungen auf dem Beton beträgt im allgemeinen 100 bis 400 µm, vorzugsweise 150 bis 300 µm. Derartige Spritzschichten weisen bei Haftfestigkeitsmessungen mittels Stirnabzug Werte zwischen 1,0 und 2,0 MPa auf. Nach dem Auftrag der Polyurethanharzschicht steigt die Haftung der Zinkschicht auf dem Beton überraschenderweise auf 2,5 bis 3,0 MPa. Wird nach dem Aushärten der Polyurethanschicht eine Epoxyharzschicht aufgetragen, werden nach deren Aushärtung Haftfestigkeiten zwischen 2,5 und 3,5 MPa gemessen.The spray layer made of zinc or zinc alloys on the concrete is generally 100 to 400 microns, preferably 150 to 300 µm. Spray layers of this type exhibit adhesive strength measurements by means of forehead deduction between 1.0 and 2.0 MPa. After the application of the polyurethane resin layer, the adhesion increases the zinc layer on the concrete surprisingly to 2.5 to 3.0 MPa. Is a after curing the polyurethane layer Epoxy resin layer are applied after they have hardened Adhesive strengths measured between 2.5 and 3.5 MPa.

Wesentlich für den Erfolg des Verfahrens ist, daß die erfindungsgemäß aufgetragene Schicht mit der Bewehrung des Stahlbetons elektrisch verschaltet wird. Dazu ist es nötig, eine elektrisch leitende Verbindung zwischen der Metallbewehrung des Stahlbetons und der Oberfläche des Betons herzustellen. Dies ist eine Maßnahme, die man bisher nur zögernd durchgeführt hat, da Teile der Bewehrung, die nicht vom Zement bedeckt sind mit der.Außenwelt in Berührung kommen und eigentlich als Fehlstellen angesehen werden, an denen es besonders rasch zu einer Korrosion des Stahlbetons kommt.It is essential for the success of the method that the invention applied layer with the reinforcement of the reinforced concrete is electrically connected. To do this, it is necessary electrically conductive connection between the metal reinforcement of the Manufacture reinforced concrete and the surface of the concrete. This is a measure that has so far been carried out hesitantly, because parts of the reinforcement that are not covered with cement of the outside world and actually as flaws be viewed where there is particularly rapid corrosion of the reinforced concrete comes.

Ein weiterer nicht vorhersehbarer Vorteil des erfindungsgemäßen Verfahrens besteht darin, daß durch die Beschichtung mit Polyurethanharz nicht nur die Haftfestigkeit der Spritzschicht auf dem Beton verbessert wird, sondern auch die Lebensdauer der Spritzschicht. Die Eigenkorrosion der Zinkschicht bei feuchten Witterungsbedingungen wird stark herabgesetzt und somit die Lebensdauer der Spritzschicht erhöht. Korrosionsversuche im Salzsprühtest nach DIN 50121-SS haben gezeigt, daß eine 100 µm dicke Schicht nach 336 Stunden bereits zu 60% abgetragen wird. Nach dem Auftrag der Polyurethanharzschicht beträgt der Abtrag der Zinkspritzschicht nur noch 13%. Sofern zusätzlich eine Epoxidharzschicht aufgetragen wird, sinkt die Eigenkorrosion der Spritzschicht auf praktisch 0.Another unpredictable advantage of the invention The method is that by coating with polyurethane resin not only the adhesive strength of the spray layer the concrete is improved, but also the lifespan of the Spray coating. The self-corrosion of the zinc layer when wet Weather conditions are greatly reduced and thus the Life span of the spray layer increased. Corrosion tests in the Salt spray test according to DIN 50121-SS have shown that a 100 microns 60% of the thick layer is removed after 336 hours. After the application of the polyurethane resin layer, the removal is the zinc spray coating only 13%. If an additional If the epoxy resin layer is applied, the inherent corrosion decreases the spray layer to practically 0.

Vor dem Auftrag der Spritzschicht aus Metall muß beim erfindungsgemäßen Verfahren dafür gesorgt werden, daß der Stahlbeton zuvor gereinigt wird, gestrahlt wird, vorgewärmt wird auf 70° bis 90°C und erst dann das Metall aufgespritzt wird. Dabei sind die Reinheit und die Rauheit der Oberfläche des Substrates von besonderer Bedeutung. Eine gewisse Scharfkantigkeit des Profils ist oftmals sogar notwendig, um die notwendige Haftfestigkeit zu gewährleisten. Auf die Vorwärmung kann nur dann verzichtet werden, wenn sichergestellt ist, daß die Betonoberfläche nicht mehr feucht ist. Andernfalls besitzt die Spritzschicht aus Zink nicht die ausreichende Haftfestigkeit.Before applying the spray layer made of metal in the invention Procedures to ensure that the reinforced concrete is cleaned beforehand, blasted, preheated to 70 ° up to 90 ° C and only then the metal is sprayed on. Are there the purity and roughness of the surface of the substrate from special meaning. A certain sharpness of the profile is often even necessary to achieve the necessary adhesive strength to ensure. Only then can preheating be dispensed with if it is ensured that the concrete surface is not is more damp. Otherwise the spray coating is made of zinc not the sufficient adhesive strength.

Für die metallischen Spritzwerkstoffe können verschiedene Spritzverfahren angewendet werden, beispielsweise das Drahtflammspritzen oder das Drahtlichtbogenspritzen. Diese Verfahren unterscheiden sich vor allem durch verschiedene Prozeßtemperaturen und damit auch durch unterschiedliche Auftragswirkungsgrade. Die Haftfestigkeiten auf den Beton hängen nicht nur von der Oberflächenvorbehandlung ab, sondern auch von der Art des zu schützenden Betons. Die Spritzschichten sind je nach Dicke und Spritzart mehr oder weniger dicht. Um einen ausreichenden Korrosionsschutz zu gewährleisten, sollten die Dicken vorzugsweise im Bereich zwischen 150 und 300 µm liegen.Various can be used for the metallic spray materials Spraying methods are used, for example wire flame spraying or wire arc spraying. This procedure differ mainly by different process temperatures and therefore also through different order efficiencies. The adhesive strengths on the concrete don't just depend on the Surface pretreatment, but also on the type of protective concrete. The spray layers are depending on the thickness and Spray type more or less dense. To a sufficient To ensure corrosion protection, the thicknesses should be preferred are in the range between 150 and 300 µm.

Versuche eine Epoxyschicht unmittelbar auf die Spritzschicht aufzubringen, haben zu völlig unbefriedigende Ergebnissen geführt, während bei zuvor vorgenommenem erfindungsgemäßen Auftrag einer Polyurethanschicht überraschend gute Ergebnisse beobachtet werden.Try an epoxy layer immediately on the spray layer to bring up, have completely unsatisfactory results performed, while previously carried out according to the invention Applying a polyurethane layer surprisingly good results to be watched.

Eine eindeutige Erklärung dieser Ergebnisse gibt es bisher nicht, jedoch spricht einiges dafür, daß die Urethan-Gruppen in der Lage sind, beim Abbinden mit Hydroxyl-Gruppen zu reagieren, wobei nicht nur Reste von Feuchtigkeit gebunden werden, sondern auch feste Bindungen zwischen dem aufgespritzten Metall und dem Polyurethanharz entstehen. Erstaunlich ist auch, daß besonders gute Ergebnisse erzielt werden, wenn nur so dünne Schichten aufgetragen werden, daß gerade die Poren des Spritzmetalls gefüllt sind, jedoch noch kein geschlossener Film gebildet wird. Die dünnen Schichten können beispielsweise aufgetragen werden durch Streichen, Rollen oder Sprühen, jedoch sollte ein meßbarer Schichtaufbau nicht stattfinden. Dennoch bewirkt bereits diese dünne Schicht eine starke Verminderung der Eigenkorrosion durch feuchte Witterungsbedingungen bei gleichzeitiger Erhöhung der Haftfestigkeit der Metallschicht auf dem Beton.So far, there has been a clear explanation of these results not, however, there is some evidence that the urethane groups are able to react with hydroxyl groups when setting, whereby not only residues of moisture are bound, but also strong bonds between the sprayed metal and the polyurethane resin. It is also surprising that particularly good results can be achieved if only as thin Layers are applied that just the pores of the spray metal are filled, but no closed film has yet been formed becomes. The thin layers can be applied, for example by brushing, rolling or spraying, however, should be a measurable layer structure does not take place. Still does even this thin layer greatly reduces self-corrosion due to damp weather conditions with simultaneous Increasing the adhesive strength of the metal layer on the concrete.

Nach dem Aushärten dieses Urethanlacks kann eine weitere Verbesserung insbesondere durch Aufbringen einer Deckschicht aus Epoxydharz erzielt werden, wobei beispielsweise der Lack Amerlock 400 GFR von der Firma Ameron, USA zu hervorragenden Ergebnissen geführt hat. Diese zusätzliche Epoxydharzschicht wird vor allem verwendet, wenn es sich um mechanisch stark belastete Flächen handelt. Gut geeignet sind aber auch Schichten aus Polyurethan oder Gemischen von Epoxyharzen und Polyurethanen.After this urethane varnish has hardened, a further improvement can be made in particular by applying a cover layer Epoxy resin can be achieved, such as the paint Amerlock 400 GFR from Ameron, USA for excellent results has led. This additional epoxy resin layer will especially used when it was mechanically heavily loaded Areas. Layers of are also well suited Polyurethane or mixtures of epoxy resins and polyurethanes.

Das erfindungsgemäße Verfahren wird durch die nachfolgenden Beispiele näher erläutert:The process according to the invention is illustrated by the following Examples explained in more detail:

Beispiel 1example 1

Ein neues Bauwerk aus Stahlbeton wird mittels Druckluftstrahlen bis zum Säuberungsgrad Sa3 und einer mittleren Rauhtiefe Rz von 45 µm vorbereitet. Anschließend wird das so vorbereitete Werkstück von anhaftenden Verunreinigungen so gut wie möglich mittels Druckluft gesäubert, auf 70 bis 90°C vorgewärmt und mit einer 150 bis 300 µm dicken Spritzschicht aus Zink versehen. Die vorgenommenen Haftfestigkeitsmessungen mittels Stirnabzug ergeben Werte zwischen 1,0 und 2,0 MPa. Anschließend wird die Spritzmetallschicht mit einer handelsüblichen, niedrigviskosen 1 K-PUR-Beschichtungslösung mittels Pinselauftrag so beschichtet, daß kein meßbarer Schichtaufbau stattfindet. Verwendet wurde der Polyurethanlack der Firma Steelpaint GmbH, Kitzingen.A new structure made of reinforced concrete is prepared by means of compressed air jets up to the Sa3 degree of cleaning and an average roughness depth R z of 45 µm. Then the workpiece prepared in this way is cleaned of adhering contaminants as well as possible using compressed air, preheated to 70 to 90 ° C and provided with a 150 to 300 µm thick spray coating made of zinc. The adhesive strength measurements carried out by means of forehead deduction result in values between 1.0 and 2.0 MPa. The sprayed metal layer is then coated with a commercially available, low-viscosity 1-component PU coating solution using a brush so that no measurable layer build-up takes place. The polyurethane varnish from Steelpaint GmbH, Kitzingen, was used.

Nach dem Trocknem des Anstriches läßt sich feststellen, daß die Haftfestigkeit der Zinkschicht auf 2,5 bis 3,0 MPa angestiegen ist.After the paint has dried, it can be seen that the Adhesive strength of the zinc layer increased to 2.5 to 3.0 MPa is.

Nach der Aushärtung der Polyurethanschicht wurde ein Teil des Substrats zusätzlich mit einer Epoxydharzschicht überzogen. Verwendet wurde das Material Amerlock 400 GFA in Schichtstärken zwischen 200 und 400 µm. Nach dem Aushärten dieser zweiten Schicht betrug die Haftfestigkeit 2,5 bis 3,5 MPa.After the polyurethane layer had hardened, part of the Additionally coated with an epoxy resin layer. The Amerlock 400 GFA material was used in layers between 200 and 400 µm. After curing this second Layer, the adhesive strength was 2.5 to 3.5 MPa.

Korrosionsversuche im Salzsprühtest nach DIN 50121-SS ergab, daß praktisch kein meßbarer Abtrag der Zinkschicht festzustellen war. Corrosion tests in the salt spray test according to DIN 50121-SS showed that practically no measurable removal of the zinc layer can be determined was.

VergleichsversucheComparative tests

Die gleiche Spritzschicht aus Zink wie im Beispiel 1 wurde unmittelbar mit dem Epoxydharz beschichtet. Die Haftfestigkeitsmessung mittels Stirnabzug bleibt bei 1,0 bis 2,0 MPa. Die Haftfestigkeit der Epoxydschicht auf der Zinkschicht war nicht beständig.The same zinc spray coating as in Example 1 was used immediately coated with the epoxy resin. The adhesive strength measurement using the forehead trigger remains at 1.0 to 2.0 MPa. The Adhesive strength of the epoxy layer on the zinc layer was not resistant.

Beispiel 2Example 2

Renovierungsbedürftige Ankerbögen in einem Seehafen werden zunächst äußerlich vom korrodierten Beton befreit bis die Bewehrungseisen frei liegen. Sie werden so miteinander verschweißt, daß sie insgesamt elektrisch leitend miteinander verbunden sind. Weiterhin werden elektrische Leitungen installiert und isoliert. Anschließend wird Reparaturmörtel in einer Stärke von bis zu 10 cm aufgetragen. Nach dem Abbinden wird auf diesen wie im Beispiel 1 eine 300 µm dicke Spritzschicht aus Zink aufgetragen und anschließend mit der niedrigviskosen PUR-Beschichtungslösung beschichtet, wobei jedoch dafür Sorge getragen wird, daß kein elektrisch leitender Kontakt zwischen den Bewehrungseisen und der Zinkschicht entsteht. Die so aufgetragene Zinkschicht wirkt als Opferanode. Durch die anschließende Beschichtung mit der PUR-Lösung erhöht sich die mechanische Stabilität der Beschichtung. Anschließend wird die Fläche wie im Beispiel 1 mit einer Epoxydharzschicht überzogen, die eine durchschnittliche Dicke von 400 µm aufweist. Es entsteht so eine gegen Seewasser und sonstige Korrosion hochbeständige Oberfläche, die einen langfristigen Schutz des Betons und der darin eingelagerten Bewehrungseisen gewährleistet.Anchor arches in need of renovation in a seaport first externally freed from corroded concrete until the Reinforcement bars are exposed. They are welded together that they are overall electrically conductive with each other are connected. Electrical lines are also installed and isolated. Then repair mortar in applied up to 10 cm thick. After setting a 300 µm thick spray layer is applied to this as in Example 1 applied from zinc and then with the low viscosity PUR coating solution coated, but for that Care is taken to ensure that there is no electrically conductive contact between the reinforcing bars and the zinc layer. The the zinc layer applied in this way acts as a sacrificial anode. Through the subsequent coating with the PUR solution increases the mechanical stability of the coating. Then the Surface as in example 1 covered with an epoxy resin layer, which has an average thickness of 400 microns. It arises such a highly resistant to sea water and other corrosion Surface providing long-term protection of the concrete and the reinforcement bars stored in it.

Claims (3)

  1. A process for improving the corrosion resistance of reinforced concrete coated with a thermal spray coating from metals, namely zinc or zinc alloys, characterized in that the spray coating is electrically interconnected with the reinforcement without any parasitic current and additionally coated with a polyurethane resin which is coated as a low-viscous solution in organic solvents, where the polyurethane layer is thinly coated such that not a continuous film is formed but only the pores of the spray coating are closed.
  2. The process according to claim 1, characterized in that subsequent to the curing of the polyurethane resin an epoxy resin layer is additionally coated.
  3. The process according to any one of claims 1 or 2, characterized in that the epoxy resin layer is coated such that it has a thickness from 200 to 400 µm after curing.
EP98951521A 1997-10-31 1998-10-14 Method for improving corrosion resistance of reinforced concrete Expired - Lifetime EP1027478B1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE19748105A DE19748105C1 (en) 1997-10-31 1997-10-31 Increasing corrosion-resistance of thermally sprayed metal coating on steel-reinforced cement concrete
DE19748105 1997-10-31
PCT/EP1998/006512 WO1999023282A1 (en) 1997-10-31 1998-10-14 Method for improving corrosion resistance of reinforced concrete

Publications (2)

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EP1027478A1 EP1027478A1 (en) 2000-08-16
EP1027478B1 true EP1027478B1 (en) 2002-01-30

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US (1) US6224943B1 (en)
EP (1) EP1027478B1 (en)
CN (1) CN1207444C (en)
AU (1) AU745500B2 (en)
BR (1) BR9813171A (en)
CA (1) CA2307831C (en)
DE (2) DE19748105C1 (en)
DK (1) DK1027478T3 (en)
ES (1) ES2172223T3 (en)
HK (1) HK1028795A1 (en)
IL (1) IL135739A (en)
NO (1) NO319769B1 (en)
PT (1) PT1027478E (en)
TR (1) TR200001150T2 (en)
WO (1) WO1999023282A1 (en)

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FR2818274B1 (en) 2000-12-18 2003-02-14 Alto Btp PROCESS FOR THE PROTECTION, REPAIR AND CONSOLIDATION OF WORKS OF ARTS COMPRISING METAL ELEMENTS INCLUDED IN A CONCRETE, PLASTER, CEMENT OR MORTAR MATRIX
US6592947B1 (en) 2002-04-12 2003-07-15 Ford Global Technologies, Llc Method for selective control of corrosion using kinetic spraying
PT1651584E (en) * 2003-07-03 2007-01-31 Grillo Werke Ag Multi-layered surface protection for reinforced concrete in order to improve protection against corrosion for reinforced concrete constructions or reinforced concrete building components and method for the production thereof
BRPI0415934A (en) * 2003-10-27 2007-01-02 Polyone Corp catholic protective coatings containing conductive carbonaceous media
US7838079B2 (en) * 2004-11-17 2010-11-23 Battelle Energy Alliance, Llc Coated armor system and process for making the same
DE102007033423B4 (en) * 2007-07-18 2015-10-08 Torkret Gmbh Protective device for corrosion-prone, driveable parking garage floor surfaces made of reinforced concrete
EP2072205A1 (en) 2007-12-17 2009-06-24 Rovalma SA Method for producing highly mechanically demanded pieces and specially tools from low cost ceramics or polymers
CN103088282A (en) * 2013-02-05 2013-05-08 华北水利水电学院 Method for thermal spraying of nanometer cemented carbide-polyurethane composite coat on surface of stainless steel
CN107532014B (en) * 2015-05-01 2021-02-05 宣伟投资管理有限公司 High performance textured coatings
CN106738234A (en) * 2016-11-15 2017-05-31 黄河科技学院 A kind of production technology of corrosion-resistant prefabricated assembling type reinforced concrete inspection shaft

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IL135739A0 (en) 2001-05-20
AU745500B2 (en) 2002-03-21
HK1028795A1 (en) 2001-03-02
CA2307831C (en) 2006-12-12
DE59802985D1 (en) 2002-03-14
DE19748105C1 (en) 1998-10-29
EP1027478A1 (en) 2000-08-16
CN1276839A (en) 2000-12-13
PT1027478E (en) 2002-06-28
US6224943B1 (en) 2001-05-01
WO1999023282A1 (en) 1999-05-14
TR200001150T2 (en) 2000-08-21
BR9813171A (en) 2000-08-22
NO319769B1 (en) 2005-09-12
IL135739A (en) 2004-09-27
CN1207444C (en) 2005-06-22
DK1027478T3 (en) 2002-05-21
NO20002130L (en) 2000-04-26
ES2172223T3 (en) 2002-09-16
NO20002130D0 (en) 2000-04-26
AU9750198A (en) 1999-05-24
CA2307831A1 (en) 1999-05-14

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