EP2484841A1 - Betonstahl mit Bitumenschutzmitteln gegen Oxidation, und Behandlungsverfahren dafür - Google Patents

Betonstahl mit Bitumenschutzmitteln gegen Oxidation, und Behandlungsverfahren dafür Download PDF

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Publication number
EP2484841A1
EP2484841A1 EP12154417A EP12154417A EP2484841A1 EP 2484841 A1 EP2484841 A1 EP 2484841A1 EP 12154417 A EP12154417 A EP 12154417A EP 12154417 A EP12154417 A EP 12154417A EP 2484841 A1 EP2484841 A1 EP 2484841A1
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EP
European Patent Office
Prior art keywords
bars
bituminous
emulsion
impregnated
metal
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Application number
EP12154417A
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English (en)
French (fr)
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EP2484841B1 (de
Inventor
Antonino Santonocito
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E04C5/01—Reinforcing elements of metal, e.g. with non-structural coatings
    • E04C5/015—Anti-corrosion coatings or treating compositions, e.g. containing waterglass or based on another metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/18—Processes for applying liquids or other fluent materials performed by dipping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/14—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to metal, e.g. car bodies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/50—Multilayers
    • B05D7/52—Two layers
    • B05D7/54—No clear coat specified
    • B05D7/544—No clear coat specified the first layer is let to dry at least partially before applying the second layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/20—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to wires

Definitions

  • the present invention regards steel bars provided with an anti-oxidizing protective means of a bituminous type and the corresponding industrial production process.
  • Steel is a material very widely used in the building industry, preferred for its particular characteristics and mechanical performance.
  • steel structural work and reinforcements are preferred in more traditional techniques, where they constitute the skeleton resistant to the stresses of bending and shear of reinforced concrete.
  • the most common corrosive agents are oxygen and water, even though it is commonly said that the metal rusts, flaking continuously: the rust, namely, the layer of steel and hence of iron that oxidizes, penetrates over time more and more deeply into the metal sections, up to total loss of the characteristics of resistance of the constructional element, or even up to its total destruction.
  • said corrosive phenomenon should not occur in so far as concrete usually constitutes a reducing and non-oxidizing alkaline environment, hence protecting the metal bars themselves.
  • the alkalinity of the environment surrounding the reinforcements decreases over time until it disappears totally on account of the entry of aggressive substances, such as carbon dioxide, sulphur dioxide, and chlorides.
  • the process of corrosion in dry environments is basically due to chemical reactions with oxidizing gases.
  • the phenomenon consists in the tendency to restore the oxidized form, which is the one in which the metals are of course stable. It envisages combination with the oxygen present in the atmosphere to form the corresponding oxide, or else with other atmospheric agents to form carbonates, sulphates, hydroxides, and sulphides.
  • corrosion occurs thanks to electrochemical reactions. These reactions are linked to the passage of electric current in the solutions.
  • a further disadvantage lies in the cost of the surface coatings that can be used, but even more in the manpower required both for the necessary operations of cleaning of the rusted parts (sandblasting in the case of structures that cannot be taken down, scraping using a steel brush, if the parts to be removed are of small size) and for the subsequent painting cycle, from the first layer of rust-resistant undercoat, also referred to as "primer”, to be applied with a paintbrush, roller, or air-less spray, in order to prevent any further undesirable oxidation of the metal, to the subsequent coats of paint with passivating pigments (necessary for obtaining a thin passive layer on steel in order to block oxidation thereof and reaction with the possible aggressive substances that can penetrate through the overlying layers of paint, forming insoluble compounds that are not aggressive for the material to be protected).
  • Another disadvantage of no less importance as compared to the previous ones is linked precisely to the cost of said paint with anti-oxidizing pigment (with a base of epoxy polyamide having a high content of metallic zinc or with a base of chromates, metaborates, or phosphates, such as zinc phosphate), for which the choice cannot be underestimated and must always be oriented towards the qualitatively better products that have optimal adhesion to the metal substrate and good anchorage to the next layer of paint.
  • a further procedure for protecting the metal surfaces of steel bars, or metal bars in general is represented by coating paints with a base of bitumens, of bituminous combinations, ofepoxyorepoxypolyurethane, of alkyl resins, of chlorinated rubber, and finally of a combination of PVC and acrylic resins, but for all these solutions the disadvantage of the cost of manpower is always present, and is comparable with, if not almost always higher than, the costs of the products to be applied themselves.
  • Hot-dip galvanizing is an industrial process that guarantees the physical protection of the steel coated by the surface layer of zinc that isolates it materially from the surrounding environment, whilst the electrochemical protection is triggered by the higher electronegativity of zinc as compared to steel. There is in fact formed a Zn-Fe cell so that the zinc is sacrificed to protect the iron above all in the accidentally damaged areas (also referred to as "cathodic protection").
  • Corrosion of the layer of zinc in fact, usually takes place above all in the first period of life of the concrete product, when the degree of alkalinity within it is still very high in so far as zinc, unlike iron, oxidizes in this type of environment, even though, in any case, the use of galvanized bars provides a non-negligible increase in durability of the reinforced concrete itself, since zinc, by corroding, performs its protective function in regard to the underlying steel. Since the products of corrosion of the zinc, in fact, do not expand as occurs in the case of rust, they do not cause mechanical damage to the surrounding concrete. Corrosion of zinc is the sign in any case of a cathodic protection on steel, which, however, as a result, progressively loses its coating. It is only upon expiry of the period of protection due to the disappearance of the protective layer of zinc that steel starts to corrode like traditional reinforcements, even though the increase in service life of the cementitious structures themselves is evident.
  • a further disadvantage of said hot-dip galvanizing process is represented by the fact that it cannot be applied on metal reinforcements of building products that have already been installed, but that require maintenance, where at most it is possible to resort to cold galvanizing, but this latter treatment is even less effective and durable than the previous one.
  • a further technically known solution has been that of coating traditional steel bars with corrosion-resistant materials, such as, for example, epoxy resins.
  • corrosion-resistant materials such as, for example, epoxy resins.
  • the main purpose of the present invention is consequently to provide at an industrial level, via a production process that is simple to implement at a minimum production cost, steel bars provided with a valid anti-oxidizing protective means.
  • a further purpose of the present invention which is no less important than the previous one, is to obtain steel bars that can be stored without undergoing oxidation even if they are left out in the open for prolonged periods of time, without any problems connected to their handling and to the necessary operations of bending and shearing, and that can at any moment be used without the need to perform undesirable treatments of brushing of the oxidative surface layer that normally forms on customary steel bars when, after being produced by wire drawing, are stored, even for a short time.
  • Another purpose of the present invention is to provide steel bars that will guarantee a centuries-long resistance of the products made of reinforced concrete built using them, thus preventing the undesirable phenomena of hidden or evident oxidation of the steel with the corresponding impoverishment of the characteristics of resistance both of the steel bars and of the reinforced concrete that coats them.
  • metal bars B of any class and diameter for use in the building sector for steel structural work or for reinforcements, characterized in that they undergo an industrial production process P with anti-oxidizing protective means of a bituminous type S b -E b , compatible in an optimal way also with any type of concrete, for building structures with or without reinforced concrete that are unattackable by corrosion and hence durable over time.
  • the present invention and the corresponding production process are altogether innovative in so far as there do not so far exist steel bars of similar conformation and characteristics and are inventive because they altogether solve the problem that has so far remained unresolved regarding corrosion of steel especially when it is present as reinforcement in buildings made of reinforced concrete.
  • the metal bars B of any class and diameter for use in the building sector for steel structural work or for reinforcements, according to the present invention are basically characterized in that they have undergone an industrial production process that envisages treatment with anti-oxidizing protective means of a bituminous type S b -E b , compatible in an optimal way also with any type of concrete, for building structures with and without reinforced concrete that are unattackable by corrosion and hence durable over time.
  • the industrial production process P is obtained via the application of a series of steps, as emerges readily from Figures 1 , 2 and 3 , respectively of impregnation F 1 , emulsion treatment F 2 , and drying F 3 , said steps being performed in temporal sequence with:
  • the metal bars B are preferably obtained using metal bars B 0 of any class and diameter for use in the building sector present on the market of the type made of low-alloy steel in so far as the steel bars used for providing a reinforcement are normally made of carbon steel and usually have a circular cross section (whence the common name of "rod").
  • Said commercially available bars B 0 are provided with an outer surface characterized by particular ribbings referred to as “knurlings”, which have the function of improving adherence of the concrete of the concrete structure to the bars themselves.
  • the bars thus obtained are referred to as “improved adherence” or “ribbed” bars and are commonly known by the name of "knurled rods".
  • the present invention can be applied in the building sector preferably in the field of reinforcements typical of structural elements, such as beams and columns, which are characterized by two series of reinforcement bars:
  • bars B 0 constituted by common low-alloy steels is justified in that they have a minimal cost on the building-sector market (belonging to this group are ordinary steels and prestressing steels), but the process P according to the present invention is applicable also on reinforcements with low sensitivity to corrosion, such as galvanized steels and stainless steels.
  • Low-alloy steel B 0 for reinforced concrete is produced inplants also in the form of bars or rolls, meshes or lattices, for direct use on the building site or as basic elements for subsequent transformations. Consequently, the process P referred to in the present invention can be applied also to said commercial products present on the market in order to bestow thereon an excellent corrosion resistance.
  • the anti-oxidizing protective means of a bituminous type S b -E b are obtained starting frombituminous substances, namely, mixtures of hydrocarbons of natural origin or of ones obtained by distillation in the processing of crude oil, or mixtures of both types of hydrocarbons.
  • bitumens can be of a natural or distilled type.
  • Natural bitumens found in oil fields in dark-to-black masses, usually impregnate porous rocks and derive from a natural distillation at low temperature occurring in the course of millennia in crude oils surfacing and coming into contact with atmospheric oxygen.
  • the first materials used by men for impermeabilization were precisely poured asphalts, constituted by a mixture of aggregates and bitumens. These mixtures also exist in the natural state in Abruzzo and Sicily (Ragusa) and, subjected to compression with purposely provided technological means, were reduced into "cakes", referred to as “asphalt cakes", which today are no longer used.
  • Distilled bitumens derive from artificial distillation, at high temperature and in a few hours, of crude oil. Distilled bitumens are today used in all works of impermeabilization for laying road surfaces, etc.
  • bitumens in production plants, are poured into tankers at a temperature of approximately 100°C, transported toconcrete-mixingplants, and poured into large tanks, where they remain at the same temperature, ready for use.
  • said bitumens are prepared with aggregate to form the bituminous conglomerates, whereas for works of impermeabilization, the bitumens are poured into purposely provided drums and cooled. Subsequently, the drums are transported to the places of use, where they are heated to a temperature of approximately 300°C and then spread on terraces, bridges under construction, etc., to form bituminous coatings.
  • Today, however, traditional bituminous coatings have been replaced by prefabricated ones, the membranes, which are more convenient to transport and install and have found widespread use.
  • bitumens takes into account the physico-chemical characteristics (softening temperature, penetration, viscosity, ductility, flammability, solubility in various solvents, etc.).
  • Natural bitumen is frequently mixed with artificial bitumen remaining from the distillation of crude oils with pitch or tar; hence, it is no longer possible to make a clear distinction between these various classes of compounds.
  • Natural bitumens burn with a sooty flame, soften with heat, acquiring binding properties, are impermeable to water, insulating, and resistant to atmospheric agents, and have a good degree of consistency.
  • bitumen can be prepared in different ways, according to the startingpoint (temperature range) of its degree of softening.
  • the first type is obtained at 30°C/50°C, the second at 50°C/70°C, and the third at 70°C/100°C.
  • the second type with softening between 50°C and 70°C, precisely on account of its degree of softening, is better suited to obtaining a greater fluidity as compared to the other two types and, consequently, in this temperature range, the so-called oxidized or blown bitumen is obtained.
  • Oxidized bitumen is a product obtained by causing oxygen or air to act in hot conditions, to produce an increase in the index of penetration in so far as a more plastic mass is obtained. Oxidation acts from the chemical standpoint by dehydrogenating the product and giving rise to compounds of higher molecular weight. Said oxidized bitumen is compressed and reduced to form cakes referred to as "oxidized-bitumen cakes" in order to obtain oxidizedbitumen ready for being softened to obtain the hot bituminous emulsion E b .
  • the industrial process P for producing the metal bars B referred to in the present invention preferably employs low-alloy steel bars B 0 currently used in buildings made of reinforced concrete and ready for use in cementitious conglomerate in the natural state (see Figure 4 ) and a pair of tanks V 1 -V 2 , the first one V 1 being used as impregnation tank and the second one V 2 as emulsion tank.
  • the steel bars (or rods) B 0 ready for use are dipped mechanically in a metal tank of dimensions suitable for the processing environment and with the required amount, containing an appropriate solution, referred to as "cold bituminous solution” S b , which, according to the present invention, has a base of oxidized bitumens and fast-drying technical solvents of a known type, also referred to as bituminous impregnating solution S b .
  • the temperature T 1 of this bituminous solution S b is preferably between 6°C and 10°C, and the time interval ⁇ t 1 is between one and two minutes.
  • step F 1 The steel bars B 0 , which are at ambient temperature, for the bituminous impregnation step F 1 are dipped in the tank V 1 (step F 1 ), which is preferably constituted by a metal tank having dimensions of approximately 20 metres in length and 10 metres in width and contains the cold bituminous solution S b .
  • the steel bars B 0 are then dipped in the cold bituminous solution S b , remaining therein for some minutes, preferably for one or at the most two minutes.
  • step F 2 After said dipping, they are removed from the bath and left in the air to dry for the time necessary (step F 2 ).
  • step F 3 the steel bars impregnated with the cold bituminous solution B 1 are dipped in the emulsion tank V 2 (step F 3 ), which is also preferably constituted by a metal tank having the dimensions of approximately 20 metres in length and 10 metres in width and contains the hot bituminous emulsion E b , where the bars will remain for approximately another two minutes.
  • the second metal tank V 2 contains the hot bituminous emulsion at a controlled temperature T 2 of between 350°C and 450°C, preferably approximately 400°C, where the bars B 1 , as has been said, remain for a time interval ⁇ t 2 of between approximately one and two minutes.
  • the bituminous emulsion E b at said temperature is very fluid and acquires the function of binder.
  • step F 4 The bars, thus impregnated and treated with the bituminous emulsion B 2 , are lifted out and left hanging the time necessary for drying (step F 4 ), leaving them to cool at ambient temperature T A for a time interval ⁇ t 3 that varies as a function of the external temperature from approximately ten minutes in winter to approximately twenty minutes in summer in order to obtain metal bars B that are unattackable by corrosion and hence durable over time.
  • the steel bars B thus impregnated, treated with the bituminous emulsion and dried, are ready for being loaded onto lorries for their subsequent transport to the building sites.
  • a correct loading and transport of the bars B it is envisaged to separate them with a sheet of polyethylene to prevent any rise in temperature from possibly heating the layer of bituminous emulsion and to prevent the bars themselves from "sticking", i.e., adhering to one another.
  • the bars B obtained with this process present the advantage that they can also subsequently be curved and bent, according to the need, in so far as the hot bituminous emulsion at a temperature of approximately 400°C coats the steel bar with a given thickness, perfectly compatible for said operations and for being used with the cementitious conglomerate for building reinforced-concrete structures.
  • bituminous emulsion In the case where it is desired to obtain a greater thickness of the bituminous emulsion, it is necessary to reduce the temperature range ⁇ T 2 of the hot emulsion from values of around 400°C to values of around 300°C or, alternatively, dip the steel bars B 2 for a second time in the same tank of bituminous emulsion V 2 in order to obtain a second layer of bituminous emulsion, which, beingdeposited over the first, bestows said greater thickness.
  • the steel bars are practically invulnerable over time in so far as, whereas the cementitious conglomerate with the passage of centuries will tend in any case to crumble and in part to pulverize, the steel bars, impregnated first with the cold bituminous solution and then with the hot bituminous emulsion, will remain intact.
  • the basic advantage of the present invention is to have devised an industrial production process that renders the steel bars (or in general the metal bars) unalterable over time, enabling a marked binding power and adherence to be obtained between the bars and the cementitious conglomerate in reinforced-concrete structures, high resistance to atmospheric agents, and unlimited durability over time.
  • the further advantages of the bars referred to in the present invention derive precisely also from the simplicity of industrial production on account of the constructional characteristics proper to the bars (as also to all the other steel elements constituting current reinforcements for building purposes, which could likewise undergo the same process of impregnation with the bituminous solution and emulsion), which thus leads to the further advantage of minimizing the production costs and hence the costs of installation and regulation (bending and cutting of the bars) on the building site.
  • the present invention can be applied to steel bars for building purposes both in steelworks, when they are produced, andindepots (warehouses, yards, etc.).
  • the bars leaving the furnace will have to be preliminarily cooled to ambient temperature before being dipped in the cold bituminous solution S b , whereas in the case where the bars are stored in depots, before dipping them in the cold bituminous solution S b , it will be necessary to subject them to a preliminary treatment to eliminate the rust that usually forms on their outer surface.
  • pickling could be carried out or some other known treatment to eliminate rust or other substances (grease, oil, etc.) that could hinder proper adhesion of the protective layer that impregnates the bars.
  • the invention has, moreover, the undoubted advantage of enabling an optimization of the operation of protection of the bars against corrosion, likewise enabling total on-line automation of the production of the rods themselves or of other commercial products present on the market, also in the form of bars or rolls, meshes or lattices, for their direct use on building sites or as basic elements for subsequent transformations; for this reason the process according to the present invention can be applied also to said commercial products.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Reinforcement Elements For Buildings (AREA)
  • Bridges Or Land Bridges (AREA)
  • Panels For Use In Building Construction (AREA)
  • Rod-Shaped Construction Members (AREA)
EP20120154417 2011-02-08 2012-02-08 Betonstahl mit Bitumenschutzmitteln gegen Oxidation, und Behandlungsverfahren dafür Not-in-force EP2484841B1 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
IT000001A ITCT20110001A1 (it) 2011-02-08 2011-02-08 Resistenza e conservazione nei secoli delle barre di acciaio per lavori in cemento armato

Publications (2)

Publication Number Publication Date
EP2484841A1 true EP2484841A1 (de) 2012-08-08
EP2484841B1 EP2484841B1 (de) 2013-11-13

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EP20120154417 Not-in-force EP2484841B1 (de) 2011-02-08 2012-02-08 Betonstahl mit Bitumenschutzmitteln gegen Oxidation, und Behandlungsverfahren dafür

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EP (1) EP2484841B1 (de)
DK (1) DK2484841T3 (de)
ES (1) ES2443586T3 (de)
IT (1) ITCT20110001A1 (de)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2950025A1 (de) * 2014-05-27 2015-12-02 Antonino Santonocito Elektromagnetische Wärmeübertragungs-Einrichtungen für Stahlstangen zwischen Arbeitsstationen, umfassend zwei Tauchtanks, enthaltend bituminöse Lösungen.
IT201800004684A1 (it) * 2018-04-18 2019-10-18 Procedimento ed impianto di rivestimento di un profilato metallico e profilato cosi' ottenuto

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB471606A (en) * 1936-03-27 1937-09-08 Sealocrete Products Ltd Improvements in or relating to concrete and like structures
DE917867C (de) * 1950-02-17 1954-09-13 Internat Ytong Co A B Verfahren zur Herstellung einer Rostschutzschicht auf staehlernen Bewehrungseinlagenfuer Beton
GB745497A (en) * 1952-12-18 1956-02-29 Skoevde Gasbetong Aktiebolag A reinforcing iron provided with a corrosion resistant coating and method for its manufacture
DD101198A1 (de) * 1973-01-08 1973-10-20

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB471606A (en) * 1936-03-27 1937-09-08 Sealocrete Products Ltd Improvements in or relating to concrete and like structures
DE917867C (de) * 1950-02-17 1954-09-13 Internat Ytong Co A B Verfahren zur Herstellung einer Rostschutzschicht auf staehlernen Bewehrungseinlagenfuer Beton
GB745497A (en) * 1952-12-18 1956-02-29 Skoevde Gasbetong Aktiebolag A reinforcing iron provided with a corrosion resistant coating and method for its manufacture
DD101198A1 (de) * 1973-01-08 1973-10-20

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2950025A1 (de) * 2014-05-27 2015-12-02 Antonino Santonocito Elektromagnetische Wärmeübertragungs-Einrichtungen für Stahlstangen zwischen Arbeitsstationen, umfassend zwei Tauchtanks, enthaltend bituminöse Lösungen.
IT201800004684A1 (it) * 2018-04-18 2019-10-18 Procedimento ed impianto di rivestimento di un profilato metallico e profilato cosi' ottenuto

Also Published As

Publication number Publication date
ITCT20110001A1 (it) 2012-08-09
DK2484841T3 (da) 2014-01-27
ES2443586T3 (es) 2014-02-19
EP2484841B1 (de) 2013-11-13

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