JP2017088907A - Repair material for steel material and repair method of steel material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To make peeling of a coating material hard to occur without reducing effect of anticorrosion even when surface preparation of a steel material is insufficient in repairing the steel material.SOLUTION: Repair person removes a corrosion product from a steel material 103 of a repair target. Then the repair person disperses powder of a base metal 104 to the steel material 103 in a resin solidified from a liquid to a solid by a chemical reaction, laminates a repair material 101 impregnated into a cloth-like conductive carrier 102 constituted by a conductive fiber to the steel material 103 and cures the repair material 101.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a steel repair material and a steel repair method.

  In order to improve the corrosion resistance of steel materials, steel materials subjected to surface treatment by galvanization or the like are used in various structures. The film formed by such a surface treatment may be worn out with time and may partially disappear depending on the use environment, and periodic repair is necessary to prevent rusting of the steel material.

  As a conventional steel material restoration method, a method in which a paint in which zinc powder is dispersed in a resin is applied to the steel material (see Non-Patent Document 1), or a method of forming a zinc film on the surface of the steel material by thermal spraying (Non-Patent Document 2). See).

Difference in rust prevention principle between global and general paint, Roval Corporation, [October 16, 2015 search], Internet <URL: http://www.roval.co.jp/> The spraying method of anticorrosion spraying / What is anticorrosion spraying? Corrosion prevention spraying cooperative, [October 16, 2015 search], Internet <URL: http://www.tscpc.jp/method/index.html>

  Among these, the film formation by thermal spraying has a problem that when the base material adjustment (removal of rust, etc.) of the steel material is insufficient, the adhesion is low and the film is easily peeled off. Also, film formation by thermal spraying requires a dedicated large device and surrounding curing, and is not suitable for on-site enforcement.

  In addition, the method of applying zinc-containing paint has the advantage that it is easy to implement on site, but if the base material of the steel material before application of zinc-containing paint is insufficient, the adhesion is low and the paint is easy to peel off There is a problem of becoming. In addition, the method of applying the zinc-containing coating material reduces the electrical conductivity of the coating material because the zinc powder is covered with the resin inside the coating material. As a result, there is a problem that the sacrificial anticorrosive effect originally expected for the zinc-containing paint is reduced.

  Then, this invention solves the above-mentioned problem, and it is a subject to provide the repair material which is hard to peel off even if it is a case where the foundation adjustment of steel materials is inadequate in restoration of steel materials, and does not reduce the effect of corrosion prevention. And

  In order to solve the above-described problems, the present invention provides a resin in which a base metal powder is dispersed and contained in a resin that is solidified from a liquid to a solid by a chemical reaction, and is composed of conductive fibers. A steel repair material characterized by being impregnated in a cloth-like carrier.

  ADVANTAGE OF THE INVENTION According to this invention, even if it is a case where the base preparation of steel materials is inadequate in restoration of steel materials, a repair material which does not peel off paint easily and does not reduce the anticorrosion effect can be provided.

FIG. 1 is an image diagram of the repair material of the present embodiment. FIG. 2 is a flowchart showing a repair procedure of a steel material using the repair material. FIG. 3 is an image diagram of a paint in the prior art. FIG. 4 is a table summarizing experimental conditions and experimental results of the repair material of the present embodiment. FIG. 5 is a diagram showing the size, flaw shape, and position of each steel material used in the experiment. FIG. 6 is an image diagram of a state of rust generated in the steel material coated by the experiment of FIG.

  Hereinafter, embodiments (embodiments) for carrying out the present invention will be described with reference to the drawings. The present invention is not limited to the embodiments described below.

  The steel repair material of this embodiment is, for example, a repair material used for a corroded galvanized steel material. This repair material is made of a resin in which a base metal (eg, zinc, zinc alloy, etc.) is dispersed in a resin that solidifies from a liquid to a solid by a chemical reaction. For example, it is impregnated with a cloth-like carrier composed of a metal nonwoven fabric.

  An image diagram of the repair material 101 of the present embodiment is shown in FIG. In FIG. 1, it is assumed that the steel material 103 is in a state where the corrosion products have already been removed. For example, the repair material 101 is obtained by impregnating a cloth-like carrier (conductive carrier) 102 made of conductive fibers (for example, metal nonwoven fabric) in which a metal powder 104 such as zinc (Zn) is dispersed in a resin. Paint. Here, it is desirable that the contents of the metal powder 104 and the conductive carrier 102 be as large as possible. For example, the total content of the metal powder 104 and the conductive support 102 is preferably 80 wt% or more, more preferably 90 wt% or more of the weight of the repair material 101.

  An example of a steel material repair procedure using such a repair material 101 will be described with reference to FIG. First, a steel material repairer removes corrosion products from the steel material (S1). Then, the repair person attaches the repair material 101 to the steel material (S2), and then hardens the repair material 101 (S3).

  In general, a paint containing a higher concentration of metal powder that is more base than steel such as zinc is expected to exhibit the effect of sacrificial corrosion protection. In this sacrificial protection, even when the coating film is scratched and the steel material is partially exposed, the zinc contained in the paint is a base metal rather than steel, so that the zinc preferentially corrodes and the resulting current flows This is a function to obtain the effect that steel does not corrode. In order to exert the effect of sacrificial protection in steel paints, the steel and the metal contained in the paint (for example, zinc (Zn)) are electrically connected, and the steel and zinc are in contact with continuous water. Need to be. Therefore, for example, as shown in FIG. 3, in the prior art, in a paint in which zinc (Zn) is added to a resin, conduction between a steel material and zinc powder and between zinc powders is limited. That is, other than the zinc (Zn) particles denoted by reference numeral 201 in FIG. Moreover, if the zinc (Zn) particle | grains shown with the code | symbol 201 are lost with progress of corrosion, sacrificial anticorrosion property will be lost completely.

  On the other hand, in the repair material 101 of the present embodiment, the conductive carrier 102 secures electrical continuity between the metal powders 104 and between the metal powder 104 and the steel material 103, so that the sacrificial anticorrosive effect is obtained. It is fully demonstrated. In addition, in the prior art, even if the content of zinc (Zn) powder in the repair material is 90 wt% or more of the entire (repair material), sufficient electrical continuity is often not secured, but the zinc powder content It has been confirmed that if the amount is increased to allow electrical continuity, the amount of resin contributing to adhesion to the steel material is reduced, so that sufficient adhesion cannot be obtained (easy to peel off). On the other hand, since the repair material 101 of the present embodiment includes the conductive carrier 102 in the resin, sufficient electrical continuity between the metal powders 104 and between the metal powder 104 and the steel material 103 is ensured. In addition, even if the adhesive force of a part of the repair material 101 is reduced, the other part is supported and thus has an effect of being difficult to peel off.

  In the following description, a case where the metal powder 104 used for the repair material 101 is zinc powder will be described as an example, but the present invention is not limited thereto. For example, as long as the metal powder 104 is a metal powder that exhibits a sacrificial anticorrosive effect with respect to the steel material (Fe) 103, a zinc alloy such as a zinc aluminum alloy or a zinc aluminum magnesium alloy, aluminum, or aluminum It may be a powder such as an alloy. The average particle diameter of the metal powder 104 is preferably as fine as possible, such as 1 to 10 μm.

  The conductive carrier 102 is preferably made of a highly conductive metal material. Moreover, since the electroconductive support | carrier 102 will exhibit the effect of sacrificial corrosion protection with respect to the steel material 103, if it is a base metal material rather than the steel material 103, it is used more suitably. In addition, it is desirable to use a noble metal material for the conductive carrier 102 rather than the metal powder 14. This is due to the following reason. That is, if a base metal material is used for the conductive carrier 102 rather than the metal powder 104, the conductive carrier 102 is consumed prior to the metal powder 104 when the sacrificial anticorrosive effect is exerted. There is a possibility that the sacrificial anti-corrosion effect cannot be exhibited even if the pass securing the property is cut and the metal powder 104 remains. However, as described above, if a metal material that is lower than the steel material 103 and more precious than the metal powder 104 is used for the conductive carrier 102, the metal powder 104 is first corroded, and sacrificial corrosion protection by the metal powder 104 is performed. This is because the sacrificial anticorrosive effect of the conductive carrier 102 is exhibited after the effect is lost.

  For example, the conductive carrier 102 is preferably a metal that is baser than the steel material 103, such as aluminum or an aluminum alloy, and that is easily processed into a fiber shape. The diameter of the metal fiber used for the conductive carrier 102 is desirably as small as possible, such as 10 to 50 μm. This is because the surface area (specific surface area) per unit volume of the conductive carrier 102 can be increased by using metal fibers that are as thin as possible.

  Further, as the resin used for the repair material 101, for example, a polyurethane-based resin, an acrylic styrene-based resin, an epoxy-based resin, an alkyl silicate-based resin, an alkyd-based resin, or the like is preferably used. It is done.

  In these resins, a one-part curable resin that cures by reacting with oxygen or moisture in the air or is cured by drying a solvent (for example, one-part curable epoxy resin, one-part curable type). A polyurethane resin or the like is preferably used. By using such a one-part curable resin material for the repair material 101, the repairer can use a resin (a two-part curable type) that cures by mixing two liquids of the main agent and the curing agent. Therefore, it is possible to reduce the time and labor required when the carrier is immersed in the conductive carrier 102 and to stabilize the construction quality.

  The work procedure of the repair person when using a one-component curable resin as the resin of the repair material 101 is as follows. For example, the repairer immerses the conductive carrier 102 in the resin in an environment in which the resin does not undergo a curing reaction, such as in a nitrogen atmosphere, after the resin 104 contains zinc or other metal powder 104 at a high concentration. I will. Then, the repairer packages the repair material 101 without oxygen or moisture so that the resin of the repair material 101 soaked in the conductive carrier 102 is not cured. After that, the repair person opens the packaging of the repair material 101 on the site, attaches the repair material 101 to the steel material 103 to be repaired (or winds), and hardens the repair material 101. By doing in this way, when the repairer performs the repair work of the steel material 103, it is only necessary to open the package at the work site and attach the repair material 101 to the steel material 103 (wrapping), so the work efficiency of the repair is improved. Can be improved.

  In the case of the conventional method of applying a paint containing zinc (Zn) powder to the steel material to be repaired, the base material of the steel material (removal of corrosion products) is blasted by ISO8501-1. It is recommended to process more than Sa2 1/2. This blasting process requires a large device and surrounding curing, so it is often difficult to perform on-site construction. In that case, it is necessary to use a power tool with a grade of St3 or higher of ISO8501-1. However, it is very time-consuming and costly to adjust the St3 level substrate of ISO8501-1 with a power tool. The paint will peel off.

  On the other hand, in the repair material 101 of the present embodiment, since the conductive carrier 102 is impregnated with the resin and metal powder 104, the adhesive strength remains in the peripheral portion even if there is a portion where the adhesive strength is partially reduced. If so, the anticorrosion effect can be maintained for a long time because the steel material 103 is not peeled off. That is, according to the repair material 101, even when the base adjustment (removal of corrosion products) grade of the steel material 103 to be repaired is low, the anticorrosion effect can be maintained for a long time. Further, if the repairer wraps the repair material 101 around the steel material 103 to be repaired one or more times and repairs, the anticorrosion effect can be maintained for a longer period because it is difficult to peel off even if the adhesion is lost. That is, according to the repair material 101 of the present embodiment, the anticorrosion effect of the repair material can be enhanced and the anticorrosion effect can be maintained for a long time as compared with the conventional technology.

(Experimental result)
In order to verify the effect of sacrificial protection of the repair material 101 of the present embodiment, the following experiment was performed. In this experiment, zinc (Zn) powder having an average of 5 μmφ was used as the metal powder 104 used for the repair material 101. Further, an aluminum fiber nonwoven fabric having an average of 20 μmφ was used as the conductive carrier 102. Further, a one-component curable epoxy resin was used as the resin used for the repair material 101. Then, the repair material 101 described above was coated on a steel material, and the effect and adhesion of sacrificial anticorrosion were compared with a steel material coated with a conventional technique (zinc rich paint). A summary of the experimental conditions and experimental results is shown in FIG. Moreover, the image figure of the state of the rust which generate | occur | produced in the steel material coated by this experiment is shown in FIG.

  As shown in FIG. 4, in this experiment, the proportion (wt%) of the zinc powder of the repair material 101 is 60% to 70%, and the proportion (wt%) of the aluminum fiber nonwoven fabric (aluminum nonwoven fabric) is 10% to 30%, the ratio of zinc powder + aluminum nonwoven fabric (wt%) is 80% to 90%, and the ratio (wt%) of one-component curable epoxy resin (epoxy resin) is 10% to 20%. For the four patterns of the repair material 101 shown, the effect and adhesion of sacrificial anticorrosion were compared with those of the conventional paint. The proportion (wt%) of zinc (Zn) powder in the prior art paint was 90%, and an aluminum fiber nonwoven fabric was not used. In addition, the ratio (wt%) of the one-component curable epoxy resin in the conventional paint was 10%.

  In the verification of the sacrificial protection effect, the sacrificial anti-corrosion performance was verified by putting artificial flaws on the steel material coated with the conventional technology (zinc rich paint) and the steel material coated with the repair material 101 shown in the above A to D with a cutter or the like. did. The thickness of the paint is 80-100 μm. In addition, as shown in FIG. 5, the size of each steel material is 70 * 150 mm and thickness 3.2 mm. The shape and position of the scratches on each coated steel material are the positions shown in FIG. These scratches (cross cuts) were made with a 9 mm cutter after the coated steel material was dried at room temperature for 2 weeks. After putting such scratches, JIS K 5600-7-1 coating test piece salt water spray test (test to evaluate the anticorrosive property of the sample by spraying salt water) on each coated steel material for 2000 hours, The degree of rust generation at the scratches on each painted steel was evaluated.

  Moreover, about the adhesive force of a coating material, each coating steel material was used for the cold-heating repeated test which carries out 100 reciprocations between temperature-30 degreeC-70 degreeC and humidity 90%, and evaluated whether the coating material was peeled off after the test.

  As a result of the experiment, as shown in FIG. 4 and FIG. 6, in the conventional technique, regarding the sacrificial corrosion resistance, red flow rust of iron occurs in the scratched portion of the coated steel material, and the sacrificial corrosion resistance is insufficient. I understood. In addition, regarding the adhesive force, it was found that the paint was peeled off (×) in a repeated test of cold heat.

  On the other hand, in the case of the repair material 101 shown in the pattern A and the pattern B, as shown in FIG. 4 and FIG. Did not occur. In other words, it was found that the sacrificial anticorrosive effect was sufficient. In addition, regarding the adhesive force, it was found that the paint did not peel off (◯) in the repeated test of cold and hot.

  Moreover, in the case of the repair material 101 shown in the pattern C and the pattern D, as shown in FIG. 4 and FIG. 6, the red spot rust of iron generate | occur | produced in the flaw part of the coating steel material regarding the effect of sacrificial corrosion prevention. In other words, it was found that the effect of sacrificial corrosion protection is slightly insufficient, but better than the prior art. In addition, regarding the adhesive force, it was found that there was no peeling of the paint (◯) in a repeated test of cold and hot.

  In other words, by making the ratio (wt%) of zinc powder + aluminum nonwoven fabric 80% or more for the repair material 101, the sacrificial anti-corrosion effect and adhesion strength higher than those of the prior art can be exhibited, especially about 90%. It was found that the effect of higher sacrificial corrosion protection was exhibited.

  The repair material 101 of the present embodiment described above uses a cloth-like carrier (conductive carrier 102) made of conductive fibers, thereby improving sacrificial corrosion resistance and realizing difficulty in peeling off the paint. That is, by supporting the metal powder 104 and the resin on the conductive carrier 102, conduction between the metal powders 104 and between the metal powder 104 and the steel material 103 is ensured through the conductive carrier 102. As a result, if the total amount of the metal powder 104 and the conductive carrier 102 is 80 wt%, it is possible to obtain a sacrificial anticorrosive effect higher than that of the prior art, and the total amount of the metal powder 104 and the conductive carrier 102 is the total. If it is 90 wt% or more, sufficiently high sacrificial corrosion resistance can be obtained. In addition, even if the adhesive force is reduced in a part of the repair material 101 due to aging deterioration or insufficient base adjustment, the peripheral portion supports the resin and metal powder 104 held by the conductive carrier 102. Therefore, there is also an advantage that peeling does not easily occur.

101 Repair material 102 Conductive carrier 103 Steel material 104 Metal powder

Claims (6)

  A resin that solidifies from a liquid to a solid by a chemical reaction and a paint containing base metal powder dispersed in steel is impregnated in a cloth-like carrier made of conductive fibers. Steel repair material.   The steel repair material according to claim 1, wherein the base metal with respect to the steel material is zinc or a zinc alloy.   2. The steel repair material according to claim 1, wherein the resin is a polyurethane, acrylic styrene, epoxy, alkyl silicate, or alkyd resin material.   2. The steel repair material according to claim 1, wherein the conductive fiber is aluminum or an aluminum alloy.   3. The steel material according to claim 1, wherein the resin is a one-component reaction-curing resin that is cured by reacting with oxygen or moisture in the air or drying the solvent of the resin. Repair material. Removing corrosion products from the steel material;
A repair material in which a base material powder composed of conductive fibers is impregnated with a paint containing a base metal powder dispersed in a resin that solidifies from a liquid to a solid by a chemical reaction. A step of affixing to the steel material;
A method of repairing a steel material, comprising: curing the repair material.

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