JPH11350104A - Rust preventing and corrosion protecting treatment for civil engineering and construction material, and civil engineering and construction material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve the transportation and work execution workability of a civil engineering and construction material by enabling a metal product to be used as the alternative to a concrete product, and to improve its corrosion resistance so that even the metal product can be used over a long period under the natural environment which is becoming worse. SOLUTION: This treatment for the rust preventing and corrosion protecting treatment of a civil engineering and construction material comprises a stage where the surface of a civil engineering and construction material made of metal is subjected to surface preparation into mat-finish-like state; a stage where the surface after surface preparation is thermally sprayed with aluminum and zinc to form a pseudoalloy film 16 enriched in aluminum; and a stage where a coating material 17, prepared by mixing aluminum oxide particles with polymerized acrylurethane resin, is applied to the pseudoalloy film. By this method, the rust preventive and corrosion protective film, excellent in adhesion and corrosion resistance, can easily be formed on the metal surface, and the lightweight and tough civil engineering and construction material made of metal, usable as the alternative to a concrete product, can be obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an architectural construction material such as a frame having a cross shape used for preventing a slope from collapsing. The frame is formed of a metal such as a steel material, and its surface is rustproofed. The present invention relates to a method of treatment and a rust-proof civil engineering building material.

[0002]

2. Description of the Related Art Civil engineering materials of this kind are generally formed of concrete. However, a concrete frame has a considerable weight and is difficult to handle during transportation and installation. In recent years, in consideration of ease of construction, etc.
That is, metal products have begun to be used.

When such a metal frame is used, since it is installed directly on the ground in a state where it is exposed to the outside air, the surface is prevented from being rusted and corroded by acid rain or acid fog. Rust and anticorrosion treatment is required. As the rust-proofing and anti-corrosion treatment means, hot-dip galvanizing is generally known as a conventional technique. In particular, as a long-term anti-corrosion and anti-corrosion film, the basis weight is 640 g / m ² (thickness is 90 μ
m) thick plating film is adopted.

[0004]

However, zinc (natural potential -1200 mm) which is effective as a cathode rust preventive film.
V) has a high ionization tendency and a high oxidizing and eluting rate even in a weakly corrosive environment. Particularly, in recent years, the concentration of acid rain or acid fog has increased due to deterioration of the natural environment. / Year, more than 7 μm / year in the mountainous area.
It was confirmed that the consumption was more than 3 times, and the elution amount was more than expected, and it was actually reduced to about 1/3 of the expected service life. , And cannot be recognized as a permanent rust-proof coating.

[0005] Therefore, in the case of a conventional metal civil engineering building material, it is necessary to solve the problem of forming a film for providing a rust-proof and corrosion-proof function for a long time even in the deterioration of the natural environment, and a method of forming the film. Have issues that must be addressed.

[0006]

According to a first aspect of the present invention, there is provided, as a first aspect, a step of subjecting a surface of a civil engineering building material formed of metal to a matte finish. A step of spraying aluminum and zinc on the undercoated surface to form an aluminum-rich pseudo alloy film, and a step of forming a room temperature drying type ceramic film as a surface film on the pseudo alloy film. A rust-preventive and anticorrosion treatment method for a civil engineering building material, and, as a second invention, a step of subjecting the surface of the civil engineering building material formed of metal to hot-dip galvanizing; And a step of applying a coating material obtained by mixing ceramic powder into an epoxy resin on the surface of the activated hot-dip galvanizing to form an intermediate coating layer, and curing the intermediate coating layer. A process of spraying aluminum and zinc on the surface to form an aluminum-rich pseudo-alloy film, and a step of forming a room-temperature-dried ceramic film as a surface film on the pseudo-alloy film. And a third invention, as a third invention, an aluminum-rich pseudo-alloy film formed on a surface of a civil engineering building material whose surface is formed of satin-like metal; And a civil engineering building material characterized by having a surface coating film of a room temperature drying type ceramic film formed in a laminated state, and as a fourth invention, a civil engineering building material formed on the surface of a civil engineering building material formed of metal. A hot-dip galvanized layer, an intermediate coating layer containing an epoxy resin and ceramic powder formed on the surface of the hot-dip galvanized layer, and an aluminum-rich layer formed on the surface of the intermediate coating layer And a pseudo-alloy coating,
A civil engineering building material characterized by having a surface coating of a room temperature drying type ceramic coating formed in a laminated state on the pseudo alloy coating.

[0007] The step of applying a matte-like undercoating process is to spray a granular material having a Mohs hardness of 7 or more, and the step of physically activating is an alkali etching process.
The room temperature drying type ceramic film has an additional requirement that it be formed of a coating material in which polymerized acrylic urethane resin is mixed with alumina oxide fine particles.

[0008] The rust-proofing and anti-corrosion treatment method according to the present invention comprises forming a pseudo-alloy film of aluminum-rich aluminum and zinc, and forming a layer of a polymerized acrylic urethane resin mixed with alumina oxide fine particles or an epoxy resin mixed with ceramic powder. And the like are integrally formed in a laminated state, and by forming these layers, it is possible to provide a long-term corrosion resistance that is seven times or more that of hot-dip galvanizing, which is considered to have high corrosion resistance.

[0009] In addition, the civil engineering building material has a surface on which a pseudo-alloy film of aluminum-rich aluminum and zinc and a polymerized acrylic urethane resin mixed with alumina oxide fine particles or an epoxy resin mixed with ceramic powder are integrally formed. Since it is formed, it is excellent in long-term corrosion resistance, and is light in weight as a whole, so that handling becomes extremely easy.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in more detail with reference to the illustrated embodiments. FIG. 1 shows a frame 1 used for preventing a slope from falling, which is one of the civil engineering and building materials according to the present invention. The frame 1 is formed by using a rigid metal plate having a predetermined thickness. It has a hollow inside and is formed in a substantially cross-shaped shape when viewed from a plane.

In the frame 1, the legs 2 to 5 extending in all directions are formed to have substantially the same length. However, the present invention is not limited to this. May be formed to have different lengths than the opposing legs 3,5. The legs 2 to 5 can be tapered and thinner toward the tip.

At the center of the frame 1 thus formed, a concave portion 6 is formed on the upper surface side, and a tendon such as a tendon described later is attached to the concave portion 6 at the time of installation by construction. . In such a configuration, the shape of the frame used conventionally can be adopted as it is.

In such a building material, rust prevention and corrosion prevention treatment is performed on the entire surface. The first method of this rust-proofing and anti-corrosion treatment is to impinge on the surface of the frame 1 by spraying natural or artificial ceramic particles (having an acute angle) having a Mohs hardness of 7 or more with a direct pressure injection nozzle,
By forming an irregular pattern having an average depth of 65 μm at 30 points or more per 1 mm 2, the entire surface of the frame 1 is formed in a substantially satin shape.

Next, a step of simultaneously melt-injecting aluminum and zinc by using a low-pressure internal melt spraying technique,
As shown in FIG. 2, a pseudo alloy film 12 of aluminum and zinc is formed on the surface of a steel material 11 constituting the frame 1. This pseudo alloy film 12 is a film of an aluminum-rich pseudo alloy by simultaneously injecting corrosion resistant aluminum as a cathode rust preventive film and zinc having a low voltage (natural potential of 1200 mmV).

In this case, the aluminum wire and the zinc wire are simultaneously supplied and sprayed. The so-called non-uniform melting spraying in which the supply speed of the aluminum wire is faster than the supply speed of the zinc wire is performed by a high-speed inverter. By using a drive power supply (40 KHz), an aluminum-rich pseudo alloy film 12 is formed.

The volume ratio of aluminum to zinc in the aluminum-rich pseudo alloy film 12 is such that aluminum is 55%.
Zinc can be formed in a range of 45 to 30% in a range of 70 to 70%, and an appropriate combination is selected and applied from these ranges. Then, the formed pseudo alloy film 12 is formed.
Since the surface of the steel material 11 is treated like a satin finish, a strong integration with the steel material 11 is established.

The aluminum-rich pseudo-alloy film 12 thus formed by thermal spraying does not become an alloy of aluminum and zinc, but forms a eutectic structure with each other. And the zinc is eluted by external factors. Therefore, by comparing the corrosion resistance of the aluminum-rich pseudo-alloy film with a single hot-dip galvanized film having the same thickness by the JISZ2371 salt spray corrosion resistance test, it was found that the aluminum-rich pseudo-alloy film has seven times or more the corrosion resistance. confirmed.

Further, a room temperature drying type ceramic film is formed as a surface film 13 on the surface of the aluminum-rich pseudo alloy film 12. This room temperature drying type ceramic film is
The step of applying a coating material obtained by mixing alumina oxide fine particles with a polymerized acrylic urethane resin is performed. In this case, a mixture of 100 to 200 parts by weight of alumina oxide fine particles with respect to 100 parts by weight of the polymerized acrylic urethane resin is used.
Brushing, roll coating, spraying, or the like can be appropriately selected.

It was found that the applied surface coating film 13 had good coating adhesion with the pseudo alloy film 12 unlike the hot dip galvanized film having a metal soap film formed on the surface. The surface coating 13 thus formed has a surface hardness of about 5H by drying at room temperature. The hardness of the alumina oxide fine particles used is approximately 7 to 8 in Mohs hardness.
It is about.

The surface coating film 13 is, of course, excellent in corrosion resistance due to its material. However, during transportation and construction of civil engineering and building materials, the hardness of the mixed alumina oxide fine particles prevents scratches and the like from being generated. I have to.

In general, when a coating film is formed on a metal surface with an ordinary rust-preventive paint, the presence of a plasticizer causes deterioration of ultraviolet rays, and when a corrosion-protective current is generated in the metal, a very small amount is required. Hydrogen gas is generated to cause a swelling phenomenon of the coating film. However, in the surface coating film 13, the amount of the binder resin is reduced by about 25% with respect to the ordinary coating material, and the amount of the plasticizer is also reduced to reduce infrared ray deterioration. In addition to the above, the gas permeation is facilitated by using a pinpoint having a diameter of 2 to 4 μm between the mixed alumina oxide fine particles, and the blistering phenomenon of the coating film is eliminated.

The second rust-proofing and corrosion-proofing method according to the present invention comprises:
As shown in FIG. 3, first, a step of forming a hot-dip galvanized layer 14 on a surface of a steel material 11 constituting a frame of a civil engineering building material, and a step of forming a metal soap formed on the surface of the hot-dip galvanized layer 14 A step of physically activating the film is performed. In this activation treatment, for example, the treatment is performed by immersion in an alkaline solution or the like, followed by washing with water and cleaning.

On the hot-dip galvanized layer 14, an irregular ceramic powder having a particle size in the range of 35 to 110 μm is coated with an epoxy resin adhesive at a weight ratio of 3: 1 (resin).
, And a step of forming a non-conductive intermediate coating layer 15 by high-pressure injection of a coating material mixed and mixed substantially uniformly.
In this case, the ceramic powder or particles are formed on the hot-dip galvanized layer 14 in a discontinuous state.

After the intermediate coating layer 15 is dried and hardened,
A pseudo alloy film 16 of aluminum and zinc is formed by thermal spraying in the same manner as in the first rust prevention / corrosion treatment method. This pseudo alloy film 16 is made of 55 to 7 aluminum.
The aluminum-rich pseudo-alloy film 16 has a range of 0% and zinc in a range of 45 to 30%.

Further, on the surface of the aluminum-rich pseudo alloy film 16, a room temperature drying type ceramic film is formed as the surface film 17 in the same manner as in the first embodiment. This room temperature drying type ceramic film is subjected to a step of applying a coating material obtained by mixing alumina oxide fine particles with a polymerized acrylic urethane resin. In this case, 100 to 20 parts by weight of the polymerized acrylic urethane resin, 100 to 20 alumina fine particles.
A mixture of 0 parts by weight is used, and as a coating means, for example, brush coating, roll coating, spraying, or the like can be appropriately selected.

The applied surface coating film 17 has good coating adhesion to the aluminum-rich pseudo alloy film 16 and has a surface hardness of about 5H by drying at room temperature, and is not only excellent in corrosion resistance but also in civil engineering. During transportation and construction of building materials, the hardness of the mixed alumina oxide particles prevents the generation of scratches and the like. Eliminate the swelling phenomenon.

The thus constructed civil engineering building material of the present invention, that is, a frame as an example, is used to prevent the slope 21 from collapsing as shown in FIG. In this case, the frame 1 is laid by connecting adjacent legs (2 and 4 or 3 and 5), and a tension member 22 such as a tendon is connected and fixed to the concave portion 6 at the center of each frame 1. ,
The frame 1 is laid on the slope 21 in a crimped state.

That is, a hole 23 for a ground anchor having a predetermined depth is formed in the slope 21 in a direction perpendicular to the slope 21, and a solidifying material 24 such as milk cement is filled in the hole. The tension member 22 is disposed via the body 25, and after the hardening material 24 is hardened, the tension member 22 is tensioned and its end is fixed in the concave portion 6 by a wedge member or the like, and the fixed end is oxidized. After a proper treatment (for example, covering with grease or stuffing concrete to harden it in a waterproof state) so as not to prevent it, the concave member 6 is covered with a lid member 26 to protect it.

The frame 1 laid in this manner is exposed to the atmosphere and, as a matter of course, receives direct rays of light and is exposed to acid rain or, in a place near the coast, to salt damage. Will be.

However, since the above-described predetermined treatment having excellent corrosion resistance is performed on the metal surface, there is no danger of corrosion over a long period of time, and the collapse of the slope can be prevented.
Although the frame has been described as an example of the civil engineering building material, the present invention is not limited to the frame, and naturally includes, for example, a column, a connecting member, and the like formed of metal.

[0031]

As described above, the rust-preventive and anti-corrosion treatment method for civil engineering building materials according to the present invention comprises a step of subjecting the surface of the civil engineering building material formed of metal to a matte finish, and Forming a pseudo-alloy film rich in aluminum by spraying aluminum and zinc on the surface, and forming a surface coating film of a room temperature drying type ceramic film on the pseudo alloy film. In addition, a rust-proof and anti-corrosion film having excellent adhesion and corrosion resistance to a metal surface can be easily formed, and an excellent effect of obtaining a metal civil engineering building material that can be used in place of a concrete product can be obtained.

Further, as a method for rust-preventing and anti-corrosion treatment of civil engineering building materials, a step of applying hot-dip galvanizing to the surface of a civil engineering building material formed of metal, and a step of physically activating the hot-dip galvanizing surface. A step of applying a coating material obtained by mixing ceramic powder into an epoxy resin on the surface of the activated hot-dip galvanizing to form an intermediate coating layer; and after the intermediate coating layer is cured, aluminum and zinc are formed on the surface. A step of forming an aluminum-rich pseudo-alloy film by thermal spraying, and a step of forming a room-temperature-drying type ceramic film on the pseudo-alloy film, further comprising a corrosion-resistant and corrosion-resistant coating. Can be formed on the metal surface in a stable state.

Further, the civil engineering building material according to the present invention comprises an aluminum-rich pseudo alloy film formed on the surface of a civil engineering building material having a matte metal surface, and a laminated state on the pseudo alloy film. With the structure having the surface coating of the formed room temperature drying type ceramic coating, the aluminum-rich pseudo-alloy coating provides corrosion resistance several times that of conventional hot-dip galvanizing. As a material, when used as a frame for preventing slope collapse, it is extremely easy to handle during transportation and construction, and it can prevent slope collapse without deterioration in corrosion resistance over a long period of time. It has the effect.

Further, as a civil engineering building material, a hot-dip galvanized layer formed on the surface of a metal-made civil engineering building material, and an epoxy resin and ceramic powder formed on the surface of the hot-dip galvanized layer are mixed. A coating layer,
By having a structure having an aluminum-rich pseudo alloy film formed on the surface of the intermediate film layer and a room temperature drying type ceramic film formed on the pseudo alloy film, a four-layer film is formed as a whole, Thereby, the above-mentioned effect can be further improved.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an example of a civil engineering building material according to the present invention.

FIG. 2 is a cross-sectional view of the first embodiment, showing a part of the civil engineering building material in an enlarged manner.

FIG. 3 is a cross-sectional view of a second embodiment showing a part of the civil engineering building material in an enlarged manner.

FIG. 4 is a schematic sectional view showing an example of use of the civil engineering building material.

[Explanation of symbols]

1 ... frame (civil engineering building material), 2, 3, 4, 5 ...
... leg, 6 ... recess, 11 ... metal (steel), 1
2, 16: pseudo alloy film, 13, 17: surface coating layer, 14: hot-dip galvanized, 15: intermediate coating layer,
21 ... slope, 22 ... tendon, 23
... anchor holes, 24 ... consolidated material, 25 ... load-bearing body, 26 ... lid material.

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[Procedure amendment]

[Submission date] May 6, 1999

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] Claims

[Correction method] Change

[Correction contents]

[Claims]

[Procedure amendment 2]

[Document name to be amended] Statement

[Correction target item name] 0006

[Correction method] Change

[Correction contents]

[0006]

According to a first aspect of the present invention, as a specific means for solving the problems of the conventional example, a Mohs hardness of 7 or more is applied to the surface of a civil engineering building material formed of metal.
A process of spraying the granular material of
A step of spraying aluminum and zinc on the surface subjected to the base treatment to form an aluminum-rich pseudo alloy film, and a step of forming a room temperature drying type ceramic film as a surface film on the pseudo alloy film. Rust prevention and corrosion treatment method for civil engineering building material characterized by the step of, as a second invention, a step of subjecting the surface of the civil engineering building material formed of metal to hot dip galvanizing; An activating step, a step of applying a coating material obtained by mixing ceramic powder into an epoxy resin on the surface of the activated hot-dip galvanizing to form an intermediate coating layer, and after the intermediate coating layer is cured, A step of spraying aluminum and zinc on the surface to form an aluminum-rich pseudo-alloy film, and a step of forming a room-temperature-dried ceramic film as a surface film on the pseudo-alloy film And rust corrosion treatment method for civil engineering and construction materials, characterized in that it consists, as a third invention, the surface of the civil engineering and construction material whose surface is formed of a metal which is processed to satin-like, is formed by thermal spraying means A civil engineering building material comprising: an aluminum-rich pseudo-alloy film; and a room-temperature-drying type ceramic film surface coating formed in a laminated state on the pseudo-alloy film. A hot-dip galvanized layer formed on the surface of civil engineering building material formed of metal, an intermediate coating layer in which an epoxy resin and ceramic powder formed on the surface of the hot-dip galvanized layer are mixed, and a surface of the intermediate coating layer An architectural building material characterized by having an aluminum-rich pseudo-alloy film formed on the substrate and a surface coating of a room-temperature-dried ceramic film formed in a laminated state on the pseudo-alloy film, It is intended to provide.

[Procedure amendment 3]

[Document name to be amended] Statement

[Correction target item name] 0007

[Correction method] Change

[Correction contents]

Further, in the present invention, an aluminum-rich
The pseudo alloy film consists of 55-70% aluminum and zinc
Is in the range of 45 to 30% , the step of physically activating is an alkali etching treatment, and the room temperature drying type ceramic film is formed of a coating material in which polymerized acrylic urethane resin and alumina oxide fine particles are mixed. Is included as an additional requirement. Things.

[Procedure amendment 4]

[Document name to be amended] Statement

[Correction target item name] 0031

[Correction method] Change

[Correction contents]

[0031]

As described above, the method for rust and corrosion prevention of civil engineering building materials according to the present invention sprays a granular material having a Moh's hardness of 7 or more on the surface of the civil engineering building material formed of metal .
Only a step of surface treatment to the textured by the steps of forming an aluminum-rich pseudo-alloy coating by spraying aluminum and zinc lower land treated surface, air drying as a surface coating on該疑similar alloy film And a step of forming a ceramic film of a metal film, which can easily form a rust-proof and corrosion-resistant film having excellent adhesion and corrosion resistance to a metal surface, and can be used in place of a concrete product. It has an excellent effect that civil engineering building materials can be obtained.

[Procedure amendment 5]

[Document name to be amended] Statement

[Correction target item name] 0033

[Correction method] Change

[Correction contents]

Further, the civil engineering building material according to the present invention comprises an aluminum-rich pseudo-alloy film formed by thermal spraying on the surface of a civil engineering building material whose surface is formed of a satin- finished metal. With a structure that has a surface coating of a room temperature drying type ceramic coating formed in a laminated state on a pseudo alloy coating , aluminum-rich
The pseudo-alloy film can be firmly and integrally formed, and the pseudo-alloy film provides several times the corrosion resistance as compared with the conventional hot-dip galvanizing, and also has the surface of the ceramic film.
The coating further improves the corrosion resistance.For example, when used as a civil engineering building material or as a frame for preventing slope collapse, handling during transport and construction becomes extremely easy, and the corrosion resistance over a long period of time. This has an excellent effect that the slope can be prevented from collapsing without deterioration.

Claims (8)

[Claims] 1. A step of subjecting a surface of a civil engineering building material formed of metal to a matte finish, and a step of spraying aluminum and zinc onto the surface subjected to the subject matter to form an aluminum-rich pseudo alloy film. And a step of forming a room temperature drying type ceramic film as a surface film on the pseudo alloy film. 2. The method according to claim 1, wherein the step of applying the matte-like undercoating comprises spraying a granular material having a Mohs hardness of 7 or more. 3. A step of subjecting a surface of a civil engineering building material formed of metal to hot-dip galvanizing; a step of physically activating the surface of the hot-dip galvanizing; Forming an intermediate coating layer by applying a coating material obtained by mixing ceramic powder into an epoxy resin; and spraying aluminum and zinc onto the surface of the intermediate coating layer after the intermediate coating layer is cured, thereby forming an aluminum-rich pseudo-alloy coating. And a step of forming a room-temperature-dried ceramic coating as a surface coating on the pseudo-alloy coating. 4. The method for preventing rust and corrosion of civil engineering building materials according to claim 1, wherein the room temperature drying type ceramic film is formed of a coating material obtained by mixing alumina fine particles with a polymerized acrylic urethane resin. 5. The method according to claim 3, wherein the step of physically activating is an alkali etching treatment. 6. An aluminum-rich pseudo-alloy film formed on a surface of a civil engineering building material whose surface is formed of a satin-like metal, and a room-temperature-drying ceramic film formed on the pseudo-alloy film in a laminated state. Civil engineering construction material characterized by having a surface coating film of: 7. A hot-dip galvanized layer formed on a surface of a civil engineering building material formed of a metal, an intermediate coating layer in which an epoxy resin and ceramic powder formed on a surface of the hot-dip galvanized layer are mixed, A civil engineering building material comprising: an aluminum-rich pseudo-alloy film formed on the surface of a coating layer; and a room-temperature-drying ceramic film surface coating formed in a laminated state on the pseudo-alloy film. 8. The civil engineering building material according to claim 6, wherein the surface coating of the room temperature drying type ceramic coating is formed of a coating material in which an acrylic urethane resin and alumina oxide fine particles are mixed.