US3479229A - Structural steel members and method of making same - Google Patents

Structural steel members and method of making same Download PDF

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Publication number
US3479229A
US3479229A US568046A US3479229DA US3479229A US 3479229 A US3479229 A US 3479229A US 568046 A US568046 A US 568046A US 3479229D A US3479229D A US 3479229DA US 3479229 A US3479229 A US 3479229A
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United States
Prior art keywords
film
steel
weight
layer
solution
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Expired - Lifetime
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US568046A
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English (en)
Inventor
Gerhard Becker
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Huettenwerk Oberhausen AG
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Huettenwerk Oberhausen 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
    • C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
    • C23C22/05—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions
    • C23C22/06—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6
    • C23C22/46—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6 containing oxalates
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D115/00—Coating compositions based on rubber derivatives
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/64—Insulation or other protection; Elements or use of specified material therefor for making damp-proof; Protection against corrosion
    • E04B1/642—Protecting metallic construction elements against corrosion
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31678—Of metal

Definitions

  • the present invention relates to a method of treating light-alloy steel bodies for improving the surface characteristics thereof, e.g. preventing corrosion, in order to render the steel members suitable for use in exposure to the atmosphere as panels, profiles or the like in abovesurface structures; more particularly, this invention relates to improvements in the surface treatment of steel bodies to modify surface-corrosion characteristics and improve corrosion resistance.
  • steels In buildings, bridges and other above-surface structures, the application of steels has generally been such as to require them to be completely concealed or encased because of the tendency to corrosion, the unaesthetic characteristics of atmospheric corrosion, the mottled appearance of the steel members after prolonged weathering, and the inability to protect such steel surfaces permanently by painting or the like.
  • steel structural members are commonly employed in buildings because of their great strength, it has been the practice to encase the structural members in concrete or to mount panels upon them.
  • a steel member may be jacketed with a corrosion-resistant and aesthetic layer of another metal (e.g. stainless steel, aluminum or an aluminum alloy) such that the cladded steel member can be exposed to the atmosphere without these disadvantages.
  • Steels of this type generally include corrosion-resistant components such as copper, nickel, chromium, vanadium and phosphorous individually or in combination and making up at most 2% by weight of the alloy. It has been found that such steels do not ensure a satisfactory bond of the oxide layer to the steel substrate and indeed, the oxide layer of these members is not unlike the loose oxides formed on common steel and iron bodies. Only after a prolonged exposure to the atmosphere is the oxide film built up to a sufiicient thickness to prevent further deterioration of the steel body. The staining of the joining surfaces is also a characteristic of these members which have a mottled appearance with weathering.
  • the principal object of the present invention to provide an improved steel structural member, adapted to be used in direct exposure to the atmosphere in building construction or the like whose surface characteristics are aesthetically pleasing, unaffected by prolonged exposure to the atmosphere and to other corrosive environments, and remain uniform without staining adjoining nonmetallic surfaces.
  • a further object of this invention is to provide an unclad steel member suitable for use as the surfacing member of structural steel elements and in building structures or the like, which is of relatively low-cost and easily produced.
  • Still another object of this invention is to provide a method of treating steel bodies (e.g. steel sheets, plates, bars and structural steel profiles) in order to render their surfaces aesthetically pleasing, to impart a uniform coloration to the surfaces, to improve the resistance to corrosion of the surfaces of the member, and to enable the member to withstand prolonged weathering without substantial modification of its surface characteristics and appearance.
  • steel bodies e.g. steel sheets, plates, bars and structural steel profiles
  • the prerusting solution adapted to generate the initial oxide film, comprises a water soluble iron salt convertible into iron oxide upon treatment of the metal surface therewith and at least one heavy metal sulfate adapted to form basic sulfates-upon exposure to the atmosphere which are scarcely soluble in Water;
  • the film-forming layer consists preferably of at least one film-forming substance selected from the group which consists of resins and/ or synthetic resins, waxes, cellulosic film formers, rubber and other elastomeric derivatives, silicates or the like, used together or individually.
  • a suitable composition for the purposes of the present invention contains:
  • Trace amounts to 0.12% carbon; 0.25 to 0.75% silicon; 0.20 to 0.50% manganese; 0.07 to 0.15% phosphorus; trace amounts to 0.05% sulphur; 0.25 to 0.55% copper; 0.30 to 125% chrominum; trace amounts to 0.65% nickel; the balance being iron (all percents by weight).
  • the prerusting solution should also include a viscosity modifier (e.g. glycerine) adapted to ensure a smooth and uniform coating of the prerust liquid upon the steel body; a wetting agent (preferably a fatty acid condensate with methyl taurine) to promote intimate contact between the treating solution and the metal; and a volatile water-miscible component (e.g. alcohol) adapted to evaporate after coating of the metal surface to facilitate drying of the prerust-treatment liquid.
  • a component e.g. oxalic acid designed to promote the formation of fine-grain iron oxide upon the metal surface with drying of the treatment liquid.
  • the iron salt is present in the treating solution in an amount ranging between and 35 weight percent While the heavy metal salt is present in an amount ranging from 0.1 to 4 weight percent.
  • the heavy metal sulfate component should include salts of at least copper and nickel so that best results are obtained when copper sulfate is present in an amount ranging between 0.1 and 2% by weight and nickel sulfate is present in an amount ranging from 0.1 to 2% by weight as well.
  • the treatment solution thus may also contain 0.1 to 1% weight glycerine, 0.1 to 2% by weight of the component (e.g. oxalic acid) promoting fine-grain oxide formation, from 0.01 to 0.1% by weight of the wetting agent, from to 50% by weight of the volatile water miscible component and the balance water.
  • the treated surface is subjected to an after-moisturization or wetting with an aqueous solution advantageously containing a watermiscible volatile component (e.g. alcohol).
  • an after-moisturization of the treated surface with, for example, a wetting solution consisting of 80 to 90% by weight water and 5 to 20% by weight alcohol, results in the formation of a relatively uniform initial rust structure or surface matrix which withstands abrasive action. In the absence of the after-moisturization treatment,'the initial rust structure is formed significantly more slowly.
  • the film-forming solution in accordance with this invention may include any of the known film formers mentioned earlier but most advantageously consists of an elastomeric material (e.g. a cyclocaoutchouc or India rubber), a solvent for the elastomeric component (e.g. a chlorinated hydrocarbon such as carbon tetrachloride), a shedding component (e.g.
  • a colloidal silica such as that marketed under the name Aerosil
  • a pigment component such as that marketed under the name Aerosil
  • a high molecular weight alcohol component such as that marketed under the name Aerosil
  • a filmforming soltuion is found to be liquid repellent but permeable to water vapor and gases so that penetration of vapors through the film-forming layer enhances the development of the progressive and aesthetic oxide layer therebelow, while the water-repellency prevents the oxide layer from washing onto adjoining surfaces and becoming discolored by weathering.
  • the elastomeric material advantageously constitutes 5 to 40% by weight, the easily vaporizable solvent between 40 and by weight, and the colloidal silica or other shedding component between 2 and 20% by weight, with the other components each making up between 0.1 and 2% by weight.
  • a method of making steel members for panels, structural surfaces and the like comprises the steps of treating the light-alloy steel body with an iron-containing prerust solution and permitting this solution to dry upon the surface of the steel body; after moisturizing the treated surface of the body to promote the formation of the fine-grain initial oxide structure or matrix; thereafter coating the surface with a film-forming substance repellent to water but adapted to pass water vapors; and exposing the film-coated surface of the metal body to atmospheric conditions whereby atmospheric oxidation continues below the film-forming layer.
  • Bodies produced in this manner can be used as surfacing sheets for panel constructions, for encasing structural members and as decoration or protecting members upon any structural elements since the oxide layer becomes progressively thicker under the influences of corrosive atmospheres. It appears that both the iron salt (preferably iron nitrate) and the heavy metal sulfates (preferably copper and/or nickel sulfate) are required in the prerust solution to ensure an adherent uniform and fine-grain initial rust formation which is subjected to further oxide formation through the film-forming layer.
  • the iron salt preferably iron nitrate
  • the heavy metal sulfates preferably copper and/or nickel sulfate
  • the film-forming layer is self-shedding and, for this purpose, may be provided With one or more chalk-like substances or chalk-forming substances designed to permit the film-forming layer to wear away with time and directly expose the underlying oxide layer which, because of the further oxidation described above, attains a final thickness prior to wearing away of the protective film sufficient to prevent further corrosion of the steel body.
  • the film-forming layer preferably contains between 10 and 20% of the elastomeric material, synthetic resin or cellulose film former, between 50 and 70% of a solvent for the latter, between 5 and 10% of a chalk-forming or shedding-promoting component (e.g. silica, silica gel, aluminum stearate, zinc stearate) or a carbonate salt (e.g. calcium carbonate) (all percentages by weight).
  • a chalk-forming or shedding-promoting component e.g. silica, silica gel, aluminum stearate, zinc stearate
  • a carbonate salt e.g. calcium carbonate
  • a further component of the film-forming layer may be the high-carbon number alcohol which serves to demoisturize or dry the underlying oxide layer.
  • the film-forming layer also includes at least one pigmentitious material designed to impart to the protective film, a coloration corresponding to the deepest oxide patina which will develop upon further oxidation through the film-forming layer.
  • at least one pigmentitious material designed to impart to the protective film, a coloration corresponding to the deepest oxide patina which will develop upon further oxidation through the film-forming layer.
  • I show a steel panel 1 which has been treated with the prerust solution on both of its surfaces and subjected to after-moisturization to form the initial oxide layers 2 upon the opposite surfaces of the sheet.
  • the initial rust layers are coated with self-shedding protective films 3 which are repellent or impenetratable to liquid water but are gas or vapor permeable. After the forming of such coatings, the panel or profile can be used upon structures in the conventional manner as facing material in direct exposure to the atmosphere.
  • the protective layer 3 is gas-permeable and the initial rust layer is a relatively porous layer, oxide formation occurs below the initial rust layers 2 to a depth represented by the dot-dash lines 4.
  • the final oxide layer is then represented by the thicknesses 5 and develops to a depth suflicient to bar further corrosion of the steel body.
  • the oxide layers 5 are found to be strongly adherent to the substrate, to be of uniform coloration and, when the self-shedding layers are pigmented to correspond to the coloration of the final oxide layers 5, no change in color will be observed with the shedding of the layers 3.
  • each of the film-forming solutions set forth above was used along a portion of the specimen and applied by spraying and brushing. In both cases, uniform coatings were obtained. Upon drying, the resulting film was found to stabilize the initial rust structure against mechanical abrasion. When the film-coated steel surfaces were subjected to high-velocity streams of water, no migration of the initial rust structure was observed and indeed the surfaces appeared to be completely impermeable to water.
  • pigments to the film-forming layer served to mass the developing coloration of the underlying oxide layer and imparted a uniform coloration to the surface which remained after the weathering and stripping of the film layer because of the deepening of the coloration of the oxide layer.
  • sufiicient pigment e.g. iron oxide hydrate
  • Additional components of the film-forming solution can include plasticizer for the elastomer or resin designed to increase its flexibility, dryers to eliminate any tackiness, and high-molecular-weight alr 7 cohols adapted to absorb moisture from the underlying layer.
  • a method of making a steel facing for structures and the like comprising the steps of:
  • the balance being iron, with a prerust solution in the form of an aqueous solution of a water-soluble iron salt and at least one heavy-metal sulfate to form an initial rust-structure layer thereon;
  • said film is composed at least in major part of an elastome'r, a synthetic resin, a cellulosic material, a wax or a film-forming silicate, and contains a shedding component facilitating weathering away of said film to expose the rust layer.
  • said heavy metal sulfate is selected from the group which consists of copper sulfate and nickel sulfate and said iron salt is iron nitrate.
  • a method of making a steel facing for structures and the like comprising the steps of:
  • said body having the following composition (all percents by weight):
  • the balance being iron
  • said prerust solution being an aqueous solution containing (all percents by weight):
  • At least one heavy metal salt selected from the group consisting of copper sulfate and nickel sulfate,
  • a vapor-permeable/liquid-impermeable-film solution for application to a rusted steel structure and adapted to weather away gradually to reveal the rust surface comprising 5% to 40% by weight of a film-forming substance selected from the group which consists of an elastomer, a synthetic resin, a cellulosic material, a wax and a film-forming silicate; 40% to 90% by weight of a solvent for said film-forming substance; 2% to 20% by weight of a shedding component facilitating weathering away of the film upon oxidation of an iron body therethrough; 0.1% to 2% by weight of a pigment imparting to said film a coloration corresponding essentially to the coloration of a rust structure beneath that film upon oxidation of an iron body therethrough; and 0.1% to 2% by weight of a component adapted to demoisturize said rust structure.
  • a film-forming substance selected from the group which consists of an elastomer, a synthetic resin, a cellulosic material, a

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Organic Chemistry (AREA)
  • Architecture (AREA)
  • Materials Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Metallurgy (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Laminated Bodies (AREA)
  • Preventing Corrosion Or Incrustation Of Metals (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
US568046A 1966-02-18 1966-07-26 Structural steel members and method of making same Expired - Lifetime US3479229A (en)

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DEH0058591 1966-02-18

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US (1) US3479229A (de)
BE (1) BE681290A (de)
DE (1) DE1521775A1 (de)
GB (1) GB1153202A (de)
LU (1) LU51024A1 (de)
NL (2) NL6606923A (de)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3537915A (en) * 1967-04-20 1970-11-03 Huettenwerk Oberhausen Ag Structural steel members and method of making same
JPS4911739A (de) * 1972-05-16 1974-02-01
US3954511A (en) * 1973-11-12 1976-05-04 Nippon Steel Corporation Surface treatment of a weather-resistant steel
US4496401A (en) * 1981-10-15 1985-01-29 Lucas Industries Corrosion resistant steel components and method of manufacture thereof
CN107100381A (zh) * 2017-05-10 2017-08-29 张增阳 一种半地埋式护林小屋
EP2876186B1 (de) * 2013-11-21 2018-07-18 Samsung Electronics Co., Ltd Zusammensetzung zur herstellung eines films eines metallobjekts, daraus hergestellter film und filmbildungsverfahren

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2588280B1 (fr) * 1985-10-03 1987-11-20 Caen Atel Const Modulaires Procede de traitement des toles exterieures metalliques des toitures de batiment, notamment des toles metalliques des toitures autoportantes
FR2593831B1 (fr) * 1986-02-06 1994-01-21 Irsid Procede de revetement protecteur d'un produit en fer ou en acier et produit revetu

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB476006A (en) * 1937-03-03 1937-11-30 Blackwell Hayes & Company Ltd Improvements relating to materials for rust-proofing metals
US2728696A (en) * 1948-12-23 1955-12-27 Singer Fritz Production of oxide coatings on ferrous surfaces and mechanically working the same
US2827399A (en) * 1956-03-28 1958-03-18 Sylvania Electric Prod Electroless deposition of iron alloys
US3178311A (en) * 1961-09-25 1965-04-13 Bunker Ramo Electroless plating process
US3370991A (en) * 1963-05-31 1968-02-27 Corning Glass Works Method of preoxidation of stainless steel

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB476006A (en) * 1937-03-03 1937-11-30 Blackwell Hayes & Company Ltd Improvements relating to materials for rust-proofing metals
US2728696A (en) * 1948-12-23 1955-12-27 Singer Fritz Production of oxide coatings on ferrous surfaces and mechanically working the same
US2827399A (en) * 1956-03-28 1958-03-18 Sylvania Electric Prod Electroless deposition of iron alloys
US3178311A (en) * 1961-09-25 1965-04-13 Bunker Ramo Electroless plating process
US3370991A (en) * 1963-05-31 1968-02-27 Corning Glass Works Method of preoxidation of stainless steel

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3537915A (en) * 1967-04-20 1970-11-03 Huettenwerk Oberhausen Ag Structural steel members and method of making same
JPS4911739A (de) * 1972-05-16 1974-02-01
US3954511A (en) * 1973-11-12 1976-05-04 Nippon Steel Corporation Surface treatment of a weather-resistant steel
US4496401A (en) * 1981-10-15 1985-01-29 Lucas Industries Corrosion resistant steel components and method of manufacture thereof
US4596611A (en) * 1981-10-15 1986-06-24 Lucas Industries Corrosion resistant steel components and method of manufacture thereof
EP2876186B1 (de) * 2013-11-21 2018-07-18 Samsung Electronics Co., Ltd Zusammensetzung zur herstellung eines films eines metallobjekts, daraus hergestellter film und filmbildungsverfahren
CN107100381A (zh) * 2017-05-10 2017-08-29 张增阳 一种半地埋式护林小屋
CN107100381B (zh) * 2017-05-10 2019-09-03 章诗辰 一种半地埋式护林小屋

Also Published As

Publication number Publication date
LU51024A1 (de) 1966-07-04
NL133681C (de) 1900-01-01
BE681290A (de) 1966-10-31
NL6606923A (de) 1967-08-21
DE1521775A1 (de) 1971-09-02
GB1153202A (en) 1969-05-29

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