CN105585883B - 用于钢筋防腐的低温烧结涂料及其涂覆方法 - Google Patents
用于钢筋防腐的低温烧结涂料及其涂覆方法 Download PDFInfo
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Abstract
本发明公开了一种用于钢筋防腐的低温烧结涂料，原料包括以下组分：纳米二氧化硅30‑50份、助熔剂20‑40份、氟化钙9‑20份、增稠剂2‑10份、密着剂2‑14份。还公开了一种用于钢筋防腐的低温烧结涂料的涂覆方法，包括以下步骤：1)干混；2)湿混；3)预处理；4)涂覆；5)烘烤；6)烧结；7)常温冷却。本发明强度高、致密性能好、防腐性能好、与混凝土粘接力强，同时保持了钢筋自身的力学性能。
Description
技术领域
本发明属于用于混凝土结构的金属材料领域，尤其是涉及一种用于钢筋防腐的低温烧结涂料及其涂覆方法。
背景技术
进入21世纪，我国已经迈入了沿海经济大发展的时代，可以预见未来一段时期内将有大批海港码头、跨海桥梁、隧道、海上采油平台等使用钢筋混凝土结构。混凝土结构中钢筋被锈蚀成为影响钢筋混凝土耐久性的一项主要因素。因此，利用新材料、新技术解决钢筋腐蚀问题是当前土木工程领域科技工作者面临的最紧迫的任务之一。
随着钢筋混凝土结构中钢筋锈蚀和防护机理研究的不断深入，钢筋覆膜技术得到了迅速发展。目前按涂层材料可以将钢筋覆膜技术分为三种：(1)金属材料。如不锈钢热喷涂涂层钢筋、镀锌钢筋等；(2)有机材料。如环氧树脂涂层钢筋；(3)无机材料。如磷酸盐涂层钢筋、瓷釉涂层钢筋等。
从工程应用情况分析，采用金属材料对钢筋进行涂层，成本较高，通常达到普通钢筋价格的2-5倍，因此不能大批量的应用于腐蚀严重的沿海大型工程中。
采用环氧树脂涂覆钢筋，普遍采用静电喷涂方法，将环氧树脂粉末喷涂在带肋钢筋和光圆钢筋的表面，使其形成一种具有外包层的钢筋。如中国专利号CN201593271公开了《一种环氧树脂涂层钢筋》，在钢筋表面涂覆有环氧树脂涂层，其有效地解决了钢筋结构容易被腐蚀的问题，可以提高建筑物的使用寿命。虽然环氧树脂涂层钢筋有很好的耐蚀性，但与混凝土的粘结强度明显降低，而且环氧树脂涂层暴露在空气中容易被氧化，其防腐性能大受影响。
中国专利CN103074960公开了《一种双层环氧树脂涂层钢筋及其制备方法》，其包括基层钢筋，基层钢筋外涂有涂层，内涂层外涂覆有外涂层。外涂层更具有耐磨抗腐蚀性能，能满足在各种恶劣环境下的建设工程的需要。但仍存在以下问题：1、其外层的环氧树脂与混凝土之间粘结力依然薄弱；2、为保证双涂层界面的粘结，需要精密的技术设备支持；3、双涂层使成本翻倍，经济性不佳。
中国专利CN104404502公开了《一种磷酸盐基钢筋防腐涂层》，该专利涉及一种用于海洋钢筋混凝土中钢筋的腐蚀涂层材料，该防腐涂层与钢筋表面的结合性能好，结构致密，固化后强度高。但其本质属于粘结剂，可用于混凝土的破损修复，但存在磷酸盐粘结剂在受拉状态，容易开裂的问题。
综上所述，现有的钢筋防腐涂层技术已不能适应高腐蚀环境中的混凝土结构中的钢筋防腐，因此寻找一种低成本、耐久性更好、防腐性能更佳的防腐涂层极其涂覆方法成为一种急需。
发明内容
为了克服现有技术存在的不足，本发明提供一种成本低、防腐性能好、能保持钢筋自身力学性能的用于钢筋防腐的低温烧结涂料及其涂覆方法。
本发明解决其技术问题所采用的技术方案是：一种用于钢筋防腐的低温烧结涂料，原料包括以下组分：纳米二氧化硅30-50份、助熔剂20-40份、氟化钙9-20份、增稠剂2-10份、密着剂2-14份。
进一步的，所述助熔剂与纳米二氧化硅的重量比为(0.5-0.75):1。
进一步的，所述增稠剂为羟甲基纤维素、羟乙基纤维素中的一种或两种。
进一步的，所述密着剂为二氧化锰、四氧化三铁中的一种或两种。
进一步的，所述助熔剂为九水偏硅酸钠、硼砂中的一种或两种。
九水偏硅酸钠和硼砂都是涂料烧结时的助熔剂，两者协同作用降低了烧结温度，改善了烧结性能。随着温度升高，助熔剂熔化之后粘连其周围的粉料，并与粉料发生复杂的化学反应。相对纳米二氧化硅，助熔剂用量过少，无法有效粘连其周围的粉料，涂层结构松散，助熔剂用量过多，过量的助熔剂无法与纳米二氧化硅结合，反而阻碍了纳米二氧化硅-助熔剂主体结构的形成，最终影响涂层结构的力学强度。
纳米二氧化硅是涂层结构的重要组成物质，纳米级的粒径保证烧结后的涂层内部的致密性。
本发明还公开了一种用于钢筋防腐的低温烧结涂料的涂覆方法，包括如下步骤：
1)干混：将按组分比例称量的纳米二氧化硅与助熔剂、氟化钙、增稠剂、密着剂倒入容器中，拌合均匀，置于混料机中充分搅拌得到混合物A；
2)湿混：在混合物A中加入水，混合物A与水的质量比为(2-5)：1，置于混料机中充分混合得到浆状涂料B，备用；
3)预处理：对钢筋表面进行除锈处理，清洗干净后烘干；
4)涂覆：将步骤3)中得到的钢筋浸入步骤2)中得到的混合物B料液中，钢筋被旋转的同时从涂料B中抽出；
5)烘烤：将步骤4)中被均匀涂覆的钢筋置于90-130℃下，烘烤20-40分钟；
6)烧结：将步骤5)中得到的烧结有涂料B的钢筋置于电炉中以3-10℃/分钟的速度升温至400-550℃，烧结10分钟；
7)常温冷却，即得。
严格控制烘干温度：过高的烘干温度会使得涂层中的水快速蒸发，造成涂层内部膨胀，影响烧结后涂层的致密性。过低的烘干温度，大大增加了烘干时间，消耗过多能源。
本发明具有的优点和积极效果是(1)突出的抗腐蚀能力。由低温涂料烧制的钢筋防腐涂层能够大幅度提升钢筋的耐腐蚀能力，达到普通钢筋耐腐蚀能力的3-4倍；(2)材料自身耐久性强。低温涂料是无机材料，自身具有较强的耐久性，可以长久、有效地发挥作用。
综上所述，本发明的有益效果是，强度高、致密性能好、防腐性能好，同时烧结温度较低，可保持钢筋自身的力学性能。
具体实施方式
为了使本技术领域的人员更好的理解本发明方案，下面将对发明实施例中的技术方案进行清楚、完整的描述，显然，所描述的实施例仅仅是本发明的一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都应当属于本发明保护的范围。
实施例1
预处理：取一段HRB335、HRB400或HPB300级钢筋，用磨砂纸除锈之后再用5％的稀硫酸冲洗表面除锈，然后用清水冲洗干净，烘干备用。
制取涂料：取45份纳米二氧化硅和27份九水偏硅酸钠、4份羟甲基纤维素、13份氟化钙、4份二氧化锰、7份四氧化三铁，九水偏硅酸钠与纳米二氧化硅的重量比为0.6，加入混料罐中用搅拌棒拌合30秒，再将混料罐置于混料机中进行干混3-5分钟，充分混合得到混合物A。干混完毕后在混合物A中加入31份水，其中混合物A与水的质量比为2.3:1，将其搅拌直到呈浆状，置入混料机中进行湿混5-7分钟，充分混合得到涂料B，取出涂料B置于容器中静置10分钟，观察到涂料B无分层、表层无水层即可。将涂料B倒入储蓄罐中备用。
涂覆：用铁夹夹住预处理过的钢筋，把钢筋浸入涂料B中，缓慢旋转钢筋的同时把钢筋从涂料B中抽出，涂料B均匀涂覆于钢筋表面。
烘烤：在烘箱中放置两块耐火垫块，把从涂料B中抽出的钢筋架立于两块耐火垫块上，在150℃下烘烤40分钟。
烧结：将从烘箱中取出的干燥钢筋放入电炉中以5℃/分钟的速度升温，直到温度达到550℃，保温烧结10分钟，自然冷却至室温，即得到涂覆有防腐涂料的钢筋。
实施例2
预处理：同实施例1。
制取涂料：取38份纳米二氧化硅和28份九水偏硅酸钠、4份羟甲基纤维素、5份羟乙基纤维素、14份氟化钙、6份二氧化锰、5份四氧化三铁，九水偏硅酸钠与纳米二氧化硅的重量比为0.74，加入混料罐中用搅拌棒拌合30秒，再将混料罐置于混料机中进行干混3-5分钟，充分混合得到混合物A。干混完毕后在混合物A中加入33份水，其中混合物A与水的质量比为2:1，将其搅拌直到呈浆状，置入混料机中进行湿混5-7分钟，充分混合得到涂料B，取出涂料B置于容器中静置10分钟，观察到涂料B无分层、表层无水层即可。将涂料B倒入储蓄罐中备用。
涂覆：同实施例1。
烘烤：在烘箱中放置两块耐火垫块，把从涂料B中抽出的钢筋架立于两块耐火垫块上，在130℃下烘烤30分钟。
烧结：将从烘箱中取出的干燥钢筋放入电炉中以5℃/分钟的速度升温，直到温度达到500℃，保温烧结10分钟，自然冷却至室温，即得到涂覆有防腐涂料的钢筋。
实施例3
预处理：同实施例1。
制取涂料：取42份纳米二氧化硅和12份九水偏硅酸钠、12份硼砂、6份羟乙基纤维素、15份氟化钙、7份二氧化锰、6份四氧化三铁，助熔剂与纳米二氧化硅的重量比为0.57，加入混料罐中用搅拌棒拌合30秒，再将混料罐置于混料机中进行干混3-5分钟，充分混合得到混合物A。干混完毕后在混合物A中加入22份水，其中混合物A与水的质量比为3:1，将其搅拌直到呈浆状，置入混料机中进行湿混5-7分钟，充分混合得到涂料B，取出涂料B置于容器中静置10分钟，观察到涂料B无分层、表层无水层即可。将涂料B倒入储蓄罐中备用。
涂覆：同实施例1。
烘烤：在烘箱中放置两块耐火垫块，把从涂料B中抽出的钢筋架立于两块耐火垫块上，在180℃下烘烤30分钟。
烧结：将从烘箱中取出的干燥钢筋放入电炉中以7.5℃/分钟的速度升温，直到温度达到430℃，保温烧结10分钟，自然冷却至室温，即得到涂覆有防腐涂料的钢筋。
实施例4
预处理：同实施例1。
制取涂料：取48份纳米二氧化硅和14份九水偏硅酸钠、10份硼砂、3份羟乙基纤维素、10份氟化钙、1份二氧化锰、4份四氧化三铁，助熔剂与纳米二氧化硅的重量比为0.5，加入混料罐中用搅拌棒拌合30秒，再将混料罐置于混料机中进行干混3-5分钟，充分混合得到混合物A。干混完毕后在混合物A中加入23.6份水，其中混合物A与水的质量比为3:1，将其搅拌直到呈浆状，置入混料机中进行湿混5-7分钟，充分混合得到涂料B，取出涂料B置于容器中静置10分钟，观察到涂料B无分层、表层无水层即可。将涂料B倒入储蓄罐中备用。
涂覆：同实施例1。
烘烤：在烘箱中放置两块耐火垫块，把从涂料B中抽出的钢筋架立于两块耐火垫块上，在160℃下烘烤30分钟。
烧结：将从烘箱中取出的干燥钢筋放入电炉中以7.5℃/分钟的速度升温，直到温度达到470℃，保温烧结10分钟，自然冷却至室温，即得到涂覆有防腐涂料的钢筋。
实施例5
预处理：同实施例1。
制取涂料：取50份纳米二氧化硅和34份硼砂、5份羟乙基纤维素、9份氟化钙、2份二氧化锰，硼砂与纳米二氧化硅的重量比为0.68，加入混料罐中用搅拌棒拌合30秒，再将混料罐置于混料机中进行干混3-5分钟，充分混合得到混合物A。干混完毕后在混合物A中加入20份水，其中混合物A与水的质量比为4.2:1，将其搅拌直到呈浆状，置入混料机中进行湿混5-7分钟，充分混合得到涂料B，取出涂料B置于容器中静置10分钟，观察到涂料B无分层、表层无水层即可。将涂料B倒入储蓄罐中备用。
涂覆：同实施例1。
烘烤：在烘箱中放置两块耐火垫块，把从涂料B中抽出的钢筋架立于两块耐火垫块上，在140℃下烘烤40分钟。
烧结：将从烘箱中取出的干燥钢筋放入电炉中以7.5℃/分钟的速度升温，直到温度达到520℃，保温烧结10分钟，自然冷却至室温，即得到涂覆有防腐涂料的钢筋。
为了验证本发明的钢筋防腐涂料和涂覆方法的效果，进行了试验。
1)分别取五组，每组四根光圆钢筋和带肋钢筋均匀涂覆本发明的防腐涂料，将其置于5％的氯化钠溶液中,通电后进行加速腐蚀试验。
表1钢筋加速腐蚀试验
从表1可得，将本发明的防腐涂料低温涂覆于光圆钢筋和带肋钢筋的表面，再将钢筋置于5％的氯化钠溶液，钢筋保持不被腐蚀的时间是无涂层钢筋的3-4倍，因此本发明的钢筋防腐涂料能有效延缓钢筋在水中的腐蚀。
2)本发明的钢筋在涂覆防腐材料后的力学性能
本发明涉及到对钢筋的高温处理(400-550℃)，众所周知钢筋在高温处理后强度会发生变化，表2显示钢筋在受到过200℃,400℃,600℃,800℃热处理后的强度和表观形态变化。
表2钢筋高温处理后的力学性能
从表2可得，当钢筋受到高温处理时，特别是温度超过600℃时，钢筋的屈服强度明显下降，当超过800℃时其极限强度下降较大，冷弯性能也较差，外部形态发生较大变化。本发明的烧结温度在600℃以下，其力学性能不会发生较大改变，保证了钢筋原有的性能。
上述具体实施方式用来解释说明本发明，而不是对本发明进行限制，在本发明的精神和权利要求的保护范围内，对本发明作出的任何修改和改变，都落入本发明的保护范围。
Claims (5)
1.一种用于钢筋防腐的低温烧结涂料，其特征在于原料包括以下组分：纳米二氧化硅30-50份、助熔剂20-40份、氟化钙9-20份、增稠剂2-10份、密着剂2-14份；所述助熔剂为九水偏硅酸钠、硼砂中的一种或两种。
2.根据权利要求1所述的涂料，其特征在于：所述助熔剂与纳米二氧化硅的重量比为(0.5-0.75):1。
3.根据权利要求1所述的涂料，其特征在于：所述增稠剂为羟甲基纤维素、羟乙基纤维素中的一种或两种。
4.根据权利要求1所述的涂料，其特征在于：所述密着剂为二氧化锰、四氧化三铁中的一种或两种。
5.一种如权利要求1-4中任一项所述用于钢筋防腐的低温烧结涂料的涂覆方法，其特征在于：包括如下步骤：
1)干混：将按组分比例称量的纳米二氧化硅与助熔剂、氟化钙、增稠剂、密着剂倒入容器中，拌合均匀，置于混料机中充分搅拌得到混合物A；
2)湿混：在混合物A中加入水，混合物A与水的质量比为(2-5)：1，置于混料机中充分混合得到浆状涂料B，备用；
3)预处理：对钢筋表面进行除锈处理，清洗干净后烘干；
4)涂覆：将步骤3)中得到的钢筋浸入步骤2)中得到的混合物B料液中，钢筋被旋转的同时从涂料B中抽出；
5)烘烤：将步骤4)中被均匀涂覆的钢筋置于90-130℃下，烘烤20-40分钟；
6)烧结：将步骤5)中得到的烧结有涂料B的钢筋置于电炉中以3-10℃/分钟的速度升温至400-550℃，烧结10分钟；
7)常温冷却，即得。
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| CN108795128B (zh) * | 2018-05-12 | 2021-06-22 | 浙江大学 | 一种低温烧结形成的双层致密金属防腐涂层、其制备方法和用途 |
| CN109592901B (zh) * | 2018-12-24 | 2021-11-02 | 黄石华中模具材料研究所 | 一种金属材料高温涂层保护剂及其应用 |
| CN109821714A (zh) * | 2019-03-01 | 2019-05-31 | 江阴市邦泰金属制品有限公司 | 一种耐腐蚀铁路钢筋网的制备方法 |
| CN112411179B (zh) * | 2020-11-30 | 2022-10-21 | 北京宇航***工程研究所 | 一种提高氧化锆纤维力学性能的涂料及其制备方法 |
| CN113770652B (zh) * | 2021-09-13 | 2024-04-02 | 泰州市新龙翔金属制品有限公司 | 一种节能型盘圆钢的加工工艺 |
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| CN105585883A (zh) | 2016-05-18 |
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