GB2216140A - A method and design for corrosion protection coating system for application to ferrous and non-ferrous metals and concrete/cementitious surfaces - Google Patents

A method and design for corrosion protection coating system for application to ferrous and non-ferrous metals and concrete/cementitious surfaces Download PDF

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Publication number
GB2216140A
GB2216140A GB8800633A GB8800633A GB2216140A GB 2216140 A GB2216140 A GB 2216140A GB 8800633 A GB8800633 A GB 8800633A GB 8800633 A GB8800633 A GB 8800633A GB 2216140 A GB2216140 A GB 2216140A
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GB
United Kingdom
Prior art keywords
coating system
protection
electrically conductive
concrete
ferrous
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB8800633A
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GB8800633D0 (en
Inventor
John Avery Edwards
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Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to GB8800633A priority Critical patent/GB2216140A/en
Publication of GB8800633D0 publication Critical patent/GB8800633D0/en
Publication of GB2216140A publication Critical patent/GB2216140A/en
Withdrawn legal-status Critical Current

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Classifications

    • 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
    • C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F13/00—Inhibiting corrosion of metals by anodic or cathodic protection
    • C23F13/02—Inhibiting corrosion of metals by anodic or cathodic protection cathodic; Selection of conditions, parameters or procedures for cathodic protection, e.g. of electrical conditions
    • 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
    • B05D1/34—Applying different liquids or other fluent materials simultaneously
    • 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
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/4596—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with fibrous materials or whiskers
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/60—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only artificial stone
    • C04B41/61—Coating or impregnation
    • 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
    • C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F2201/00—Type of materials to be protected by cathodic protection
    • C23F2201/02—Concrete, e.g. reinforced

Abstract

A method of applying a protective coating system comprising carbon fibres or other electrically conductive fibre or metal filaments in an organic or inorganic resin based paint or a cementitious liquid matrix or any other material or substance is applied to a surface by means of a pressure fed concentric spray gun or fibre glass chopper gun or similar equipment. The corrosion protection coating system will provide - a durable surface protection from corrosive environments - act as an anode in a carthodic protection system for metal structures and/or steelwork encased in concrete - permit application at varying thicknesses to any surface contour - contain appropriate volumes of electrically conductive material to satisfy protection and electrical conductivity usage requirements - a coating system containing structural and shear strengths - a corrosion protection coating system which can be adjusted to meet permeability/impermeability requirements, resistance to corrosive chemical environments, aesthetic requirements, surface protection.

Description

A method and design for corrosion protection coating systems for application to Ferrous and non-Ferrous Metals and Concrete/Cementitious surfaces.
This invention is for a designed method of applying a protective organic or inorganic liquid coating system for the corrosion protection and reinstatement of concrete structures and buildings from corrosive atmospheric or contained environments involving Chlorides, Sulphates, Carbon Dioxides and other elemental corrosive substances. The formation of the protective coating system and application method enables the system to be used as an anode in a cathodic protection system for ferrous and non-ferrous metals and for steelwork encased in concrete or cementitious matrix.
Diffusion of carbon dioxide gas into concrete neutralises the high alkalinity of the concrete mass and destroys the passive environment protecting the steel reinforcement. Degradation of the concrete and steel reinforcement is further exacerbated by diffusions of chlorides and sulphates. The corrosion process may also originate from calcium chlorides used as a curing agent during construction. Similarly ferrous and non-ferrous metals used in constructions such as industrial structures, tanks, containers, bridges, and other metal fabrications, are subjected to corrosive environments and chemical attack.
The areas and surfaces referred to require protection from corrosive environments by means of paint or cementitious coating systems.
This invention is a method for the application of a primer and high build paint or cementitious coating systems to a properly prepared surface. Surface preparation will comply with British Standards Codes of Practice for ferrous and non-ferrous metal surfaces and concrete surfaces.
The method incorporates the simultaneous application of carbon fibre or similar electrically conductive fibre or metallic strip or filament together with liquid paint or a cementitious matrix to apply a uniform integrally mixed coating over the surface to be treated. Application will be through specialist dual feed pressure fed spray gun such as a GRC Concentric Spray Gun Pll as illustrated at Appendix 1 or a Fibre Glass Chopper Gun or similar equipment.
The integrally mixed coating system will be applied at varying thicknesses of from 50 microns dry film thickness to 5.0. centimetres thick in a resin or matrix selected to satisfy the surface protection criteria.
The primer and the protective coating system formulations can be based upon organic resins such as tung oil phenolic, phenolic, chlorinated rubber, epoxy, epoxy ester, polyurethane, alkyd, vinyl, acrylic, acrylated rubber, polyvinyl acetate, polyvinyl butinol, or blends of these resins or any other organic or inorganic materials contained in either a solvent or water solution. In addition the coating system can be based upon a cement matrix and or slurry with or without sand, aggregate, fillers or paint resins.
This method of application combining electrically conductive fibre, strip or filament together with a protective coating system matrix will produce within the mass a weave or mat of interlocking electrically conductive material which will be continuous throughout the coating surface treatment at a density to satisfy the substrate protection requirements. The electrically conductive weave or mat produced within the coating system creates a path or circuit which will provide a conductive anode in a cathodic protection system.
The formulation and choice of resin base or cementitious matrix used in the integrally mixed composite coating system will provide protection to the substrate surface from attack by atmospheric and environmental corrosive chemical pollutants and liquids. In addition the coating system will provide durable protection as well as an aesthetically decorative appearance.
This composite protective coating system together with the method of application enables usage or installation onto all types and contours of metal surfaces and concrete surfaces.

Claims (9)

1 A method of applying by means of a pressure fed GRC Concentric Spray Gun 1'11 or Fibre Glass Chopper Gun or similar equipment to a properly prepared surface a protective coating system comprising carbon fibres or other electrically conductive fibre or metal filaments in an organic or inorganic resin based paint or a cementitious liquid matrix or any other material or substance.
A method as claimed in Claim 1 will provide a durable 2 coating system incorporating a primer coat for the protection of ferrous and non-ferrous metals and concrete surfaces from attack by atmospheric and environmental corrosive chemical polluants and liquids.
3 A method as claimed in Claims 1 and 2 which by incorporating the electrically conductive carbon fibre or other electrically conductive fibres or metal filaments will provide or act as an anode in a cathodic protection system for the protection of metals or steelwork encased in concrete from corrosion attack.
4 A method as claimed in Claims 1 - 3 which will permit application at various thicknesses of 50 microns to 5.0 centimetres containing appropriate fibre densities or concentrations in order to satisfy both protective and electrically conductive usage requirements.
5 A method as claimed in Claims 1 - 4 which will provide protection from attack in corrosive environments and simultaneously provide an aesthetically decorative appearance.
6 A method as claimed in Claim 1 whereby the carbon fibres or other electrically conductive fibre or metal filament incorporated will impart both structural strength and shear strength to the composite coating system which will bridge minor cracks or hairline crazing in the substrate and subsequently counteract slight substrate surface movement.
7 A method as claimed in Claim 1 incorporating a protective coating system which by choice of resin base or adjustment of the formulation can be either moisture, vapour, or solvent permeable or impermeable in order to meet usage and service requirements.
For example in order to use this protective coating system as an anode for a cathodic protection system for ferrous or non-ferrous metal surfaces the coating system would incorporate resin based formulation products which will be moisture, vapour or liquid impermeable. For the protection of concrete/ cementitious substrates the binder or resin blend or cementitious matrix would be designed to provide the degree of moisture, vapour or liquid permeability required for the contract installation and usage.
8 A method as claimed in Claims 1 - 7 which can be applied onto all types and contours of metal surfaces and concrete surfaces, providing both electrical conductivity and surface protection.
Amendments to the claims have been filed as follows 1 A method of applying by means of a pressure fed GRC Concentric Spray Gun Pll or Fibre Glass Chopper Gun or similar equipment to a properly prepared surface a protective coating system comprising carbon fibres or other electrically conductive fibre or metal filaments in an organic or inorganic resin based paint or a cementitious liquid matrix or any other material or substance which can then be the anode in a cathodic protection system for steelwork and/or steelwork encased in concrete.
2 A method as claimed in Claim 1 which will provide a durable coating system incorporating a primer coat for the protection of ferrous and non-ferrous metals and concrete surfaces from attack by atmospheric and environmental corrosive chemical pollutants and liquids.
3 A method as claimed in Claims 1 and 2 which by incorporating the electrically conductive carbon fibre or other electrically conductive fibres or metal filaments will provide or act as an anode ina cathodic protection system for the protection of metals or steelwork encased in concrete from corrosion attack.
4 A method as claimed in Claims 1 - 3 which will permit application at various thicknesses of 50 microns to 5.0 centimetres containing appropriate fibre densities or concentrations in order to satisfy both protective and electrically conductive or resistivity usage requirements.
5 A method as claimed in Claims 1 - 4 which will provide protection from attack in corrosive environments and simultaneously provide an aesthetically decorative appearance.
6 A method as claimed in Claim 1 whereby the carbon fibres or other electrically conductive fibre or metal filament incorporated will impart both structural strength and shear strength to the composite coating system which will bridge minor cracks or hairline crazing in the substrate and subsequently counteract slight substrate surface movement.
7 A method as claimed in Claim 1 incorporating a protective coating system which by choice of resin base or adjustment of the formulation can be either moisture, vapour, or solvent permeable or impermeable in order to meet usage and service requirements. For example in order to use this protective coating system as an anode for a cathodic protection system for ferrous or non-ferrous metal surfaces the coating system would incorporate resin based formulation products which will be moisture, vapour or liquid impermeable. For the protection of concrete/cementitious substrates containing steelwork the binder or resin blend or cementitious matrix would be designed to provide the degree of moisture, vapour or liquid permeability required for the contract installation and usage.
8 A method as claimed in Claims 1 - 7 which can be applied onto all types and contours of metal surfaces and concrete surfaces providing both electrical conductivity and/or resistivity and surface protection.
9 A method as claimed in Claims 1 - 8 which can be incorporated in a bridge deck waterproofing membrane system of whatever nature to act as an anode in a cathodic protection system.
GB8800633A 1988-01-13 1988-01-13 A method and design for corrosion protection coating system for application to ferrous and non-ferrous metals and concrete/cementitious surfaces Withdrawn GB2216140A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB8800633A GB2216140A (en) 1988-01-13 1988-01-13 A method and design for corrosion protection coating system for application to ferrous and non-ferrous metals and concrete/cementitious surfaces

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB8800633A GB2216140A (en) 1988-01-13 1988-01-13 A method and design for corrosion protection coating system for application to ferrous and non-ferrous metals and concrete/cementitious surfaces

Publications (2)

Publication Number Publication Date
GB8800633D0 GB8800633D0 (en) 1988-02-10
GB2216140A true GB2216140A (en) 1989-10-04

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Family Applications (1)

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GB8800633A Withdrawn GB2216140A (en) 1988-01-13 1988-01-13 A method and design for corrosion protection coating system for application to ferrous and non-ferrous metals and concrete/cementitious surfaces

Country Status (1)

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GB (1) GB2216140A (en)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1992001824A1 (en) * 1990-07-17 1992-02-06 Kenneth Brian Pithouse The protection of cementitious material
EP0499438A1 (en) * 1991-02-12 1992-08-19 Ici Americas Inc. Reinforced concrete system
EP0730046A1 (en) * 1995-03-01 1996-09-04 EKO d.o.o. Electroconductive anticorrosive system
WO1999023282A1 (en) * 1997-10-31 1999-05-14 Grillo-Werke Ag Method for improving corrosion resistance of reinforced concrete
GB2360472A (en) * 2000-03-24 2001-09-26 Joseph Ash Storage Tanks Ltd Method of coating storage tanks with concrete

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3151050A (en) * 1963-02-15 1964-09-29 David K Wilburn Laminated anti-corrosive paint system
GB1323417A (en) * 1969-08-28 1973-07-18 Courtaulds Ltd Protecting composite structures from corrosion
GB2032806A (en) * 1978-09-25 1980-05-14 Woellner Werke Method and apparatus for applying an insulating coating to metallic or non-metallic objects
EP0122785A2 (en) * 1983-04-15 1984-10-24 RAYCHEM CORPORATION (a Delaware corporation) Electrochemical method and apparatus
EP0147977A2 (en) * 1983-12-13 1985-07-10 RAYCHEM CORPORATION (a California corporation) Novel anodes for cathodic protection
GB2170512A (en) * 1985-01-08 1986-08-06 Taylor Woodrow Const Ltd Conductive paint for cathodic protection of steel or like reinforcement in concrete
EP0210058A1 (en) * 1985-07-19 1987-01-28 Acheson Industries, Inc., Conductive cathodic protection compositions and methods

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3151050A (en) * 1963-02-15 1964-09-29 David K Wilburn Laminated anti-corrosive paint system
GB1323417A (en) * 1969-08-28 1973-07-18 Courtaulds Ltd Protecting composite structures from corrosion
GB2032806A (en) * 1978-09-25 1980-05-14 Woellner Werke Method and apparatus for applying an insulating coating to metallic or non-metallic objects
EP0122785A2 (en) * 1983-04-15 1984-10-24 RAYCHEM CORPORATION (a Delaware corporation) Electrochemical method and apparatus
EP0147977A2 (en) * 1983-12-13 1985-07-10 RAYCHEM CORPORATION (a California corporation) Novel anodes for cathodic protection
GB2170512A (en) * 1985-01-08 1986-08-06 Taylor Woodrow Const Ltd Conductive paint for cathodic protection of steel or like reinforcement in concrete
EP0210058A1 (en) * 1985-07-19 1987-01-28 Acheson Industries, Inc., Conductive cathodic protection compositions and methods

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1992001824A1 (en) * 1990-07-17 1992-02-06 Kenneth Brian Pithouse The protection of cementitious material
EP0499438A1 (en) * 1991-02-12 1992-08-19 Ici Americas Inc. Reinforced concrete system
EP0730046A1 (en) * 1995-03-01 1996-09-04 EKO d.o.o. Electroconductive anticorrosive system
WO1999023282A1 (en) * 1997-10-31 1999-05-14 Grillo-Werke Ag Method for improving corrosion resistance of reinforced concrete
US6224943B1 (en) 1997-10-31 2001-05-01 Grillo-Werke Ag Method for improving the corrosion resistance of reinforced concrete
GB2360472A (en) * 2000-03-24 2001-09-26 Joseph Ash Storage Tanks Ltd Method of coating storage tanks with concrete

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Publication number Publication date
GB8800633D0 (en) 1988-02-10

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WAP Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1)