Process method for renovating old corrugated beam guardrail plate

Abstract

The invention discloses a renovating process method for an old corrugated beam guardrail plate. The renovating process method comprises the following steps of construction preparation; cleaning, selecting and stacking old plates; shaping an old plate structure; polishing and cleaning the old plate; performing hot-dip galvanizing; hot dipping and plastic spraying; baking and curing; packaging and stacking finished products; the old plate is renovated through mutual combination of the hot-dip galvanizing process and the hot-dip plastic spraying process, the guardrail plate is promoted to be immersed in molten zinc liquid, the zinc liquid is evenly attached to the surface of the guardrail plate, a uniform zinc coating is formed, and after cooling and curing, the production line type hot-dip plastic spraying structure is utilized, so that under plastic spraying of a coating agent, the surface of the guardrail plate is coated with the zinc liquid, and the surface of the guardrail plate is coated with the zinc liquid. The adhesive force of a galvanized film of the guardrail plate is remarkably improved, the corrosion resistance of the guardrail plate is further improved, and therefore the problems of resource consumption and waste caused by the fact that an old corrugated beam guardrail plate is treated as scrap iron are solved, and meanwhile the comprehensive strength and corrosion resistance of the renovated guardrail plate are improved.

Description

Technical Field

[0001] The invention relates to the technical field of renovation of corrugated beam guardrail plates, and in particular to a process method for renovation of old corrugated beam guardrail plates. Background Art

[0002] The corrugated beam guardrail is the most widely used guardrail on highways. It consists of two corrugated steel guardrail panels and two posts fixedly clamped between them. The two posts are fixedly clamped between the two corrugated steel guardrail panels. When the highway is in normal operation, the guardrail can be easily inserted into the pre-set plug-in holes at the opening by using the plug-in posts, which plays an isolation and protection role, and at the same time echoes the guardrail belt on the outside of the highway;

[0003] With the rapid development and progress of my country's expressways, the former expressways are being rebuilt and expanded, and many old corrugated beam guardrails will be eliminated. Scrapping them will lead to a waste of resources. These old corrugated beam steel guardrails are hot-dip galvanized plates, and the galvanized layer is partially oxidized, peeled off, the base is rusted, and the appearance is deformed. However, a large number of galvanized anti-corrosion layers are not damaged, and the mechanical properties of more than 95% of the old plates can still meet the design requirements. Usually, a large number of old corrugated beam steel guardrails are scrapped, resulting in consumption and waste of resources. Therefore, the renovation of the original old corrugated beam guardrails has become a major problem in the existing technology. Summary of the invention

[0004] The purpose of the present invention is to provide a process method for refurbishing old corrugated beam guardrail panels to solve the related problems raised in the above background technology.

[0005] To achieve the above object, the present invention provides the following technical solution: a process for refurbishing an old corrugated beam guardrail, comprising the following steps:

[0006] S1. Construction preparation;

[0007] Dismantle old boards, transport them to the processing plant, install, debug and maintain mechanical equipment, prepare various raw materials and team members;

[0008] S2, cleaning, selecting and stacking old boards;

[0009] Check the old guardrail panels, pick out the deformed and severely rusted ones for disposal, clean the qualified ones, remove the dirt and rust, and then sort and mark them;

[0010] S3, old board structure reshaping;

[0011] By using machinery, the guardrail panels damaged during disassembly, transportation and storage are straightened and corrected to ensure that the size of the guardrail panels meets the design specifications. Local deformation that cannot be corrected by machinery is adjusted manually, and old panels that cannot be adjusted by machinery or manual labor and do not meet the design specifications are scrapped;

[0012] S4, grinding and cleaning of old boards;

[0013] Shot blasting and polishing: The old plate needs to be treated with surface dirt before being shot blasted to remove rust and plastic; Laser plus manual assisted polishing: Finally, use laser cleaning, grinding machine with wire wheel polishing to remove rust, burrs, oxide scale and other debris adhering to the surface of the guardrail plate. The complete galvanized layer on the old plate should be retained; Drying: After washing, hang the guardrail plate on a special fixed frame for spraying, dry it on the assembly line, and blow it dry with compressed air;

[0014] S5, hot dip galvanizing;

[0015] Use hot-dip galvanizing process to form a zinc layer on the surface of the guardrail plate, and form a corrosion-resistant zinc layer on the surface of the plate body;

[0016] S6, hot dip spraying:

[0017] Use hot dip spraying process for assembly line spraying, including film agent, electrostatic automatic fixing gun, groove gun, manual gun, burner head, and activated carbon for spraying;

[0018] S7, baking and curing;

[0019] Send the sprayed guardrail panels into the drying tunnel for baking and curing;

[0020] S8, finished product packaging and stacking;

[0021] After spraying is completed and naturally cooled and dried, they are stacked; the refurbished guardrail panels are packaged; the packaged refurbished guardrail panels are stacked.

[0022] Preferably, the burner head uses gas or electricity, which makes it easy to reserve an electric control position when the burner head is installed, facilitating later modifications.

[0023] Preferably, the guardrail board is cured by baking in a drying oven at a temperature of 180°C to 230°C.

[0024] Preferably, the guardrail board is naturally cooled and dried after being baked and cured.

[0025] Preferably, the coating agent used in hot dip spraying of the guardrail plate is a phosphate coating agent.

[0026] Preferably, the old guardrail boards are visually inspected one by one, and qualified old guardrail boards are cleaned in two cleaning steps of pre-cleaning and full cleaning. The cleaning step is mainly to remove impurities such as dirt, advertising stickers, asphalt, mortar, rust, etc. attached to the guardrail boards.

[0027] Preferably, a plating aid is added to the guardrail plate during the hot-dip galvanizing process to form a thin metal film on the surface of the guardrail, which helps the adhesion of the galvanized layer.

[0028] Preferably, the guardrail plate is inspected, trimmed, passivated, etc. after galvanizing to improve the corrosion resistance and appearance quality of the galvanized layer.

[0029] Preferably, the corrugated beam guardrail plate is dehydrated after spraying, wherein the dehydration temperature is generally between 130°C and 160°C, and the time is 5 to 10 minutes. The corrugated beam guardrail plate after dehydration will be cured in a drying oven, and the curing temperature is generally between 180°C and 230°C, and the curing time is 10 to 14 minutes. During the curing process, the temperature and time in the drying oven need to be monitored to ensure that they meet the curing requirements of the powder coating.

[0030] Compared with the prior art, the present invention provides a process for refurbishing an old corrugated beam guardrail plate, which has the following beneficial effects:

[0031] 1. The present invention renovates old plates through the combination of hot-dip galvanizing and hot-dip spraying processes, so that the guardrail plate is immersed in molten zinc liquid, and the zinc liquid is evenly attached to the surface of the guardrail plate to form a uniform galvanized layer. After cooling and solidification, an assembly line hot-dip spraying structure is used to significantly improve the adhesion of the galvanized coating of the guardrail plate under the spray coating of the film agent, and further enhance the corrosion resistance of the guardrail plate, thereby solving the resource consumption and waste problems caused by the treatment of old corrugated beam guardrail plates as scrap iron, while enhancing the comprehensive strength and corrosion resistance of the refurbished guardrail plates.

[0032] 2. The present invention uses hot-dip galvanizing and hot-dip plastic spraying to renovate the process, so that every part of the plated piece can be plated with zinc, and the recessed parts, sharp corners and hidden parts of the plate body can be fully polished and spray-coated as well as cooled and dried. Compared with the conventional renovation process, it is more durable. At the same time, the electrostatic adsorption technology is adopted to allow the powder to be firmly attached to the metal surface and not easy to fall off, so that the plastic spraying layer has higher hardness and wear resistance, and can effectively resist the erosion of the external environment. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 This is a process flow chart for refurbishing the corrugated beam guardrail of the present invention. DETAILED DESCRIPTION

[0034] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0035] See also Figure 1 The present invention provides a technical solution: a process for renovating an old corrugated beam guardrail, comprising the following steps:

[0036] S1. Construction preparation;

[0037] Dismantle old boards, transport them to the processing plant, install, debug and maintain mechanical equipment, prepare various raw materials and team members, prepare various raw materials required, and ensure that team members are ready;

[0038] S2, cleaning, selecting and stacking old boards;

[0039] Check the old guardrail panels, pick out the deformed and severely rusted ones for disposal, clean the qualified ones, remove the dirt and rust, sort and mark them, conduct visual inspection on the original guardrail panels one by one, and select the deformed or severely rusted panels as waste. For the reusable old guardrail panels, conduct preliminary screening to determine whether they meet the standards of guardrail panels. The qualified panels will be further cleaned to remove the attached dirt, advertising stickers, asphalt, mortar, rust and other impurities. After cleaning, the panels will be neatly stacked and marked;

[0040] S3, old board structure reshaping;

[0041] By using machinery, the guardrail panels damaged during disassembly, transportation and storage are straightened and corrected to ensure that the size of the guardrail panels meets the design specifications. Local deformation that cannot be corrected by machinery is adjusted manually, and old panels that cannot be adjusted by machinery or manual labor and do not meet the design specifications are scrapped;

[0042] S4, grinding and cleaning of old boards;

[0043] 1. Shot blasting and grinding: The old plate needs to be treated with surface dirt before blasting and rust removal. The old plate needs to be treated with surface dirt before blasting and rust removal. The total power is 245KW, and 12 groups of blasting heads are used to remove the sprayed plastic layer of the old guardrail plate. The rust removal level reaches Sa3 level, making the metal surface clean, without visible grease, dirt, oxide scale, rust and spray coating, and the surface has a uniform metallic color. Secondly, because there is a lot of dust on the surface coating and rust layer of the guardrail plate after shot blasting, a multi-stage separation method is used to separate the shot sand to ensure the cleanliness of the circulating abrasive entering the shot blasting machine;

[0044] 2. Laser plus manual assisted grinding: Finally, use laser cleaning, grinding machine with wire wheel grinding to remove rust, burrs, oxide scale and other debris adhering to the surface of the guardrail. It can effectively remove rust, spikes, oxide layer and other attachments on the guardrail. The complete galvanized layer on the old plate should be retained as much as possible.

[0045] 3. Drying: After washing, hang the guardrail on a special spraying fixed frame for assembly line drying. The cleaned guardrail needs to be hung on a special spraying fixed frame, and then dried on a 160-degree assembly line, and compressed air is used to dry the guardrail;

[0046] S5, hot dip galvanizing;

[0047] Use hot-dip galvanizing process to form a zinc layer on the surface of the guardrail

[0048] 1. Plating aid: Immerse the guardrail board in the plating aid to form a thin metal film on its surface, which helps the adhesion of the galvanized layer.

[0049] 2. Hot-dip galvanizing: Immerse the guardrail board in molten zinc liquid so that the zinc liquid evenly adheres to the surface of the guardrail board to form a galvanized layer.

[0050] 3. Cooling: Take the galvanized guardrail plate out of the zinc liquid and cool it to solidify the galvanized layer.

[0051] 4. Post-treatment: Check, trim, passivate and other treatments on the galvanized guardrail to improve the corrosion resistance and appearance quality of the galvanized layer;

[0052] S6, hot dip spraying:

[0053] In-line spraying using hot dip spraying process, including:

[0054] 1. The coating agent is a phosphate coating agent, which can significantly improve adhesion and double the corrosion resistance, and is a good base for the coating;

[0055] 2. Install electrostatic automatic fixing guns, hook guns, and manual guns, including 9 hook guns, 12 automatic fixing guns, and 2 manual guns;

[0056] 3. The burner head can use both gas and electricity. When installing the burner head, reserve the electric control position to facilitate later modification, so that the burner head can use both electricity and gas;

[0057] 4. The use of activated carbon in plastic spraying is green and environmentally friendly;

[0058] S7, baking and curing;

[0059] 1. Send the sprayed guardrail board into the drying oven for baking and curing. Then dehydrate the sprayed corrugated beam guardrail board. The dehydration temperature is generally 130℃~160℃ and the time is 5~10min. The dehydrated corrugated beam guardrail board will be cured in the drying oven. The curing temperature is generally 180℃~230℃ and the curing time is 10~14min. During the curing process, the temperature and time in the drying oven need to be monitored to ensure that they meet the curing requirements of the powder coating.

[0060] 2. After curing, the corrugated guardrail needs to be taken out of the curing oven and cooled naturally or forcedly to ensure that the coating is fully hardened and achieves the ideal mechanical properties;

[0061] 3. After the drying and curing process is completed, the guardrail needs to be inspected for quality, including the appearance, thickness, adhesion, etc. of the coating to ensure that the coating is uniform, defect-free, and fully cured;

[0062] S8, finished product packaging and stacking;

[0063] 1. Guardrail panels can be packaged and stacked only after spraying and natural cooling and drying for 36 hours;

[0064] 2. Every 60 refurbished boards are packed into a bundle. To protect the anti-corrosion layer of the refurbished boards from being damaged, straw ropes are used to separate the layers.

[0065] 3. Use a forklift to stack the refurbished boards. The stacking height should not exceed 5 bundles. Three wooden planks should be placed under each bundle to ensure that the refurbished boards do not deform. After stacking, they should be covered with colored strips to prevent contamination of the refurbished boards.

[0066] Example 1, work arrangements are made by dividing the staff into four teams:

[0067] 1. The team members are divided into four teams. The first team is the transfer, cleaning and sorting team. After the old panels arrive at the factory, they will be screened first, then preliminarily cleaned, and then transferred. This team will then transfer, preliminarily clean, visually sort and screen the old guardrail panels.

[0068] 2. The second team is the mechanical correction team, which corrects and reshapes some old guardrails that are not seriously deformed or damaged, and restores their appearance dimensions to a level that meets the standards;

[0069] 3. The third team is the grinding and cleaning team, responsible for rust removal, grinding and cleaning of old guardrail panels;

[0070] 4. The fourth team is the spraying team, which is responsible for the spraying of the old guardrail panels and the subsequent curing work. Through the mutual cooperation of the four teams, the renovation work can be carried out, which greatly improves the work efficiency of the renovation of the old guardrail panels.

[0071] Example 2, quality control measures:

[0072] 1. Material quality control: During the renovation process, the old guardrail panels must first be strictly screened to ensure that they meet the renovation conditions. Guardrail panels that are severely rusted or deformed should be scrapped. Guardrail panels that meet the renovation requirements must be thoroughly cleaned to remove rust and dirt on the surface to ensure that the refurbished coating can adhere well.

[0073] 2. Structural shaping: Use mechanical equipment to correct the old guardrail to ensure that its size and shape meet the design requirements. This step is crucial to ensuring the anti-collision performance of the guardrail.

[0074] 3. Surface treatment: Before spraying, the old guardrail should be polished and cleaned to remove the oxide scale and oil stains on the surface. This step usually includes cleaning with a high-pressure water gun and polishing with a grinder.

[0075] 4. Coating process: Use high-performance anti-corrosion coatings, such as epoxy zinc-rich primer and polyurethane topcoat, to spray the guardrail panels. During the coating process, the thickness and uniformity of the coating must be strictly controlled to ensure that the coating has good anti-corrosion properties and appearance quality.

[0076] 5. Quality inspection: The refurbished guardrail panels need to undergo strict quality inspection, including appearance inspection, dimension measurement, coating thickness test, etc., to ensure that they meet the relevant national standards and specifications.

[0077] 6. Supervision of the construction process: During the renovation process, professional supervisors should conduct on-site supervision to ensure that the construction operations comply with the prescribed process and quality requirements.

[0078] 7. Completion acceptance: After the construction is completed, a comprehensive acceptance work will be carried out, including inspection of the appearance, size, connection firmness, coating quality, etc. of the guardrail panels to ensure that the refurbished guardrail panels meet the design and use requirements. Appearance quality requirements: The surface of the component spray coating should be uniform and complete, with consistent color. The surface should be practical and smooth, without sagging, dripping or excess lumps, and the surface should be free of defects such as missing spraying, exposed iron, scratches, etc.

[0079] 8. Record and document management: Throughout the renovation process, construction logs, quality inspection reports and acceptance results should be recorded in detail to facilitate traceability and future quality control.

[0080] To sum up, the renovation method of the corrugated beam guardrail plate refurbishes the original old corrugated beam guardrail plate, solves the resource consumption and waste problems caused by treating the old corrugated beam guardrail plate as scrap iron, and at the same time reduces carbon emissions, reduces project costs, and achieves good economic and social benefits.

[0081] Finally, it should be noted that the above content is only used to illustrate the technical solution of the present invention, rather than to limit the scope of protection of the present invention. Simple modifications or equivalent substitutions of the technical solution of the present invention by ordinary technicians in this field do not deviate from the essence and scope of the technical solution of the present invention.

Claims

1. A process for refurbishing an old corrugated beam guardrail, characterized in that: The following steps are involved: S1. Construction preparation; Dismantle old boards, transport them to the processing plant, install, debug and maintain mechanical equipment, prepare various raw materials and team members; S2, cleaning, selecting and stacking old boards; Check the old guardrail panels, pick out the deformed and severely rusted ones for disposal, clean the qualified ones, remove the dirt and rust, and then sort and mark them; S3, old board structure reshaping; By using machinery, the guardrail panels damaged during disassembly, transportation and storage are straightened and corrected to ensure that the size of the guardrail panels meets the design specifications. Local deformation that cannot be corrected by machinery is adjusted manually, and old panels that cannot be adjusted by machinery or manual labor and do not meet the design specifications are scrapped; S4, grinding and cleaning of old boards; Shot blasting and grinding: the old board needs to be treated with surface dirt before being shot blasted to remove rust and plastic; Laser plus manual assisted grinding: finally, laser cleaning and grinding with a grinder and a wire wheel are used to remove rust, burrs, oxide scale and other debris adhering to the surface of the guardrail board; Drying: After washing, hang the guardrail on a special fixed rack for spraying, dry it on the assembly line, and blow it dry with compressed air; S5, hot dip galvanizing; Use hot-dip galvanizing process to form a zinc layer on the surface of the guardrail plate, and form a corrosion-resistant zinc layer on the surface of the plate body; S6, hot dip spraying; Use hot dip spraying process for assembly line spraying, including: film agent, electrostatic automatic fixing gun, groove gun, manual gun, burner head, activated carbon; S7, baking and curing; Send the sprayed guardrail panels into the drying tunnel for baking and curing; S8, finished product packaging and stacking; After spraying is completed and naturally cooled and dried, they are stacked; then the refurbished guardrail panels are packaged; the packaged refurbished guardrail panels are stacked.

2. The method for renovating an old corrugated beam guardrail according to claim 1, characterized in that: The burner head uses gas or electricity.

3. The method for renovating an old corrugated beam guardrail according to claim 1, characterized in that: The guardrail plate is cured by baking in a drying oven at a temperature of 180° C. to 230° C.

4. The method for renovating an old corrugated beam guardrail according to claim 1, characterized in that: The guardrail plate is naturally cooled and dried after being baked and cured.

5. The method for renovating an old corrugated beam guardrail according to claim 1, characterized in that: The coating agent used for the guardrail plate in hot dip spraying is a phosphate coating agent.

6. The method for renovating an old corrugated beam guardrail according to claim 1, characterized in that: The old guardrail panels are visually inspected one by one, and qualified old guardrail panels are cleaned in two cleaning steps: pre-cleaning and full cleaning.

7. The method for renovating an old corrugated beam guardrail according to claim 1, characterized in that: The guardrail plate is added with a plating aid in the hot-dip galvanizing process to form a thin metal film on the surface of the guardrail.

8. The method for renovating an old corrugated beam guardrail according to claim 1, characterized in that: The guardrail plate is inspected, trimmed, passivated and other treatments after galvanizing.

9. The method for renovating an old corrugated beam guardrail according to claim 1, characterized in that: After the corrugated beam guardrail plate is sprayed, it is then dehydrated.

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