Anti-crack (hydrophobic) decorative scraping and spraying material for weather-resistant thin overlay in salt corrosion environment
By using a composite design of weather-resistant thin-layer covering materials, the problems of insufficient crack resistance, durability, and adhesion of decorative materials in salt-corrosion environments are solved, achieving comprehensive protection and decoration effects in salt-corrosion environments and extending the service life of the structure.
Patent Information
- Application Number
- CN202511375806.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-25
- Publication Date
- 2026-01-02
AI Technical Summary
Existing decorative materials have poor crack resistance and durability in salt corrosion environments, are easily penetrated by corrosive media leading to deterioration and failure, and have insufficient adhesion to complex substrates, resulting in delamination and hollowing.
We employ weather-resistant, thin-layer, crack-resistant, waterproof, decorative trowel/spray material. Through a composite design of rigid skeleton (cement-based material + fiber reinforcement) + flexible buffer (polymer powder) + interface protection (composite water-repellent agent + polymer powder film formation + penetration crystallization), we can synergistically solve the problems of protection, decoration, and durability in salt corrosion environments.
It achieves excellent salt corrosion resistance, long-term weather resistance, crack resistance, water repellency and good decorative effect in salt corrosion environment, significantly extends the service life of the structure and simplifies the construction process.
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Abstract
Description
Technical Field
[0001] This invention relates to the field of building materials, specifically to a concrete structure protection and repair material applicable to high-salt corrosion environments (such as marine engineering, coastal buildings, salt lake areas, de-icing salt-eroded roads, etc.). Background Technology
[0002] In saline-corrosion environments (such as marine engineering, coastal areas, areas around salt lakes, and roads in northern regions where de-icing salt is frequently used in winter), corrosive ions such as chloride and sulfate easily lead to corrosion, cracking, and peeling of the surface decorative layer in concrete structures, severely affecting their durability and aesthetics. Existing common decorative materials (such as ordinary mortar and waterproof coatings) have significant shortcomings in saline-corrosion environments: poor crack resistance and durability, easily penetrated by corrosive media leading to deterioration and failure; traditional waterproofing relies heavily on surface coatings, which are easily damaged under long-term saline corrosion, allowing moisture to seep into the substrate and exacerbate corrosion; and they lack adhesion to complex substrates (such as existing concrete), easily resulting in delamination and hollowing. Therefore, developing a repair material that combines crack resistance, water repellency, decorative properties, and long-term weather resistance, along with excellent construction adaptability and interfacial bonding performance, has become a key challenge in improving the protective effect of concrete in saline-corrosion environments. Summary of the Invention
[0003] The technical problem to be solved by the present invention is to overcome the shortcomings of the prior art and provide a thin-layer coating material for salt corrosion environments. This material achieves a comprehensive balance in terms of crack resistance, water repellency, salt corrosion resistance, durability and construction adaptability, and meets the requirements for long-term service.
[0004] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:
[0005] 1. A weather-resistant, thin-layer, crack-resistant, waterproof (water-repellent) decorative trowel / spray coating material for use in salt-corrosion environments, comprising the following components by weight:
[0006] Silicate cement: 200-350 parts
[0007] Slag powder: 40-80 parts
[0008] Nano titanium dioxide 20-60
[0009] Nano silica: 20-80 parts
[0010] Heavy calcium carbonate powder: 10-50 parts
[0011] Polymer powder: 15-40 parts
[0012] Penetrating crystallizing waterproofing agent: 10-40 parts
[0013] Coupling agent: 2-8 parts
[0014] Powdered air-entraining agent: 0.1–0.5 parts
[0015] Powdered defoamer: 0.5–1.5 parts
[0016] Powder water-reducing agent: 1-3 parts
[0017] HPMC (200,000 mPa·s): 0.5–1.5 parts
[0018] HPMC (40,000 mPa·s): 0.5–1.5 parts
[0019] Compound water-repellent agent: 2-6 parts
[0020] Basalt fiber: 1-5 parts
[0021] Lignin fiber: 1-6 parts
[0022] Fine quartz sand (40-200 mesh): 350-600 parts
[0023] This invention addresses the challenge of balancing protection, decoration, and durability in salt-corrosion environments through a composite design concept of "rigid skeleton (cement-based material + fiber reinforcement) + flexible buffer (polymer powder) + interface protection (composite water-repellent agent + polymer powder film formation + penetration crystallization)". The material exhibits excellent salt corrosion resistance, long-term weather resistance, crack resistance, water repellency, and good decorative effect.
[0024] As a further improvement to the above technical solution:
[0025] 2. The material as described in claim 1, wherein the silicate cement is P·O 42.5, serving as the main cementing material.
[0026] 3. The material as described in claim 1, wherein the slag powder is grade S95 and is used as a dense filler material.
[0027] 4. The material as described in claim 1, characterized in that: the nano-titanium dioxide used as the salt-resistant component is anatase.
[0028] 5. The material as described in claim 1, wherein the nano-silica is fumed multi-level porous silica.
[0029] 6. The material as described in claim 1, wherein the heavy calcium carbonate powder is 800-1250 mesh and is used to improve the surface appearance quality.
[0030] 7. The material as described in claim 1, characterized in that: the polymer powder is hydrophobic and is used to improve bonding strength, form a dense film to block water, and provide hydrophobicity.
[0031] 8. The material as described in claim 1, characterized in that: the penetrating crystallizing waterproofing agent is a lithium silicate crystallizing agent, which penetrates into the concrete matrix and achieves waterproofing by blocking pores through secondary crystallization, thereby improving the overall impermeability.
[0032] 9. The material as described in claim 1, wherein the coupling agent is a titanate composite type, used to enhance the bonding force between new and old concrete and mortar interfaces.
[0033] 10. The material as described in claim 1, wherein the air-entraining agent is K12 powder used to improve the workability and operability of the slurry, and to buffer surface ice expansion stress to improve frost resistance.
[0034] 11. The material as described in claim 1, wherein the defoamer is P803 powder, used to eliminate bubbles generated during mixing and spraying.
[0035] 12. The material as described in claim 1, wherein the water-reducing agent is melamine powder used to reduce water consumption and improve the density and strength of the material.
[0036] 13. The material as claimed in claim 1, wherein the HPMC is 200,000 mPa·s and 40,000 mPa·s to improve water retention, reduce cracking caused by water evaporation, and enhance adhesion.
[0037] 14. The material as described in claim 1, wherein the hydrophobic agent is an organic-inorganic composite used to impart hydrophobicity to the material surface, increase the contact angle between water molecules and the material surface, and reduce the contact time.
[0038] 15. The material as described in claim 1, wherein the basalt fiber is 8 mm in length and is used to enhance toughness, disperse stress, and inhibit shrinkage cracking.
[0039] 16. The material as claimed in claim 1, characterized in that: the lignin fibers are easily dispersible and used for guiding...
[0040] HPMC aggregates on the surface, synergistically enhancing water retention and crack resistance.
[0041] 17. The material as described in claim 1, wherein the fine quartz sand is 40-200 mesh as aggregate.
[0042] 18. A method for preparing a weather-resistant (repellent) material as described in claims 1-17, characterized in that: it employs a "dry powder premixing + on-site water addition and stirring" process, comprising the following steps:
[0043] Preparation method of the present invention:
[0044] As a general inventive concept, this invention also provides a method for preparing a weather-resistant waterproof (hydrophobic) material:
[0045] 1. First, put the weighed polymer powder, penetrating crystallizing waterproofing agent, titanate coupling agent, composite water-repellent agent, powder melamine water-reducing agent, HPMC, K12 air-entraining agent, and P803 defoamer into the small material premixer in sequence and mix them thoroughly for 5 minutes.
[0046] 2. Add P·O 42.5 cement, S95 slag powder, nano titanium dioxide, nano silica, heavy calcium carbonate powder, and fine quartz sand into a twin-shaft zero-gravity dry powder mixer in sequence, and premix at 300-500 rpm for 3 minutes.
[0047] 3. In step 2 without shutting down the machine, basalt fiber and lignin fiber are added sequentially through an airflow dispersion device (air pressure 0.3-0.5MPa), and premixed for 3 minutes;
[0048] 4. In step 3 without stopping the machine, add the premixed material from step 1 through the feed port of the mixer, and stir for another 10 minutes to obtain the finished material;
[0049] 5. Pass the finished material obtained in step 4 through a 0.6mm square hole sieve to remove agglomerated particles, and then package and transport it to the site for use.
[0050] During on-site construction, the dry powder mortar can be mixed with water according to the recommended water-cement ratio and then applied by troweling or spraying.
[0051] Compared with the prior art, the advantages of the present invention are as follows:
[0052] 1. Synergistic Enhancement of Multiple Performances: By optimizing the cementitious system (cement + slag + nano-silica), fiber reinforcement (basalt fiber + easily dispersible lignin fiber for synergistic toughening and crack resistance), hydrophobic system (composite hydrophobic agent + hydrophobic adhesive powder + penetrating crystallizing waterproofing agent forming a double barrier), salt-resistant component (nano-titanium dioxide), and decorative component (fine sand + heavy calcium carbonate), a comprehensive protective structure of "dense internally and hydrophobic externally" is achieved. This material, after a 90-day salt spray test (5% NaCl), exhibits a mass loss rate ≤0.8%, excellent crack resistance, hydrophobicity, and durability, while maintaining good decorative effects. Tests show: 28-day impermeability pressure ≥1.5MPa (comparative example ≤1.2MPa), bond strength retention rate ≥85% after 360-day salt spray cycles, surface hydrophobic angle ≥110°, and mass loss rate ≤0.5% after 360-day salt spray cycles.
[0053] 2. Highly efficient and convenient application: The optimized dry powder formula and premixing process ensure product stability and ease of application. On-site mixing with water yields a slurry with excellent workability and thixotropic properties, suitable for troweling or spraying, significantly simplifying the process and reducing application difficulty.
[0054] 3. Long-lasting weather resistance and strong environmental adaptability: Optimized corrosion-resistant components (S95 slag, nano-titanium dioxide, nano-silica) and the use of titanate coupling agents to strengthen interfacial bonding greatly improve the long-term stability of the material in harsh salt-corrosion environments (coastal areas, saline-alkali land, industrial salt spray). Hydrophobic and impermeable properties effectively block corrosive ions, significantly extending the structural service life.
[0055] 4. Significant advantages in comparative data: As shown in Table 3, the material of this invention is superior to the representative comparative sample and similar products on the market in all key performance indicators (compressive strength, impermeability, water absorption, bonding strength, crack resistance, freeze-thaw stability). Example
[0056] The present invention will be further described in detail below. Unless otherwise specified, the instruments or materials used in the present invention are commercially available.
[0057] The weather-resistant, thin-layer anti-cracking, waterproof (water-repellent) decorative trowel / spray material for salt-corrosion environments in this embodiment comprises, by weight:
[0058] 1. 300 parts of P.O42.5 silicate cement
[0059] 2. 40 parts of S95 slag powder
[0060] 3. 20 parts of nano titanium dioxide
[0061] 40 parts of nano-silica
[0062] 5. 800-1250 mesh heavy calcium carbonate powder, 25 parts
[0063] 6. 20 parts of water-repellent polymer powder
[0064] 7. 20 parts of penetrating crystallizing waterproofing agent
[0065] 8. 3 parts of titanate composite coupling agent
[0066] 9.3 parts of K12 powder air-entraining agent
[0067] 10. 0.7 parts of P803 powder defoamer
[0068] 11. Two parts of powdered melamine water-reducing agent
[0069] 12,200,000 mPa·s HPMC (1 part)
[0070] 13.40,000 mPa·s HPMC (1 part)
[0071] 14. 3 parts of compound water-repellent agent
[0072] Two parts of 15.8mm basalt fiber
[0073] 16. Two parts of easily dispersible lignin fibers
[0074] 520 parts of 17.40-200 mesh fine quartz sand
[0075] Comparative Example 1:
[0076] This comparative example describes a weather-resistant waterproof (water-repellent) material, the raw materials of which include the following components: 200 parts of ordinary silicate cement, 40 parts of slag powder, 20 parts of nano titanium dioxide, 40 parts of nano silica, 25 parts of heavy calcium carbonate powder, 20 parts of polymer adhesive powder (water-repellent type), 20 parts of penetrating crystallizing waterproofing agent, 3 parts of titanate coupling agent, 0.3 parts of K12 air-entraining agent, 0.7 parts of powdered defoamer, 2 parts of melamine water-reducing agent, 1 part of HPMC (200,000 mPa·s), 1 part of HPMC (40,000 mPa·s), 3 parts of composite water-repellent agent, 2 parts of basalt fiber, 2 parts of easily dispersible lignin fiber, and 520 parts of fine quartz sand.
[0077] Comparative Example 2:
[0078] This comparative example describes a weather-resistant waterproof (water-repellent) material, the raw materials of which include the following components: 300 parts of ordinary silicate cement, 40 parts of slag powder, 20 parts of nano titanium dioxide, 0 parts of nano silica, 40 parts of heavy calcium carbonate powder, 20 parts of polymer powder (water-repellent type), 20 parts of penetrating crystallizing waterproofing agent, 3 parts of titanate coupling agent, 0.3 parts of K12 air-entraining agent, 0.7 parts of powdered defoamer, 2 parts of melamine water-reducing agent, 1 part of HPMC (200,000 mPa·s), 1 part of HPMC (40,000 mPa·s), 3 parts of composite water-repellent agent, 2 parts of basalt fiber, 2 parts of easily dispersible lignin fiber, and 520 parts of fine quartz sand.
[0079] Comparative Example 3:
[0080] This comparative example describes a weather-resistant waterproof (water-repellent) material, the raw materials of which include the following components: 300 parts of ordinary silicate cement, 40 parts of slag powder, 20 parts of nano titanium dioxide, 40 parts of nano silica, 25 parts of heavy calcium carbonate powder, 20 parts of polymer powder (water-repellent type), 10 parts of penetrating crystallizing waterproofing agent, 1 part of titanate coupling agent, 0.3 parts of K12 air-entraining agent, 0.7 parts of powdered defoamer, 2 parts of melamine water-reducing agent, 1 part of HPMC (200,000 mPa·s), 1 part of HPMC (40,000 mPa·s), 3 parts of composite water-repellent agent, 2 parts of basalt fiber, 2 parts of easily dispersible lignin fiber, and 520 parts of fine quartz sand.
[0081] Comparative Example 4:
[0082] This comparative example describes a weather-resistant waterproof (water-repellent) material, the raw materials of which include the following components: 300 parts of ordinary silicate cement, 40 parts of slag powder, 20 parts of nano titanium dioxide, 40 parts of nano silica, 25 parts of heavy calcium carbonate powder, 20 parts of polymer powder (water-repellent type), 20 parts of penetrating crystallizing waterproofing agent, 3 parts of titanate coupling agent, 0.3 parts of K12 air-entraining agent, 0.7 parts of powdered defoamer, 2 parts of melamine water-reducing agent, 1 part of HPMC (200,000 mPa·s), 1 part of HPMC (40,000 mPa·s), 3 parts of composite water-repellent agent, 0 parts of basalt fiber, 0 parts of easily dispersible lignin fiber, and 520 parts of fine quartz sand.
[0083] Comparative Example 5:
[0084] This comparative example describes a weather-resistant waterproof (water-repellent) material, the raw materials of which include the following components: 300 parts of ordinary silicate cement, 40 parts of slag powder, 20 parts of nano titanium dioxide, 40 parts of nano silica, 50 parts of heavy calcium carbonate powder, 20 parts of polymer powder (water-repellent type), 20 parts of penetrating crystallizing waterproofing agent, 3 parts of titanate coupling agent, 0.3 parts of K12 air-entraining agent, 0.7 parts of powdered defoamer, 2 parts of melamine water-reducing agent, 1 part of HPMC (200,000 mPa·s), 1 part of HPMC (40,000 mPa·s), 3 parts of composite water-repellent agent, 2 parts of basalt fiber, 2 parts of easily dispersible lignin fiber, and 495 parts of fine quartz sand.
[0085] Comparative Example 6:
[0086] This comparative example describes a weather-resistant waterproof (water-repellent) material, the raw materials of which include the following components: 300 parts of ordinary silicate cement, 40 parts of slag powder, 20 parts of nano titanium dioxide, 40 parts of nano silica, 25 parts of heavy calcium carbonate powder, 20 parts of polymer powder (ordinary emulsion), 20 parts of penetrating crystallizing waterproofing agent, 3 parts of titanate coupling agent, 0.3 parts of K12 air-entraining agent, 0.7 parts of powdered defoamer, 2 parts of melamine water-reducing agent, 1 part of HPMC (200,000 mPa·s), 1 part of HPMC (40,000 mPa·s), 3 parts of composite water-repellent agent, 2 parts of basalt fiber, 2 parts of easily dispersible lignin fiber, and 520 parts of fine quartz sand.
[0087] Comparative Example 7:
[0088] This comparative example describes a weather-resistant waterproof (water-repellent) material, the raw materials of which include the following components: 300 parts of ordinary silicate cement, 40 parts of slag powder, 20 parts of nano titanium dioxide, 40 parts of nano silica, 25 parts of heavy calcium carbonate powder, 20 parts of polymer powder (water-repellent type), 20 parts of penetrating crystallizing waterproofing agent, 1 part of titanate coupling agent, 0.3 parts of K12 air-entraining agent, 0.7 parts of powdered defoamer, 2 parts of melamine water-reducing agent, 1 part of HPMC (200,000 mPa·s), 1 part of HPMC (40,000 mPa·s), 3 parts of composite water-repellent agent, 2 parts of basalt fiber, 2 parts of easily dispersible lignin fiber, and 520 parts of fine quartz sand.
[0089] Comparative Example 8:
[0090] This comparative example describes a weather-resistant waterproof (water-repellent) material, the raw materials of which include the following components: 300 parts of ordinary silicate cement, 40 parts of slag powder, 20 parts of nano titanium dioxide, 40 parts of nano silica, 25 parts of heavy calcium carbonate powder, 20 parts of polymer adhesive powder (water-repellent type), 20 parts of penetrating crystallizing waterproofing agent, 3 parts of titanate coupling agent, 0 parts of K12 air-entraining agent, 0.7 parts of powdered defoamer, 2 parts of melamine water-reducing agent, 1 part of HPMC (200,000 mPa·s), 1 part of HPMC (40,000 mPa·s), 3 parts of composite water-repellent agent, 2 parts of basalt fiber, 2 parts of easily dispersible lignin fiber, and 520 parts of fine quartz sand.
[0091] Comparative Example 9:
[0092] This comparative example describes a weather-resistant waterproof (water-repellent) material, the raw materials of which include the following components: 300 parts of ordinary silicate cement, 40 parts of slag powder, 20 parts of nano titanium dioxide, 40 parts of nano silica, 25 parts of heavy calcium carbonate powder, 20 parts of polymer powder (water-repellent type), 20 parts of penetrating crystallizing waterproofing agent, 3 parts of titanate coupling agent, 0.3 parts of K12 air-entraining agent, 0.7 parts of powdered defoamer, 2 parts of melamine water-reducing agent, 0.5 parts of HPMC (200,000 mPa·s), 0.5 parts of HPMC (40,000 mPa·s), 3 parts of composite water-repellent agent, 2 parts of basalt fiber, 2 parts of easily dispersible lignin fiber, and 520 parts of fine quartz sand.
[0093] Comparative Example 10
[0094] This comparative example describes a weather-resistant waterproof (water-repellent) material, the raw materials of which include the following components: 300 parts of ordinary silicate cement, 40 parts of slag powder, 20 parts of nano titanium dioxide, 40 parts of nano silica, 25 parts of heavy calcium carbonate powder, 20 parts of polymer powder (water-repellent type), 20 parts of penetrating crystallizing waterproofing agent, 3 parts of titanate coupling agent, 0.3 parts of K12 air-entraining agent, 0.7 parts of powdered defoamer, 2 parts of melamine water-reducing agent, 1 part of HPMC (200,000 mPa·s), 1 part of HPMC (40,000 mPa·s), 3 parts of composite water-repellent agent, 2 parts of basalt fiber, 2 parts of easily dispersible lignin fiber, and 520 parts of river sand.
[0095] Comparative Examples 1-10, their raw material composition is shown in Table 1.
[0096] The key adjustments for each comparison ratio and the resulting performance defects are shown in Table 2.
[0097]
[0098] Table 2: Key Adjustments and Performance Defects in the Comparative Example (Compared with the Example)
[0099]
[0100] Performance testing and comparison:
[0101] Key performance tests were conducted on the examples, representative comparative examples (1,3,5,7) and commercially available similar materials (according to CECS195:2006 "Technical Specification for Application of Polymer Cement Penetrating Crystalline Waterproofing Materials"). The results are shown in Table 3.
[0102] Table 3: Comparison of Performance Test Data of Examples, Comparative Examples, and Commercially Available Materials
[0103]
[0104] Note: Commercially available materials comply with CECS195:2006 standards.
[0105] The materials in the examples exhibited superior overall performance. The roles of key components were verified through comparison:
[0106] The lack of hydrophobic polymer powder and waterproofing agent led to waterproofing failure (Comparative Examples 3, 6);
[0107] Fiber loss leads to reduced crack resistance (Comparative Example 4);
[0108] Imbalances in the proportions of core components (too little cement - Comparative Example 1) or insufficient key additives (titanium ester coupling agent - Comparative Example 7, K12 air-entraining agent - Comparative Example 8, HPMC - Comparative Example 9) can lead to a significant decrease in performance.
[0109] The material of this invention is particularly suitable for building protection, decoration and existing concrete repair projects in harsh environments such as marine engineering, coastal engineering, salt lake areas, and de-icing salt roads. Excellent crack resistance, water repellency and decorative effects can be achieved through double or multi-layer construction, improving efficiency and reducing application risks.
[0110] The above embodiments are merely illustrative examples of the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, any person skilled in the art can make corresponding possible changes and modifications to the technical solutions of the present invention, or modify them into equivalent embodiments with equivalent changes, without departing from the scope of the technical solutions of the present invention.
Claims
1. A weather-resistant, thin-layer, crack-resistant, waterproof (water-repellent) decorative trowel / spray coating material for use in salt-corrosion environments, characterized in that: The raw materials include the following components: 200-350 parts of silicate cement 40-80 parts of slag powder Nano titanium dioxide 20-60 20-80 parts of nano-silica 10-50 parts of heavy calcium carbonate powder 15-40 parts of polymer powder, 10-40 parts of penetrating crystallizing waterproofing agent 2-8 parts of titanate coupling agent 0.1–0.5 parts of K12 air-entraining agent, 0.5–1.5 parts of powdered defoamer, 1-3 parts of melamine water-reducing agent HPMC (200,000 mPa·s) 0.5–1.5 parts, HPMC (40,000 mPa·s) 0.5–1.5 parts, 2-6 parts of compound water-repellent agent, 1-5 parts basalt fiber 1-6 parts of easily dispersible lignin fibers 350-600 parts of fine quartz sand.
2. The weather-resistant waterproof material according to claim 1, characterized in that: The nano-titanium dioxide is anatase.
3. The weather-resistant waterproof material according to claim 1, characterized in that: The nano-silica is gas-phase hierarchical porous silica.
4. The weather-resistant waterproof material according to claim 1, characterized in that: The polymer powder is hydrophobic and its function is to improve adhesion and form a dense, waterproof film.
5. The weather-resistant waterproof material according to claim 1, characterized in that: The penetrating crystallizing waterproofing agent is a lithium silicate crystallizing agent that penetrates into the existing concrete, undergoes secondary crystallization, and blocks the pores, thereby achieving waterproofing and seepage prevention.
6. The weather-resistant waterproof material according to claim 1, characterized in that: The coupling agent is a titanate composite, which serves to enhance interfacial adhesion.
7. The weather-resistant waterproof material according to claim 1, characterized in that: The water-reducing agent is melamine powder, which reduces water consumption and increases strength.
8. The weather-resistant waterproof material according to claim 1, characterized in that: The HPMC units are 200,000 and 40,000 units, and their function is to improve adhesion, lock in moisture, and reduce shrinkage caused by moisture evaporation.
9. The weather-resistant waterproof material according to claim 1, characterized in that: The hydrophobic agent is a composite of organic and inorganic components, and its function is to reduce the contact area and residence time of water molecules on the surface of the structure.
10. The method for preparing weather-resistant waterproof (hydrophobic) materials according to claims 1-9, characterized in that: After mixing the above-mentioned dry powder materials in the prescribed order, sieving, and packaging, they can be transported to the site, mixed with water, and used.