Anti-corrosion and fireproof integrated coating system for bridge steel structure surface

Abstract

The utility model discloses an anti-corrosion and fireproof integrated coating system for the surface of a bridge steel structure. The anti-corrosion and fireproof integrated coating system comprises a primer layer coated on the surface of a steel structure base body, an aerogel thermal insulation coating layer is sprayed on the outer surface of the primer layer; a fiber web reinforcing layer is arranged in the middle of the aerogel heat-preservation coating layer, and the outer surface is coated with a solvent-free epoxy coating; and a fluorocarbon protection layer is adhered to the outer surface of the solvent-free epoxy coating. The primer layer has excellent adhesive force and corrosion resistance; the aerogel thermal insulation coating layer delays heat transfer and reduces the thickness of the coating; the fiber web reinforcing layer obviously improves the crack resistance of the coating; the solvent-free epoxy coating forms a heat insulation fireproof layer through high-temperature carbon formation; and the fluorocarbon protection layer has waterproof and weather-resistant properties. By optimizing the coating structure, the thickness of the coating is reduced, the heat insulation performance, the toughness and the crack resistance of the coating are remarkably improved, meanwhile, the requirement for efficient protection of the steel structure under the hydrocarbon fire disaster condition is met, the corrosion resistance and the fire resistance of the coating are improved, and the coating is particularly suitable for the special-shaped part area of the steel structure.

Description

TECHNICAL FIELD

[0001] The embodiment of the utility model belongs to the technical field of anticorrosion and fireproof protection, more particularly relates to a bridge steel structure surface anticorrosion and fireproof integrated coating system. BACKGROUND

[0002] In bridge engineering, steel structure is widely used due to its high strength, light weight, fast construction speed and strong plasticity, however, steel is easily affected by corrosion and fire due to long-term exposure to natural environment, which not only reduces the strength and stability of steel structure, but also shortens the service life of the bridge. Therefore, effective anticorrosion and fireproof treatment on the surface of steel structure is particularly important. Although the existing anticorrosion and fireproof coating system can protect the steel structure from corrosion and fire to some extent, it has the problems of large coating thickness, easy cracking and peeling, which affects the anticorrosion and fireproof effect of the coating, and for special-shaped part areas such as cable clamp, fork ear, anchor cup, cable guide pipe and anchor plate of suspension bridge, the adaptability of the existing anticorrosion and fireproof coating system in these areas is poor due to the complex shape of these areas and the difficulty in uniform coating. The coating in these areas is prone to problems such as uneven thickness and incomplete coverage, which affects the anticorrosion and fireproof effect. SUMMARY

[0003] In view of the above defects or improvement needs of the prior art, the utility model provides a bridge steel structure surface anticorrosion and fireproof integrated coating system, which can reduce the coating thickness, improve the crack resistance of the coating, improve the anticorrosion and fireproof effect, and be used in special-shaped part areas such as cable clamp, fork ear, anchor cup, cable guide pipe and anchor plate of suspension bridge by optimizing the coating structure combination.

[0004] In order to achieve the above purpose, the utility model provides a bridge steel structure surface anticorrosion and fireproof integrated coating system, which comprises:

[0005] A primer layer is coated on the surface of the steel structure base body with a thickness of 40-50 microns;

[0006] An aerogel thermal insulation coating layer is sprayed or coated on the outer surface of the primer layer with a thickness of 3-5 mm;

[0007] A fiber mesh reinforced layer is arranged in the aerogel thermal insulation coating layer with a thickness of 0.4-0.6 mm;

[0008] A solvent-free epoxy coating layer is sprayed or coated on the outer surface of the aerogel thermal insulation coating layer with a thickness of 3-5 mm;

[0009] A fluorocarbon protective layer is pasted on the outer side of the solvent-free epoxy coating layer with a thickness of 0.4-0.6 mm.

[0010] Further, the primer layer is an epoxy primer layer, an epoxy zinc-rich primer layer or an inorganic zinc-rich primer layer.

[0011] Further, the fiber mesh reinforcement layer is woven by carbon fiber or high-silica fiber.

[0012] Further, the fluorocarbon protective layer adopts a fluorocarbon polymer waterproof layer matching the shape of the steel structure substrate.

[0013] Further, the total thickness is not more than 10mm.

[0014] Overall, compared with the prior art, the above technical scheme conceived by the utility model can achieve the following beneficial effects:

[0015] (1) The corrosion and fireproof integrated coating system of the bridge steel structure surface of the utility model optimizes the coating structure, sets an aerogel thermal insulation coating layer between the primer layer and the solvent-free epoxy coating layer, and sets a fiber mesh reinforcement layer woven by carbon fiber or high-silica fiber in the aerogel thermal insulation coating layer, solves the problems of insufficient heat insulation performance of the coating under fire conditions and easy cracking of the coating under complex stress environment, leading to insufficient crack resistance, significantly improves the heat insulation performance, toughness and crack resistance of the coating, and improves the corrosion and fireproof effect.

[0016] (2) The corrosion and fireproof integrated coating system of the bridge steel structure surface of the utility model pastes a fluorocarbon polymer waterproof layer outside the solvent-free epoxy coating layer to form a fluorocarbon protective layer, is suitable for the surfaces of various complex-shaped steel structures, is especially suitable for the regions of special-shaped parts such as cable clamps, fork ears, anchor cups, cable guide pipes and anchor plates, solves the problems of complex shape of the regions of special-shaped parts, great difficulty in spraying or brushing construction, easy uneven coating or dead angle of protection, accurate matching of the regions of special-shaped parts by pasting construction, ensures uniform coating, significantly improves the weather resistance of the coating, enables the coating to better resist the erosion of environmental factors such as ultraviolet rays and acid rain, prolongs the service life of the coating, and at the same time, the pasting construction makes the surface of the component more smooth and improves the appearance quality.

[0017] (3) The corrosion and fireproof integrated coating system of the bridge steel structure surface of the utility model optimizes the coating structure, adopts the combination of a strong-adhesion primer layer, a light-weight aerogel thermal insulation coating layer, a high-strength fiber mesh reinforcement layer, an environmentally-friendly solvent-free epoxy coating layer and a weather-resistant fluorocarbon protective layer, and controls the total thickness to be below 10mm, significantly reduces the thickness of the coating, and at the same time, ensures the corrosion and fireproof performance. BRIEF DESCRIPTION OF DRAWINGS

[0018] Figure 1 Fig. 1 is a structure schematic view of the corrosion and fireproof integrated coating system of the bridge steel structure surface of the utility model embodiment;

[0019] In all the drawings, the same reference signs refer to the same technical features, specifically: 1 - primer layer, 2 - aerogel thermal insulation coating layer, 3 - fiber reinforced layer, 4 - solvent-free epoxy coating, 5 - fluorocarbon protective layer. DETAILED DESCRIPTION

[0020] In order to make the purpose, technical scheme and advantages of the utility model clearer, the utility model will be described in further detail below in combination with the drawings and examples. It should be understood that the specific examples described herein are only used to explain the utility model and not to limit the utility model. In addition, the technical features involved in each embodiment of the utility model described below can be combined with each other as long as there is no conflict.

[0021] It should be noted that if the embodiments of the utility model involve directional indications (such as up, down, left, right, front, back, etc.), the directional indications are only used to explain the relative position relationship, movement condition, etc. between the components in a certain posture (as shown in the drawings), if the certain posture changes, the directional indications will also change accordingly. In addition, the technical solutions of each embodiment can be combined with each other, but it must be based on the fact that a person skilled in the art can realize it, when the combination of technical solutions contradicts each other or cannot be realized, it should be considered that the combination of technical solutions does not exist, nor is it within the protection scope required by the utility model.

[0022] In the utility model, the term "comprises", "includes" or any other variant thereof is intended to cover non-exclusive inclusion, so that the process, method, article or device including a series of elements not only includes those elements, but also includes other elements not explicitly listed or inherent to such process, method, article or device. Without more limitations, the elements defined by the statement "comprise" do not exclude the presence of other identical elements in the process, method, article or device including the elements.

[0023] The technical scheme of the utility model will be described below in combination with the drawings and through specific embodiments.

[0024] Example 1

[0025] As Figure 1 shown, the utility model provides a bridge steel structure surface anticorrosion and fireproof integrated coating system, including primer layer 1, aerogel thermal insulation coating layer 2, fiber reinforced layer 3, solvent-free epoxy coating 4 and fluorocarbon protective layer 5.

[0026] After the surface of the steel structure substrate is cleaned, a layer of the primer layer 1 is coated, with a thickness of 40-50 μm, the outer surface of the primer layer 1 is sprayed or coated with the aerogel thermal insulation coating 2 with a thickness of 3-5 mm, the aerogel thermal insulation coating 2 is provided with a fiber mesh reinforcement layer 3 with a thickness of 0.4-0.6 mm in the middle, the outer surface of the aerogel thermal insulation coating 2 is sprayed or coated with the solvent-free epoxy coating 4 with a thickness of 3-5 mm, and the outer side of the solvent-free epoxy coating 4 is pasted with the fluorocarbon protective layer 5 with a thickness of 0.4-0.6 mm, to form a corrosion and fireproof coating system.

[0027] Preferably, the primer layer 1 has significant corrosion resistance and can be an epoxy primer layer or an epoxy zinc-rich primer layer or an inorganic zinc-rich primer layer. The epoxy primer layer can achieve excellent adhesion at a lower surface treatment level, reduce construction difficulty, and increase the adhesion of the corrosion-resistant coating; the epoxy zinc-rich primer layer has better flexibility and better construction performance, and can adapt to the slight deformation of the substrate without cracking; the inorganic zinc-rich primer layer has excellent adhesion, rust resistance, salt spray resistance and high temperature resistance, and is suitable for corrosion protection of steel structures in harsh conditions.

[0028] The aerogel thermal insulation coating layer 2 has excellent thermal insulation performance and light weight characteristics, can effectively delay heat transfer, improve fireproof effect, and reduce the overall weight and thickness of the coating.

[0029] The fiber mesh reinforcement layer 3 is woven from carbon fiber or high-silica fiber, the aerogel thermal insulation coating is uniformly coated on the primer layer 1, and before the aerogel thermal insulation coating layer is completely dried, the carbon fiber or high-silica fiber mesh is uniformly laid on the aerogel thermal insulation coating layer, and a layer of aerogel thermal insulation coating is coated on the fiber mesh again to form the aerogel thermal insulation coating layer 2 containing the fiber mesh reinforcement layer 3, which enhances the toughness and strength of the aerogel thermal insulation coating layer 2, absorbs and disperses stress when the coating is subjected to external force, prevents cracks and damage of the coating, significantly improves the crack resistance of the coating, and provides strong anchoring force for the solvent-free epoxy coating 4.

[0030] The solvent-free epoxy coating 4 forms a thermal insulation and fireproof layer by high-temperature carbonization, sacrificing part of the coating thickness, to prevent ablation of the flame to the bottom layer.

[0031] The fluorocarbon protective layer 5 is formed by pasting the fluorocarbon polymer waterproof layer on the outer surface of the solvent-free epoxy coating 4. On the one hand, the surface of the component is more smooth by filling and repairing the surface of the solvent-free epoxy coating 4 with butyl rubber, and the appearance quality is improved. On the other hand, the fluorocarbon film has excellent waterproofness and weather resistance, can shield ultraviolet rays in sunlight, and greatly prolongs the service life of the fireproof coating. It is especially suitable for repairing local components of old bridges or parts of new bridges with high requirements for weather resistance and appearance quality, especially in the area of special-shaped parts. During construction, the fluorocarbon protective layer 5 is matched with the special-shaped part through lofting to ensure that the shape of the fluorocarbon protective layer 5 matches the special-shaped part. The special-shaped part includes a cable clamp, a fork ear, an anchor cup, a cable guide pipe, an anchor plate and the like.

[0032] In summary, the bridge steel structure surface corrosion and fireproof integrated coating system can reduce the coating thickness, improve the crack resistance of the coating, improve the corrosion and fireproof effect, and be used in the area of special-shaped parts such as cable clamps, fork ears, anchor cups, cable guide pipes and anchor plates.

[0033] Example 2

[0034] A kind of old suspension bridge lock clamp structure steel structure surface corrosion and fireproof coating system, old bridge cable clamp steel structure surface is treated, remove rust, impurity and old coating. Coating a layer of primer layer 1, thickness is 45 μm, the primer layer 1 uses low surface treatment epoxy primer, can realize excellent adhesion under lower surface treatment grade, reduce construction difficulty, increase the adhesion of corrosion protection coating at the same time;

[0035] Aerogel thermal insulation coating layer 2 is formed by spraying or coating the aerogel thermal insulation coating with a thickness of about 3-5mm on the surface of the epoxy primer layer. A layer of fiber mesh woven with carbon fiber or high-silicon fiber with a thickness of about 0.5mm is laid in the aerogel thermal insulation coating layer, and then the aerogel thermal insulation coating is continuously sprayed to completely cover the fiber mesh.

[0036] A solvent-free epoxy coating 4 with a thickness of about 3-5mm is sprayed or coated on the surface of the aerogel thermal insulation coating layer 2, and a solvent-free epoxy coating is formed after drying.

[0037] A fluorocarbon polymer waterproof layer with a thickness of 45 μm is pasted on the surface of the solvent-free epoxy coating to form a fluorocarbon protective layer 5. The fluorocarbon polymer waterproof layer with a thickness of 0.4mm-0.6mm is selected, and the fluorocarbon polymer waterproof layer is cut and lofted according to the shape and size of the cable clamp steel structure to ensure that it can tightly fit the surface of the steel structure. The fluorocarbon polymer waterproof layer is pasted with a special adhesive to form the fluorocarbon protective layer 5. The coating is maintained to ensure that the adhesive is completely cured.

[0038] The old bridge cable clamp steel structure surface in this embodiment has problems such as rust, residual old coating, unevenness, and the like, and the surface treatment is difficult. The primer layer uses a low-surface-treatment epoxy primer, which can achieve excellent adhesion at a lower surface treatment level, without the need for excessive polishing or cleaning of the old bridge steel structure surface, thereby reducing construction difficulty and cost. Moreover, the low-surface-treatment epoxy primer can be compatible with residual coating or slight rust layer on the old bridge surface, forming a good bonding force to provide a reliable adhesion basis for the subsequent coating.

[0039] Example 3

[0040] A new anticorrosion and fireproof coating system for the surface of a new suspension bridge cable clamp steel structure, which cleans and treats the surface of the new bridge cable clamp steel structure to remove impurities and surface dust. A layer of the primer layer 1 is coated, with a thickness of 45 μm, and the primer layer 1 uses a high-temperature-resistant inorganic zinc-rich primer.

[0041] An aerogel thermal insulation coating layer 2 is formed by spraying or coating the surface of the epoxy primer layer with an aerogel thermal insulation coating with a thickness of about 3-5 mm. A layer of carbon fiber or high-silica fiber woven fiber mesh with a thickness of about 0.5 mm is laid in the aerogel thermal insulation coating layer, and then the aerogel thermal insulation coating is continuously sprayed to completely cover the fiber mesh.

[0042] A layer of solvent-free epoxy coating 4 with a thickness of about 3-5 mm is sprayed or coated on the surface of the aerogel thermal insulation coating layer 2, and a solvent-free epoxy coating layer is formed after drying.

[0043] A fluorocarbon polymer waterproof layer with a thickness of 45 μm is pasted on the surface of the solvent-free epoxy coating layer to form a fluorocarbon protective layer 5. A fluorocarbon polymer waterproof layer with a thickness of 0.4-0.6 mm is selected, and the fluorocarbon polymer waterproof layer is cut and laid out according to the shape and size of the cable clamp steel structure to ensure that it can closely fit the surface of the steel structure. The fluorocarbon protective layer 5 is formed by pasting the fluorocarbon polymer waterproof layer with a special adhesive, and the coating is cured to ensure that the adhesive is completely cured.

[0044] The surface of the new bridge cable clamp steel structure in this embodiment is subjected to strict rust removal and cleaning treatment, and is smooth and free of rust, which is suitable for using a high-performance primer. The primer layer uses an inorganic zinc-rich primer with strong adhesion, excellent corrosion resistance, and good high-temperature resistance, which forms a dense protective layer on the high-cleaning surface.

[0045] The anti-corrosion and fireproof integrated coating system in the above embodiments adopts different primer layers for different steel structures, a fiber mesh reinforcing layer is additionally arranged in the aerogel thermal insulation coating layer, on one hand, the total weight and thickness of the coating layer are reduced by the light weight characteristics of the gel thermal insulation coating, and the total thickness is controlled to be less than 10 mm; on the other hand, the crack resistance of the coating layer is significantly improved; and a fluorocarbon polymer waterproof layer is pasted outside the fireproof layer, so that different irregular part areas can be adapted, and the weather resistance of the coating system is improved. The anti-corrosion and fireproof coating system can resist hydrocarbon fire, under the HC carbon hydrogen temperature rise curve condition, when the steel plate temperature is 300 DEG C, the protection time is not less than 60 minutes, and the safety of the bridge steel structure under the fire condition is significantly improved.

[0046] Those skilled in the art can easily understand that the above description is only a preferred embodiment of the present application, and is not used to limit the present application, and any modification, equivalent replacement and improvement made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A corrosion and fire protection integrated coating system for the surface of a bridge steel structure, characterized in that, It comprises: a primer layer (1) coated on the surface of the steel structure substrate, with a thickness of 40-50 μm; an aerogel thermal insulation coating layer (2) sprayed or applied on the outer surface of the primer layer (1), with a thickness of 3-5 mm; a fiber mesh reinforcement layer (3) arranged in the aerogel thermal insulation coating layer (2), with a thickness of 0.4-0.6 mm; a solvent-free epoxy coating layer (4) sprayed or applied on the outer surface of the aerogel thermal insulation coating layer (2), with a thickness of 3-5 mm; a fluorocarbon protective layer (5) attached to the outer side of the solvent-free epoxy coating layer (4), with a thickness of 0.4-0.6 mm.

2. The anticorrosion and fireproof integrated coating system for the surface of a bridge steel structure according to claim 1, characterized in that, The primer layer (1) is an epoxy primer layer, an epoxy zinc-rich primer layer or an inorganic zinc-rich primer layer.

3. The anticorrosion and fireproof integrated coating system for the surface of a bridge steel structure according to claim 1, characterized in that, The fiber mesh reinforcement layer (3) is woven from carbon fibers or high-silica fibers.

4. The anticorrosion and fireproof integrated coating system for the surface of a bridge steel structure according to claim 1, characterized in that, The fluorocarbon protective layer (5) is a fluorocarbon polymer waterproof layer matching the shape of the steel structure substrate.

5. The anticorrosion and fireproof integrated coating system for the surface of a bridge steel structure according to claim 1, characterized in that, The total thickness is not more than 10 mm.

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