A concrete corrosion protection coating structure

Abstract

The utility model provides a kind of concrete anticorrosive coating structure, belong to concrete technical field, including concrete base surface, concrete base surface is equipped with bottom layer, intermediate layer and main anticorrosive layer;Bottom layer is located concrete base surface surface, intermediate layer is located bottom layer side away from concrete base surface, main anticorrosive layer is located intermediate layer side away from bottom layer;Main anticorrosive layer includes epoxy dense layer and anticorrosive surface layer, epoxy dense layer and intermediate layer contact;Multiple groups of rectangular barrier cavities are equipped in epoxy dense layer, rectangular barrier cavity is filled with rectangular aluminium oxide ceramic block, and epoxy dense layer is filled with ceramic particle and is arranged to form high-density barrier;The device is layered by the layered setting of bottom layer, intermediate layer and main anticorrosive layer, and the connecting pore of permeation hole sealing layer and the pore of concrete base surface are through, the moisture curing layer is embedded with permeation hole sealing layer by rectangular protrusion, the binding force of active ceramic microcrystalline in zigzag notch and base surface enhances bottom layer.

Description

Technical Field

[0001] This utility model belongs to the field of concrete technology, and more specifically, it relates to a concrete anti-corrosion coating structure. Background Technology

[0002] In fields such as building construction, bridge construction, and water conservancy facilities, concrete structures often face problems such as rainwater erosion, chemical corrosion, and weathering in humid environments. In order to extend the service life of concrete structures, ensure the stability and safety of engineering structures, and avoid potential hazards such as reduced structural strength, cracking, and leakage caused by corrosion, it is often necessary to apply an anti-corrosion coating to the concrete base surface. At this time, a concrete anti-corrosion coating structure is needed to protect the concrete base surface and facilitate long-term stable use in complex service environments.

[0003] However, traditional concrete anti-corrosion coatings lack a layered and densely reinforced protective structure, resulting in a simple coating structure, high porosity, weak bonding with the concrete substrate, and weak resistance to penetration and wear. Corrosive media can easily penetrate into the concrete through the coating pores. During long-term service, the coating is prone to aging and peeling failure, which not only leads to accelerated corrosion of the concrete structure and frequent repairs and renovations, increasing maintenance costs, but also affects the normal use of the project due to structural safety hazards, and may even cause safety accidents, thus restricting the service life and reliability of the concrete structure. Utility Model Content

[0004] To address the aforementioned technical problems, this utility model provides a concrete anti-corrosion coating structure to solve the technical issues in the prior art where traditional concrete anti-corrosion coatings lack a layered, coordinated, and densely reinforced protective structure, resulting in a simple coating structure, high porosity, and weak resistance to penetration and wear.

[0005] The purpose and effect of this utility model's concrete anti-corrosion coating structure are achieved by the following specific technical means: A concrete anti-corrosion coating structure includes a concrete substrate, on which a base layer, an intermediate layer, and a main anti-corrosion layer are provided. The base layer is located on the surface of the concrete substrate, the intermediate layer is located on the side of the base layer away from the concrete substrate, and the main anti-corrosion layer is located on the side of the intermediate layer away from the base layer. The main anti-corrosion layer includes an epoxy dense layer and an anti-corrosion surface layer, with the epoxy dense layer in contact with the intermediate layer. The epoxy dense layer contains multiple sets of rectangular barrier cavities, each filled with rectangular alumina ceramic blocks, and the epoxy dense layer is also filled with arranged ceramic particles to form a high-density barrier.

[0006] According to a preferred embodiment, the anti-corrosion surface layer is made of fluorocarbon resin, and the anti-corrosion surface layer is located on the side of the epoxy dense layer away from the intermediate layer. The anti-corrosion surface layer is provided with an interlocking protrusion on the side close to the epoxy dense layer, and the interlocking protrusion is interlocked with the epoxy dense layer.

[0007] According to a preferred embodiment, the bottom layer includes a permeable sealing layer and a moisture curing layer, wherein the permeable sealing layer is bonded to the concrete substrate; the permeable sealing layer contains multiple sets of connecting pores, which communicate with the pores in the concrete substrate.

[0008] According to a preferred embodiment, the moisture-curing layer is located on the side of the permeation sealing layer away from the concrete substrate; the permeation sealing layer has multiple sets of rectangular anchoring grooves, and the moisture-curing layer is fitted into the permeation sealing layer through rectangular protrusions.

[0009] According to a preferred embodiment, the moisture-curing layer is provided with multiple sets of serrated grooves, and the multiple sets of serrated grooves are filled with active ceramic microcrystals.

[0010] According to a preferred embodiment, the intermediate layer includes a transition layer and a reinforcing layer, the transition layer being located on the upper surface of the bottom layer; the transition layer has an annular groove, and the annular groove is filled with elastic sealant.

[0011] According to a preferred embodiment, the reinforcing layer is made of basalt fiber, and the fiber ends of the reinforcing layer are embedded in the annular groove and bonded to the elastic sealant.

[0012] Compared with the prior art, the present invention has the following beneficial effects: 1. In this utility model, through the layered arrangement of the bottom layer, intermediate layer and main anti-corrosion layer, the connecting pores of the permeable sealing layer are connected to the pores of the concrete substrate. The moisture curing layer is embedded with the permeable sealing layer through rectangular protrusions. The active ceramic microcrystals in the serrated grooves enhance the bonding force between the bottom layer and the substrate. The elastic sealant of the intermediate layer fills the annular groove. The basalt fiber reinforcement layer is embedded in the groove and bonded to the sealant, improving the overall structural strength of the coating. The alumina ceramic blocks and ceramic particles of the main anti-corrosion layer form a high-density barrier to prevent the intrusion of corrosive media.

[0013] 2. In this utility model, through the coordinated arrangement of each layer, the epoxy dense layer and the fluorocarbon resin anti-corrosion surface layer are firmly embedded by interlocking protrusions. The fluorocarbon resin material has both weather resistance and corrosion resistance. The layered structure and each interlocking structure enhance the stability of the interlayer connection, prevent the coating from falling off, and take into account both anti-corrosion reliability and structural durability, extend the service life of concrete base surface, and are suitable for various concrete scenarios that require anti-corrosion protection. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the assembled structure of this utility model; Figure 2 This is a schematic diagram of the disassembled structure of this utility model; Figure 3 yes Figure 2 Enlarged view of region A in the middle; Figure 4 This is a cross-sectional view of the present invention.

[0015] In the diagram, the correspondence between component names and drawing numbers is as follows: 11. Concrete base; 12. Base layer; 13. Intermediate layer; 14. Main anti-corrosion layer; 15. Epoxy dense layer; 16. Anti-corrosion surface layer; 17. Rectangular barrier cavity; 18. Rectangular alumina ceramic block; 19. Ceramic particles; 21. Embedded protrusions; 22. Permeable sealing layer; 23. Moisture curing layer; 24. Connecting pores; 25. Rectangular anchoring groove; 26. Rectangular protrusion; 27. Serrated groove; 28. Active ceramic microcrystals; 29. ​​Transition layer; 31. Reinforcing layer; 32. Annular groove; 33. Elastic sealant. Detailed Implementation

[0016] The embodiments of this utility model will be described in further detail below with reference to the accompanying drawings and examples. The following examples are used to illustrate the technical solution of this utility model, but should not be used to limit the scope of protection of this utility model. Example

[0017] like Figures 1 to 4 As shown, this utility model provides a concrete anti-corrosion coating structure, including a concrete base surface 11, on which a bottom layer 12, an intermediate layer 13 and a main anti-corrosion layer 14 are provided; the bottom layer 12 is located on the surface of the concrete base surface 11, the intermediate layer 13 is located on the side of the bottom layer 12 away from the concrete base surface 11, and the main anti-corrosion layer 14 is located on the side of the intermediate layer 13 away from the bottom layer 12; the main anti-corrosion layer 14 includes an epoxy dense layer 15 and an anti-corrosion surface layer 16, the epoxy dense layer 15 is in contact with the intermediate layer 13; the epoxy dense layer 15 is provided with multiple sets of rectangular barrier cavities 17, the rectangular barrier cavities 17 are filled with rectangular alumina ceramic blocks 18, and the epoxy dense layer 15 is filled with ceramic particles 19 to form a high-density barrier.

[0018] Specifically, the concrete substrate 11 needs to be pre-treated: thoroughly remove surface laitance, oil stains and loose particles, wash it clean with a high-pressure water gun and let it air dry naturally to ensure that there are no impurities on the surface that would affect the bonding of the coating; the bottom layer 12, the intermediate layer 13 and the main anti-corrosion layer 14 are stacked in sequence to form an integrated anti-corrosion system, with no obvious gaps between the layers; the epoxy dense layer 15 of the main anti-corrosion layer 14 is coated with solvent-free epoxy paint, and multiple sets of rectangular barrier cavities 17 are reserved during the coating forming process, and rectangular alumina ceramic blocks 18 are embedded in the cavities. The rectangular alumina ceramic blocks 18 have excellent wear resistance and barrier properties, which can block the penetration of corrosive media; at the same time, ceramic particles 19 are uniformly mixed into the epoxy paint matrix, and the particles are arranged with each other to form a dense physical barrier, further enhancing the anti-corrosion and sealing performance of the epoxy dense layer 15.

[0019] The anti-corrosion surface layer 16 is made of fluorocarbon resin, and the anti-corrosion surface layer 16 is located on the side of the epoxy dense layer 15 away from the intermediate layer 13. The anti-corrosion surface layer 16 is provided with an interlocking protrusion 21 on the side of the epoxy dense layer 15, and the interlocking protrusion 21 is interlocked with the epoxy dense layer 15.

[0020] Specifically, the anti-corrosion surface layer 16 is made of fluorocarbon resin, which has excellent weather resistance, acid and alkali corrosion resistance and UV resistance. On the side of the anti-corrosion surface layer 16 near the epoxy dense layer 15, an integrally formed interlocking protrusion 21 is provided. The surface of the epoxy dense layer 15 has a corresponding matching interlocking groove. During installation, the interlocking protrusion 21 is completely embedded into the groove. The good compatibility between fluorocarbon resin and epoxy resin achieves a firm bond. By increasing the contact area between the two coatings, the interlayer bonding strength is improved, and delamination and peeling are avoided during long-term use.

[0021] The bottom layer 12 includes a permeable sealing layer 22 and a moisture curing layer 23. The permeable sealing layer 22 is bonded to the concrete base surface 11. Multiple sets of connecting pores 24 are distributed in the permeable sealing layer 22, and the connecting pores 24 are connected to the pores of the concrete base surface 11.

[0022] Specifically, the penetrating sealing layer 22 uses a low-viscosity epoxy penetrating primer, which is uniformly applied to the surface of the concrete substrate 11 through a spraying process. The coating can penetrate deep into the concrete surface and fill the capillary pores of the substrate. During the curing process of the coating, multiple sets of connecting pores 24 are naturally formed. These pores are interconnected with the pores of the concrete substrate 11 itself, forming an anchoring structure. This not only enhances the adhesion between the penetrating sealing layer 22 and the concrete substrate 11, but also blocks the pore channels and prevents corrosive media from seeping into the interior from the pores.

[0023] The moisture-curing layer 23 is located on the side of the permeation sealing layer 22 away from the concrete base surface 11; the permeation sealing layer 22 has multiple sets of rectangular anchoring grooves 25, and the moisture-curing layer 23 is fitted into the permeation sealing layer 22 through rectangular protrusions 26.

[0024] Specifically, the moisture-curing layer 23 uses a single-component moisture-curing polyurethane coating, which is applied to the surface of the permeation sealing layer 22 and cured at room temperature. Multiple sets of rectangular anchoring grooves 25 are evenly opened on the surface of the permeation sealing layer 22 in the longitudinal and transverse directions. When the moisture-curing layer 23 is formed, rectangular protrusions 26 are formed accordingly. The size of the protrusions matches the rectangular anchoring grooves 25. During installation, the rectangular protrusions 26 are completely embedded in the rectangular anchoring grooves 25 to form a mechanical interlocking structure, which improves the interlayer bonding force between the permeation sealing layer 22 and the moisture-curing layer 23 and avoids peeling during use.

[0025] The moisture-curing layer 23 has multiple sets of serrated grooves 27, and the multiple sets of serrated grooves 27 are filled with active ceramic microcrystals 28.

[0026] Specifically, the moisture-cured layer 23 has multiple sets of serrated grooves 27 pre-set on the side near the intermediate layer 13, and the grooves are staggered. Active ceramic microcrystals 28 are uniformly filled into the serrated grooves 27, and the microcrystals are integrated with the moisture-cured layer 23. Its high hardness characteristics can enhance the wear resistance of the coating surface. At the same time, the active ingredients in the microcrystals can react with the corrosive media they come into contact with to form a secondary protective film, further improving the overall anti-corrosion capability of the bottom layer 12.

[0027] The intermediate layer 13 includes a transition layer 29 and a reinforcing layer 31. The transition layer 29 is located on the upper surface of the bottom layer 12. The transition layer 29 has an annular groove 32, which is filled with elastic sealant 33.

[0028] Specifically, the transition layer 29 of the intermediate layer 13 is made of modified epoxy resin coating, which is uniformly coated on the surface of the moisture-curing layer 23 to serve as a transition between the bottom layer 12 and the reinforcing layer 31. Multiple sets of annular grooves 32 are uniformly opened on the surface of the transition layer 29 in the circumferential direction, and elastic sealant 33 is filled into the grooves. The sealant adheres to the groove wall and has excellent elasticity and aging resistance after curing. It can absorb the thermal expansion and contraction stress caused by temperature changes in the coating and prevent the coating from cracking.

[0029] The reinforcing layer 31 is made of basalt fiber, and the fiber ends of the reinforcing layer 31 are embedded in the annular groove 32 and bonded to the elastic sealant 33.

[0030] Specifically, the reinforcing layer 31 is made of bidirectional interwoven basalt fiber cloth, which has high strength and corrosion resistance. During installation, the fiber ends of the fiber cloth are trimmed into a dispersed shape and embedded into the annular groove 32 of the transition layer 29. It is then bonded to the elastic sealant 33 and cured. The main body of the fiber cloth is laid flat on the surface of the transition layer 29 and is firmly bonded to the transition layer 29 and the epoxy dense layer 15 respectively by epoxy resin adhesive. The high strength of basalt fiber can enhance the crack resistance and impact resistance of the entire anti-corrosion system and prevent the coating from being damaged or failing due to external impact or structural deformation.

[0031] The specific usage and function of this embodiment are as follows: Before use, the concrete substrate 11 must be pre-treated: thoroughly remove laitance, oil stains, and loose particles from the surface, rinse with a high-pressure water gun, and allow to air dry naturally to ensure that there are no impurities on the surface that could affect the adhesion of the coating, thus laying the foundation for subsequent coating application. The pre-treated substrate should be coated with the base coat 12 as soon as possible to avoid secondary contamination.

[0032] The construction of the base layer 12 is the foundation of the anti-corrosion system: first, a low-viscosity epoxy penetrating primer is evenly coated on the surface of the concrete base 11 through a spraying process to form a penetrating sealing layer 22; the coating can penetrate deep into the concrete surface, fill the capillary pores of the base surface, and naturally form multiple sets of connecting pores 24 during the curing process, which are interconnected with the pores of the concrete base 11 itself to form an anchoring structure, which not only enhances the adhesion between the penetrating sealing layer 22 and the base surface, but also blocks the pore channels to prevent corrosive media from seeping in from the pores; After the permeation sealing layer 22 has cured, a single-component moisture-curing polyurethane coating is applied to its surface to form a moisture-curing layer 23. The rectangular anchoring groove 25 pre-set on the surface of the permeation sealing layer 22 is engaged with the rectangular protrusion 26 formed during the molding of the moisture-curing layer 23 to form a mechanical interlocking structure, which improves the interlayer bonding force and avoids peeling. At the same time, the serrated groove 27 on the side of the moisture-curing layer 23 near the intermediate layer 13 is filled with active ceramic microcrystals 28. The microcrystals are combined with the coating, and their high hardness enhances the surface wear resistance. The active ingredients can also react with the corrosive medium to form a secondary protective film, further strengthening the anti-corrosion ability of the bottom layer 12.

[0033] The intermediate layer 13 serves as a connecting and reinforcing layer: a modified epoxy resin coating is uniformly applied to the surface of the moisture-curing layer 23 to form a transition layer 29, achieving a smooth connection between the bottom layer 12 and the reinforcing layer 31; the annular groove 32 on the surface of the transition layer 29 is filled with elastic sealant 33, which, after curing, possesses excellent elasticity and aging resistance, and can absorb the thermal expansion and contraction stress caused by temperature changes in the coating, preventing the coating from cracking. Subsequently, a bidirectional interwoven basalt fiber cloth is laid as the reinforcing layer 31. The fiber ends of the fiber cloth are trimmed into a dispersed shape and embedded in the annular groove 32 to adhere and cure with the elastic sealant 33. The main part of the fiber cloth is laid flat on the surface of the transition layer 29 and bonded to the transition layer 29 and the subsequent epoxy dense layer 15 respectively through epoxy resin adhesive; the high strength characteristics of basalt fiber enhance the crack resistance and impact resistance of the entire anti-corrosion system, preventing the coating from being damaged or failing due to external impact or structural deformation.

[0034] The construction of the main anti-corrosion layer 14 forms the final protective barrier: a solvent-free epoxy coating is applied to the surface of the reinforcing layer 31 to form a dense epoxy layer 15; rectangular alumina ceramic blocks 18 are embedded in multiple sets of rectangular barrier cavities 17 reserved during the coating molding process. The ceramic blocks have excellent wear resistance and barrier properties, which can block the penetration of corrosive media; at the same time, ceramic particles 19 are uniformly mixed into the epoxy coating matrix, and the particles are arranged to form a dense physical barrier, further enhancing the anti-corrosion and sealing performance. After the dense epoxy layer 15 has cured, a fluorocarbon resin anti-corrosion surface layer 16 is applied to its surface. The interlocking protrusions 21 on the side of the anti-corrosion surface layer 16 near the dense epoxy layer 15 are completely embedded in the matching interlocking grooves on the surface of the dense epoxy layer 15. The good compatibility between fluorocarbon resin and epoxy resin is used to achieve adhesion, increase the interlayer contact area, improve the bonding strength, and prevent delamination and peeling during long-term use. The anti-corrosion surface layer 16 itself has excellent weather resistance, acid and alkali corrosion resistance and UV resistance, which can resist external environmental erosion and extend the service life of the entire anti-corrosion system.

[0035] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. It is obvious to those skilled in the art that this utility model is not limited to the details of the above exemplary embodiments.

Claims

1. A concrete anti-corrosion coating structure, comprising a concrete substrate (11), characterized in that: The concrete base (11) is provided with a bottom layer (12), an intermediate layer (13) and a main anti-corrosion layer (14); the bottom layer (12) is located on the surface of the concrete base (11), the intermediate layer (13) is located on the side of the bottom layer (12) away from the concrete base (11), and the main anti-corrosion layer (14) is located on the side of the intermediate layer (13) away from the bottom layer (12); the main anti-corrosion layer (14) includes an epoxy dense layer (15) and an anti-corrosion surface layer (16), the epoxy dense layer (15) is in contact with the intermediate layer (13); the epoxy dense layer (15) is provided with multiple sets of rectangular barrier cavities (17), the rectangular barrier cavities (17) are filled with rectangular alumina ceramic blocks (18), and the epoxy dense layer (15) is filled with ceramic particles (19) to form a high-density barrier.

2. The concrete anti-corrosion coating structure according to claim 1, characterized in that: The anti-corrosion surface layer (16) is made of fluorocarbon resin, and the anti-corrosion surface layer (16) is located on the side of the epoxy dense layer (15) away from the intermediate layer (13). The anti-corrosion surface layer (16) is provided with an interlocking protrusion (21) on the side of the epoxy dense layer (15), and the interlocking protrusion (21) is interlocked with the epoxy dense layer (15).

3. The concrete anti-corrosion coating structure according to claim 1, characterized in that: The bottom layer (12) includes a permeable sealing layer (22) and a moisture curing layer (23). The permeable sealing layer (22) is attached to the concrete base surface (11). Multiple sets of connecting pores (24) are distributed in the permeable sealing layer (22), and the connecting pores (24) are connected to the pores of the concrete base surface (11).

4. The concrete anti-corrosion coating structure according to claim 3, characterized in that: The moisture-curing layer (23) is located on the side of the permeation sealing layer (22) away from the concrete base surface (11); the permeation sealing layer (22) has multiple sets of rectangular anchoring grooves (25), and the moisture-curing layer (23) is fitted with the permeation sealing layer (22) through rectangular protrusions (26).

5. The concrete anti-corrosion coating structure according to claim 4, characterized in that: The moisture-curing layer (23) has multiple sets of serrated grooves (27), and the multiple sets of serrated grooves (27) are filled with active ceramic microcrystals (28).

6. The concrete anti-corrosion coating structure according to claim 1, characterized in that: The intermediate layer (13) includes a transition layer (29) and a reinforcing layer (31). The transition layer (29) is located on the upper surface of the bottom layer (12). The transition layer (29) has an annular groove (32) and the annular groove (32) is filled with elastic sealant (33).

7. The concrete anti-corrosion coating structure according to claim 6, characterized in that: The reinforcing layer (31) is made of basalt fiber, and the fiber ends of the reinforcing layer (31) are embedded in the annular groove (32) and adhered to the elastic sealant (33).

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