Painting method and coating laminate

Abstract

To provide a coating method which suppresses generation of rust and enables formation of coating film capable of retaining an aesthetic appearance for a long period, with respect to concrete base metal containing metallic fibers, and to provide a coating film laminate obtained according to the coating method.SOLUTION: In a coating method for concrete base metal, the concrete base metal contains metallic fibers, and after coating a rust-prevention undercoat material to form an undercoat material layer, a finishing material is coated to form a finishing material layer on the concrete base metal.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to a method for coating a concrete substrate, and to a coated laminate obtained by the said coating method. [Background technology]

[0002] Traditionally, concrete-based materials such as precast concrete panels have been used as materials to make up the exterior walls of buildings.

[0003] In such concrete-based materials, it is also common practice to apply a coating to the surface to enhance its aesthetic appeal. For example, Patent Document 1 discloses the application of a coating to a concrete surface using a water-repellent agent, a surface preparation agent, a filler, a topcoat paint, etc.

[0004] On the other hand, it is known that metal fibers are mixed into cement compositions containing cement or inorganic powders to increase the strength of concrete-based materials and then hardened (for example, Patent Document 2). [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] Japanese Patent Publication No. 2008-88018 [Patent Document 2] Japanese Patent Publication No. 2017-100888 [Overview of the project] [Problems that the invention aims to solve]

[0006] However, when a cement composition material containing metal fibers, such as that described in Patent Document 2, is applied to the surface, rust may occur over time, potentially impairing the aesthetic appearance of the coating.

[0007] The present invention has been made in view of such problems, and an object thereof is to provide a painting method capable of suppressing the generation of rust and forming a coating film that can maintain aesthetic appearance over a long period of time on a concrete base containing metal fibers, and a coating film laminate obtained by the painting method.

Means for Solving the Problems

[0008] As a result of intensive studies to solve the above problems, the present inventor has found that by using a painting method in which an anti-rust primer is applied to a concrete base containing metal fibers to form a primer layer, and then a finishing material is applied to form a finishing material layer, generation of rust can be suppressed and a coating film laminate capable of maintaining aesthetic appearance over a long period of time can be obtained, and thus the present invention has been completed.

[0009] That is, the present invention relates to a painting method for a concrete base, wherein the concrete base contains metal fibers, and after applying an anti-rust primer to the concrete base to form a primer layer, a finishing material is applied to form a finishing material layer.

[0010] In the painting method of the present invention, it is preferable to perform putty treatment on the holes on the surface of the primer layer after applying an anti-rust primer to the concrete base to form a primer layer and before applying the finishing material to form a finishing material layer.

[0011] The present invention relates to a coating film laminate characterized by being obtained by the above painting method.

Effects of the Invention

[0012] According to the painting method of the present invention, it is possible to obtain a coating film laminate in which a coating film capable of suppressing the generation of rust and maintaining aesthetic appearance over a long period of time is formed on a concrete base containing metal fibers, which is useful.

Modes for Carrying Out the Invention

[0014] [Concrete surface] The present invention relates to a coating method for a concrete substrate, characterized in that the concrete substrate contains metal fibers. The inclusion of metal fibers in the concrete substrate enhances its strength (compressive strength, flexural strength, cracking strength, etc.) and durability, making it highly useful.

[0015] The aforementioned concrete substrate is characterized by containing metal fibers. Such a concrete substrate is obtained by hardening a mixture of cement, aggregate, admixture, metal fibers, and water, and its strength, durability, etc., can be enhanced by the action of the metal fibers. Examples of such concrete substrates include metal fiber-containing precast concrete.

[0016] Examples of the aforementioned metal fibers include steel fibers, plated steel fibers, and stainless steel fibers. These can be used individually or in combination of two or more types.

[0017] The length of the metal fibers is preferably 2 to 80 mm, the diameter of the metal fibers is preferably 0.01 to 1 mm, and the aspect ratio (length of metal fibers / diameter of metal fibers) is preferably 10 to 200. Furthermore, the content ratio of the metal fibers in the concrete substrate is preferably 0.1 to 10% by mass.

[0018] The concrete substrate may further contain organic fibers. Examples of the organic fibers include polypropylene fibers, vinylon fibers, ethylene vinyl alcohol copolymer fibers, nylon fibers, cellulose fibers, polyacetal fibers, acrylic fibers, polyethylene fibers, aqueous vinylon fibers, and jute fibers. These can be used individually or in combination of two or more.

[0019] [Undercoat layer] The present invention relates to a painting method characterized by applying a rust-preventive primer to the concrete substrate to form a primer layer. The rust-preventive primer plays a role in suppressing the occurrence of rust caused by metal fibers in the concrete substrate.

[0020] The aforementioned rust-preventive primer may contain a resin and a rust inhibitor. Examples of the resin include polyvinyl chloride resin, epoxy resin, acrylic resin, urethane resin, acrylic silicone resin, or composite resins thereof. These can be used individually or in combination of two or more. Examples of such resin forms include water-soluble resins, water-dispersible resins (resin emulsions), solvent-soluble resins, solvent-free resins, non-water-dispersible resins, and powder resins. These resins may also have crosslinking reactivity.

[0021] In particular, epoxy resins are preferred as the resin in the aforementioned rust-preventive primer. Examples of epoxy resins include bisphenol type epoxy resins such as bisphenol A type epoxy resin and bisphenol F type epoxy resin, phenol novolac type epoxy resins such as phenol novolac type bisphenol A epoxy resin and phenol novolac type bisphenol F epoxy resin, novolac type epoxy resins such as cresol novolac type epoxy resin and bisphenol A novolac type epoxy resin, alicyclic epoxy resins, hydrogenated bisphenol A type epoxy resins, guccidyl ether type epoxy resins, bisphenol S type epoxy resins, biphenyl type epoxy resins, dicyclo type epoxy resins, naphthalene type epoxy resins, butadiene-based epoxy resins, ε-caprolactone-modified epoxy resins, thiol-based epoxy resins, amine-modified epoxy resins, rubber-modified epoxy resins, urethane-modified epoxy resins, polyol-modified epoxy resins, fatty acid-modified epoxy resins, and the like. These can be used individually or in combination of two or more types.

[0022] When the epoxy resin is used as the rust-preventive primer, an amine curing agent can be used as the curing agent. Examples of the amine curing agent include polyamine compounds such as aliphatic polyamines, alicyclic polyamines, aromatic polyamines, heterocyclic polyamines, aliphatic polyamides, alicyclic polyamides, aromatic polyamides, aliphatic polyamideamines, alicyclic polyamideamines, and aromatic polyamideamines. These can be used individually or in combination of two or more.

[0023] Commercially available or known materials can be used as the rust inhibitor. Specifically, examples include phosphate-based rust inhibitors such as zinc phosphate, iron phosphate, aluminum phosphate, magnesium phosphate, zirconium phosphate, manganese phosphate, and calcium phosphate; silicate-based rust inhibitors such as potassium silicate, calcium silicate, strontium silicate, barium silicate, titanium silicate, aluminum silicate, and magnesium silicate; phosphite-based rust inhibitors such as zinc phosphite, iron phosphite, and aluminum phosphite; molybdate-based rust inhibitors such as calcium molybdate, aluminum molybdate, and barium molybdate; vanadium-based rust inhibitors such as vanadium oxide; and chromate-based rust inhibitors such as strontium chromate, zinc chromate, calcium chromate, potassium chromate, and barium chromate. These can be used individually or in combination of two or more.

[0024] The rust inhibitor can be mixed with 100 parts by mass of the resin (solid content) in a ratio of preferably 1 to 150 parts by mass, more preferably 5 to 100 parts by mass. If the ratio of the rust inhibitor is within the above range, a sufficient effect of suppressing rust generation caused by metal fibers in the concrete substrate can be obtained.

[0025] In addition to the above-mentioned components, the rust-preventive primer may contain, for example, coloring pigments, extender pigments, plasticizers, preservatives, fungicides, algaecides, antibacterial agents, defoamers, leveling agents, coupling agents, wetting agents, pigment dispersants, surfactants, anti-settling agents, anti-sagging agents, matting agents, catalysts, curing accelerators, ultraviolet absorbers, light stabilizers, antioxidants, etc., within a range that does not significantly impair the effects of the present invention.

[0026] The aforementioned primer layer can be formed by applying (coating) and drying the rust-preventive primer described above.

[0027] The painting (coating) method can be appropriately employed, for example, spray painting, roller painting, or brush painting. Drying can be carried out at room temperature (preferably 0 to 40°C), and can also be carried out by heating if necessary.

[0028] The amount of the aforementioned rust-preventive primer to be applied is preferably 0.05 to 0.5 kg / m². 2 , more preferably 0.08 to 0.3 kg / m 2 That is the case.

[0029] In the painting method of the present invention, it is preferable to apply a rust-preventive primer to the concrete substrate to form a primer layer, and then, before applying the finishing material to form a finishing layer, to fill in the pores on the surface of the primer layer with putty. By performing such putty treatment, the effect of suppressing the occurrence of rust caused by metal fibers in the concrete substrate can be further enhanced. The putty treatment can be performed by filling the pores on the surface of the primer layer with putty material.

[0030] As the putty material, various resins can be used as the main component. For example, silicone-based putty material, modified silicone-based putty material, polysulfide-based putty material, modified polysulfide-based putty material, epoxy-based putty material, acrylic urethane-based putty material, polyurethane-based putty material, acrylic-based putty material, SBR-based putty material, butyl rubber-based putty material, etc., can be used.

[0031] As the putty material, it is preferable to use an epoxy-based putty material mainly composed of epoxy resin. In such an epoxy-based putty material, an amine curing agent can be used as the curing agent. The epoxy resin and the amine curing agent can be the same as those exemplified in the rust-preventive primer.

[0032] As the putty material, in addition to the various resins mentioned above, a material containing fillers, coloring pigments, etc., can be used.

[0033] Examples of the aforementioned fillers include calcium carbonate, clay, talc, mica, kaolin, zeolite, diatomaceous earth, and one or more of these can be used.

[0034] The ratio of the filler is preferably 50 to 400 parts by mass, more preferably 80 to 300 parts by mass, per 100 parts by mass (solid content) of the resin. If the ratio of the filler is within the above range, it is preferable in terms of workability, rust resistance, etc.

[0035] Examples of the aforementioned coloring pigments include titanium dioxide, zinc oxide, aluminum oxide, carbon black, graphite, black iron oxide, iron-chromium composite oxide, manganese-bismuth composite oxide, manganese-yttrium composite oxide, iron-manganese composite oxide, iron-copper-manganese composite oxide, iron-chromium-cobalt composite oxide, copper-chromium composite oxide, copper-manganese-chromium composite oxide, red iron oxide, molybdate orange, permanent red, permanent carmine, anthraquinone red, perylene red, quinacridone red, yellow iron oxide, titanium yellow, first yellow, benzoimidazolone yellow, chromium green, cobalt green, phthalocyanine green, ultramarine, Prussian blue, cobalt blue, phthalocyanine blue, quinacridone violet, and dioxazine violet. By appropriately selecting and using one or more of these coloring pigments, the color tone of the putty material can be set.

[0036] It is desirable that the color tone of the putty material differs from that of the primer. This ensures that the putty material is properly applied and is also preferable in terms of rust resistance.

[0037] The color difference (△E) between the putty material and the primer is preferably 3 or more, and more preferably 5 or more. Specifically, the putty material and the primer are applied to a standard white sheet at a rate of 0.2 kg / m². 2Paint it, place the painted surface horizontally, and when it is dried for 48 hours under standard conditions (temperature 23°C, relative humidity 50%), the L of the coating film * value, a * value, b * value (average value of 3 measurement points) can be calculated by the following formula. L * value, a * value, b * The values of L * a * b * in the CIELAB color space are the L * value, a * value, b * values, and can be measured using a color difference meter. <Formula> ΔE = {(L * 1 - L * 2) 2 + (a * 1 - a * 2) 2 + (b * 1 - b * 2) 2} 0.5 (In the formula, L * 1, a * 1, b * 1 respectively represent the L * , a * , b * of the rust preventive primer, and L * 2, a * 2, b​​​​​​​​​​​​​​​In this invention, the application of the rust-preventive primer makes it easier to identify pores caused by the surface condition of the concrete material. Therefore, it becomes easier to identify the pores that are the target of the putty treatment, allowing for efficient putty treatment, and it is also advantageous in terms of rust resistance.

[0040] The amount of putty material used can be set appropriately depending on the condition of the voids, etc., but preferably 0.2 kg / m 2 More preferably, 0.01 to 0.1 kg / m 2 That is the case.

[0041] [Finishing layer] The present invention's painting method is characterized by forming a finishing layer by applying a finishing material to a primer layer. This application of the finishing material allows for the application of desired colors, enhances the suppression of rust formation caused by metal fibers in the concrete substrate, and maintains aesthetic appeal over a long period. Furthermore, it can improve physical properties such as waterproofing, weather resistance, and stain resistance.

[0042] The finishing material can include, for example, a resin and a pigment. Examples of resins in the finishing material include vinyl acetate resin, polyester resin, alkyd resin, vinyl chloride resin, epoxy resin, acrylic resin, urethane resin, acrylic silicone resin, fluororesin, etc., or composite resins thereof. Examples of such resin forms include water-soluble resins, water-dispersible resins (resin emulsions), solvent-soluble resins, solvent-free resins, non-aqueous-dispersible resins, powder resins, etc., and among these, one or more selected from water-soluble resins, water-dispersible resins, solvent-soluble resins, and non-aqueous-dispersible resins are preferred. Furthermore, these resins may also have crosslinking reactivity.

[0043] As the aforementioned pigment, coloring pigments and / or extender pigments can be used.

[0044] Examples of the aforementioned coloring pigments include titanium dioxide, zinc oxide, aluminum oxide, carbon black, graphite, black iron oxide, iron-chromium composite oxide, manganese-bismuth composite oxide, manganese-yttrium composite oxide, iron-manganese composite oxide, iron-copper-manganese composite oxide, iron-chromium-cobalt composite oxide, copper-chromium composite oxide, copper-manganese-chromium composite oxide, red iron oxide, molybdate orange, permanent red, permanent carmine, anthraquinone red, perylene red, quinacridone red, yellow iron oxide, titanium yellow, first yellow, benzoimidazolone yellow, chromium green, cobalt green, phthalocyanine green, ultramarine, navy blue, cobalt blue, phthalocyanine blue, quinacridone violet, dioxazine violet, aluminum pigment, pearl pigment, etc. These can be used individually or in combination of two or more.

[0045] Examples of the aforementioned extender pigments include heavy calcium carbonate, light calcium carbonate, kaolin, clay, pottery clay, china clay, diatomaceous earth, hydrated fine silica, talc, barite powder, barium sulfate, precipitated barium sulfate, barium carbonate, magnesium carbonate, silica powder, and aluminum hydroxide. These can be used individually or in combination of two or more.

[0046] The finishing material may contain various components other than those mentioned above, as long as the effects of the present invention are not significantly impaired. Examples of such components include thickeners, film-forming aids, leveling agents, coupling agents, wetting agents, plasticizers, antifreeze agents, pH adjusters, extender pigments, preservatives, antifungal agents, antialgal agents, antibacterial agents, dispersants, defoaming agents, adsorbents, fibers, crosslinking agents, ultraviolet absorbers, light stabilizers, antioxidants, decontamination agents, hydrophilic agents, water repellents, catalysts, solvents, water, and the like.

[0047] The finishing material can be manufactured by uniformly mixing the resin, the pigment, and, if necessary, the various components mentioned above, using conventional methods. The finishing material can be in the form of, for example, a one-component, two-component, or multi-component type.

[0048] The aforementioned finishing material can be one or more types of finishing materials. Examples of such finishing materials include a main material, an intermediate coating material, a top coating material, and so on.

[0049] The aforementioned topcoat material forms a coating film on the surface side of the finishing material layer, plays a role in providing color, and exhibits physical properties such as weather resistance and stain resistance.

[0050] The resin used for the topcoat is preferably one or more types selected from acrylic resin, urethane resin, acrylic silicone resin, fluororesin, etc.

[0051] The topcoat material is preferably one that contains a coloring pigment as a pigment. This makes it possible to impart a desired color.

[0052] The ratio of coloring pigment in the topcoat is preferably 1 to 500 parts by mass, more preferably 5 to 200 parts by mass, and even more preferably 10 to 150 parts by mass, per 100 parts by mass of resin solids. A ratio of coloring pigment within this range is preferable in terms of coloring, weather resistance, and other factors.

[0053] As for the topcoat material, one that forms a coating film with a contact angle to water of 70° or less is preferable in terms of stain resistance and other properties. Such a topcoat material can be obtained, for example, by incorporating a low-staining agent, a hydrophilic agent, etc.

[0054] The degree of gloss (sheen) of the topcoat material can be set as appropriate. For example, materials exhibiting gloss levels such as high gloss, 70% gloss, 50% gloss, 30% gloss, and matte can be used.

[0055] The 60° specular gloss of the topcoat material is preferably greater than 15, and more preferably 20 or greater. Such a topcoat material is suitable in terms of rust resistance and other properties. The specular gloss of the topcoat material is obtained by applying the topcoat material to a glass plate using a film applicator with a gap of 150 μm, and then measuring the specular gloss (average value of 10 measurement points at a measurement angle of 60 degrees) after drying the coated surface horizontally under standard conditions (temperature 23°C, relative humidity 50%) for 48 hours.

[0056] The aforementioned intermediate coating material forms a coating film beneath the topcoat material and contributes to improving adhesion, opacity, etc. For example, when a fluororesin-based topcoat material is used as the topcoat material, an acrylic resin-based intermediate coating material, a urethane resin-based intermediate coating material, etc., can be used as the intermediate coating material.

[0057] The main material forms a coating film on the surface side of the undercoat layer and contributes to improving physical properties such as waterproofing, substrate conformability, adhesion, and strength. The main material may contain at least a resin and a pigment.

[0058] The main resin material can be one or more types selected from epoxy resin, acrylic resin, urethane resin, acrylic silicone resin, etc. Flexible epoxy resin is particularly preferred as the main resin material due to its rust-inhibiting effect, waterproofing properties, and substrate conformability.

[0059] Examples of the aforementioned flexible epoxy resins include aliphatic-modified epoxy resins, butadiene-based epoxy resins, ε-caprolactone-modified epoxy resins, thiol-based epoxy resins, amine-modified epoxy resins, rubber-modified epoxy resins, urethane-modified epoxy resins, polyol-modified epoxy resins, and fatty acid-modified epoxy resins. These can be used individually or in combination of two or more. Among these, urethane-modified epoxy resins are preferred.

[0060] The pigment in the main material is preferably one that includes an extender pigment. The ratio of the extender pigment in the main material is preferably 30 to 500 parts by mass, more preferably 50 to 400 parts by mass, per 100 parts by mass of resin solids, from the viewpoint of waterproofness, substrate conformability, adhesion, strength, etc.

[0061] The main material may also contain coloring pigments in addition to extender pigments. The pigment volume concentration of the main material is preferably 10-70%, more preferably 20-60%. Such a pigment volume concentration is suitable in terms of waterproofing, substrate conformability, adhesion, strength, etc.

[0062] In the present invention, a finishing material layer can be formed by applying the finishing material (for example, a main material, an intermediate coating material, a top coating material, etc.), and specifically, the following methods can be employed. (1) Apply only the topcoat material as the finishing material to form a finishing layer. (2) As a finishing material, an intermediate coating material and a top coating material are applied to form a finishing layer. (3) As a finishing material, the main material and the top coat material are applied to form a finishing layer. (4) As a finishing material, the main material, intermediate coating material, and top coating material are applied to form a finishing material layer.

[0063] In applying the aforementioned finishing material, known painting tools can be used. Examples of such painting tools include sprayers, rollers, brushes, and the like.

[0064] The amount of the finishing material applied can be set appropriately depending on the type of finishing material and the type of painting equipment, but for topcoats and intermediate coats, it is preferably 0.05 to 0.5 kg / m 2 , more preferably 0.08 to 0.4 kg / m 2 It can be within the range of, and for the main material, preferably 0.1 to 4 kg / m 2 , more preferably 0.2~3 kg / m 2 It can be within the range of

[0065] When applying the finishing material, it may be diluted as needed. The finishing material can be dried at room temperature (preferably 0-40°C), and may also be heated if necessary.

[0066] In this invention, it is desirable that the finishing layer be elastic. The elasticity of the finishing layer further enhances the effect of suppressing rust formation caused by metal fibers in the concrete substrate, allowing for sufficient aesthetic appeal over a long period. Furthermore, it can also further improve physical properties such as waterproofing and substrate conformability.

[0067] If the finishing layer is elastic, the elongation rate of the finishing layer is preferably 30 to 500%, and more preferably 50 to 300%. The elongation rate is the value measured by the method of "elongation test at 20°C" in JIS A6909 "7.29 Elongation test".

[0068] [Laminated coating] The present invention is characterized by obtaining a coated laminate on a concrete substrate by the aforementioned coating method. Such a coated laminate can suppress the occurrence of rust caused by metal fibers in the concrete substrate and maintain its aesthetic appearance for a long period of time.

[0069] The average dry film thickness (average value of the total dry film thickness of the primer layer and the finish layer) of the coating film layer constituting the aforementioned coating laminate is not particularly limited, but is preferably less than 100 μm, more preferably 40 to 99 μm, and even more preferably 50 to 98 μm. In the present invention, due to the action of rust-preventive primers and the like, rust resistance can be obtained even with such a relatively thin film thickness. [Examples]

[0070] The following examples illustrate the features of the present invention. However, the present invention is not limited to the examples provided herein.

[0071] The following materials were prepared as the concrete base, primer, putty, intermediate coat, and topcoat.

[0072] [Concrete surface] • Substrate 1: Precast concrete containing metal fibers • Substrate 2: Precast concrete (without metal fibers)

[0073] [Undercoat material] • Primer 1: Rust-preventive solvent-based primer (a two-component epoxy resin rust-preventive primer consisting of a main component comprising soluble epoxy resin, rust inhibitor, coloring pigment, extender pigment, and aromatic solvent, and an amine curing agent. Color: reddish-brown. Rust inhibitor ratio: 28 parts by mass per 100 parts by mass of resin solids.) • Primer 2: Rust-preventive water-based primer (a two-component epoxy resin rust-preventive primer consisting of a main component mainly composed of epoxy resin emulsion, rust inhibitor, coloring pigment, extender pigment, and water, and an amine curing agent. Color: reddish-brown. Rust inhibitor ratio: 15 parts by mass per 100 parts by mass of resin solids.) • Primer 3: Solvent-based primer (A two-component epoxy resin primer consisting of a main component comprising soluble epoxy resin, coloring pigment, extender pigment, and aromatic solvent, and an amine curing agent. Color: Reddish-brown.) • Primer 4: Water-based primer (a two-component epoxy resin primer consisting of a main component with epoxy resin emulsion, coloring pigment, extender pigment, and water as its main components, and an amine curing agent. Color: reddish-brown.)

[0074] [Putty material] • Putty 1: Epoxy resin putty material (a two-component epoxy resin putty material consisting of a main component mainly composed of epoxy resin, filler, coloring pigment, and aromatic solvent, and an amine hardener. Color: Gray. Filler ratio: 150 parts by mass per 100 parts by mass of resin solids.)

[0075] [Intermediate coating material] • Intermediate coating material 1: Solvent-based intermediate coating material (a two-component urethane resin intermediate coating material consisting of a main component mainly composed of soluble polyol, coloring pigment, and aromatic solvent, and a polyisocyanate curing agent) • Intermediate coating material 2: Water-based intermediate coating material (a one-component urethane resin intermediate coating material mainly composed of acrylic urethane resin emulsion, coloring pigment, and water)

[0076] [Top coat material] • Topcoat 1: Solvent-based topcoat (A two-component fluororesin topcoat consisting of a main component mainly composed of soluble fluoropolyol, colored pigment, and aromatic solvent, and a hardener mainly composed of polyisocyanate and silicate compounds. 60° specular gloss 82.) • Topcoat 2: Water-based topcoat (A two-component fluororesin topcoat consisting of a main component mainly composed of fluororesin emulsion, coloring pigment, and water, and a hardener mainly composed of silicate compounds. 60° mirror gloss 80.)

[0077] (Example 1) Apply 0.12 kg / m² of primer to the substrate. 2 The surface was spray-painted and allowed to dry for 24 hours to form a primer layer. Intermediate coat 1 was then applied to this primer layer at a rate of 0.1 kg / m². 2 After spray painting and drying for 24 hours, apply topcoat 1 at a rate of 0.1 kg / m². 2 The material was spray-painted and allowed to dry for 168 hours to form a finishing layer. The average dry thickness of the paint film layer was 80 μm.

[0078] (Example 2) Apply 0.12 kg / m² of primer to the substrate. 2 The surface was spray-painted and allowed to dry for 24 hours to form a primer layer. Next, putty 1 (with a color difference of 30 from primer 1) was used with a spatula to fill any pores on the surface of the primer layer. After drying for 24 hours, intermediate coat 1 was applied to this primer layer at a rate of 0.1 kg / m². 2 After spray painting and drying for 24 hours, apply topcoat 1 at a rate of 0.1 kg / m². 2 The material was spray-painted and allowed to dry for 168 hours to form a finishing layer. The average dry thickness of the paint film layer was 80 μm.

[0079] (Example 3) The test specimens were prepared in the same manner as in Example 1, except that primer 2, intermediate coat 2, and topcoat 2 were used as the primer, intermediate coat, and topcoat, respectively (average dry film thickness of the painted coating layer: 80 μm).

[0080] (Example 4) The test specimens were prepared in the same manner as in Example 2, except that primer 2, intermediate coat 2, and topcoat 2 were used as the primer, intermediate coat, and topcoat, respectively (color difference between primer 2 and putty material 1: 28, average dry film thickness of the painted coating layer: 80 μm).

[0081] (Comparative Example 1) Except for using primer 3 as the undercoat material, the test specimens were prepared in the same manner as in Example 1 (average dry film thickness of the painted coating layer: 80 μm).

[0082] (Comparative Example 2) The test specimens were prepared in the same manner as in Example 1, except that primer 4, intermediate coat 2, and topcoat 2 were used as the primer, intermediate coat, and topcoat, respectively (average dry film thickness of the painted coating layer: 80 μm).

[0083] (Reference example 1) Except for using base material 2 as the substrate and primer material 3 as the undercoat material, the test specimen was prepared in the same manner as in Example 1 (average dry film thickness of the painted coating layer: 80 μm).

[0084] (Evaluation of corrosion resistance) The test specimens obtained using the above method were subjected to a 120-cycle test in accordance with Cycle D of JIS K5600-7-9:2006 "Long-term durability of coatings - Cycle corrosion test method," and the number of rust spots on the surface of the test specimens was measured. The evaluation criteria are as follows. In the case of an A or B evaluation, the level was evaluated as being at a level that does not pose any problems in practical use. A: No rust occurred. B: Number of rust spots: 1-5 C: Number of rusted areas: 6-10 D: Number of rusted areas: 11 or more

[0085] (Evaluation of aesthetic appeal) Similar to the evaluation of corrosion resistance described above, each test specimen was subjected to a 120-cycle test in accordance with Cycle D of JIS K5600-7-9:2006 "Long-term durability of coatings - Cycle corrosion test method". The appearance of the test specimens before and after the test was then compared and observed to evaluate their aesthetics. The evaluation criteria are as follows. A and B ratings indicate that the specimen is at a level where there are no practical problems. A: No change in appearance B: Area contaminated by rust stains is less than 1% C: Area contaminated by rust stains: more than 1% but less than 5% D: Area contaminated by rust stains exceeds 5%

[0086] The results of the above evaluation are shown in Table 1 below.

[0087] [Table 1]

[0088] From the evaluation results in Table 1 above, it was confirmed that all examples exhibited excellent rust resistance and aesthetic appeal. On the other hand, in Comparative Examples 1 and 2, rust occurred because a rust-preventive primer was not used as the undercoat material, resulting in poor rust resistance. Furthermore, the presence of rust also resulted in poor aesthetic appeal, indicating practical problems.

Claims

1. A coated laminate obtained by a coating method for a concrete substrate, The aforementioned concrete substrate contains metal fibers, After applying a rust-preventive primer to the aforementioned concrete substrate to form a primer layer, a finishing material is applied to form a finishing material layer, thereby forming a paint film layer. A coated film laminate characterized in that the average dry film thickness of the aforementioned coated film layer is less than 100 μm.

2. After applying a rust-preventive primer to the aforementioned concrete substrate to form a primer layer, Before applying the aforementioned finishing material to form a finishing layer, The coated laminate according to claim 1, characterized in that putty treatment is performed on the voids on the surface of the primer layer.

3. The coating laminate according to claim 2, characterized in that the color difference (△E) between the putty material used for the putty treatment and the primer material is 3 or more.

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