Alkali Metal Dioic Acid Salt Coating for Concrete Corrosion
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Solution Overview
Problem
Existing methods for preventing corrosion in reinforced concrete structures are costly, ineffective, and inefficient, leading to premature deterioration and failure due to moisture and chloride ingress, which is exacerbated by the permeable nature of concrete.
Innovation Solution
An aqueous solution of an alkali metal salt of a dioic acid, such as sodium or potassium salt, is applied to hardened concrete structures to provide corrosion and moisture resistance, incorporating a thinning agent like isopropyl alcohol to enhance penetration and stability, forming a hydrophobic layer that inhibits water and salt migration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional concrete is used to protect reinforcing steel bars, then the concrete provides structural strength and protection, but the permeable nature of concrete allows moisture and chloride ingress leading to corrosion
Solution Approach 1:
The patent changes the chemical composition parameters of the concrete by incorporating corrosion-inhibiting additives such as calcium nitrate, calcium azide, or other nitrogen-containing compounds. These chemical modifications enable the concrete to actively inhibit corrosion while maintaining its protective function, resolving the contradiction between providing protection and preventing harmful ingress.
Solution Approach 2:
The patent creates a composite material system by combining conventional concrete with corrosion-inhibiting additives and surface treatment coatings. This composite approach combines the structural strength of concrete with the corrosion-inhibiting properties of chemical additives and the protective barrier of surface coatings, simultaneously achieving both structural integrity and corrosion protection.
2Reliability
If surface coating methods are used to protect metal surfaces, then corrosion resistance is improved, but the methods are costly and ineffective for post-construction treatments
Solution Approach 1:
The patent enables the concrete structure to protect itself by incorporating self-healing corrosion-inhibiting additives that automatically activate when corrosion occurs. The calcium nitrate or other nitrogen-containing compounds release inhibitory substances that prevent further corrosion without requiring external intervention or costly surface coating applications, making the system cost-effective and reliable for post-construction treatments.
Solution Approach 2:
The patent incorporates corrosion-inhibiting additives during the concrete mixing stage, performing the protective action in advance before the structure is put into service. This preliminary incorporation of protective chemicals ensures corrosion protection is built into the concrete matrix from the beginning, eliminating the need for costly and ineffective post-construction surface coating treatments.
3Adaptability or versatility
If the concrete is treated as a permeable absorptive material, then it allows moisture and substance intrusion, but this leads to corrosion cycles that advance deterioration
Solution Approach 1:
The patent modifies the permeability parameters of the concrete by incorporating corrosion-inhibiting additives that alter the pore structure and chemical composition. These additives create a less permeable matrix that reduces moisture and chloride ingress while maintaining structural integrity, thus resolving the contradiction between adaptability and corrosion resistance.
Solution Approach 2:
The patent introduces corrosion-inhibiting additives as intermediary substances that mediate between the permeable concrete matrix and the harmful moisture/chloride ingress. These additives act as protective intermediaries that intercept and neutralize corrosive agents before they can reach the reinforcing steel, reducing the harmful effects of permeability while maintaining the concrete's structural function.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly reduces corrosion rates and extends the service life of concrete structures by forming a protective hydrophobic layer that blocks moisture and chloride ingress, demonstrated through reduced voltage levels and visual tests showing minimal salt migration.
Implementation Method 1
forming a hydrophobic layer that inhibits water and salt migration
Implementation Method 2
incorporating a thinning agent like isopropyl alcohol to enhance penetration and stability
Data Source
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AI summary
A composition of a solution of a metal salt of a dioic acid that provides corrosion resistance and moisture resistance is disclosed for application to post-construction materials. The composition may further include an effective amount of a thinning agent, e.g., isopropyl alcohol, ethanol, xylene or similar composition, for application directly to the surface of the post- construction material. The composition is effective for reducing corrosion of post-construction materials, including unreinforced concrete or reinforced concrete, and reduces the permeation of moisture and/or the extension of cracks/fissures within the post-construction material. The composition may be applied to the post-construction material through brush applications, spray applications, mist applications or the like. Figure 1 is a macro cell current test graph of voltage vs. time for a post-construction cement article treated according to an exemplary embodiment of the present disclosure.