Multi-Layer Anti-Corrosion Coating for Submerged Floating Tunnel Concrete
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Solution Overview
Problem
Submerged floating tunnel pipe sections face challenges with poor bonding strength between fiberglass reinforced plastic and concrete, insufficient durability, and scouring effects from seawater and marine organisms, which affect the anti-corrosion performance and mechanical integrity.
Innovation Solution
A multi-layered anti-corrosion material system comprising an organosilicon material as the base layer, high-strength fiberglass reinforced plastic as the middle layer, and a hydrophobic nano-SiO2 and nano-TiO2 fluoropolymer as the surface layer, enhancing bonding, durability, and resistance to seawater scouring and organism attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If fiberglass reinforced plastic coating is applied for anti-corrosion treatment, then anti-corrosion protection is provided, but bonding strength with concrete base layer deteriorates
Solution Approach 1:
An organosilicon material is introduced as an intermediate bonding layer between the concrete base layer and the fiberglass reinforced plastic coating. This intermediate layer improves chemical bonding and physical adhesion, resolving the contradiction by providing both corrosion protection and strong bonding without direct contact between the coating and concrete.
Solution Approach 2:
The anti-corrosion system uses a composite structure combining organosilicon material, fiberglass fabric, and resin in multiple layers. This composite approach allows each layer to perform its specific function optimally while working together to achieve both strong bonding and effective corrosion resistance.
2Ease of manufacture
If conventional anti-corrosion materials are used, then application is simplified, but durability life deteriorates
Solution Approach 1:
The patent specifies precise parameter ranges for resin content (30-50% by weight of fiberglass fabric), layer thicknesses (0.5-2.0mm per layer), and curing conditions to optimize both application ease and durability. These controlled parameters ensure consistent high-performance results while maintaining practical applicability.
Solution Approach 2:
The concrete surface undergoes preliminary treatment including cleaning, roughening, and application of organosilicon material before applying the fiberglass coating. This preliminary preparation ensures optimal bonding conditions and long-term durability while maintaining a systematic and manageable application process.
3Object-affected harmful factors
If fiberglass reinforced plastic is applied on seabed with strong current, then corrosion protection is achieved, but scouring resistance deteriorates
Solution Approach 1:
The multi-layer composite structure with organosilicon base layer, fiberglass fabric, and resin creates a cohesive system with enhanced mechanical strength and scouring resistance. The interlocking layers and chemical bonds provide resistance against strong currents and wave action while maintaining corrosion protection.
Solution Approach 2:
The patent applies the coating system to the curved surface of pipe sections, ensuring uniform coverage and optimal mechanical properties. The curvature of the pipe sections naturally distributes hydrodynamic forces, enhancing scouring resistance when combined with the composite coating structure.
4Quantity of substance
If standard coating thickness is applied, then material usage is reduced, but bonding strength and durability deteriorate
Solution Approach 1:
The patent optimizes the thickness of each layer within specific ranges (0.5-2.0mm per layer) to achieve the minimum effective protection. This parameter optimization ensures adequate bonding strength and durability while minimizing material consumption through precise control of coating thickness.
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 improves the bonding strength and durability of the anti-corrosion system, providing enhanced protection against seawater corrosion and scouring, with a projected lifespan of at least 120 years for the submerged floating tunnel pipe sections.
Implementation Method 1
the penetration depth in concrete is not less than 2.5 mm
Implementation Method 2
a hydrophobic material is adopted on the surface of the fiberglass reinforced plastic to slow down scouring of seawater flow
Data Source
AI summary
An anti-corrosion material and anti-corrosion method for submerged floating tunnel pipe section concrete is provided. The anti-corrosion material includes: a base layer material, a middle layer material and a surface layer material. The base layer material is an organosilicon material. The middle layer material is high-strength and high-durability fiberglass reinforced plastic. The surface layer material is a hydrophobic material. The anti-corrosion method includes: preparing fiberglass reinforced plastic; cleaning a surface of a submerged floating tunnel pipe section concrete material, preparing an organosilicon material, and coating the organosilicon material onto the surface of the pipe section concrete material; and preparing a hydrophobic material, and spray-coating the hydrophobic material onto a surface of the fiberglass reinforced plastic. The organosilicon material is adopted to improve the durability of the pipe section concrete and the bonding performance between the fiberglass reinforced plastic and the pipe section concrete.