JPH0233434B2 - KOZAINOREJINMORUTARUHIFUKUHO - Google Patents

Description

[Detailed Description of the Invention] (Summary of the Invention, Field of Industrial Application) This invention applies a fluid curable resin liquid, which is a component of resin mortar, and a filler (aggregate, etc.) to the surface of a steel material. Separately supplying and preparing a substantially non-flowing resin mortar composition on the surface of the steel material, simultaneously forming a thin layer (lining layer) of this resin mortar on the surface of the steel material, and repeating these operations. In this method, a thick resin mortar layer is formed, a curable resin liquid is cured, and a steel material coated with a thick resin mortar cured coating layer can be easily produced.

The steel material coated with the resin mortar hardened layer formed by the coating method of this invention has excellent corrosion resistance,
It has protective coating properties and is a useful basic material for construction and civil engineering.

(Prior art) In order to prevent corrosion on the surface of steel materials, various coating materials,
Various methods of covering with lining materials etc.
Conventionally, methods have been proposed, such as (1) a method of bonding a plastic film or tape to the surface of a steel material with an adhesive, and (2) a method of bonding a thermoplastic resin film or sheet extruded from an extrusion molding machine. (3) Electrostatic coating or fluid dipping of powdered thermoplastic resin onto the heated steel surface, followed by cooling and coating. (4) After spraying or applying a thermosetting resin liquid to form a thin film of the resin liquid, Methods for coating by curing thin films have already been proposed, and some of these methods have been put into practice.

(Problems to be Solved by the Invention) A steel material having a coating layer formed from a thermoplastic resin by the methods (1) to (3) above has a corrosion-resistant coating layer that is
Physical properties such as heat resistance, abrasion resistance, and hardness have not always been sufficient depending on the purpose of the anti-corrosion coated steel.

In addition, the coating method using a thermosetting resin liquid according to method (4) above still does not provide satisfactory physical properties such as abrasion resistance and impact resistance.
In addition, when spraying or applying these thermosetting resin liquids to the surface of steel materials (particularly irregularly curved surfaces such as circumferential surfaces and uneven surfaces), the lower part of the resin liquid is This has the drawback that it often drips and flows out toward the surface, resulting in the formation of an uneven coating layer, making it difficult to form a thick and uniform coating layer. In addition, if the curing speed of the thermosetting resin is increased to prevent the above-mentioned dripping, the storage stability of the resin liquid deteriorates, and the coating operation must be shortened, making it difficult to form a uniform coating layer. This makes things extremely difficult.

On the other hand, high viscosity resin mortar, in which a high proportion of fillers such as aggregates are blended into a curable resin liquid, is used in the construction and construction fields for its chemical resistance, heat resistance, abrasion resistance, hardness, and impact resistance. Because it forms a hardened layer with excellent physical properties such as hardness, it is generally used to form flat floors in buildings, and is also sometimes used to coat the surfaces of other flat materials. However, due to the high viscosity of the resin mortar, the coating work was done by hand, using a trowel, etc., similar to general cement mortar. In order to form an anticorrosion coating layer on the surface of a steel material having an irregularly curved surface as described above, skill is required, and an efficient industrial coating method has not been known.

(Means for Solving the Problems, Effects) The inventors have developed a steel material (particularly a steel material having an irregularly curved surface) having a hardened coating layer of resin mortar that has excellent physical protection performance, as described above. As a result of intensive study on a resin mortar coating method for steel materials that can be efficiently manufactured to avoid problems, we first coated or sprayed a hardening resin liquid with low viscosity onto the surface of the steel material. Immediately, filler such as aggregate for resin mortar is sprinkled on the thin layer of resin liquid on the surface of the steel material, and the filler such as aggregate is added to the hardening resin liquid. Form a thin layer of high viscosity or non-flowable resin liquid mixed in a high proportion, that is, a non-flowable resin mortar layer, then repeat each of the above operations to form a thick resin mortar layer, and then The inventors discovered that by curing the curable resin liquid of the entire resin mortar layer, a cured resin mortar coating layer could be easily applied to the surface of steel materials, and the present invention was completed.

That is, in this invention, a fluid curable resin liquid having a viscosity of about 0.05 to 200 poise is applied or sprayed onto the surface of a steel material, and a thin layer of the resin liquid is formed on the surface of the steel material. Immediately, a fine filler is deposited by scattering or spraying on the thin layer of the resin liquid, and the filler and the resin liquid are blended to have a high viscosity of about 500 poise or more or a substantially non-stick layer. Form a fluid resin mortar layer, and then repeat the above-mentioned operations of forming a thin layer of resin liquid, dispersing filler (aggregate, etc.), and forming a resin mortar layer to form a thick resin mortar layer. Finally, the present invention provides a method for coating steel with resin mortar, which is characterized by curing the curable resin liquid of the thick resin mortar layer.

According to the coating method of the present invention, a thick resin mortar hardened coating layer with excellent physical properties can be applied to steel materials (especially
It can be easily formed industrially with excellent reproducibility on the surface of steel materials with various irregularly curved surfaces.

In particular, this invention uses a "low viscosity curable resin liquid" that can be applied industrially uniformly, and immediately after forming a thin layer of the resin liquid to a uniform thickness on the surface of the steel material, A filler (such as aggregate) is sprayed onto the thin layer of resin liquid on the surface of the steel material, suppressing the fluidity of the thin layer of resin liquid and preventing it from dripping. By forming a ``high viscosity or non-flowable resin mortar layer'', it is possible to stably form a hardened resin mortar coating layer of uniform thickness on the surface of steel materials.
This point is the most distinctive and important point in the present invention.

The steel material having the resin mortar hardened coating layer formed by the coating method of the present invention has physical properties that the anticorrosion coating layer had in the original cured resin mortar with filler such as aggregate mixed in. Since it is a hardened layer that has the same excellent physical properties as Tomatsutaku, such as chemical resistance, heat resistance, abrasion resistance, hardness, and impact resistance, it has extremely high anticorrosion performance.

(Detailed Description of the Present Invention) The curable resin liquid used in the present invention has a rotational viscosity of approximately
The fluidity of the curable resin liquid is from 0.05 to 200 poise, preferably from 0.1 to 100 poise, making it easy to form a thin layer of resin liquid with a uniform thickness on the surface of various shapes of steel materials. It is necessary to form and be able to combine with the dispersed filler in a short time.

Furthermore, the curable resin liquid used in this invention is
It is preferable to have a pot life such that when a thin layer of resin liquid is formed by coating or spraying on steel material, it will not harden until the next spraying of the filler, and the pot life is about 10 minutes to 2
It is appropriate to use a curable resin liquid that exhibits a hardening time, especially about 20 minutes to 1 hour.Furthermore, when coated on steel material and mixed with filler and cured, it binds filler (aggregate, etc.). It is preferable that the main component be a curable resin that acts as a coating agent and has the ability to bond with sufficient adhesive force to the surface of the steel material to be coated.

In this invention, as the curable resin liquid, thermosetting resins, room temperature curable resins, etc. used in ordinary resin mortar can be used as long as they have the rotational viscosity described above at the temperature during the coating or spraying operation. All resin liquids can be used as the main component. For example, the main component is a two-component curable resin such as epoxy resin, unsaturated polyester resin, or polyurethane resin, and contains appropriate curing agents, additives, etc. Examples include uncured liquid materials.

The filler used in this invention is preferably one that does not particularly accelerate the curing of the thin layer of the curable resin liquid formed on the surface of the steel material, and It must have such properties, shape, and size that it can be easily sprayed or sprayed onto a thin layer of resin liquid by a known method, and that it can easily penetrate and be incorporated into this thin layer of resin liquid. Aggregates such as finely crushed stone powder, fine sand, silica sand, etc. for cement mortars, which are suitable and have the above-mentioned properties, or are incorporated as reinforcing agents into thermoplastic resins or thermosetting resins. Suitable examples include common inorganic fillers such as short glass fibers, glass powder, glass flakes, calcium carbonate, talc, alumina, various short metal fibers, and metal powders, as well as various inorganic colorants. .

In this invention, the filler is particularly
The angle of repose, which indicates self-flowing property, must be approximately 60° or less as measured by the injection method, or approximately 80° or less as measured by the spatula angle, so that it can easily penetrate into the thin layer of the resin liquid. Therefore, it is preferable.

In addition, the particle size of the filler or the maximum diameter of the cross section of the short fibers is 1/2 or less, especially 1/4 of the thickness of the resin mortar layer (the layer that is finally formed).
The particle size or the maximum diameter of the cross section of short fibers is in the range of approximately 0.001 to 1000 μ, especially 0.01 to 500 μ. It is preferable that the resin liquid be within the range of 100 to 100% in order to allow sufficient penetration of the resin liquid between the fillers, to prevent the formation of voids or bubbles between each resin mortar layer, and to prevent peeling or chipping between each layer. For the same reason as mentioned above, it is preferable that the short fibrous filler has a length of about 1 cm or less, particularly about 0.01 to 5 mm.

The coating method of this invention, for example, coats the surface of steel material with
A predetermined amount of the above-mentioned fluid curable resin liquid is used, and the curable resin liquid is sprayed with air or airless spray at a temperature that does not cause curing of the curable resin liquid (at room temperature or under heating, particularly preferably at a temperature of about 0 to 0). At a temperature of 60°C), the resin liquid is sprayed uniformly on the surface of the steel material, or the resin liquid is applied onto the surface of a coating roll and the roll is pressed against the surface of the steel material. A thin layer of curable resin is formed on the surface of the steel material.

In the coating method of the present invention, it is most suitable from the viewpoint of workability to form a thin layer of the resin liquid on the surface of the steel material by spraying the curable resin liquid. The method of forming a thin layer of resin liquid using this "spray" involves moving the spray nozzle or moving the steel material to be coated (vibration,
It is possible to form a uniform thin layer of resin liquid while rotating or moving the material. Furthermore, depending on the shape of the steel material, it is possible to form a uniform thin layer of resin liquid while moving the material. When coating the steel material, it is possible to perform spraying operations on the surface of the steel material while rotating or inverting the steel material using the longitudinal direction of the material as the axis of rotation, thereby creating a thin layer of resin liquid with a uniform thickness. Therefore, it is suitable for forming a coating layer on a portion of a steel material to be coated, and for improving productivity and workability.

In the above-mentioned method for forming a thin layer of resin liquid using a spray, the curable resin liquid used has a temperature of about 0.5 to 100 poise, particularly about 1 to 50 poise, at the temperature of the spray nozzle outlet during the application or spraying operation. In order to spray uniformly,
Preferably, the thin layer of resin liquid formed on the surface of the steel material satisfies the following inequality in the relationship between the rotational viscosity (η) of the curable resin liquid used and the thickness (d) of the thin layer. In other words, when using a curable resin liquid with a specific viscosity (η), the thin layer of resin liquid must have a thickness determined by the following inequality or less to prevent sagging of the thin layer of resin liquid. To prevent this phenomenon, or to form a thin layer of even and uniform resin liquid, or to prevent the amount of filler from becoming uneven when sprayed on the thin layer of resin liquid, etc. Therefore, it is appropriate.

d≦35/[log η] In the coating method of the present invention, the method for spreading and adhering the filler (aggregate, etc.) onto the thin layer of resin liquid on the surface of the steel material includes, for example, simply ,
A fine filler can be sprayed by dropping it from above a moving or rotating steel material, or the filler can be supplied to a container with a slit placed above the steel material, and the container can be moved or sprayed. A method of dispersing by moving or rotating the container and dropping it in a band shape from a slit in the container onto the steel material;
Examples include a method of dispersing fine fillers together with a fluid such as air in the form of a mist or sandstorm using an air spray or blower.

In the above-mentioned spraying of filler, the amount of filler supplied onto the resin liquid on the surface of the steel material is about 1 to 20 times the volume of filler actually deposited on the thin layer of resin liquid.
In particular, it is appropriate to supply an excess amount of 1.5 to 15 times, and the excess filler that is not retained in the thin layer of resin liquid can be recovered from above the steel material by an appropriate method. Since the filler is substantially free from adhesion of resin liquid, it can be passed through a filter or the like and used again as it is.

In the coating method of the present invention, as described above, fine fillers (such as aggregates) are spread and adhered onto the thin layer of resin liquid on the surface of the steel material. The resin liquid layer and the filler layer are bonded in a layered manner, but over time, the resin liquid layer and the filler layer are bonded together for a relatively short period of time, for example, about 0.1 to 30 minutes.
In particular, over a period of 0.2 to 15 minutes, the filler penetrates into the thin layer of resin liquid, or the resin liquid fills between the fillers without any gaps, and eventually the rotational viscosity of the filler reaches approximately The resin mortar layer has a high viscosity of 500 poise or more, especially 1000 poise or more, or is substantially non-flowing, and is uniform throughout. Therefore, after the spraying of the filler is completed, only for a short period of time for the above-mentioned uniformity, that is, until the curable resin liquid oozes out onto the top surface of the filler layer and covers the surface, the following steps must be carried out. Not performing any operations
This is preferable in order to prevent the inclusion of air bubbles.

In addition, in this invention, the composition ratio of the resin mortar layer described above is such that the volume of the filler is preferably 1 to 10 times the volume of the curable resin liquid, particularly 1.5 to 8 times the volume of the curable resin liquid. .

In addition, in this invention, by making the volume of the blended filler considerably smaller than the amount of the resin liquid, the resin liquid layer that oozes out onto the surface of the filler layer described above has a smooth surface. Since it will be formed,
For such purposes, it is appropriate to reduce the volume of the blended filler to about 1 to 5 times the volume of the resin liquid.

In this invention, the thickness of each resin mortar layer is about 100 to 1000μ, especially about 200 to 800μ, although it varies depending on the thickness of the thin layer of resin liquid. It is suitable for forming a coating layer with a uniform thickness without any scratches or from the viewpoint of workability.

The coating method of the present invention involves forming a thin layer of the above-mentioned curable resin liquid, dispersing (or spraying) the filler,
and the operation of forming the resin mortar layer at least 2 times, especially 3 to 20 times, more preferably 5 to 20 times.
Repeat 15 times until the total thickness is about 0.5~10mm,
In particular, a thick resin mortar layer of about 1 to 6 mm is formed, and finally, the curable resin contained inside this thick resin mortar layer is heated or cured at room temperature to form a resin mortar layer on the surface of the steel material. This forms a cured coating layer.

Examples are shown below.

Example 1 Curable resin epoxy resin (manufactured by Yuka Shell Co., Ltd.,
A room-temperature curing agent consisting of 100 parts by weight of Epicoat 828), 70 parts by weight of a room-temperature curing agent (manufactured by Yuka Ciel Co., Ltd., Epomate B001), and 50 parts by weight of liquid rubber (manufactured by BF Gutdrich Co., Ltd., Hiker ATBM) as an additive. Resin liquid (rotational viscosity at 25℃; 22 poise, 25℃
(pot life: 30 minutes) using a high-viscosity airless coating machine at a back pressure of 100 kg/cm ² and at room temperature.
A thin layer of resin liquid is discharged from a mixing nozzle in the form of a mist onto the outer circumferential surface of a steel pipe (outer diameter 400 mm) that is arranged horizontally and rotates at a rotational speed of 100 rpm with its central axis as the rotation axis. Spray the resin liquid uniformly to a thickness of 30μ to form a thin layer of the resin liquid, and immediately place a container above the steel pipe with a slit approximately 2 mm wide and approximately 30 cm long. Standard sand (aggregate; Toyoura 5
Standard sand was dropped in a strip for about 10 seconds at a supply rate of 10 g/cm ² from the slit of the container, and the rotating steel pipe with a thin layer of the resin liquid was spread. After adhering to the surface, and then leaving it for about 30 seconds, the resin liquid oozes out onto the surface, forming a highly viscous and substantially non-flowing uniform resin mortar layer (1 volume of resin liquid, 4 volumes of filler). After confirming that a thick resin mortar layer has been formed, repeat the same operation as described above 7 times to form a thick resin mortar layer, and then rotate the steel pipe with the thick resin mortar layer formed on it for about 20 minutes. The resin liquid oozed out on the surface of the entire resin mortar layer, forming a smooth surface layer, and the entire resin mortar layer had an extremely high viscosity (the viscosity was about 5000 poise or more) and became virtually non-existent. Since it became fluid, the rotation of the steel pipe was stopped and
Leave it at room temperature for about 48 hours to cure the curable resin liquid in the entire resin mortar layer at room temperature, and create a resin mortar cured coating layer (anticorrosion coating layer) with a thickness of about 2.5 mm.
It was formed on the circumferential surface of the steel pipe.

The steel pipe having the anti-corrosion coating layer thus obtained has an adhesion force of the resin mortar hardened coating layer to the steel pipe of 120 Kg/cm ² , a compressive strength of the hardened coating layer of 620 Kg/cm ² , and a The impact strength of the cured coating layer was 16.0 Kg·m, indicating that the resin mortar cured coating layer had excellent corrosion resistance.

Example 2 100 parts by weight of a styrene solution of unsaturated polyester as a curable resin, 30 parts by weight of liquid rubber (same as in Example 1) as an additive, 1 part by weight of methyl ethyl ketone peroxide as a curing catalyst, and other additives (to accelerate curing) A curable resin liquid (rotational viscosity at 25°C: 13 poise, pot life at 25°C: 35 minutes) consisting of 0.2 parts by weight of cobalt naphthenate was used as an agent).
A resin mortar with a thickness of 2.5 mm was cured by performing the same operation as in Example 1, except that 150 to 350 mesh scaly glass flakes (made by Nippon Glass Fiber Co., Ltd., blown glass flakes) were used as the filler. A coating layer (anticorrosion coating layer) was formed on the circumferential surface of the steel pipe.

The steel pipe having the anti-corrosion coating layer thus obtained has an adhesion force of the resin mortar hardened coating layer to the steel pipe of 40 kg/cm ² , a compressive strength of the hardened coating layer of 500 kg/cm ² , and a The impact strength of the cured coating layer was 12.0 Kg·m, indicating that the resin mortar cured coating had excellent corrosion resistance.

Claims (1)

[Claims] 1. After coating or spraying a fluid curable resin liquid with a viscosity of about 0.05 to 200 poise on the surface of the steel material to form a thin layer of the resin liquid on the surface of the steel material. Immediately, a fine filler is spread or sprayed onto the thin layer of the resin liquid, and the filler and the resin liquid are blended to have a high viscosity of about 500 poise or more or substantially A non-fluid resin mortar layer is formed, and the above-mentioned operations of forming a thin layer of resin liquid, dispersing the filler, and forming a resin mortar layer are repeated to form a thick resin mortar layer, and finally, , A method for coating steel materials with resin mortar, which is characterized by curing the curable resin liquid of this thick resin mortar layer.