JP3907457B2 - Anticorrosion panel - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an anticorrosion panel for protecting a concrete structure.
[0002]
[Prior art]
Among concrete structures, those used under severe environmental conditions, such as sewerage facilities and livestock excreta treatment facilities, are subjected to anticorrosion treatment. As the anti-corrosion method, the painting method is mainly carried out, but in the past results of this coating method, there are problems such as pinholes in the coating film, and corrosion occurs in a short period of about 5 years, There is a situation where repair work must be done again.
[0003]
Therefore, instead of the painting method, a molded plate type anticorrosion coating method (sheet lining) using resin concrete plates such as vinyl ester resin or FRP plates such as glass fiber reinforced unsaturated polyester has begun to attract attention. However, all of these are heavy in weight and have a problem in workability. On the other hand, a product made of a polyolefin-based resin having acid resistance and alkali resistance for a long time and using a sheet having a thickness of about 1 mm for corrosion prevention has been proposed. A polyolefin sheet represented by polyethylene, polypropylene, or the like has a large number of protrusions on the sheet in order to adhere to concrete. However, the thermal expansion coefficient of these sheets is about 10 times larger than that of concrete, and has a problem of long-term stability of concrete structures due to peeling or cracking due to temperature changes in the use environment. Moreover, although the joint part of the polyolefin sheet is processed by heat fusion, defects are likely to occur if the inspection is not sufficient.
[0004]
[Problems to be solved by the invention]
Accordingly, an object of the present invention is to solve the above-mentioned problems and to provide a corrosion-resistant panel that is lightweight, excellent in workability, excellent in adhesion to concrete, and excellent in long-term stability.
[0005]
[Means for Solving the Problems]
In order to achieve this object, the anticorrosion panel of the present invention has the following configuration.
(1) A corrosion panels for protecting the concrete structure, a core material made of a fiber reinforced polyolefin resin, and corrosion resistance resin film are integrated with each of the front surface and the back surface of the core member, wherein An anticorrosion panel comprising: a material having an anchoring effect on a mortar that is integrated with a surface of a corrosion-resistant resin film on a surface corresponding to a concrete side of the anticorrosion panel and is applied to the surface of the concrete structure.
[0006]
(2) The core material has a composition-mass ratio of short glass fiber / polyolefin resin = 30 to 70/70 to 30, a basis weight of 1 to 6 kg / m ² , and a density of 0.4 to 1.2 g. An anticorrosion panel, characterized by being formed of a material that is / cm ³ .
[0007]
(3) The anticorrosion panel characterized in that the material having an anchor effect on the mortar constructed on the surface of the concrete structure is any one of a woven fabric, a knitted fabric, a mesh-like material and a three-dimensional woven fabric having alkali resistance. .
[0008]
The anticorrosion panel comprised as mentioned above is lightweight, is excellent in adhesiveness with a concrete surface by the material which has an anchor effect, and is excellent in long-term stability. Therefore, the anticorrosion panel covering concrete structure which covered the concrete surface using this anticorrosion panel is protected for a long time even in a severe environment.
[0009]
Moreover, it is more preferable that the thickness of the anticorrosion panel is 1 to 9 mm, and the adhesive strength with the concrete measured using a Kenken-type adhesive strength tester is 0.2 N / mm ² or more.
[0010]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described in detail.
The anticorrosion panel of the present invention comprises a core material made of a fiber-reinforced polyolefin resin, a corrosion-resistant resin film integrated on each of the front and back surfaces of the core material, and a corrosion-resistant resin on the surface corresponding to the concrete side of the anticorrosion panel are those integrated in the surface of the film and a material having an anchor effect for construction have been mortar on the surface of the concrete structure, it is intended to provide a coating of the concrete surface of a material having an anchor effect.
[0011]
First, a core material made of polyolefin resin reinforced with fibers will be described. As the fiber for reinforcement, a short fiber material having a high bending elastic modulus such as a short glass fiber and a short carbon fiber can be used. In the case of short glass fibers, those having a fiber diameter of 6 to 20 microns and a fiber length of 6 to 30 mm are effective for ensuring the bending strength / elastic modulus and density of the core material.
[0012]
As the matrix resin, a polyolefin resin is used, and examples thereof include polyethylene, polypropylene, and copolymers thereof.
A method for producing a core material made of these short fibers / resins is described in Japanese Patent No. 2971161. In this document, a so-called wet papermaking method is employed to uniformly mix materials having different specific gravity and shape. For example, a sheet in which a glass short fiber having a fiber diameter of 6 to 20 microns and a fiber length of 6 to 30 mm and a resin having a particle diameter of 20 to 200 mesh is uniformly dispersed in water is prepared, and the sheet is continuously drawn on a mesh belt. After forming the product, dehydration, drying and winding are performed. As a result, a raw material sheet (web) is obtained in which the short fibers and the resin are kept in a homogeneous state. The advantage of this method is that the glass short fiber used can maintain the fiber length in the opened state. And the core material of a panel can be manufactured by applying the hot press method to the obtained raw material sheet. A method other than the wet papermaking method can be used as long as the density of the core material can be adjusted without damaging the short glass fibers.
[0013]
When short glass fibers are used as reinforcing fibers, the blending ratio of short glass fibers and polyolefin resin is in the range of short glass fibers / polyolefin resin = 30 to 70/70 to 30 in terms of mass ratio. It is preferable.
[0014]
Basis weight of the core material is preferably in the range of ^{1000g / m 2 ~6000g / m 2} .
Preferably, the density of the core material is in the range of ^{0.4g / cm 3 ~1.2g / cm 3} . In the case of a raw material sheet obtained by a wet papermaking method, the density of the core material was adjusted by preheating to a semi-molten or molten state at a temperature equal to or higher than the softening temperature of the polyolefin resin using the raw material sheet, and then performing a hot press. Later, it is possible to adjust the clearance in the cooling zone using the bending elastic recovery force (self-restoring force) of the used reinforcing fiber, and then to cool and solidify. If it does in this way, it can be set as desired panel thickness simultaneously. The hot pressing process may be any of a continuous pressing method, a semi-continuous pressing method, and a batch pressing method in which heating and cooling can be performed continuously. However, the semi-continuous / continuous method is preferable from the viewpoint of productivity.
[0015]
Next, the corrosion resistant resin film as a material constituting the anticorrosion layer will be described. The inner surface and ceiling surface of a water tank in a concrete sewage treatment plant are exposed to an acidic solution and atmosphere harmful to concrete. Therefore, as the corrosion-resistant resin film, polyethylene, polypropylene, and copolymer films / sheets thereof excellent in chemical resistance, particularly acid resistance, can be preferably used. The thickness is preferably 0.1 to 1.5 mm.
[0016]
Films and sheets made of fluorine-based resins can also be used as corrosion-resistant resin films. For example, polytetrafluoroethylene (PTFE), fluorinated ethylene propylene copolymer (FEP), tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (PFA), polychlorotrifluoroethylene (PCTFE), ethylene-tetrafluoroethylene copolymer (ETFE) , Polyvinylidene fluoride (PVDF), polyvinyl fluoride (PVF), and the like. Films and sheets made of these fluororesins can be used alone or as a film or sheet laminated and laminated in advance with polyethylene or polypropylene. And an anticorrosion layer can be formed by integrating this film sheet | seat with a core material at the time of the hot press of the above-mentioned core material, or another process.
[0017]
The above-mentioned corrosion-resistant resin film is provided on the front side of the panel-shaped core material in order to impart corrosion resistance in a corrosive environment. In addition, the back side of the panel-shaped core material, that is, the surface on the concrete side is also affected by the alkaline water solution caused by the infiltrated water and concrete, so as to prevent the alkaline aqueous solution from penetrating into the core material, Similarly, a corrosion-resistant resin film is provided. Thereby, the anticorrosion layer which has the tolerance to the alkaline solution resulting from concrete is formed. As such an alkali-resistant material, polyethylene, polypropylene, copolymer films / sheets thereof and the like can be preferably used. The thickness is preferably 0.1 mm to 1.5 mm.
[0018]
When the surface of a concrete structure constructed with mortar is covered with the anticorrosion panel of the present invention, a material having an anchoring effect on the mortar is provided on one side of the panel, that is, the surface corresponding to the concrete side.
[0019]
As the material having the anchor effect, a fiber material having alkali resistance can be suitably used. The basis weight is suitably in the range of 50 to 500 g / m ² . As the fiber material, a woven fabric, a knitted fabric, a mesh-shaped material, a three-dimensional woven material, or the like can be used. Examples of the fiber material include vinylon, nylon 6, nylon 66, aromatic nylon, polyolefin fiber material, and the like.
[0020]
In the method of manufacturing the anticorrosion panel described above, the raw material sheet (web), the anticorrosion resin film constituting the anticorrosion layer, and the anticorrosion resin film constituting the other surface (back surface) of the core material are laminated and hot pressed. Therefore, the method of simultaneously forming the core material and integrating with the film is most economical and preferable. However, the formation of the core material and the integration with the film can be performed for each process. In addition, the raw material which has an anchor effect with mortar is provided in the corrosion-resistant resin film which comprises the back surface side of a core material.
[0021]
The thickness of the panel thus obtained is preferably in the range of 1 to 9 mm. When the thickness of the panel is less than 1 mm, the thermal dimensional stability effect of the fiber-reinforced core material, that is, the effect of suppressing the thermal expansion coefficient is not sufficient, and the thermal expansion coefficient of the panel becomes high. On the other hand, when the thickness of the panel exceeds 9 mm, the weight of the panel increases, and the workability when joining the panel to the mortar constructed on the surface of the concrete structure is deteriorated.
[0022]
Next, the concrete surface covering work using the above-described anticorrosion panel will be described.
The target of construction includes new construction and repair of existing equipment. Hereinafter, the work procedure will be described by taking the repair of existing equipment as an example, but the present invention is not limited to this method.
(1) Removal of corrosion / deterioration part: The concrete deterioration part is removed by high-pressure water washing or chipping.
(2) Repair of concrete: After cleaning the deteriorated part, repair the defective surface by spraying or plastering using non-shrink mortar or polymer cement mortar.
(3) Installation of the anticorrosion panel: Before the mortar is solidified, the anticorrosion panel is attached to a predetermined position based on an allocation diagram planned in advance and fixed by an anchor action.
(4) Joint portion treatment: A gap between the panels (joint portion) is filled with a sealing material having anticorrosion performance.
[0023]
Thus, by applying the above-mentioned anticorrosion panel and its construction method to the surface of a concrete frame that may be corroded or corroded, a concrete structure having excellent anticorrosion properties can be provided. In the concrete structure covered with this anticorrosion panel, the adhesion force measured with a Kenken type adhesion tester has a performance of 0.2 N / mm ² or more as the adhesion force between the anticorrosion panel and the concrete. It is preferable. Facilities / locations in corrosive environments include water tanks in sewer facilities where hydrogen sulfide may be generated, pools exposed to water in which chlorine or ozone is dissolved, rivers or waterways containing wastewater from sewage or mines, beaches, etc. Use in corrosive gas, acid rain and sulfur-rich environments such as districts and hot spring areas, storage tanks for industrial cleaning water and waste liquid, livestock treatment plants, etc.
[0024]
Moreover, said anti-corrosion panel can obtain a thing with favorable adhesiveness with a concrete surface with the raw material which has the anchor effect with respect to the mortar constructed in the surface of the concrete structure.
[0025]
【Example】
Hereinafter, the present invention will be specifically described by way of examples. However, the present invention is not limited to these examples.
[0026]
First, the anticorrosion panel will be described.
Each material which comprises a corrosion prevention panel was comprised as follows. The panel size was 0.5 m wide, 1 m long, and 6 mm thick.
[0027]
As a material of the core material, a short glass fiber having a diameter of 13 μm and a length of 13 mm and a polypropylene powder having a particle size of 50 to 100 mesh are used, and a mixing ratio of the short glass fiber and the polypropylene powder is 50/50 by mass ratio. A raw material sheet (web) having a basis weight of 2800 g / m ² obtained by a wet papermaking method was used.
[0028]
Next, as a corrosion-resistant resin film, a polypropylene film (sheet) having a thickness of 1 mm was used on both surfaces of the core material. Further, as a material having an anchoring effect on the mortar constructed on the surface of the concrete structure, a vinylon plain weave cloth having a basis weight of 200 g / m ² was used. In addition, in order to make it adhere | attach with a corrosion-resistant resin film, the polyolefin-type hot-melt resin of the amount of 50 g / m < ² > was melt-laminated beforehand on the single side | surface of this plain-woven cloth.
[0029]
A corrosion-resistant resin film was laminated on both sides of the raw material sheet (web), and integral molding was performed by a continuous press method using a double belt press machine. As for the conditions, after preheating, continuous hot pressing is performed at 200 ° C. in the heating zone, and clearance adjustment between the belts is subsequently performed in the cooling zone, followed by cooling and solidification, and the thickness is 6 mm and the density is 0.7 g / cm. ³ panels were obtained.
[0030]
On the one side (upper surface) of this panel, the above-mentioned plain woven cloth was laminated with the hot-melt resin laminated surface on the panel side, and joined with a pair of heating rollers to prepare a panel.
[0031]
The obtained panel was cut into a width of 0.5 m and a length of 1 m. As the treatment of the end face (small edge), the above-mentioned polypropylene film (sheet) cut to a width of 6 mm was attached at a temperature of 200 ° C. using a polyolefin-based hot melt resin, and the anticorrosion panel was prepared for repair construction.
[0032]
In addition, the existing facilities were repaired using the above anticorrosion panels.
First, the corroded concrete part was removed with 150 MPa ultrahigh pressure water, and polymer cement mortar was sprayed to repair the defect part. An anticorrosion panel was affixed and fixed to the concrete surface finished with this mortar so that the material having an anchor effect would come into contact with the mortar surface. Thereafter, the joint was sealed with silicone resin to complete the anticorrosion panel-coated concrete structure.
[0033]
The obtained anticorrosion panel-coated concrete structure was excellent in corrosion resistance and thermal dimensional stability, and even when exposed to a corrosive environment, it was excellent in stability over a long period of time.
[0034]
Separately, in order to conduct an adhesion test, a 30 cm square anticorrosion panel was adhered and fixed to the mortar finish surface similar to the above, and a Kenken adhesive strength tester was used to determine the adhesive force between the mortar finish surface and the anticorrosion panel after one week. When used and measured, the adhesive strength was 6 N / mm ² .
[0035]
【The invention's effect】
As described above, according to the present invention, since the core material of the panel is formed of a polyolefin-based resin reinforced with fiber, the panel can be configured to be light and have a low waist, and therefore, the operation of joining the concrete frame is easy. Excellent safety. In addition to the above properties, the anticorrosion panel is formed by integrally forming a material having an anchoring effect on the surface of the concrete structure on the surface of the corrosion-resistant resin film corresponding to the concrete side. The anti-corrosion panel-coated concrete whose surface is covered with this anti-corrosion panel is free from peeling and cracking due to temperature changes in the usage environment, and is stable over long periods under severe environmental conditions. It will have.

Claims (5)

An anticorrosion panel for protecting a concrete structure, comprising a core material made of a fiber-reinforced polyolefin resin, an anticorrosion resin film integrated on each of the front and back surfaces of the core material, and the anticorrosion panel anticorrosion panel; and a material having an anchor effect is integrated to the surface of the corrosion-resistant resin film surface corresponding to the concrete side for the construction have been mortar on the surface of the concrete structure. The core material has a composition-mass ratio of short glass fiber / polyolefin resin = 30 to 70/70 to 30, a basis weight of 1000 to 6000 g / m ² , and a density of 0.4 to 1.2 g / cm ^3. The anticorrosion panel according to claim 1, wherein the anticorrosion panel is formed of a material which is   The material having an anchoring effect on mortar applied on the surface of a concrete structure is any one of a woven fabric, a knitted fabric, a mesh-like material, or a three-dimensional woven fabric having alkali resistance. Anticorrosion panel as described.   The anticorrosion panel covering concrete structure characterized by the surface of concrete being covered with the anticorrosion panel of any one of Claims 1-3. The thickness of the anticorrosion panel is 1 to 9 mm, and the adhesion between the anticorrosion panel and the concrete measured using a Kenken-type adhesive strength tester is 0.2 N / mm ² or more. The anticorrosion panel covering concrete structure of description.