A Research And Development Of New Anti-corrosive Water-based Coating For Steel Structure Construction

Steel structure engineering is a structure of steel which gives priority to steel production and it is one of the main Building structure type.The annual production of steel is more than one billion tons, it is estimated that the steel due to corrosion is approximately equivalent to30%of the annual production, of which about1/3can not be recycled and permanent lossed, bringing about thousand billions dollars economic losses. In addition to a lot of steel in the Outdoor is subjected to atmospheric corrosion,the metal equipments surround the coast and in the chemical production are particularly seriously eruded by acid, alkali, salt and other corrosive media.It is not only required to put a lot of money and manpower to carry out year-round anti-corrosion maintenance, but also exists a potential security risks.Proceed to solve the corrosion problem is not realistic from the steel structure itself in terms of the stock of science and technology, the cost of typical stainless steel is very high, the price is several times to more than10times over the specifications of ordinary quality steel, and it has limited service life. Other Corrosion resistant materials have a serious problems such as limited use life and poor economy, while the use of paint coating to prevent metal corrosion is the most widely used and most effective, economic means. And because of the volatile organic compounds(VOC) in the solvent-based coatings is polluted to the atmosphere. Therefore, it is necessary to develop long life, low cost, safe and non-toxic, energy saving and environmental protection, easy construction, applicable to a wide range of new water-based Steel anti-corrosion coatings. Moreover, the study is conducive to the development of the green economy and circular economy, in line with the requirements of sustainable development. This paper fully integrated market, focused on the differences for different user groups on the prices of anti-corrosion coatings, construction, service life, developed three new water-based steel anti-corrosion coatings to meet the needs of different user groups.Preparation of the target product is divided into four steps:Step1,screep and prepare for anti-rust paint, through layers of screening a number of anti-rust paint, considering the service life, non-toxic, energy conservation and environmental protection, convenient construction, applicable range and economic factors; through the experimental contrast, final with compound iron powder and modified titanium zinc phosphate blends with the scheme as a product anti-rust pigment; Step2,screen and identify the base material which the target product needs, taking several factors into account, final with PF-1high-grade water-based fluorocarbon emulsion, PE-2150B water-based acrylic emulsion, BH-620water-based epoxy resin emulsion as the base material; Step3,design process, refer to the conventional coating process,combine with new material properties and the requirements of the target product to design product process; Step4,confirm the target product formula, this step is the most complex one, it needs to improve product corrosion resistance as far as possible, but it also needs to take into account the dozens basic performances of the product, and control the cost of production.When exploring the best formula of the target product, this paper use the SPSS15.0Software to design orthogonal experiment schedule and entered orthogonal experiment results into the adjusted orthogonal experimental schedule, analysis and get the orthogonal experimental variance table and single factor tables, thus effectively arrange the experiments and statistic scientifically in order to optimize the formulation design.In this paper, we use KH-120Precision salt water spray test machine, QHQ coating pencil scratch hardness tester, QFZ film adhesion tester, JTX-Ⅱ architectural coatings abrasion instrument and other equipment and carry on3major categories of more than20kinds of the indicators of performance testing on the paint sample, Including the dozen detection of paint and varnish which has conventional requirements, particularly the six kinds detection for corrosion resistance. Each test is in strict accordance with the national standard requirements and carry on a number of parallel and contrast tests to ensure the accuracy of the test and normative.This paper analysis and evaluate the test results of coating performance,discussed the impact of the resin, antirust pigment, the main raw material on the conventional coating performance, do a more detailed analysis focusing on the film impact resistance, hardness, drying time, covering power four important indicators and describe the mechanism of producing the results.And determine the process conditions of paint preparation, as well as the ratio of talc, precipitated barium sulfate these fillers and additives in coatings, further limits the range of the ratio of base and anti-rust pigment in paint.In this paper, the corrosion resistance of the coating formulation of the optimization of design and corresponding results are analyzed and discussed. Discuss respectively in terms of the choice of anti-rust paint and the base material, the orthogonal experiments and analysis of variance, and three anti-corrosion coatings, corrosion resistance research. The impact of salt spray resistance from the amount of the compound of iron titanium powder, modified zinc phosphate amount of salt spray resistance, emulsion, the impact of salt spray resistance, coating of pH on the impact of salt spray resistance. PVC on five aspects of the impact of salt spray resistance were conducted in-depth discussion of three new water-based anti-corrosion coatings, anti-corrosion performance. The compound of iron titanium powder on the impact of salt spray resistance,modified zinc phosphate amount on the impact of salt spray resistance, the amount of the emulsion on the impact of salt spray resistance, coating of pH on the impact of salt spray resistance. PVC on five aspects of the impact of salt spray resistance were conducted in-depth discussion of anti-corrosion performance of the three new water-based anti-corrosion coatings, anti-corrosion performance. Thus determine the optimal ratio system of Water-based acrylic anti-corrosion coatings is that acrylic emulsion25%wt,25%by weight of the composite iron titanium powder,5%by weight of the modified zinc phosphate, pH value of8, of PVC in30%to40%, its coatings salt spray resistance is up to408hours; The optimal ratio of anti-corrosion coating water-based fluorocarbon coating system is that fluorocarbon emulsion25%wt,25%by weight of the composite iron titanium powder,5%by weight of the modified zinc phosphate, pH value of8, of PVC in25%to40%, its coatings salt spray resistance is up to864hours; The optimal ratio of water-based epoxy anticorrosive paint coating system is that Fluorocarbon emulsion25%wt,25%by weight of the composite iron titanium powder,5%by weight of the modified zinc phosphate, pH value of7, PVC,25%to35%, its paint resistant to salt spray is up to1296hours.