Abrasion-resistant coating material and method of using the same

Abstract

A coating material, including a bottom layer, a middle layer and a surface layer. The bottom layer is an epoxy mortar having a thickness of between 1 and 3 mm, the middle layer is an epoxy resin adhesive having a thickness of between 0.1 and 0.5 mm, and the surface layer is a nanomaterial-modified polyaspartic having a thickness of between 0.3 and 0.5 mm. The epoxy resin adhesive has a viscosity of between 50 and 200 mPa.Math.s.

Claims

1. A coating material, consisting of a bottom layer, a middle layer, and a surface layer; wherein: the bottom layer consists of an epoxy mortar having a thickness of critically between 1 and 3 mm; the middle layer consists of an epoxy resin adhesive having a thickness of critically between 0.1 and 0.5 mm; the surface layer is a polyaspartic comprising a nanomaterial grafted to an isocyanate and having a thickness of critically between 0.3 and 0.5 mm; the epoxy mortar has a viscosity of between 20,000 and 50,000 mPa.Math.s; and the epoxy resin adhesive has a viscosity of critically between 50 and 200 mPa.Math.s; the epoxy resin adhesive consists of a first component and a second component, the first component consists of between 50 and 60 parts by weight of bisphenol-A epoxy resin, between 20 and 30 parts by weight of furfural, and between 20 and 30 parts by weight of acetone; the second component is a diamine or polyamine curing agent; and a weight ratio of the first component to the second component is between 4:1 and 6:1.

2. The material of claim 1, wherein a surface drying time of the epoxy mortar is between 1 and 5 hours, and a curing time thereof is between 5 and 20 hours.

3. The material of claim 1, wherein a surface drying time of the epoxy resin adhesive is between 1 and 2 hours, and a curing time thereof is between 0.5 and 2 hours.

4. The material of claim 1, wherein the polyaspartic comprises a first component and a second component; the first component is obtained by polymer grafting between 1 and 6 parts by weight of an inorganic nanomaterial to between 50 and 60 parts by weight of isocyanate; and the second component is obtained by adding between 0 and 3 parts by weight of iron black, between 0 and 5 parts by weight of titanium dioxide, and between 0 and 1 part by weight of a dispersant to between 5 and 15 parts by weight of a reactive diluent, stirring and collecting a filtrate, and adding to the filtrate between 20 and 40 parts by weight of polyaspartate.

5. The material of claim 4, wherein the inorganic nanomaterial is nano SiO.sub.2.

6. The material of claim 4, wherein the reactive diluent is propylene carbonate, toluene, xylene, or cyclohexane.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a physical appearance of a concrete sample containing no abrasion resistant coating layer after a scouring test in accordance with one embodiment of the invention;

(2) FIG. 2 is a physical appearance of a concrete sample containing an abrasion resistant coating layer after a scouring test in accordance with one embodiment of the invention;

(3) FIG. 3 is a physical appearance of a dam containing an abrasion resistant coating layer in accordance with one embodiment of the invention; and

(4) FIG. 4 is a physical appearance of a dam containing an abrasion resistant coating layer after one year of use in accordance with one embodiment of the invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS

(5) For further illustrating the invention, experiments detailing a coating material and use thereof are described hereinbelow combined with the drawings. It should be noted that the following examples are intended to describe and not to limit the invention.

(6) As used herein, the term polyaspartic refers to an aliphatic polyurea derived from the reaction product of an aliphatic polyisocyanate and a polyaspartic ester.

Example 1

(7) Preparation of a Bottom Layer of Coating Material

(8) The bottom layer is an epoxy mortar having an initial viscosity of 20,000 mPa.Math.s, a surface drying time of 5 hours, and a curing time of 20 hours.

(9) Preparation of a Middle Layer of Coating Material

(10) The middle layer is an epoxy resin adhesive comprising a first component and a second component with a weight ratio thereof being 4:1. The first component is a modified bisphenol-A epoxy resin comprising 50 parts by weight of bisphenol-A epoxy resin, 25 parts by weight of furfural, and 25 parts by weight of acetone; the second component is a diamine curing agent, that is, m-phenylenediamine. The epoxy resin adhesive has a viscosity of 200 mPa.Math.s, a surface drying time of 2 hours, and a curing time of 2 hours.

(11) Preparation of a Surface Layer of Coating Material

(12) The surface layer is nanomaterial-modified polyaspartic comprising a first component and a second component. In preparation of the first component, 2 parts by weight of nano SiO.sub.2 are mixed with 98 parts by weight of isocyanate at a pressure of 2 megapascal for 4 hours. The second component is obtained by adding 1.2 parts by weight of iron black, 0.3 part by weight of a dispersant to 10 parts by weight of a reactive diluent, that is, xylene, stirring and collecting a filtrate, and adding to the filtrate 80 parts by weight of polyaspartate.

(13) The stirring is carried out using a low speed machine to prevent bubbling.

(14) Coating Method

(15) The floating ash on the surface of a concrete sample is removed, and 1 mm of the bottom layer is coated on the surface. After the bottom layer is completely cured, 0.5 mm of the middle layer is coated on the surface of the bottom layer. Prior to the surface drying of the middle layer, coat the surface layer thrice on the surface of the middle surface until the thickness reaches 0.5 mm. Low ambient temperature increases the viscosity of the epoxy mortar and reduces the fluidity, and the epoxy mortar can first be heated in a 40-50 C. water bath to reach a low viscosity and then coated. After the surface layer is completely cured, a concrete sample 1 containing an abrasion resistant coating layer is obtained.

(16) Scouring tests are carried out respectively for 72 hours to the concrete sample 1 containing an abrasion resistant coating layer and a concrete sample containing no abrasion resistant coating layer using an underwater steel ball method. The results are shown in FIGS. 1 and 2. The concrete sample containing no abrasion resistant coating layer is seriously destroyed, with a mass loss of 8.5%. The concrete sample 1 containing an abrasion resistant coating layer basically keeps intact, with a mass loss of less than 2%.

(17) The surface of a dam concrete is cleaned using a hydraulic giant, and 2 mm of the bottom layer is coated on the dam surface after drying. After the bottom layer is completely cured, 0.4 mm of the middle layer is coated on the surface of the bottom layer. Prior to the surface drying of the middle layer, coat the surface layer twice on the surface of the middle surface until the thickness reaches 0.4 mm. After the surface layer is completely cured, a concrete dam containing an abrasion resistant coating layer is obtained. One year later, the results are shown in FIGS. 3 and 4. Prior to coating the coating material, the surface of the concrete dam is seriously scoured and destroyed. One year later after coating the material, the physical appearance of the dam basically keeps intact, which shows the coating material can effectively protect the concrete dam from abrasion.

Example 2

(18) Preparation of a Bottom Layer of Coating Material

(19) The bottom layer is an epoxy mortar having an initial viscosity of 50,000 mPa.Math.s, a surface drying time of one hour, and a curing time of 5 hours.

(20) Preparation of a Middle Layer of Coating Material

(21) The middle layer is an epoxy resin adhesive comprising a first component and a second component with a weight ratio thereof being 5:1. The first component is a modified bisphenol-A epoxy resin comprising 60 parts by weight of bisphenol-A epoxy resin, 20 parts by weight of furfural, and 30 parts by weight of acetone; the second component is a polyamine curing agent, that is, triethylamine. The epoxy resin adhesive has a viscosity of 100 mPa.Math.s, a surface drying time of 1.5 hours, and a curing time of one hour.

(22) Preparation of a Surface Layer of Coating Material

(23) The surface layer is nanomaterial-modified polyaspartic comprising a first component and a second component. In preparation of the first component, 10 parts by weight of nano SiO.sub.2 are mixed with 90 parts by weight of isocyanate at a pressure of 3 megapascal for one hour.

(24) The second component is obtained by adding 3 parts by weight of titanium dioxide to 5 parts by weight of a reactive diluent, that is, cyclohexane, stirring and collecting a filtrate, and adding to the filtrate 70 parts by weight of polyaspartate.

(25) The stirring is carried out using a low speed machine to prevent bubbling.

(26) Coating Method

(27) The floating ash on the surface of a concrete sample is removed, and 2 mm of the bottom layer is coated on the surface. After the bottom layer is completely cured, 0.4 mm of the middle layer is coated on the surface of the bottom layer. Prior to the surface drying of the middle layer, coat the surface layer twice on the surface of the middle surface until the thickness reaches 0.4 mm. Low ambient temperature increases the viscosity of the epoxy mortar and reduces the fluidity, and the epoxy mortar can first be heated in a 40-50 C. water bath to reach a low viscosity and then coated. After the surface layer is completely cured, a concrete sample 2 containing an abrasion resistant coating layer is obtained.

Example 3

(28) Preparation of a Bottom Layer of Coating Material

(29) The bottom layer is an epoxy mortar having an initial viscosity of 30,000 mPa.Math.s, a surface drying time of 3 hours, and a curing time of 15 hours.

(30) Preparation of a Middle Layer of Coating Material

(31) The middle layer is an epoxy resin adhesive comprising a first component and a second component with a weight ratio thereof being 6:1. The first component is a modified bisphenol-A epoxy resin comprising 55 parts by weight of bisphenol-A epoxy resin, 30 parts by weight of furfural, and 20 parts by weight of acetone; the second component is a diamine curing agent, that is, hexanediamine. The epoxy resin adhesive has a viscosity of 50 mPa.Math.s, a surface drying time of one hour, and a curing time of 0.5 hour.

(32) Preparation of a Surface Layer of Coating Material

(33) The surface layer is nanomaterial-modified polyaspartic comprising a first component and a second component. In preparation of the first component, 5 parts by weight of nano SiO.sub.2 are mixed with 95 parts by weight of isocyanate at a pressure of 2 megapascal for 2 hours. The second component is obtained by adding 1 part by weight of iron black, 1 part by weight of titanium dioxide, and 0.1 part by weight of a dispersant to 8 parts by weight of a reactive diluent, that is, toluene, stirring and collecting a filtrate, and adding to the filtrate 75 parts by weight of polyaspartate.

(34) The stirring is carried out using a low speed machine to prevent bubbling.

(35) Coating Method

(36) The floating ash on the surface of a concrete sample is removed, and 3 mm of the bottom layer is coated on the surface. After the bottom layer is completely cured, 0.1 mm of the middle layer is coated on the surface of the bottom layer. Prior to the surface drying of the middle layer, coat the surface layer once on the surface of the middle surface until the thickness reaches 0.3 mm. Low ambient temperature increases the viscosity of the epoxy mortar and reduces the fluidity, and the epoxy mortar can first be heated in a 40-50 C. water bath to reach a low viscosity and then coated. After the surface layer is completely cured, a concrete sample 3 containing an abrasion resistant coating layer is obtained.

Example 4

(37) Preparation of a Bottom Layer of Coating Material

(38) The bottom layer is an epoxy mortar having an initial viscosity of 40,000 mPa.Math.s, a surface drying time of 3 hours, and a curing time of 18 hours.

(39) Preparation of a Middle Layer of Coating Material

(40) The middle layer is an epoxy resin adhesive comprising a first component and a second component with a weight ratio thereof being 5:1. The first component is a modified bisphenol-A epoxy resin comprising 60 parts by weight of bisphenol-A epoxy resin, 20 parts by weight of furfural, and 30 parts by weight of acetone; the second component is a polyamine curing agent, that is, triethylamine. The epoxy resin adhesive has a viscosity of 100 mPa.Math.s, a surface drying time of 1.5 hours, and a curing time of one hour.

(41) Preparation of a Surface Layer of Coating Material

(42) The surface layer is nanomaterial-modified polyaspartic comprising a first component and a second component. In preparation of the first component, 6 parts by weight of nano SiO.sub.2 are mixed with 60 parts by weight of isocyanate at a pressure of 2 megapascal for 3 hours. The second component is obtained by adding 5 parts by weight of titanium dioxide and one part by weight of a dispersant to 10 parts by weight of a reactive diluent, that is, propylene carbonate, stirring and collecting a filtrate, and adding to the filtrate 30 parts by weight of polyaspartate.

(43) The stirring is carried out using a low speed machine to prevent bubbling.

(44) Coating Method

(45) The floating ash on the surface of a concrete sample is removed, and 2 mm of the bottom layer is coated on the surface. After the bottom layer is completely cured, 0.4 mm of the middle layer is coated on the surface of the bottom layer. Prior to the surface drying of the middle layer, coat the surface layer twice on the surface of the middle surface until the thickness reaches 0.4 mm. Low ambient temperature increases the viscosity of the epoxy mortar and reduces the fluidity, and the epoxy mortar can first be heated in a 40-50 C. water bath to reach a low viscosity and then coated. After the surface layer is completely cured, a concrete sample 4 containing an abrasion resistant coating layer is obtained.

Example 5

(46) Preparation of a Bottom Layer of Coating Material

(47) The bottom layer is an epoxy mortar having an initial viscosity of 40,000 mPa.Math.s, a surface drying time of 3 hours, and a curing time of 18 hours.

(48) Preparation of a Middle Layer of Coating Material

(49) The middle layer is an epoxy resin adhesive comprising a first component and a second component with a weight ratio thereof being 5:1. The first component is a modified bisphenol-A epoxy resin comprising 60 parts by weight of bisphenol-A epoxy resin, 20 parts by weight of furfural, and 30 parts by weight of acetone; the second component is a polyamine curing agent, that is, triethylamine. The epoxy resin adhesive has a viscosity of 100 mPa.Math.s, a surface drying time of 1.5 hours, and a curing time of one hour.

(50) Preparation of a Surface Layer of Coating Material

(51) The surface layer is nanomaterial-modified polyaspartic comprising a first component and a second component. In preparation of the first component, 3 parts by weight of nano SiO.sub.2 are mixed with 50 parts by weight of isocyanate at a pressure of 2 megapascal for 3 hours. The second component is obtained by adding 3 parts by weight of iron black to 5 parts by weight of a reactive diluent, that is, toluene, stirring and collecting a filtrate, and adding to the filtrate 20 parts by weight of polyaspartate.

(52) The stirring is carried out using a low speed machine to prevent bubbling.

(53) Coating Method

(54) The floating ash on the surface of a concrete sample is removed, and 2 mm of the bottom layer is coated on the surface. After the bottom layer is completely cured, 0.4 mm of the middle layer is coated on the surface of the bottom layer. Prior to the surface drying of the middle layer, coat the surface layer twice on the surface of the middle surface until the thickness reaches 0.4 mm. Low ambient temperature increases the viscosity of the epoxy mortar and reduces the fluidity, and the epoxy mortar can first be heated in a 40-50 C. water bath to reach a low viscosity and then coated. After the surface layer is completely cured, a concrete sample 5 containing an abrasion resistant coating layer is obtained.

Example 6

(55) Preparation of a Bottom Layer of Coating Material

(56) The bottom layer is an epoxy mortar having an initial viscosity of 40,000 mPa.Math.s, a surface drying time of 3 hours, and a curing time of 18 hours.

(57) Preparation of a Middle Layer of Coating Material

(58) The middle layer is an epoxy resin adhesive comprising a first component and a second component with a weight ratio thereof being 5:1. The first component is a modified bisphenol-A epoxy resin comprising 60 parts by weight of bisphenol-A epoxy resin, 20 parts by weight of furfural, and 30 parts by weight of acetone; the second component is a polyamine curing agent, that is, triethylamine. The epoxy resin adhesive has a viscosity of 100 mPa.Math.s, a surface drying time of 1.5 hours, and a curing time of one hour.

(59) Preparation of a Surface Layer of Coating Material

(60) The surface layer is nanomaterial-modified polyaspartic comprising a first component and a second component. In preparation of the first component, 1 part by weight of nano SiO.sub.2 are mixed with 55 parts by weight of isocyanate at a pressure of 2 megapascal for 3 hours.

(61) The second component is obtained by adding one part by weight of iron black, one part by weight of titanium dioxide, and 0.5 part by weight of a dispersant to 15 parts by weight of a reactive diluent, that is, toluene, stirring and collecting a filtrate, and adding to the filtrate 40 parts by weight of polyaspartate.

(62) The stirring is carried out using a low speed machine to prevent bubbling.

(63) Coating Method

(64) The floating ash on the surface of a concrete sample is removed, and 2 mm of the bottom layer is coated on the surface. After the bottom layer is completely cured, 0.4 mm of the middle layer is coated on the surface of the bottom layer. Prior to the surface drying of the middle layer, coat the surface layer twice on the surface of the middle surface until the thickness reaches 0.4 mm. Low ambient temperature increases the viscosity of the epoxy mortar and reduces the fluidity, and the epoxy mortar can first be heated in a 40-50 C. water bath to reach a low viscosity and then coated. After the surface layer is completely cured, a concrete sample 6 containing an abrasion resistant coating layer is obtained.

(65) While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects, and therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention.