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Construction and Building Materials 251 (2020) 118946

Contents lists available at ScienceDirect

Construction and Building Materials


journal homepage: www.elsevier.com/locate/conbuildmat

Fabrication of superhydrophobic concrete used in marine environment


with anti-corrosion and stable mechanical properties
Lulu Lei, Qing Wang ⇑, Shuangshuang Xu, Ning Wang, Xu Zheng
Institute of NanoEngineering, College of Civil Engineering and Architecture, Shandong University of Science and Technology, Shandong 266590, PR China

h i g h l i g h t s

 The prepared superhydrophobic concrete possessed excellent superhydrophobicity.


 The excellent anti-corrosion property of superhydrophobic concrete was displayed.
 Superhydrophobic concrete showed superhydrophobicity after mechanical polishing.

a r t i c l e i n f o a b s t r a c t

Article history: Concrete is one of the wide used building materials in both marine engineering and architecture field. The
Received 30 October 2019 first step of concrete structure deterioration is that corrosive medium invades into concrete. In this paper,
Received in revised form 15 March 2020 a non-toxic fabricating method of superhydrophobic concrete with anti-corrosion and stable mechanical
Accepted 29 March 2020
properties was proposed. Copper mesh and stearic acid were used to obtain the hierarchical micro-nano
structure and low surface energy. The results indicate that the water contact angle and water slide angle
of fabricated superhydrophobic concrete reached 159° and 5°, respectively. In addition, even after 60 s of
Keywords:
mechanical polishing, the water contact angle was still greater than 150°. Moreover, compared with ordi-
Superhydrophobic concrete
Mechanical stability
nary concrete, the anti-corrosion of fabricated superhydrophobic concrete was greatly improved. The fab-
Environment-friendly ricated environment-friendly superhydrophobic concrete with anti-corrosion and stable mechanical
Anti-corrosion properties has important potential application value in the marine engineering.
Marine engineering Ó 2020 Elsevier Ltd. All rights reserved.

1. Introduction in superhydrophobic property. Therefore, both two factors must be


present to prevent water from entering the concrete and causing
Concrete is one of the wide used building materials in architec- damage [13]. To be specific, due to the hierarchical micro-nano
ture field [1,2]. However, ordinary concrete (O-concrete) cannot structure of the S-C surface and modification of low surface energy,
inhibit corrosion well all the time. This is due to that concrete the surface can trap a large amount of air to form an air cushion
immersed in a humid or marine environment for a long time is sus- [14,15]. Water rests on the structured air/solid interface, so the
ceptible to corrosion by seawater corrosive media [3,4]. Moreover, water droplets on the rough surface are easy to roll, which is con-
the steel inside concrete will be inevitably affected by corrosion sistent with the description of the Cassie-Baxter model [16,17]. The
[5]. Serious corrosion will cause damage to the internal compo- superhydrophobic property can prevent harmful substances from
nents of concrete, which may shorten the lifespan of concrete entering the concrete to slow down the corrosion of steel inside
greatly and rise potential security risk [6–8]. Therefore, it has the concrete [18]. Therefore, forming superhydrophobic surface is
become an urgent topic to prevent the internal corrosion of con- an effective strategy to avoid corrosion of reinforced concrete.
crete in the marine environment. At present, many researchers have successfully prepared super-
In recent years, superhydrophobic materials have made great hydrophobic concrete and applied it to prevent internal corrosion
progress in the construction industry due to the excellently of concrete reinforcement. For example, Song et al. [19] success-
hydrophobic, self-cleaning and anti-corrosion properties [9–12]. fully prepared superhydrophobic concrete with excellent anti-
The combination of low surface energy and rough structure results corrosion property by using fluoroalkylsilane as modifier. Wei
et al. [20] reported the preparation of superhydrophobic concrete
with outstanding self-cleaning property by adding silane into ordi-
⇑ Corresponding author. nary concrete. She et al. [16] reported a method of preparing S-
E-mail address: qwang@sdust.edu.cn (Q. Wang).

https://doi.org/10.1016/j.conbuildmat.2020.118946
0950-0618/Ó 2020 Elsevier Ltd. All rights reserved.
2 L. Lei et al. / Construction and Building Materials 251 (2020) 118946

concrete by direct spraying nano-silica gel functionalized with low


surface-energy surfactants. Although the above methods have suc-
cessfully prepared superhydrophobic concrete, non-environment-
friendly modifiers such as fluorine and silane were used. Such toxic
modifiers are not only harmful to human health but also have
potential adverse effects on the environment.
Stearic acid (STA, CH3(CH2)16COOH) is an environment-friendly
practical material which consists of 1-CH3, 16-CH2 and 1–COOH
groups [15,21]. The carboxyl group of the stearic acid can be
grafted to the hydroxyl group in the concrete to reduce surface
energy. It can be used as a modifier from the perspective of envi-
ronment protection [22]. Hence, stearic acid is often used as a
modified material in the preparation of superhydrophobic surface.
For example, Wang et al. [23] used stearic acid as a modifier to pre-
pare superhydrophobic concrete by solution immersion. Charikleia
et al. [24] reported the preparation of hydrophobic powders by
using stearic acid and dry grinding paper sludge ash. Qu et al. Fig. 1. Scheme of preparation process of S-concrete.
[25] reported a ball milling method using low-cost stearic acid to
prepare superhydrophobic ground granulated blast furnace slag.
However, the surface microstructure of superhydrophobic concrete steps, except that copper mesh and mixed solution were not
prepared via above methods is fragile due to the low adhesion added.
between the modified materials and concrete. The superhydropho-
bic surfaces prepared by these methods are likely to be destroyed 2.3. Characterization
and then lose the superhydrophobicity. Therefore, it is necessary to
prepare a superhydrophobic concrete with excellently mechanical The surface morphology of the concrete (S-concrete and O-
property used for anti-corrosion applications. concrete) was explored using scanning electron microscope
In this manuscript, an environment-friendly method to fabri- (SEM, APREO, FEI Co., Ltd. USA) at an accelerating voltage High
cate superhydrophobic concrete with good anti-corrosion and Voltage of 2 kV. The crystal structure and element composition
stable mechanical properties was proposed. The copper mesh of the samples were analyzed by X-ray diffractometer (XRD, Rigaku
(50 lm aperture, 90 lm wire diameter) and STA were used to Ultima IV, Rigaku Co., Ltd., Japan) and Fourier transform infrared
obtain the hierarchical micro-nano structure and decrease the sur- spectrometer (Nicolet 380 FT-IR, Thermo Electron Co., Ltd. USA),
face energy, respectively [15,19]. The effect of different STA con- respectively.
centration on the wettability of superhydrophobic concrete was
investigated. In addition, the mechanical property of superhy- 2.4. Wettability test
drophobic concrete was investigated by plane polishing machine
and the self-cleaning property was evaluated. Moreover, the anti- An optical contact angle measurement instrument (DSA30,
corrosion property of superhydrophobic concrete was explored Kruss Co., Ltd., Germany) was used to measure water contact angle
through electrochemical workstation. The fabricated superhy- (WCA) of sample at room temperature. The home-made experi-
drophobic concrete displays good self-cleaning, anti-corrosion mental device was used to measure water sliding angle (WSA) of
and mechanical properties, which is expected to improve the lifes- S-concrete [26,27].
pan of marine concrete.
2.5. Self-cleaning test

2. Experiments In order to investigate the self-cleaning property of sample, fine


sand with a particle size of less than 250 um was used as contam-
2.1. Materials inant. First, the sample was tilted onto a petri dish. Subsequently,
the samples were coated with a thick layer of fine sand. Finally, a
Portland cement (PO42.5) and fine sand (size < 250 lm) were micropipette was used to clean the surface with 10uL water dro-
purchased from Hangzhou Ouchuang paint Co., Ltd., (Hangzhou, plets [15].
China). STA and anhydrous ethanol were acquired from the Tianjin
Kemiou Chemicals Development Co., Ltd. (Tianjin, China). Copper 2.6. Mechanical property test
mesh was provided by Shanghai Huaxin Metal Mesh factory
(Shanghai, China). The mechanical property of superhydrophobic concrete was
explored using a plane polishing machine with 600 #artificial
2.2. Fabrication of superhydrophobic concrete emery paper (2206 Standard, Deshuo Industrial Co., Ltd., Nanjing).
The no-load speed was 13,000/min and abrade force is 13.8 N. First,
Fig. 1 shows the preparation process of superhydrophobic con- the sample was mechanically polished for 10 s, 30 s and 60 s,
crete. Firstly, 45 mL anhydrous ethanol and 2.1 g STA were put into respectively. And then 10uL of water droplets (the water droplets
a beaker and stirred with a magnetic stirrer for 30 min to form a were dyed blue by methyl blue) were sucked by a micropipette
mixed solution. Then, 300 g portland cement, 300 g fine sand to impact the sample.
and 135 mL water were putted into above mixed solution, and
evenly stirred to form concrete. Finally, fresh concrete was placed 2.7. Anti-corrosion test
in a petri dish with copper mesh prepositioned at the bottom, and
the top of the concrete was covered with a layer of copper mesh. The anti-corrosion property of sample was tested using electro-
After 24 h of curing, the copper mesh was removed to obtain chemical workstation (CHI660E, Shanghai Chenhua instruments
S-concrete. Besides, the fabrication of O-concrete took the same Co., LTD.) in 3.5 wt% NaCl solution. In a standard three-electrode
L. Lei et al. / Construction and Building Materials 251 (2020) 118946 3

system, platinum electrode and saturated calomel electrode were gite needles shown in Fig. 2b) [16]. From the above, it can be
used as counter electrode and reference electrode, respectively. concluded that the transition from O-concrete to S-concrete was
The iron nail with an exposed length of 2 cm was used as working successfully achieved by using the STA and the copper mesh. It
electrode. The potentiodynamic polarization curves were deter- was confirmed that the addition of STA can reduce the surface
mined at a scanning rate of 5 Mv/s from 1 and 0 V/SCE. The elec- energy of concrete, and prevent water from entering the concrete
trochemical impedance spectroscopy (EIS) measurement was [26,30]. All these findings prove that the concrete surface has a
carried out in a frequency range of 0.1 Hz to 100,000 Hz, with stable superhydrophobic structure.
the amplitude of 10 mV. Before testing, all the samples were
soaked in NaCl solution for 24 h to avoid the inaccuracy of the
experimental results during testing [28].

3.1.2. Chemical composition analysis


3. Results and discussion XRD patterns of O-concrete and S-concrete are shown in Fig. 3a.
The main components of S-concrete and O-concrete are the same,
3.1. Morphology and chemical composition namely quartz sand, ettringite, hydrated calcium silicate and cal-
cium hydroxide.
3.1.1. Morphology analysis In order to further investigate the crystal structure and chemi-
The morphologies of S-concrete and O-concrete are displayed in cal composition of the samples, the samples were tested by FT-IR
Fig. 2. Before investigation, all concrete must be sprayed with gold spectra. As shown in Fig. 3b, compared to the O-concrete, the
clusters to ensure the accuracy of the experiment. From a macro wavebands around 2918 cm1 and 2850 cm1 in the S-concrete
perspective, the surfaces of the original samples in Fig. 2b are belong to methyl symmetric and asymmetric stretching vibration
smoother than the surfaces in the Fig. 2a of superhydrophobic peaks of –CH2 and –CH3, respectively (–CH3 and –CH2 comes from
sample. The surface of S-concrete is rougher than O-concrete under STA, which can decrease the surface free energy of concrete). The
dual effects of copper mesh and STA. To be specific, the concrete results indicate that STA had been successfully grafted on concrete,
surface was divided into small squares of hierarchical micro- which has excellent consistency with the report in references
nano structure using copper mesh, which produced a rough struc- [25,32]. The O–H related band is near 1640 cm1 and 3341 cm1
ture. Under the influence of the STA, the hydroxyl groups in the O- [30,31], attributing to the characteristic of Si–OH, indicating that
concrete and the carboxyl groups in the STA were successfully there are hydroxyl functional groups [33] in concrete. In addition,
grafted to form a hydrophobic tail chain. In addition, the hydration the –COOH group on the surface of STA reacts with the –OH group
product calcium hydroxide further reacted with STA to produce in concrete, ensuring that STA can be successfully grafted to the
calcium stearate, which formed a layer of insoluble calcium stea- concrete surface. Thus the S-concrete shows good superhydropho-
rate on the S-concrete surface [23]. An additional calcium stearate bicity. FT-IR spectra confirmed the successful grafting of STA in
fiber structure greatly increased the roughness of the concrete (red concrete, and the results showed that silica in sand was success-
arrows represent calcium carbonate crystals, as shown in Fig. 2b). fully modified by STA. In addition, it was found that no harmful
Stearic acid reacted with the rough solid surface and produced nee- substances containing fluorine existed in the prepared S-concrete
dle bars, which is consistent with previous research [23,29]. through the components investigating of S-concrete. Therefore,
For O-concrete, the roughness was only formed by calcium car- this environment-friendly preparation method is expected to be
bonate crystal and ettringite needle (yellow arrows indicate ettrin- applied in the future.

Fig. 2. Surface morphologies of the S-concrete (a) and O-concrete (b) under different magnification.
4 L. Lei et al. / Construction and Building Materials 251 (2020) 118946

Fig. 4. (a) Different droplets on S-concrete surface and (b) Mechanism diagram of S-
concrete microstructure.

Fig. 3. (a) XRD pattern and (b) FT-IR spectra.

3.2. Wettability

3.2.1. Wettability analysis


The wettability of S-concrete for different droplets (tea, water
dyed blue, milk, coffee) is displayed in Fig. 4a. The results show
that the as-prepared S-concrete also has excellent hydrophobicity
to various droplets. The WCA of the droplets was all up to 155°,
because of the existence of the hierarchical micro-nano structure
formed on S-concrete surface. As shown in Fig. 4b, the structure
of S-concrete consists of hierarchical micro-nano structure and
nano-scale irregular fiber, which increases the surface roughness
of the samples. This type of micro-nano structure makes a stable
air cushion trapped between the droplet and the micro-nano com-
posite structure, which holds up the droplet and prevents the dro-
plet from wetting the surface of the samples [16].

3.2.2. Effects of STA on wettability


Superhydrophobic concrete was fabricated by successfully
grafting STA on the concrete, the WCA and WSA were 159° and
5°, respectively. The successful grafting of hydrophobic alkyl Fig. 5. (a) Mechanism diagram of stearic acid modification and (b) Effect of stearic
groups is critical for the superhydrophobicity of concrete. The acid concentration on wettability.

mechanism of STA decreasing surface energy is shown in Fig. 5a,


the hydroxyl groups (– OH) in the O-concrete and the carboxyl –COOH in STA can react with the –OH groups in nature materials
groups (–COOH) in the STA are successfully grafted and a long of concrete, such as quartz sand, calcium silicate hydrate, calcium
hydrophobic tail chain is formed. In addition, the reactive group hydroxide and ettringite. Meanwhile, the hydration product
L. Lei et al. / Construction and Building Materials 251 (2020) 118946 5

Fig. 6. (a–c) The self-cleaning process of S-concrete and (d) Mechanism diagram of self-cleaning.

Fig. 7. Mechanical property test of S-concrete using mechanical polishing.

calcium hydroxide further reacts with STA to produce calcium It follows that when the addition of STA is less than 0.8 g, the
stearate, as shown in Eq. (1), to bond low surface energy groups hydroxyl groups in concrete cannot be completely grafted with
to the surface and reduce the surface energy [16]. the carboxyl groups in STA. When the addition of STA is more than
0.8 g, the concrete surface may be agglomerated, thereby reducing
Ca(OH)2 + CH3 (CH2 )16 COOH@Ca[OOC(CH2 )16 CH3 ]2 + H2 O ð1Þ
the WCA [25]. Therefore, considering all the conditions, the S-
Therefore, the addition of STA not only consumes calcium stea- concrete prepared with STA content of 0.8 g was selected to
rate, but also produces water, promotes cement hydration and achieve the best WAC.
makes the structure denser [29].
Fig. 5b shows the effect of different concentration of STA on 3.3. Self-cleaning property
WCA and WSA of fabricated concretes. The results indicate that
the WCA had an upward trend with the increase of STA content. The surfaces of marine concretes are easy to be contaminated
When the STA content reached 0.8 g, the WCA reached its maxi- with pollutants. The cumulation of pollutants for a long time will
mum, and then maintained a stable state. While WSA decreased have a negative impact on the performance of concrete [20]. And,
first and then increased slightly. The WSA of S-concrete with a in marine environments, marine structures can be coastal slopes.
STA content of 0.6 g and 0.8 g was around 4° and 5°, respectively. When sea sand is sent to the coastal slopes, the sea sand can be car-
6 L. Lei et al. / Construction and Building Materials 251 (2020) 118946

sion potential indicates better anti-corrosion. Therefore, the anti-


corrosion of S-concrete is better than O-concrete. In addition, it
was found that, after the S-concrete and O-concrete were placed
in 3.5 wt% NaCl solution for one month, the iron nail in O-
concrete (right) had been completely corroded, while the iron nail
in S-concrete (left) were intact. The corrosion of the concrete can
be easily seen from the illustration in Fig. 8. All these findings
prove that S-concrete had excellent anti-corrosion property.

4. Conclusions

A kind of superhydrophobic concrete with environment-


friendly, mechanical stability and anti-corrosion properties was
successfully fabricated by using copper mesh and STA. The results
show that when the STA content was 0.8 g, the WCA and WSA of S-
concrete reached the optimal values, which were 159° and 5°,
respectively. Besides, compared with ordinary concrete, contami-
nants on S-concrete surface can be carried away by water droplets,
Fig. 8. Polarization curves of Supehydrophobic concrete and Ordinary concrete.
which can effectively prevent concrete from being polluted. More-
over, in 3.5 wt% NaCl solution, the function of resisting chloride ion
ried away by the sea water. For example, sea sand contains harmful erosion of the S-concrete was exhibited. Furthermore, the fabri-
chlorine ions. When the sea sand is attached to the surface of coast cated S-concrete still displayed outstanding superhydrophobicity
slop, the steel inside the concrete will be corroded, which will have under high frequency polishing by plane polishing machine. It is
a negative impact on the building [34]. Inspired by the self- expected that this facile and environment-friendly strategy for
cleaning effect of lotus, self-cleaning property of S-concrete was anti-corrosion in concrete will be used in marine environment.
explored by using fine sand as contaminants. As shown in Fig. 6a,
the S-concrete is placed obliquely and covered with a layer of fine Author contributions
sand. A micropipette was used to clean the surface with 10uL
water droplets. As shown in Fig. 6b-c, when the water droplets fall L.L., S.X. N.W. and X. Z. conducted the experiments and data
from the sample surface, the fine sand is carried away and a clear analysis under the advising of Q.W.; L.L. and Q.W. wrote the
path appears. The mechanism of self-cleaning is shown in Fig. 6d, manuscript.
an air layer is existed between the micro-nano structures and
water drops [17,35], which makes the S-concrete have excellent Declaration of Competing Interest
self-cleaning property. The above results indicate that the self-
cleaning ability will facilitate the durable applications of S- The authors declare that they have no known competing finan-
concrete in complex marine environments. cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
3.4. Mechanical property
Acknowledgments
Mechanical stability is a key factor affecting the hydrophobic
property S-concrete. This is because most S-concretes have fragile This work was supported by the Taishan Scholar Project of
micro-nano structures and poor mechanical properties, so the Shandong Province (No. TSHW20130956) and the Natural Science
superhydrophobic performance will be destroyed under the effect Foundation of Shandong Province, China (No. ZR2017MA013).
of external forces. The research on mechanical property of S-
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