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About steel bridge corrosion protection by spraying zinc and aluminum

Key Word: Nickel-based highly weather-resistant steel material, zinc / aluminum spraying, flying salt content, LCC
Affiliation name: Shimane Prefecture

Matsue Prefectural Land Development Office

Presenter: Toru Endo, Planning Member

1.First of all Kamoshima Ohashi (hereinafter referred to as "Honbashi") is a first-class river on the main line.

1.1. Summary of announcement It is a bridge that crosses the Takatsu River and is a large structure even in the main line.

Prevention in the construction of Kamoshima Ohashi on the general prefectural road Kujo Inter Line In addition, it became a critical path for the start of service.

Initially, the food specifications were nickel-based high weathering steel. Toko Therefore, it was a bridge that could not be delayed in completion.

In the imminent situation of the superstructure order preparation stage Overview of Kamoshima Ohashi

It seems that it exceeds the anticorrosion performance of Kell-based high weathering steel. Type: Steel 6-span continuous minority plate girder bridge (PC floor slab)

High flying salt content was reported. Extension: L = 395m

In this presentation, based on the limited time and observation data, Steel weight: W = 1,439t

Judging the suitability of Kell-based high weathering steel, LCC instead Maintenance period: 2003-2007

We report an example of using excellent zinc / aluminum spraying. 2. Judgment of application of nickel-based high weathering steel

The Kamoshima Ohashi is being considered for the old paint system. 2.1. Characteristics of nickel-based high weathering steel

1.2. Overview of Hisagi Inter Line Nickel-based high weathering steel is toned with nickel, etc.

The Kujo Inter Line (hereinafter referred to as the "main line") is a high-speed transportation system. A weathering steel with improved anticorrosion performance. Its anticorrosion performance

Land transportation for the purpose of forming a network and eliminating traffic congestion in the city Flying salt content 0.4-0.6mdd (mg / d (dm2 = 10cm2) / day: Me

"Masuda Road" maintained by the Ministry and "Nakayoshi" maintained by Masuda City F Recommended value) (normal weathering steel is about 0.05mdd)

The project started in 2001 in collaboration with "Takujo Line". ancestor It is said, but it depends on the temperature, humidity, terrain, etc.

Then, in March 2007, it was partially put into service and is now in Heisei. It is said that it will be done, and there is no clear standard at this time

We are proceeding with the business with the aim of opening the entire line around 2009. (figure- Is the actual situation.

1) At the main bridge, the flying salt of the Shimane Prefecture Road Business Design Guidelines

1.3. Overview of Kamoshima Ohashi 0.4mdd (0.3-0.4mdd: see Fig. 2) or more from the quantity distribution map

Kamoshima Ohashi

Fig. 1 Outline of Kushiro Inter Line

 Adoption of nickel-based high weathering steel, considering the period

It was a situation where it was necessary to immediately judge whether or not it was possible.

2.3. Judgment using statistical methods

Therefore, in order to make up for the lack of observation data, direct flight

Give up predicting the amount of coming salt, ① Nickel is the amount of coming salt

About 0.5mdd, which is considered to be the prima facie limit of high weathering steel

Whether it greatly exceeds. ② How long is the bridge erection point?

Is it a degree environment? Indirect evaluation of these two points

Kamoshima Ohashi

I decided.

In (1), the two-month observation data obtained at this time

Figure 2 Flying salt distribution map

About the data, the amount of flying salt in the Shimane Prefecture Road Business Design Guidelines

Assuming that the distribution map is positive, perform statistical processing to determine the probability of its appearance.

I asked. As a result, the observed debut in February 2004

Distance from the shoreline0.9km

At the erection site of the main bridge, the data is once every several hundred years, and an additional 0.6.

Manyo Park
It is a probability of appearing once in 100 years at Manyo Park upstream of km.

It turned out.
1.5km

On the other hand, regarding (2), corrosion of existing painted bridges in the vicinity

We conducted a situational survey. As a result, 300m above the erection point

2.0km

B-painted bridges that are applied to the slightly corrosive environment of the current

Frequently repainted at a rate of 10 to 20 years

Therefore, the erection point is C-based paint, that is, severe corrosion.

It was presumed to be the environment (see Table-2).

From the above two results, nickel-based highly weather-resistant steel materials

Figure 3 Flying salt observation point

It was judged that it could not be applied. After ordering Motohashi

Make sure that it is below, and perform further weather resistance surface treatment. Also continued to investigate the amount of flying salt at the site where the main bridge was erected.

In addition, nickel-based high weathering steel is used. Around that time, the average annual amount of incoming salt was 1.32 mdd.

Was. Table-1 Amount of flying salt at each observation point Unit: mdd

2.2. More than expected salt content October H15 November December January 16. February March

However, December 2003, when preparations for ordering were in progress. Bridge erection point (0.9km) 2.07 0.56

In addition, we conducted a survey of the amount of flying salt about 1 km upstream from Kamoshima Ohashi. Manyo Park (1.5km) 0.68 0.32
Observed an abnormally high amount of flying salt from the Ministry of Land, Infrastructure, Transport and Tourism Faction river (2.0 km) 0.20 0.89 0.26 0.62 0.33 0.28
I was informed that it was done. (See Fig. 3) So, in a hurry, Motobashi
Table-2 Estimated number of years supported by anticorrosion method

When I made an observation at the erection point, it seemed to be abnormal as well.

B-1 C-4 Zinc / aluminum Zinc aluminum + fluorine Weathering steel

High values are observed, and nickel-based high weathering steel is used for corrosion protection.
General environment 20 years 60 years 100 years - Over 100 years

It was also considered to exceed the performance. (See Table-1)

Somewhat harsh environment 15 years 45 years 70 years - Over 100 years

Originally, to judge the propriety of adopting weathering steel, etc.

Severe environment 10 years 30 years 60 years 90 years -
In the case of flying salt calculated from at least one year's worth of flying salt
(Excerpt from steel bridge cycle cost P19)

Use the quantity value. On the other hand, at the Takatsugawa Bridge, in a hurry
3. Adoption of zinc / aluminum spraying

Although the observation was started, only the observation data for 2 months was collected.
3.1. Selection of new anticorrosion specifications

I couldn't collect. On the other hand, when the Kujo Inter Line opens
Nickel-based highly weatherproof steel is no longer applicable
Therefore, in general, Honbashi adopts C-based paint from the above-mentioned environment. Then, it is said to have a service life of about 90 years. However

Will be done. However, in the road bridge specification, in the bridge On the other hand, it is clear because it is still expensive and it is a new technology.

The target period for durability should be 100 years as a guide. It is disadvantageous in terms of actual results and the fact that accurate specifications have not been determined.

It has been shown.Note 1On the other hand, C-based painting in the environment is a sentence. There is a point. In addition, it is unique, such as not being able to spray in narrow areas.

About 30 years from the situation of the dedication (see Table 2) and the existing bridges in the vicinity Has drawbacks. Thermal spraying depends on the metal used and the thermal spraying method.

It was estimated to be the service life of the degree. Therefore, there are quite a few types, but the metal used is zinc a.

On the other hand, Motohashi forms a high-speed network and serves as a road. The thermal spraying method for Lumi alloy is frame thermal spraying (alloy spraying: Fig.-

High importance. Because it crosses the Takatsu River, which is a first-class river 6) or arc spraying (pseudoalloy spraying)

Repainting work is not easy. For some reason, paint many. At Kamoshima Ohashi, Zinc Al has a lot of construction results.

It was decided that it was necessary to select the clothing type more carefully. Fluororesin coating on top of thermal spraying and frame spraying

For this reason, the repainting cost is included with 100 years as a guide. It is adopted.

Assuming life cycle cost (hereinafter referred to as "LCC")

In recent years, C-4 series coating and adoption examples have been seen.

A comparative study of zinc aluminum spraying was conducted.

3.2. Characteristics of zinc / aluminum spraying

Anticorrosion measures commonly used for bridges are mainly shown in Figure 4.

There are five types shown. Of these, thermal spraying was about 100 years ago.

Introduced in the book, it is a steel structure for offshore oil drilling in the North Sea. Figure-5 Metal used for thermal sprayingNote 2

It is also used in extremely harsh environments, but because it is expensive

It wasn't widespread. However, the improvement of the thermal spraying technology itself and L

As CC has attracted attention, it has been adopted in recent years.

Is increasing. The anticorrosion performance of thermal spraying is subordinate to the alloy that is sprayed.

When lead / aluminum alloy (see Fig. 5) is used, sub

In addition to the lead and aluminum coating effect, zinc sacrificial anticorrosion

It is effective and has excellent performance such as scratch resistance compared to general painting.

Have. In addition, although it is the result of the material piece test, the service life

Has been around for 60 years (at a harsh environment) and has become an "LCC".

It can be said that it is an excellent paint. Also, in combination with existing paint Figure-6 Frame thermal spraying conceptual diagram and photographs

In some cases, in combination with heavy anticorrosion coating (fluorine, etc.)

3.3. Comparison of anticorrosion specifications

Paint Dress ① General painting

A guideline for the target number of years of durability is set as a guideline of 100 years.

Surface coating ② Heavy-duty anti-corrosion coating

However, in reality, the examination method is not clear,

It was necessary to make various individual judgments in making the comparison.

bridge
Beam
of On the other hand, when considering LCC in general, only maintenance costs
Prevention Metal coating ③ Plating
Food In addition to including the renewal fee, about the parts such as floor slabs and bearings
direction
Law ④ Thermal spraying

Should be considered individually. But this time, compare

Since the target of is anti-corrosion specifications, only anti-corrosion specifications are considered.

Modification of the steel material itself ⑤ Weathering steel It was decided to be the target of.

Figure 4 Main anti-corrosion methods for bridges Then, the following three types were selected as the specifications to be compared.

① C-4 coating (fluororesin)

Steel Road Bridge Painting / Anti-corrosion Handbook (PI-18 18Addition)
 (2) Zinc / aluminum spraying + sealing treatment

③ Zinc / aluminum spraying + sealing treatment + C-4 system coating

In addition, the period until repainting is "Life cycle of steel bridge"

Comparison in the environment at Motohashi with reference to "Lucost" etc.

As shown in Fig. 7, ③ "Zinc / aluminum spraying + C"

-4 (Fluorine) Was also advantageous. In comparison,

Regarding Ren (existing painting and rust stripping work), conventional

With 2 or 3 types of general keren (keren performed with a power tool, etc.)

It is becoming mainstream now, but it is a rare species at that time.

(See Fig. 9). Furthermore, in Figure 7, the social discount

Figure-9 Blasting work (work equivalent to type 1 keren)
We do not consider the lead rate, but even if we introduce this discount rate, the result

Did not change. For reference, it is assumed that nickel is high.

Table-3 Zinc / aluminum spray coating specifications at Kamoshima Ohashi
Ratio including bridge superstructure construction cost as weatherproof steel can be used

The comparison results are shown in Figure-8. [General part]

Zinc (85) / aluminum (15) alloy spraying 100 μm

Epoxy resin-based pore-sealing agent 160g / ㎡

Epoxy resin undercoat 300g / ㎡

Fluororesin paint 170g / ㎡

Fluororesin coating 140g / ㎡

[Narrow part / bolt part]

Super pressure film type epoxy resin 300 μm

Epoxy resin undercoat 60 μm

Fluororesin paint 30 μm

Fluororesin coating 25 μm

Fig. 7 Unit price per square meter by painting method

Base material adjustment Thermal spraying

Sealing Undercoat painting

Fluorine coating (2 layers)

Figure-10 Surface covering procedure at Kamoshima Ohashi

Figure-8 Total amount of bridges by anticorrosion method

3.4. Construction of zinc / aluminum spraying It cannot be installed in places where shadows are formed. for that reason,

Table 3 shows the specifications of zinc / aluminum spraying at the main bridge. Especially in the bolt part, use galvanized bolts.
The construction is done except for on-site welds and bolts. Epoxy film type epoxy resin was used to secure the service life.

Most of it is done in the factory. Thermal spraying is compared with construction equipment On the other hand, a series of thermal spraying and painting procedures is shown in Fig. 10.

Because it is sprayed in a large spray shape, it is used in narrow areas and bols. As shown, thermal spraying is a high-grade inorganic material in general painting.
It is better to understand that it is like a glitch primer. I think that the.

It's easy to do. In addition, because the sprayed surface is porous, "sealing treatment" 4.2. Desired improvements for thermal spraying

It is necessary to perform the padding. This time, we adopted zinc / aluminum spraying from the initial impression.

In the actual construction, the current work performed at the on-site weld Although the construction was relatively smooth, from the plan to the design,

In field spraying, the blasting work of the substrate adjustment has an effect on the surrounding area. As an orderer involved in the construction, the following points have been revised.

It was bigger than I expected. In addition, the super pressure film type d at the bolt part I want to hope for good.

The workability of Poxy resin is poor, and it is necessary to rework it many times. 1. 1. Ensuring economic efficiency

There was a point. In addition, it is factory painting (see Fig. 11). 2. 2. Establishment of thermal spraying specifications

Therefore, how to repair the defect of thermal spraying during transportation etc. 3. 3. Enablement of thermal spraying in narrow areas and bolts

Hot-dip galvanized metal because the standards such as the law were not set. 4. Further verification of anticorrosion performance

If you do not set this standard independently with reference to the standard of the key etc. 4.3. Postscript

did not become. However, there is no particular difficulty in thermal spraying itself. Thermal spraying is excellent in anticorrosion performance and can cope with harsh environments.

The construction went smoothly. Weathering steel

If it is possible to adopt materials and concrete-based structures, its superiority

Sex decreases. Even in this study, weatherproof steel can be used.

If it is possible, not only painting but also thermal spraying will be eliminated. child

Therefore, thermal spraying can only be adopted in limited environments and conditions.

It will not be. On the other hand, the increase in maintenance and renewal costs, which will become a problem in the future.

Considering the size, thermal spraying is possible when repainting existing bridges.

It is an effective construction method, and as mentioned above, the level of maintenance and renewal costs in the future

It seems that it will contribute to the conversion. In addition, individual abutments and piers

Corrosion-prone parts such as the lower flange and coating

A bridge that cannot be constructed with Class 1 Keren, which has a large environmental load when replacing

Fig. 11 Thermal spraying work (machine construction)

It seems that it will be an effective technology. From this, now
4. Summary
Thermal spraying technology with later comprehensive efforts to reduce LCC

4.1. Impact of changes to the Steel Road Bridge Painting Handbook

I would like to expect further improvement.

This study at Motohashi was not revised in December 2005.

It was done in, and now the situation is a little when reconsidered

Seems to be different. It is LC as mentioned above

Since C has come to be regarded as important, Fluorine coating(C

-5) and Type 1 Keren (Rc-I) are specifiedNote 3Being one kind

This is because the cost of Keren is cheaper than at the time of consideration.

To.

For this reason, Motohashi when considering the social discount rate at this time

In the environment in, the difference between C-4 coating and zinc / aluminum spraying

Will almost disappear. However, on the other hand, C-4 painting

Requires at least several repainting operations in 100 years Figure-12 View of Kamoshima Ohashi from the left bank

Because of this, there are doubts about the soundness of steel materials such as girders.
Note 1: Road Bridge Specification / Explanation I / II (H14.3: P7)

Thermal spraying is effective against the leveling of maintenance and renewal costs that will increase in the future.
Note 2: Material for anticorrosion and thermal spraying cooperative

Presumed to be a technology, it retains the superiority of thermal spraying

Note 3: Steel road bridge painting / anti-corrosion handbook (H17.12: PⅡ-30,92)