混凝土表面处理及涂装工艺.doc

Beijing Celeb Corrosion Protection Engineering Co., Ltd.北京九州华清防腐工程科技有限公司Painting Procedure施工工艺规程Issue No.1Date of Issue2012.5.2Doc. Ref.CBM001Page19 of 21Reversion No.0Date of Rev.Surface Preparation & Coating to Concrete混凝土表面处理及涂装1.0Purpose目的This procedure covers the application of all concrete coating systems applied by CELEB.本施工工艺规程规范所有北京九州华清防腐混凝土涂装系统的施工。2.0Scope范围This procedure will be followed in all applications.本规程应贯彻于所有施工过程中。3.0Responsibilities责任3.1The Project Manager 项目经理- Operation and management of grinding and painting works. Plan work schedules. Maintained strict conformance to clients required specifications.负责研磨和涂装作业的管理及运作工作。准备工作进度表。严格遵照客户要求的涂装系统及规范施工。-Liaise with Engineers, Production, Q.C. Personnel and other contractors on work schedules, job performance and implementation on quality control requirements. Exercised quality control surveillance on conformance to required specifications.协调施工各方，确保按质量按进度施工作业，控制质量以符合业主的涂装系统规范。3.2The Supervisor 监理 - To ensure that all tests are undertaken and, in the case of witness tests the client representative is present.保证执行各项检测工作，检测时应有客户代表在场。3.3The Forman -领班 - To ensure that all work conforms to specifications and is done in a workman like manner.保证按标准施工，施工人员工作态度端正。4.0References标准Where referred to in this specification, the latest edition of the following specifications, standards and other documents apply.本规程参照以下标准及规范制定：ASTM D4227-99 “Standard Practice for the Qualification of Coating Applicators for Application of Coatings to Concrete Surfaces”ASTM D4258-83 “Standard Practice for Surface Cleaning Concrete for Coating”ASTM D4259-88 “Standard Practice for Abrading Concrete”ASTM D4261“Standard Practice for Surface Cleaning Concrete Unit Masonry for Coating” 5.0Documentation文件Daily Work Report / 每日工作报告Daily Q.C Report / 质量日报表6.0Procedure规程6.1 Inspection of the Concrete Substrate混凝土基层检测It is to determine the concretes general condition, soundness, presence of contaminants, presence of moisture vapor emissions and the best methods to use in preparation of the surface to meet the requirements of the client or the manufacturers recommendation.对混凝土通过现场堪察及基层检测，掌握混凝土的总体情况、表面坚实度、污染情况及潮气含量，从而决定表面处理最佳方式，以达到客户和材料生产商的要求。6.2Pre-clean all surfaces by brooming and if necessary accomplished by scrubbing with heavy duty cleaner / degreaser or low pressure water cleaning (less than 5,000 psi) or chemical washing to remove oils, grease, wax, fatty acids and other contaminations.先用扫帚清洁地表，必要时使用深度清洁剂去除地表污渍，或用低压水冲洗（不超过5,000 psi），也可以使用化学溶液去除油污，油脂，表腊，脂肪酸或其它污染。6.3 Removal of Surface Laitance and Creation of Surface Profile去除水泥翻沫，提供粗糙度Removal of surface laitance and /or curing compound and creation of surface profile can be accomplished by a number of methods each utilizing a selection of tools, equipment and materials to accomplish the intended purpose, (See table below). Selection is dependent upon the type of surface to be prepared and the type of system to be installed. In addition, floors, walls, ceilings, trenches, tanks and sumps each have their own particular requirements. The type and thickness of the selected coating system also plays an important role in the selection process. Regardless of the method selected or tools employed, we must provide a surface that will accept the application of polymer-based products and allow the mechanical bond of the polymer securely to the concrete. 去除水泥翻沫及养护剂、脱模剂需使用手动工具或设备来完成。根据待涂装地坪的表面以及不同的涂装系统，选择不同的作业工具和作业方法(见下表)。此外，地坪、墙壁、天花板、地沟、水槽和水罐对工具使用会有不同的要求。而且工具选择与所选用的涂装厚度和类型也有关系。无论选择哪种类型的工具，我们必需提供一个适合聚合树脂材料涂装的表面，且保证涂装材料与地坪有良好的机械附着力。 The following table provides a guide for the degree of surface profile required for the coating or overlay to be applied and the preparation methods used to generate each profile to the specified standard.以下表格为各类涂装系统所需达到的粗糙度进行分类并对相应的表面处理方法提供了指南。 Classification ofCoating System涂装系统的分类DFT厚度(micron)Methods of Surface Preparation地坪表面处理方法Sealers封闭剂0-100Detergent Scrub / 清洁剂清洗Low Pressure Water Cleaning低压水洗Grinding / 研磨Thin Film封闭薄涂100-400Grinding / 研磨Abrasive Blasting / 喷砂Steel Shot Blasting / 钢丸喷砂High-Build厚涂400-1000Abrasive Blasting / 研磨Steel Shot Blasting / 钢丸喷砂自流平Self-Levelling1,000-3,000Abrasive Blasting / 研磨Steel Shot Blasting / 钢丸喷砂 Scarifying / Milling / 铣刨Needle Scaling / 针枪High Pressure Water Jetting高压水洗聚合砂浆Polymer Overlay3,000-6,000Abrasive Blasting / 研磨Steel Shot Blasting / 钢丸喷砂Scarifying / Milling / 铣刨Needle Scaling / 针枪High Pressure Water Jetting高压水洗Scabbling / 粗琢Surfaces to receive the bonded coating system must be inspected after the surface is prepared to insure that the substrate is sound, clean, textured and structurally durable. Areas found to be unsound or non-durable must be removed and replaced as stated in section 7.5. Dust or other deleterious substances not removed after the initial surface preparation must be vacuumed, leaving the surface dust free and clean.表面处理完成后，检查地坪以保证地坪表面良好、清洁、有合适的纹理且表层结构牢固。如发现有不良不坚实表面，应立即进行处理，具体见第7.5章。经初次表面处理未能移去的灰尘或表面碎屑，应真空吸尘，使地表干净无尘。 6.4Removal and Replacement of Non-durable Concrete修复混凝土缺陷Localized weak or deteriorated concrete must be removed to sound concrete and replaced with PC cementitious or polymer concrete repair mortars, or an engineered concrete mix design utilizing polyacrylate polymer additive. For application of these systems and compatibility with the selected polymer sealer, coating, lining or topping refer to the Technical Data Sheets. Occasionally, plain fresh concrete is required and must be bonded to existing concrete. When bonding fresh concrete to existing, prepare the existing concrete surface by scabbling, scarifying, abrasive (sand) blasting, needle scaling, high pressure water jetting (5,000 to 45,000 psi), or steel shot blasting.除去薄弱或损坏的混凝土表层，然后使用聚合混凝土或聚合砂浆进行修补。也可使用聚合改良混凝土进行修补。关于选择和施工兼容的密封剂、地坪涂装材料、贴面材料及聚合面层材料，参照技术说明书。有时，需要在已有混凝土层上浇筑混凝土，应该对原有混凝土层表面进行表面处理。使用粗琢、铣刨、喷砂、针枪、高压水泵(5,000psi 至 45,000psi)或钢丸喷砂来确保新旧混凝土层之间的附着力。Standard / 标准:ACI 503.4-92 “Standard Specification for Repairing Concrete with Epoxy Mortar”6.5 Repair of Surface Irregularities修补砼表面不平整处All surface irregularities including bugholes, spalls, cracks, deteriorated joints, slopes, areas near transition zones, such as around drains and doorways, etc. must be filled and resurfaced with a specified quick-setting cementitious grout or solvent-free epoxy mortar, in accordance with the manufacturers recommendations, prior to coating.对于砼表面不平整，包括蜂窝、散裂、裂缝、伸缩缝损坏、倾斜、过渡区域如地沟或门廊周围等，用专用快干水泥砂浆或无溶剂的环氧砂浆填充。填充作业根据材料供应商的建议在涂装以前完成。6.6 Isolation / Bridging of Cracks or Joints分隔 / 跨接裂缝或伸缩缝For additional crack bridging capabilities a proper isolation / bridging system with fiberglass scrim cloth and / or elastic sealant shall be applied before coating of the entire surfaces.必要时，在对整个表面进行涂装前，使用纤维布或弹性密封胶来组成一个裂缝跨接系统。6.7 Painting / Coating涂装6.7.1 General / 概述All surfaces to be coated shall be clean, sound and dry before application of the first coat.涂装前，砼表面应清洁、干燥、坚实。 The water / vapor content of the concrete substrate shall not exceed 4% or specifiedin the manufacturers recommendation. 根据材料供应商的建议，混凝土基层水份含量不应该超过4%。No coating shall be applied when substrate temperature is less than 3C above dew point, or the relative humidity is higher than 85%, so as to avoid the risk of condensation during painting.基层温度不高于露点温度3C以上或相对湿度高于85%时，不得进行涂装施工，以防涂装过中有水汽凝结在基层表面。 No coating shall be applied when the atmosphere and substrate temperature exceed the limitation specified by the paint manufacturers. 当空气温度或基层表面温度超过材料生产商规定的界限时，不得进行涂装施工。 No coating shall be applied to seal the construction or working joints, or on the top of joint sealant.不得在结构缝、工作缝以及伸缩缝胶的表面上涂装。A minimum coving is necessary, if coating has to be applied at the corners, so as to avoid the risk of cracking by stress.对棱角部位需实施拱圆或凹圆线，防止由压力造成的裂缝。Storage, mixing to an even consistency, thinning and application of paints and coating materials and the type of application equipment shall meet the instructions and recommendations of the paint supplier. Mixing, by high speed shakers or rotary mixers with flat blade and speed control, shall be done in a well ventilated and dust free area.涂装材料的存放、搅拌、稀释和施工等所使用的工具应按照材料供应商的建议。在使用手动搅拌器，高速搅拌设备或可控速螺旋桨搅拌器进行搅拌时，应该在通风无尘的区域进行。Paint supplier instructions and recommendations regarding induction period, pot life, drying/curing intervals between successive coats and final curing periods before being put into service, shall be followed. Successive coats shall be of a different shade to ensure full cover.所有材料供应商有关材料熟化时间，施工寿命，重涂时间，完全固化时间的说明都应严格遵守。后续涂层应当采用不同的颜色，以确保完全履盖。 Such instructions and recommendations shall be mentioned on paint suppliers data sheets and be appropriate for prevailing environmental conditions.在材料供应商的材料说明书中，以上指导和推荐时间应该都有提到，且应用于通常所讲的环境条件下。 Paints shall not be used beyond the date of expiry, as indicated on the container, or alternatively as stated by the supplier for given batches. All paint shall be used in order to its successive manufacture and / or delivery.过期材料不再使用，材料的使用期限可以从包装上或批号合格证上得到。同类材料使用先后顺序应根据生产或到货的先后顺序进行。Precautions shall be taken to prevent the coating from being applied to equipment or area to be protected. Masking Tape, plastic film or some other suitably impervious material shall be used, and all materials shall be removed after painting has been completed and accepted.涂装过程中要防止材料污染设备或错涂到需要保护的非施工区域。使用保护胶带，塑料薄膜或其它可以用作保护措施的材料。施工完成后，应移去这些保护材料。6.7.2 Spray Application喷涂施工Application by spraying is in special cases suitable for compatible coating system on new construction and for maintenance painting of large areas.在一些特定情况下，使用相匹配的材料对新的结构进行大面积作业。另外，它还适合使用于大面积修补施工。Spraying equipment, guns, nozzle sizes and pressure ranges shall meet the paint suppliers recommendations.喷涂设备，喷漆枪，喷嘴尺寸和喷涂压力应与材料供应商的推荐相一致。 Each coat shall be applied uniformly and completely over the entire surface free from runs and sags.每道涂装应连贯作业完成，做 到涂层均匀无流挂。Before spraying each coat, all awkward areas such as foundations, edges, corners, shall be applied with stripe coats by brush or roller to ensure that these areas receive minimum specified film thickness.每层涂装前，所有难以施工到的部位如底座、边缘、角落，应使用刷子或滚筒预涂，以保证这些部位的涂层厚度达到规定的最小值。6.7.3 Brush Application刷涂Brush application shall be done on areas, which cannot be properly sprayed or roller applied and for stripe coats. It is also a sufficient method to work the paint into the surface where there is difficulty to achieve sufficient adhesion by normal penetration of the paint itself. In fact, brush application shall be the preferred process for primer.刷涂适合使用于预涂和无法进行喷涂或滚涂的区域。另外，在无法利用涂料自身渗透性而达到良好附着力的时候，刷涂可以将涂料挤放待施工表面，是一种有效的施工方法。事实上，许多底涂都适合采用刷涂。 Brushes shall be of a type and size which permits proper application of paint. Round or oval brushes are most suitable for irregular surfaces. Wide flat brushes shall be used for large flat areas. The brushing shall be done such that a uniform coat, with no deep or detrimental brush marks, is obtained. Paint shall be worked into all corners and crevices. Runs and sags shall be avoided.油漆刷型号和尺寸大小应该保证施工正常进行。圆形或椭圆的刷子最适合使用于不规则施工表面。宽的扁刷子适合使用于面积较大的平面区域施工。刷涂效果应连贯一致，涂装表面不应留下明显的刷痕，无流挂。6.7.4 Roller Application滚涂As a conventional coating method roller application shall be adopted for free flowing materials with little or no fillers. Special rollers shall be used for certain texture effects.作为一种传统的涂装方式，滚涂适合用于不加或加入少量骨料的流淌性涂装材料的施工。如果要产生纹理状表面效果，则需使用特殊的压花滚筒。Proper overlapping and cross wise application will minimize the roller marks and un-uniform distribution of the paint.让部分涂层适当的重叠并以交叉方式实施滚涂，将会使滚筒印痕最小化并使涂装表面更均匀连贯。The form, size and material of the roller to be used shall be compatible with the coating materials. 滚筒型号，大小，质地应与涂装材料性能相适合。 6.7.5 Trowel Application镘涂Trowel application shall be the preferred process for coating system with cementitious and thixotropic materials and resin coating with filler content (typically self-leveling coating) on horizontal and vertical surfaces. It can achieve the best possible adhesion at the interface between the coatings and the underlying concrete. This is what guarantees the life and success of a coating system.镘涂适用于水平或竖直面上水泥性或触变性材料，以及搭了骨料的树脂材料的施工，尤其是自流平材料。它能最大限度地确保涂层间以及涂层与砼基面之间的附着力，从而保证涂装系统的使用寿命，以及涂装更好的施工。Regardless of which kind of coating system to be installed, the trowel application shall ensure an even distribution of the coating materials and a consistent overall finish. 无论采取何种涂装系统，镘涂都要求做到涂装材料分布均匀，涂层表面平整连贯。 The form, size and material of the trowel to be used shall be compatible with the coating materials. 镘刀的形状，大小及材质应根据涂装材料性能来选择。 6.8 Crack / Joint Sealing裂缝或伸缩缝打胶Control / expansion joints, construction joints, and moving cracks should be sealed with the selected system flexible sealant.控制缝 /伸缩缝，结构缝和活动裂缝应采用匹配的弹性胶进行密封。Isolation and/or expansion joints should be detailed in accordance with the plans and specifications of an architectural or engineering design professional for the type of structure being considered. 分隔缝或伸缩缝设计应由建筑或工程设计方面专业人员根据其结构类型进行规划。 Traffic joints, or joints between concrete substrate and other substrates shall be applied with compatible primer for sealant to ensure sufficient adhesion.承受交通负载的伸缩缝或混凝土基层与其它材质基层之间的连接缝，应使用相匹配的底涂，以确保密封胶的附着力。6.9 Repair of Defects修补Coating systems, whether applied to new construction or to existing installations, are likely to require repair and maintenance in areas of damage, delineation-bonding, insufficient film thickness and other defects.任何涂装系统，无论是在新结构上的涂装还是在原有涂层上的重涂，都常常需要针对涂层受损、剥落、厚度不达标以及其它问题进行修补或养护。The type of coating materials used for repair and maintenance shall be identical to, or in any case compatible with the original materials.任何情况下，修补用的涂装材料应与原涂层材料相匹配。The best possible surface preparation technique(s) shall be selected for repair and maintenance, depending on the size of areas to be coated, the type of repair coating materials to be used and the restrictions / safety aspects involved.最佳的表面处理方法应当根据待修补区域的大小、修补材料的性能以及现场的安全规章来选择。 The following order of preference shall be adopted:可按以下顺序来筛选： Steel shot blast or wet blast cleaning to remove existing coatings Grinding on the existing coatings to achieve adhesion key High pressure water jet cleaning or vacuum cleaning Sand papering (only in exceptional cases and only for minor repair work).钢丸喷砂或湿喷砂，去除旧涂装对现有涂层进行打磨，以确保良好的附着力高压水清洗或真空吸尘 砂纸打磨(适用于特殊情况或小面积修补)Surface preparation of defective or damaged areas shall be extended over the surrounding sound coating for a minimum of 25 mm on all sides, and the edgesshall be tapered.缺陷或受损部位的表面处理，应扩大并超出周边涂层各边缘至少25mm，边界应当有良好的楔形过渡。 Surfaces to be coated which become contaminated with oil, grease, salts, etc. shall be cleaned with solvents or with detergent / fresh solutions, followed by arinse with clean fresh water.如果待涂装地表面受油污，油脂，盐份等污染，应用溶济或洗涤剂进行清洗，最后再以清水冲洗干净。Repair coatings shall be applied such that the final coat overlaps the surrounding sound coating for a minimum 25 mm on all sides. For color coding and / or cosmetic reasons it may be necessary to extend the topcoat over a larger surrounding area.涂装修补区域及其周围25mm左右，面涂应与其周边区域衔接良好。出于颜色或美观考虑，可将面涂扩大至一个相对较大的范围。 7.0 Testing / Inspection测试 / 检验7.1Compressive Strength Test抗压强度7.1.1 Compressive strength test shall be conducted at least 28 days after concrete pored.抗压强应测试应在混凝土浇筑至少28天以后进行 7.1.2 Using the Rebound Test Hammer or equivalent instrument使用回弹测试仪 或类似设备7.1.3Before any synthetic coating is applied, the compressive strength of the concrete substrate shall be at least 25N/mm2.工业地坪涂装要求混凝土基层的抗压强度值至少应达到25N/mm27.2Surface Tensile Strength Test表面抗拉强度7.2.1Surface tensile strength test shall be conducted at least 28 days after concrete pored.表面抗拉强度测试应在混凝土浇筑至少28天以后进行7.2.2Using the Pull-Off Tester or equivalent instrument使用拉力测试仪器或类似设备 7.2.3 Before any synthetic coating is applied, the tensile strength of the concrete substrate shall be at least 1.5N/mm2.工业地坪涂装要求混凝土表面抗拉强度值至少达到1.5N/mm2 7.3Dew Test露点7.3.1Dew tests shall be conducted every 4 hours (more often if required).露点测试每4小时进行一次(需要时可增加测试次数)7.3.2The results of each test are recorded in the Site Log.将测试结果记录在工地日志中The site log shall record the following:工地日志记录如下信息:Time / 测试时间Dry Bulb Temp / 干球温度Wet Bulb Temp / 湿球温度Relative Humidity / 相对湿度Dew Point / 露点温度 Substrate Temperature / 基层温度 7.3.3Before any synthetic coating is applied, the substrate temperature shall be at least 3o C above dew point.在材料混合好准备施工前，施工地面温度至少高于露点温度3o C以上 7.4W.F.T. Test湿膜厚度7.4.1 Apply the coating material to surface and test with the gage immediately.涂装材料涂布好后，立即使用湿膜卡进行测试7.4.2 The gage shall be applied on an area that allows both end tabs to be in contact with substrate.将湿膜卡放置于两端都可以接触地面的地方7.4.3 Set one tab firmly on the substrate and lower the gage until the other tab rests firmly on the substrate at the same time.将湿膜卡一端紧靠地表，直到另一端也同样紧密接触地表。7.4.4 Remove the g