Dock abrasion-resistant area anti-corrosion mortar, hydraulic corrosion-resistant propylene emulsion mortar

As a composite material modified from cement mortar by acrylic copolymer emulsion (abbreviated as propylene emulsion), propylene emulsion mortar has become one of the key materials for repairing damages in dock hydraulic structures due to its excellent bonding performance, corrosion resistance, and impact wear resistance. Its application effect in harsh working conditions such as the tidal zone and splash zone is remarkable.

Analysis of Core Performance Indicators

The performance advantages of propylene emulsion mortar stem from the synergistic effect of the polymer film and cement hydration products. Its key performance indicators include:

1. Mechanical Properties:

   • Compressive Strength: Typically can reach above 40MPa, ensuring the repair layer has sufficient load-bearing capacity.

   • Flexural Strength/Bonding Strength: This is its core advantage. The flexural strength is significantly higher than that of ordinary mortar, and the bonding strength with old concrete usually exceeds 1.5MPa, even reaching above 2.0MPa, effectively preventing debonding and spalling of the repair layer.

   • Tensile Strength: Markedly improved, addressing the brittleness of cement-based materials.

2. Durability and Protective Performance:

   • Chloride Ion Penetration Resistance: The electric flux value or chloride ion diffusion coefficient is far lower than that of ordinary mortar, effectively blocking chloride ion intrusion, protecting internal reinforcement, and delaying steel corrosion.

   • Resistance to Acid and Salt Erosion: After dry-wet cycle tests, the strength loss rate is much lower than the standard requirements, making it suitable for environments subject to seawater corrosion.

   • Freeze-Thaw Resistance: After 300 freeze-thaw cycles, the relative dynamic elastic modulus can remain above 80%, with minimal mass loss, making it suitable for docks in northern freezing regions.

   • Abrasion Resistance: The wear loss is significantly lower than that of ordinary cement mortar, enabling it to withstand long-term冲刷 wear from water flow carrying sediment.

   • Water Permeability Resistance: The impermeability grade can reach above P10, demonstrating good compactness.

Typical Damage Repair Applications in Docks

Propylene emulsion mortar is suitable for repairing various damages in dock structures caused by冲刷, wear, corrosion, freeze-thaw, and other factors:

1. Repair of Panel Concrete Spalling and Steel Corrosion: Remove loose concrete, perform derusting and rust prevention treatment on the reinforcement, and then use propylene emulsion mortar for layered pressing repair. Its high bonding strength ensures firm integration of new and old materials, while its impermeability and corrosion resistance provide long-term protection for the repaired area and reinforcement.

2. Repair of冲磨 Damage in Water Level Fluctuation Zone and Splash Zone: This area is most severely affected by waves, ice flow, floating object impacts, and sediment冲刷. The excellent impact wear resistance and freeze-thaw resistance of propylene emulsion mortar make it an ideal material for surface repair of components such as beams, slabs, and columns in this area, effectively extending the service life of the structure.

3. Protection and Repair of Pile Foundations: For damaged anti-corrosion coatings on steel pipe piles or surface damage on concrete piles, applying propylene emulsion mortar can serve as a protective reinforcement layer, resisting seawater corrosion and minor collisions from vessel berthing and departure.

4. Crack Grouting and Defect Repair: For stable cracks in concrete structures, low-viscosity propylene emulsion mortar can be used for pressure crack filling; for surface defects such as honeycombs and pockmarks, propylene emulsion mortar can be used for leveling repair.

Key Controls in Construction Process

• Substrate Treatment: Must be thoroughly roughened, cleaned, fully moistened but without free water, which is a prerequisite for ensuring bonding effectiveness.

• Material Preparation: Strictly mix according to the design ratio (typically the propylene emulsion content is about 15%~20% of the cement weight), ensure uniform mixing, and control workability.

• Construction and Curing: During application, compact and smooth the mortar. After construction, it is advisable to cover with plastic film for moisture retention first, followed by water sprinkling curing for no less than 14 days to ensure good formation of the polymer film.

Through its comprehensive performance, propylene emulsion mortar provides a reliable technical solution for the durability repair and protection of dock hydraulic concrete structures.