High-performance hydraulic impact-resistant, abrasion-resistant, and corrosion-resistant mortar

High-elasticity impact- and abrasion-resistant polymer mortar has become a core material in the protection of hydraulic structures against impact and abrasion, owing to its excellent mechanical properties and durability. It demonstrates outstanding protective effects, especially in critical areas such as hydraulic wave-swept zones and hydropower station pier columns.

I. Material Characteristics and Protective Mechanism

This material is based on polymer-modified cementitious substrates, and its protective capability stems from three key characteristics:

1. High Elasticity and Toughness: The introduced polymer molecular chains effectively absorb and dissipate impact energy. When subjected to high-speed water flow, sediment, or floating ice impact, the material does not undergo brittle spalling like ordinary concrete. Instead, it buffers stress through micro-deformation, significantly reducing material loss.

2. Exceptional Impact and Abrasion Resistance: The formed dense microstructure and high-strength cementitious matrix effectively resist the abrasion and cutting actions of suspended and bed loads (such as sediment and pebbles) in water flow. Its wear resistance is several times higher than that of ordinary concrete.

3. Strong Bonding and Impermeability: It exhibits high bonding strength with old concrete substrates, enabling integrated stress distribution. Simultaneously, its extremely low permeability effectively prevents the intrusion of water and harmful ions, avoiding internal damage caused by freeze-thaw cycles and chemical erosion, thereby enhancing durability.

II. Application in Hydraulic Wave-Swept Zones

Wave-swept zones of hydraulic dams, such as upstream slopes, stilling basins, and spillways, endure long-term severe冲刷 from waves, wet-dry cycles in fluctuating water level areas, and potential ice impact.

• Application Areas: Primarily used for surface protection in flow-passing areas of the aforementioned regions, often as a 20-50mm thick impact- and abrasion-resistant overlay.

• Solution: In such areas, its high elasticity converts the substantial kinetic energy of waves into deformation energy within the material, which is then dissipated, reducing direct impact damage. Its excellent abrasion resistance withstands continuous wear from sediment-laden waves on slopes. During construction, it is typically applied by spraying or manual troweling onto prepared (roughened, cleaned, and moistened) concrete substrates to form a tough and intact protective layer, effectively extending the service life of structures in wave-swept zones and reducing economic losses and operational risks from frequent maintenance.

III. Application in Hydropower Station Pier Columns

Pier columns in hydropower stations, especially those in the support hinge areas of radial gates, operate in extremely harsh conditions. They not only withstand the complex effects of high-velocity (up to 30-40m/s) discharge flow but also endure direct impact from water jets behind the gate, vibration, and cavitation erosion.

• Application Areas: Mainly applied to upstream faces, side surfaces, and areas around gate slots that are prone to high-velocity flow impact and cavitation damage.

• Solution: In these areas, the material's core role is to resist impact vibration and cavitation. Its toughness buffers impacts and vibrations from gate operation and flow pulsations, preventing concrete fatigue cracking. The dense structure and high strength effectively resist冲磨 from high-speed sediment-laden flow and significantly enhance the material's critical cavitation strength, making it more resistant to damage from shock waves generated by collapsing cavitation bubbles. Construction typically involves vertical formwork pouring or high-pressure jetting to form a reinforcement layer tightly integrated with the base concrete, greatly improving the pier column's disaster resistance and operational safety.