Wind Turbine Foundation Epoxy Polyurethane Anti-Corrosion Coating Wind Turbine Foundation Anti-Corrosion Process

Wind power projects are typically constructed in areas such as the Gobi Desert, tidal flats, salt ponds (special water bodies), and landfill sites. The various corrosive salts in the water and soil of the project area (mainly SO₄^2- and Cl^-), pH levels, etc., all have a certain corrosive effect on the concrete structures of the foundations.  

To meet the design life of approximately 25 years for wind power projects, efforts are made to enhance the impermeability, frost resistance, and corrosion resistance of the wind power concrete structures.

II. Wind Turbine Foundation Epoxy-Polyurethane Coating

The wind turbine foundation epoxy-polyurethane system consists of an epoxy primer, epoxy mica iron intermediate coat, and weather-resistant aliphatic polyurethane topcoat.

1. Epoxy Primer: Composed of epoxy resin, curing agent, additives, solvents, etc. It features a hard film with excellent adhesion, flexibility, abrasion resistance, and impact resistance. It is resistant to alkali, water, saline water, oil, and chemicals. Its technical parameters are as follows:

Packaging: Drum, Component A 20kg/drum, Component B 4kg/drum

2. Epoxy Mica Iron Intermediate Coat: A cold-curing epoxy coating composed of gray mica iron oxide as pigment, epoxy resin as base material, and polyamide resin as curing agent. Due to the properties of mica iron oxide and epoxy resin, the film is tough with good adhesion, flexibility, abrasion resistance, and sealing performance.

Basic Parameters:

Color: Gray. Specific Gravity: 1.36g/cm³. Flash Point: 27°C

Theoretical Consumption: 90-180g/m². Dry Film Thickness: 30-60μm

Drying Time: At 25°C, surface dry: ≤4 hours; hard dry: ≤24 hours; full cure: 7 days

Mixing Ratio: At 25°C, Component A: Component B = 22:3 (by weight). The ratio can be adjusted appropriately based on temperature.

Induction Time: (25°C) 30min. Pot Life: (25°C) 8 hours

Packaging: Drum, Component A 22kg/drum, Component B 3kg/drum

3. Weather-Resistant Aliphatic Polyurethane Topcoat: Weather-resistant aliphatic polyurethane paint is a type of outdoor weather-resistant topcoat, fully named aliphatic acrylic-modified polyurethane topcoat. This paint features good decorative properties, UV resistance, acid resistance, solvent resistance, and excellent abrasion resistance. Aliphatic polyurethane paint is commonly used as a topcoat for reinforced concrete structures, outdoor storage tanks, steel structure projects, etc. Its technical parameters are as follows:

Packaging Specification: 20kg paint + 4kg hardener

Color: Various colors, can be matched according to RAL color chart, GSB paint film standard color card, physical samples, etc.

Gloss: Glossy to matte adjustable

III. Construction Process

Base Treatment → Apply Primer → Apply Intermediate Coat → Apply Topcoat → Curing and Acceptance

IV. Construction Technique

1. Base Treatment

(1) The base should be dry, clean, free of oil stains, and without obvious defects;

(2) Sand, remove dust and adhered contaminants; if oil stains are present, clean with alcohol or other solvents;

(3) For defects such as honeycombs and pockmarks on the base surface, repair and level with primer (A:B=5:1) mixed with an appropriate amount of cement or stone powder.

2. Application of Primer

(1) Mix the primer uniformly at a ratio of A:B=5:1 and allow it to mature (stand) for 30min before application. Each batch should be used within 2 hours.

(2) The primer can be applied using airless spraying, roller coating, or brush coating methods. Recommended consumption is 0.2kg/m². For vertical surfaces, apply from top to bottom, evenly and without missing spots.

(3) After 24 hours of primer application, the intermediate coat can be applied.

3. Application of Intermediate Coat

(1) Mix the intermediate coat uniformly at a ratio of A:B=5:1 and allow it to mature (stand) for 20min before application. Each batch should be used within 4 hours.

(2) The intermediate coat can be applied using airless spraying, roller coating, or brush coating methods. Recommended consumption is 0.6kg/m². For vertical surfaces, apply from top to bottom, with an interval of about 12 hours between two coats. Apply the two coats in a cross pattern, evenly.

(3) After applying the second intermediate coat, evenly sprinkle fine quartz sand of 80 mesh or above on the surface to enhance the adhesion of the topcoat.

(4) After 12 hours of intermediate coat application, the topcoat can be applied.

4. Application of Topcoat

(1) Mix the topcoat uniformly at a ratio of A:B=5:1 and allow it to mature (stand) for 30min before application. Each batch should be used within 2 hours.

(2) The topcoat can be applied using airless spraying, roller coating, or brush coating methods. Recommended consumption is 0.3kg/m². For vertical surfaces, apply from top to bottom, evenly and without missing spots.

5. Curing and Acceptance