輕型鋼結構因自重輕、強度高、施工周期短等優(yōu)勢，在現代建筑、工業(yè)設備及基礎設施領域廣泛應用。然而，鋼材的腐蝕問題始終是影響其使用壽命的關鍵因素。據統(tǒng)計，全球每年因金屬腐蝕造成的經濟損失約占GDP的3%-5%，其中鋼結構腐蝕占比顯著。因此，科學有效的防腐蝕處理技術對保障輕型鋼結構的安全性、經濟性及環(huán)境適應性具有重要意義。

　　Lightweight steel structures are widely used in modern construction, industrial equipment, and infrastructure fields due to their advantages of light weight, high strength, and short construction period. However, the corrosion problem of steel has always been a key factor affecting its service life. According to statistics, the annual economic losses caused by metal corrosion worldwide account for about 3% -5% of GDP, with steel structure corrosion accounting for a significant proportion. Therefore, scientifically effective anti-corrosion treatment technology is of great significance in ensuring the safety, economy, and environmental adaptability of lightweight steel structures.

　　腐蝕的本質是鋼材與環(huán)境介質發(fā)生電化學反應的過程。當鋼材表面存在水膜、氧氣及電解質時，會形成微電池反應：鐵作為陽極被氧化為Fe2?，電子通過金屬基體流向陰極區(qū)域，與氧氣、水反應生成OH?，最終形成鐵銹。這一過程不僅導致截面削弱，還會引發(fā)應力集中，加速結構失效。防腐蝕處理的核心在于阻斷腐蝕反應鏈，具體可通過物理屏蔽、電化學保護、材料改性及環(huán)境隔離等路徑實現。

　　The essence of corrosion is the process of electrochemical reaction between steel and environmental media. When there is a water film, oxygen, and electrolyte on the surface of steel, a micro battery reaction is formed: iron is oxidized as an anode to Fe2? Electrons flow through the metal substrate to the cathode region, reacting with oxygen and water to form OH?, ultimately forming rust. This process not only leads to the weakening of the cross-section, but also causes stress concentration, accelerating structural failure. The core of anti-corrosion treatment is to block the corrosion reaction chain, which can be achieved through physical shielding, electrochemical protection, material modification, and environmental isolation.

　　表面預處理是防腐蝕施工的基礎環(huán)節(jié)。鋼材表面銹蝕等級按GB 8923標準劃分為A（原銹面）、B（初銹）、C（氧化皮剝離）、D（全面銹蝕）四級，其中D級銹蝕需徹底清除。常用處理方法包括：

　　Surface pretreatment is the fundamental step in anti-corrosion construction. The corrosion grade of steel surface is divided into four levels according to GB 8923 standard: A (original rust surface), B (initial rust), C (oxide scale peeling), and D (comprehensive rust), among which D level rust needs to be thoroughly removed. Common processing methods include:

　　機械處理：噴砂法可達到Sa2.5級以上清潔度，粗糙度控制在40-75μm，增強涂層附著力；拋丸處理適用于規(guī)則型材，效率高但存在死角問題。

　　Mechanical treatment: Sandblasting method can achieve a cleanliness level of Sa2.5 or above, with roughness controlled at 40-75 μ m, enhancing coating adhesion; Shot blasting treatment is suitable for regular profiles, with high efficiency but there are blind spots.

　　化學處理：酸洗可快速溶解銹層，但需控制濃度（通常鹽酸濃度5%-15%）及時間，避免過蝕；環(huán)保型生物除銹劑正逐步替代傳統(tǒng)強酸。

　　Chemical treatment: Acid washing can quickly dissolve rust layers, but the concentration (usually 5% -15% hydrochloric acid concentration) and time need to be controlled to avoid over corrosion; Environmentally friendly biological rust removers are gradually replacing traditional strong acids.

　　手工處理：適用于局部修補，但勞動強度大，質量不穩(wěn)定。

　　Manual processing: suitable for local repairs, but with high labor intensity and unstable quality.

　　涂層防護體系是應用最廣泛的防腐方案。典型的三層結構包括：

　　The coating protection system is the most widely used anti-corrosion solution. A typical three-layer structure includes:

　　底漆層：以環(huán)氧富鋅底漆為主，鋅粉含量≥80%，通過陰極保護延長基材壽命，干膜厚度40-60μm。

　　Primer layer: mainly composed of epoxy zinc rich primer, with a zinc powder content of ≥ 80%, extending the substrate life through cathodic protection, and a dry film thickness of 40-60 μ m.

　　中間漆層：環(huán)氧云鐵漆可增加涂層厚度至100-150μm，其鱗片狀結構有效阻隔介質滲透。

　　Intermediate paint layer: Epoxy cloud iron paint can increase the coating thickness to 100-150 μ m, and its flake like structure effectively blocks the penetration of the medium.

　　面漆層：氟碳漆耐候性優(yōu)異，保色期達15年以上，適用于外墻裝飾；聚硅氧烷漆兼具耐化學品性，適用于化工環(huán)境。

　　Topcoat layer: Fluorocarbon paint has excellent weather resistance and a color retention period of over 15 years, suitable for exterior wall decoration; Polysiloxane paint has chemical resistance and is suitable for chemical environments.

　　涂層總厚度需滿足C5-M高腐蝕環(huán)境要求（≥320μm），施工環(huán)境濕度≤85%，溫度5-38℃，雨后或結露狀態(tài)嚴禁作業(yè)。

　　The total thickness of the coating must meet the requirements of C5-M high corrosion environment (≥ 320 μ m), with a construction environment humidity of ≤ 85% and a temperature of 5-38 ℃. Operations are strictly prohibited after rain or condensation.

　　金屬鍍層技術提供長效防護方案。熱浸鍍鋅層厚度通常65-85μm，中性鹽霧試驗可達1000h以上，適用于輸電塔、光伏支架等戶外設施。熱噴涂鋁（鋅）復合涂層通過電弧噴涂形成150-200μm厚層，配合封閉漆使用，耐蝕性是熱鍍鋅的2-3倍，尤其適合海洋環(huán)境。需注意，鍍層厚度與壽命呈指數關系，每增加25μm鋅層，防護壽命延長約2-3年。

　　Metal plating technology provides long-term protection solutions. The thickness of hot-dip galvanized layer is usually 65-85 μ m, and the neutral salt spray test can reach more than 1000 hours. It is suitable for outdoor facilities such as transmission towers and photovoltaic brackets. Thermal spray aluminum (zinc) composite coating is formed with a thickness of 150-200 μ m by arc spraying, and when used in conjunction with sealing paint, its corrosion resistance is 2-3 times that of hot-dip galvanizing, making it particularly suitable for marine environments. It should be noted that the thickness of the coating is exponentially related to its lifespan. For every 25 μ m increase in zinc coating, the protective lifespan is extended by about 2-3 years.

　　電化學保護技術針對特殊工況。犧牲陽極法采用鎂合金（適用于土壤）、鋅合金（適用于淡水）陽極，連接電纜電阻需≤0.1Ω。外加電流法通過鈦基混合氧化物陽極，輸出電流密度0.02-0.2A/m2，適用于橋梁墩柱、地下管線等。監(jiān)測系統(tǒng)需定期檢測保護電位（-0.85V至-1.2V vs. SCE），確保極化效果。

　　Electrochemical protection technology is designed for special working conditions. The sacrificial anode method uses magnesium alloy (suitable for soil) and zinc alloy (suitable for freshwater) anodes, and the resistance of the connecting cable should be ≤ 0.1 Ω. The external current method uses a titanium based mixed oxide anode to output a current density of 0.02-0.2A/m2 Suitable for bridge piers, columns, underground pipelines, etc. The monitoring system needs to regularly detect the protective potential (-0.85V to -1.2V vs. SCE) to ensure polarization effectiveness.

　　新型防護材料與技術不斷突破。石墨烯改性環(huán)氧涂料將滲透性降低至10??cm/s以下，耐鹽霧試驗突破5000h。自修復微膠囊涂料含雙環(huán)戊二烯單體，劃痕處自動聚合，修復效率達85%以上。此外，冷噴涂鋅鋁復合粉體技術實現低溫沉積（≤80℃），避免基材變形，已用于異形構件修復。

　　New protective materials and technologies are constantly breaking through. Graphene modified epoxy coating reduces permeability to 10?? Below cm/s, the salt spray resistance test exceeded 5000 hours. The self-healing microcapsule coating contains dicyclopentadiene monomer, which automatically polymerizes at the scratch site, with a repair efficiency of over 85%. In addition, the cold spray zinc aluminum composite powder technology achieves low-temperature deposition (≤ 80 ℃) to avoid substrate deformation and has been used for repairing irregular components.

　　全生命周期管理是保障防腐效能的關鍵。新建工程需建立防腐檔案，記錄材料批次、施工參數及環(huán)境數據。運營階段每2-3年進行涂層厚度檢測（電磁測厚儀）、附著力測試（拉開法）及銹蝕面積評估（ISO 4628標準）。修復時采用局部打磨至St3級，涂刷過渡層后再復涂，避免新舊涂層剝離。對于C5級以上環(huán)境，建議采用"涂層+鍍層"復合體系，壽命預測模型顯示其防護周期可達普通涂層的2.5倍。

　　Whole life cycle management is the key to ensuring the effectiveness of anti-corrosion measures. New construction projects require the establishment of anti-corrosion archives, recording material batches, construction parameters, and environmental data. During the operation phase, coating thickness testing (electromagnetic thickness gauge), adhesion testing (pull open method), and corrosion area evaluation (ISO 4628 standard) are conducted every 2-3 years. When repairing, use local polishing to St3 level, apply a transition layer, and then reapply to avoid peeling off the new and old coatings. For environments above C5 level, it is recommended to use a "coating+plating" composite system, and the life prediction model shows that its protection period can reach 2.5 times that of ordinary coatings.

　　輕型鋼結構防腐蝕處理已從單一技術向系統(tǒng)化解決方案演進。通過材料科學、電化學及智能制造技術的融合，新型防腐體系在耐久性、環(huán)保性及經濟性間實現平衡。未來，隨著數字孿生技術在腐蝕監(jiān)測中的應用，鋼結構防腐蝕管理將邁向預測性維護新階段。

　　The anti-corrosion treatment of lightweight steel structures has evolved from a single technology to a systematic solution. Through the integration of materials science, electrochemistry, and intelligent manufacturing technology, the new anti-corrosion system achieves a balance between durability, environmental friendliness, and economy. In the future, with the application of digital twin technology in corrosion monitoring, the anti-corrosion management of steel structures will move towards a new stage of predictive maintenance.

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