High-performance offshore wind power steel-UHPC combined pipe structure and manufacturing and construction method thereof

Abstract

The invention discloses a high-performance offshore wind power steel-UHPC combined pipe structure and a manufacturing construction method thereof.The steel-UHPC combined pipe structure comprises a steel pipe and studs and further comprises a UHPC outer wrapping layer wrapping the steel pipe from the outer side, the outer surface of the steel pipe is connected with the studs in a welded mode, the UHPC outer wrapping layer is fixedly connected with the steel pipe through the studs, and the UHPC outer wrapping layer is fixedly connected with the steel pipe through the studs. A rib net of a net structure is further arranged in the UHPC outer wrapping layer, the rib net is connected with the studs through spot welding or binding, and the steel pipe, the studs, the UHPC outer wrapping layer and the rib net form a steel-UHPC combined pipe structure used as a pipe pile or a jacket foundation or a tower drum or an anti-collision component or a cable tying component. The durability and bearing capacity of the wind power structural component can be effectively improved, the reliability of the wind power structure is improved, the service life is prolonged, and the maintenance cost is reduced.

Description

Technical Field

[0001] The present invention relates to the field of offshore wind power pipe pile or conductor frame foundation, tower, anti-collision and mooring component protection technology, and specifically to a high-performance offshore wind power steel-UHPC combined pipe structure and a manufacturing and construction method thereof. Background Art

[0002] As global climate change and energy crises intensify, governments and energy companies are actively seeking sustainable energy solutions. Offshore wind power, as a clean and renewable energy source, has become an important direction for global energy transformation due to its huge development potential and low environmental impact. Compared with traditional onshore wind power, offshore wind power has the advantages of higher wind speed, more stability, and less land space occupation. Especially in coastal countries and regions with rich wind resources, the development and utilization of offshore wind power has received great attention.

[0003] However, offshore wind power piles or jacket foundations, towers, anti-collision and mooring components, as key supporting structures for wind turbines, face severe challenges from the marine environment. The marine environment is characterized by high salt, high humidity, high ultraviolet radiation and frequent extreme weather events. These factors act together on the wind power structure system, leading to problems such as corrosion, fatigue and structural performance degradation. Natural forces such as wind, waves and currents will generate dynamic loads on the towers, and long-term effects may cause structural damage and functional failure. Salt spray and chloride ions in seawater will accelerate the corrosion process of materials, especially in steel structures, where corrosion problems are particularly prominent, seriously affecting the durability and safety of the structure.

[0004] The attachment and growth of marine organisms will also affect wind turbine structures, not only increasing the surface roughness of the structure, but also changing the fluid dynamic characteristics, thus affecting the efficiency and stability of wind turbines. Microbial corrosion in the marine environment is also a problem that cannot be ignored. Some microorganisms can metabolize the metal elements in steel structures and accelerate the corrosion process.

[0005] In addition, when daily maintenance ships are operating at sea, the wind power foundation system needs to provide support points for mooring. Frequent docking and anchoring of ships cause the foundation components, especially the anti-collision column and the mooring cable components, to be constantly hit and rubbed by ships. This long-term physical impact makes the anti-corrosion coating on the anti-collision column and the mooring cable components connected to it very easy to be damaged, and once damaged, the repair work is extremely difficult. It is particularly worth noting that some maintenance ships or out-of-control ships may cause more serious local impacts on the anti-collision column in an emergency or improper operation due to their large tonnage and high speed. Such impacts may not only directly destroy the structural integrity of the anti-collision column, but also affect the stability and safety of the entire wind power facility.

[0006] Therefore, in order to ensure the long-term stable operation and structural safety of offshore wind power structure systems, effective protection measures must be taken. These measures need to be able to resist the erosion of the marine environment, reduce maintenance costs, extend the service life of the structure, and meet the requirements of environmental protection and sustainable development. This includes but is not limited to the development of new anti-corrosion materials, the use of advanced protection technologies, the improvement of wind power structure design, and the implementation of effective monitoring and maintenance strategies.

[0007] At present, the traditional protection methods for offshore wind power structural components mainly include heavy anti-corrosion coatings, reinforced concrete outsourcing, etc. Although these methods can provide protection to a certain extent, there are still some obvious disadvantages and limitations, as described below:

[0008] 1. Limited durability

[0009] Although traditional anti-corrosion coatings are easy to apply, their durability is limited. Long-term exposure to harsh marine environments may cause the coating to gradually fail and require regular maintenance and re-coating, which not only increases long-term operating costs, but may also cause the protective layer to break if maintenance is not timely, exposing the wind power structure to corrosion.

[0010] 2. High maintenance cost

[0011] Traditional protection methods usually require regular inspection and maintenance, which leads to high maintenance costs. Especially in offshore environments, maintenance work is not only costly but also poses certain safety risks.

[0012] 3. Increase the deadweight of the structure

[0013] Since ordinary concrete has low resistance to corrosion from media such as chloride ions, the use of traditional concrete outer coating for corrosion protection requires increasing the thickness of the concrete outer coating. Although this can improve the durability of the wind power structure to a certain extent, due to the large thickness of the concrete structure, this method will increase the deadweight of the structure, which not only puts higher requirements on the design, transportation and installation of the wind power structure, but may also affect the stability and bearing capacity of the structure.

[0014] 4. Limited impact and erosion resistance

[0015] When faced with unexpected impacts such as ship collisions and extreme water flow erosion, traditional protection technologies may not provide sufficient impact and wear resistance, resulting in damage to wind power structures. This risk is particularly significant under extreme weather conditions.

[0016] 5. Environmental issues

[0017] Traditional coatings and materials may contain harmful substances, causing potential pollution to the marine ecological environment. With the improvement of environmental protection requirements, the use of these materials is increasingly restricted.

[0018] 6. High life cycle cost

[0019] Due to the need for maintenance and repair, the total cost of traditional protection technology throughout its life cycle is high, which includes not only direct economic costs, but also downtime caused by maintenance and potential safety risks.

[0020] Although traditional offshore wind power structure protection technology can provide protection to a certain extent, it has obvious shortcomings in durability, maintenance cost, structure deadweight, impact and scour resistance, environmental issues and life cycle cost. Summary of the invention

[0021] In view of the shortcomings of the prior art, one of the purposes of the present invention is to propose a new type of offshore wind power structure, namely a high-performance offshore wind power steel-UHPC combined pipe structure, which aims to improve the durability and bearing capacity of components such as pipe piles or conductor frame foundations, towers, anti-collision and mooring cables, improve the reliability of wind power structures, extend service life, and reduce maintenance costs.

[0022] One of the purposes of the present invention is achieved by the following technical solution:

[0023] A high-performance offshore wind power steel-UHPC combined pipe structure, comprising a steel pipe and a bolt, and also comprising a UHPC outer layer covering the steel pipe from the outside, the outer surface of the steel pipe is welded to the bolt, the UHPC outer layer is fixedly connected to the steel pipe through the bolt, a mesh-shaped reinforcement net is further arranged in the UHPC outer layer, the reinforcement net is connected to the bolt by spot welding or binding, the steel pipe, the bolt, the UHPC outer layer and the reinforcement net constitute a steel-UHPC combined pipe structure used as a pipe pile or as a conductor frame foundation or as a tower or as an anti-collision component or as a mooring component.

[0024] The combined pipe structure of the present invention uses steel pipes as the main load-bearing components and UHPC materials as the outer structure. The UHPC material has ultra-high strength and durability, can effectively resist the erosion of the marine environment, extend the service life of the offshore wind power structure, can reduce the corrosion burden of the offshore wind power steel structure, effectively reduce the workload of operation and maintenance, and significantly reduce the operating cost. In addition, the reinforcement mesh of the present invention has a strong hoop constraint effect, increases the ductility of the structure, improves the crack resistance of UHPC, and the reinforcement mesh is connected with the bolts, which can improve the overall strength and durability of the steel-UHPC combined pipe structure.

[0025] The present invention also has the following preferred design:

[0026] The steel-UHPC composite pipe structure of the present invention is manufactured in sections. The steel-UHPC composite pipe structure is formed by connecting a plurality of composite pipe segments. End connecting steel plates are provided at both ends of each composite pipe segment. The end connecting steel plates are fixedly connected to the steel pipes of the composite pipe segments. The composite pipe segments are assembled through the end connecting steel plates to form an integral structure.

[0027] The reinforcement mesh of the present invention includes longitudinal reinforcements and transverse reinforcements. The longitudinal reinforcements are arranged along the length direction of the steel pipe, and the transverse reinforcements are arranged along the circumferential direction of the steel pipe to form annular reinforcements. The longitudinal reinforcements and the transverse reinforcements are formed into a mesh structure by binding and welding. The reinforcement mesh is attached to the outer surface of the steel pipe structure, and the longitudinal reinforcements and / or transverse reinforcements can be connected to the bolts by spot welding or binding.

[0028] The longitudinal ribs of the present invention are arranged at intervals of 50 mm to 100 mm, and the transverse ribs are arranged at intervals of 50 mm to 100 mm. Ribs with a diameter of 6 mm to 12 mm can be used.

[0029] The longitudinal reinforcement and the transverse reinforcement of the present invention are steel bars and / or FRP bars.

[0030] The outer surface of the steel pipe of the present invention has a plurality of studs evenly arranged along the length direction and the circumferential direction, and the transverse and longitudinal arrangement spacing of the studs can be 150 mm to 300 mm, so as to enhance the bonding effect between the steel structure and the UHPC.

[0031] The second object of the present invention is to provide a manufacturing and construction method of the above-mentioned high-performance offshore wind power steel-UHPC combined pipe structure, comprising the following steps:

[0032] S1. The two ends of the steel pipe are welded to connect the steel plates;

[0033] S2. Clean and pretreat the surface of the steel structure formed by connecting the steel pipe and the end connecting steel plate in step S1 to remove surface impurities, including oil stains and rust;

[0034] S3. Studs are welded on the outer surface of the steel pipe;

[0035] S4. Laying out the reinforcement mesh, connecting the reinforcement mesh to the studs by spot welding or tying;

[0036] S5. A UHPC outer cladding is constructed on the outside of the steel pipe by pouring or spraying to obtain a combined pipe segment;

[0037] S6. Maintaining the combined pipe segment;

[0038] S7. The combined pipe segment is transported to the construction site by a vehicle and / or a ship, and the combined pipe segment is firmly fixed to the vehicle or ship to prevent displacement or sliding during transportation;

[0039] S8. Use a lifting device to hoist the combined pipe segments, and sequentially connect the end connecting steel plates between adjacent combined pipe segments by welding and / or flange connection. The combined pipe segments are connected to form a steel-UHPC combined pipe structure.

[0040] In the step S5 of the present invention, the UHPC outer cladding constructed by casting is constructed by using a structural formwork, and the structural formwork is removed after the construction of the UHPC outer cladding is completed.

[0041] In the step S6 of the present invention, the combined pipe segment is cured by high-temperature steaming in a prefabrication plant, or the combined pipe segment constructed on site is cured by film coating.

[0042] The UHPC material of the UHPC outer cladding of the present invention has an axial compressive strength of not less than 120 MPa, an axial tensile strength of not less than 7 MPa, and a fiber volume content of not less than 2%.

[0043] The present invention has the following beneficial effects:

[0044] 1. The combined pipe structure of the present invention uses steel pipes as the main load-bearing components and UHPC materials as the outer layer structure. UHPC materials have ultra-high strength and durability, can effectively resist the erosion of the marine environment, extend the service life of offshore wind power structures, can reduce the corrosion burden of offshore wind power steel structures, have good anti-collision performance, and improve the overall safety of wind power structures. The present invention can effectively reduce the workload of operation and maintenance and significantly reduce operating costs.

[0045] 2. The reinforcement mesh of the present invention has a strong hoop restraint effect, increases the ductility of the structure, and improves the crack resistance of UHPC. The reinforcement mesh is connected with the studs, which can improve the overall strength and durability of the steel-UHPC composite pipe structure.

[0046] 3. The high toughness and crack resistance of the UHPC material of the present invention improve the stability of wind power structures under extreme environmental conditions.

[0047] 4. The construction and maintenance process of the UHPC outer cladding of the present invention is relatively simple and easy to operate, which is conducive to improving construction efficiency and ensuring quality.

[0048] 5. The structural system of the present invention is applicable to offshore wind power structural components of various sizes and shapes, and has strong versatility and adaptability.

[0049] In summary, by adopting the protection technology of the offshore wind power structure system of the present invention, the durability and safety of the offshore wind power structure can be effectively improved, providing strong technical support for the sustainable development of offshore wind power. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] Figure 1 It is a plan view of the offshore wind power steel-UHPC combined pipe structure of the present invention;

[0051] Figure 2 yes Figure 1 The AA cross-sectional view of the steel-UHPC composite tube structure shows the vertical structural composition of the steel-UHPC composite tube structure;

[0052] Figure 3 yes Figure 1 The BB cross-sectional view of the steel-UHPC composite pipe structure shows the transverse structural composition of the steel-UHPC composite pipe structure;

[0053] Figure 4 It is a large-scale drawing of the steel pipe and studs in the steel-UHPC composite pipe structure of the present invention, showing the plane detail structure after the studs are welded on the outside of the steel pipe;

[0054] Figure 5 It is a large-scale drawing of the connection between the longitudinal reinforcement and the transverse reinforcement in the steel-UHPC composite pipe structure of the present invention, showing the detailed structure of the reinforcement network formed by the longitudinal and transverse reinforcements.

[0055] Figure 6 yes Figure 1 A large-scale drawing of the middle and end connection steel plates, showing the detailed structure of the end connection steel plates.

[0056] Description of reference numerals:

[0057] 10-steel-UHPC composite pipe structure, 1-steel pipe, 2-bolt, 3-longitudinal reinforcement, 4-transverse reinforcement, 5-UHPC outer cladding, 6-end connecting steel plate. DETAILED DESCRIPTION

[0058] The technical solution of the present invention is described in detail below in conjunction with the accompanying drawings and embodiments so that those skilled in the art can better understand and implement the technical solution of the present invention.

[0059] like Figures 1 to 6As shown, a high-performance offshore wind power steel-UHPC combined pipe structure 10 includes a steel pipe 1 and a bolt 2, and also includes a UHPC outer layer 5 covering the steel pipe 1 from the outside, the outer surface of the steel pipe 1 is welded to the bolt 2, the UHPC outer layer 5 is fixedly connected to the steel pipe 1 through the bolt 2, and a mesh-shaped reinforcement net is also arranged in the UHPC outer layer 5, and the reinforcement net is connected to the bolt 2 by spot welding or binding. The steel pipe 1, the bolt 2, the UHPC outer layer 5 and the reinforcement net constitute a steel-UHPC combined pipe structure 10 used as a pipe pile or as a conductor frame foundation or as a tower or as an anti-collision component or as a mooring component.

[0060] The composite pipe structure uses a steel pipe 1 as the main load-bearing member, the wall thickness of the steel pipe 1 is preferably 16 mm to 28 mm, and the UHPC material is used as the outer layer structure. The axial compressive strength of the UHPC material is not less than 120 MPa, the axial tensile strength is not less than 7 MPa, and the fiber volume content is not less than 2%.

[0061] In one embodiment, the steel-UHPC composite pipe structure 10 is manufactured in sections. The steel-UHPC composite pipe structure 10 is formed by connecting a plurality of composite pipe segments. End connecting steel plates 6 are provided at both ends of each composite pipe segment. The end connecting steel plates 6 are fixedly connected to the steel pipe 1 of the composite pipe segment. The composite pipe segments are assembled through the end connecting steel plates 6 to form an integral structure. The thickness of the end connecting steel plates 6 is 20 mm to 40 mm.

[0062] In one embodiment, the reinforcement mesh includes longitudinal reinforcement 3 and transverse reinforcement 4. The longitudinal reinforcement 3 is arranged along the length direction of the steel pipe 1, and the transverse reinforcement 4 is arranged along the circumferential direction of the steel pipe 1 to form an annular reinforcement. The longitudinal reinforcement 3 and the transverse reinforcement 4 are formed into a mesh structure by binding and welding. The reinforcement mesh is attached to the outer surface of the steel pipe 1 structure, and the longitudinal reinforcement 3 and / or the transverse reinforcement 4 can be connected to the bolt 2 by spot welding or binding.

[0063] In one embodiment, the longitudinal reinforcement 3 is arranged at a spacing of 50 mm to 100 mm, and the transverse reinforcement 4 is arranged at a spacing of 50 mm to 100 mm, and reinforcements with a diameter of 6 mm to 12 mm can be used. Specifically, the longitudinal reinforcement 3 and the transverse reinforcement 4 are steel bars and / or FRP bars. FRP bars are formed by gluing multiple strands of continuous fibers (such as glass fibers, carbon fibers, etc.) through base materials (such as polyamide resins, polyethylene resins, epoxy resins, etc.), extruding and drawing through special molds. Common fiber materials used for FRP bars generally include glass fiber reinforced plastics (Glass Fiber Reinforced Plastics, abbreviated as GFRP), carbon fiber reinforced plastics (Carbon Fiber Reinforced Plastics, abbreviated as CFRP), aramid fiber reinforced plastics (AFRP bars), etc., which have the advantages of light weight, high tensile strength, strong corrosion resistance, strong material bonding, and strong magnetic wave permeability.

[0064] In one embodiment, a plurality of studs 2 are evenly arranged on the outer surface of the steel pipe 1 along the length direction and the circumferential direction. The studs 2 are welded to the steel pipe 1. The horizontal and vertical arrangement spacings of the studs 2 can be 150 mm to 300 mm, which are used to enhance the bonding effect between the steel structure and the UHPC. The studs 2 can be 35×13 mm cylindrical head studs.

[0065] The manufacturing and construction method of the above-mentioned high-performance offshore wind power steel-UHPC composite pipe structure first needs to divide the segments according to the design drawings in the steel structure processing plant, make the steel pipe 1 according to the segment length, and process the end connecting steel plate 6 according to the size of the design drawings. The specific manufacturing and construction method of the steel-UHPC composite pipe structure 10 includes the following steps:

[0066] S1. The ends of the steel pipe 1 are welded to the steel plate 6;

[0067] S2. Clean and pretreat the surface of the steel structure formed by connecting the steel pipe 1 and the end connecting steel plate 6 in step S1 to remove surface impurities, including oil stains and rust;

[0068] S3. The outer surface of the steel pipe 1 is welded with studs 2;

[0069] S4. Laying out the reinforcement mesh and connecting the reinforcement mesh with the stud 2;

[0070] S5. The UHPC outer cladding 5 is constructed on the outside of the steel pipe 1 by pouring or spraying to obtain a combined pipe segment;

[0071] S6. Maintaining the combined pipe segment;

[0072] S7. The combined pipe segment is transported to the construction site by a vehicle and / or a ship, and the combined pipe segment is firmly fixed to the vehicle or ship to prevent displacement or sliding during transportation;

[0073] S8. Use a lifting device to hoist the combined pipe segments, and sequentially connect the end connecting steel plates between adjacent combined pipe segments by welding and / or flange connection. The combined pipe segments are connected to form a steel-UHPC combined pipe structure.

[0074] Wherein, in step S5, the UHPC outer cladding 5 constructed by casting is constructed by using a structural template, and the structural template is removed after the construction of the UHPC outer cladding 5 is completed. The UHPC outer cladding 5 constructed by spraying does not require a template.

[0075] In step S6, when the combined pipe segment is manufactured in a prefabrication plant, high-temperature steam curing is preferably adopted; if the combined pipe segment needs to be constructed on site, film coating curing is preferably adopted.

[0076] In order to meet the design requirements of pipe piles or jacket foundations, towers and other structures of offshore wind power systems, the axial compressive strength of the UHPC material of the UHPC outer layer shall not be less than 120MPa, the axial tensile strength shall not be less than 7MPa, and the fiber volume content shall not be less than 2%.

[0077] The above embodiments are only preferred embodiments of the present invention, but cannot be used as limitations of the invention. Any modifications and improvements based on the concept of the present invention should fall within the protection scope of the present invention. The specific protection scope shall be subject to the claims.

Claims

1. A high-performance offshore wind power steel-UHPC composite pipe structure, comprising a steel pipe and a bolt, characterized in that: It also includes a UHPC outer cladding covering the steel pipe from the outside, the outer surface of the steel pipe is welded to the stud, the UHPC outer cladding is fixedly connected to the steel pipe through the stud, a mesh-shaped reinforcement net is also arranged in the UHPC outer cladding, the reinforcement net is connected to the stud by spot welding or binding, and the steel pipe, the stud, the UHPC outer cladding and the reinforcement net constitute a steel-UHPC combined pipe structure used as a pipe pile, or as a conductor frame foundation, or as a tower, or as an anti-collision component, or as a mooring component.

2. The high-performance offshore wind power steel-UHPC combined pipe structure according to claim 1 is characterized in that: The steel-UHPC combined pipe structure is formed by connecting a plurality of combined pipe segments. End connecting steel plates are provided at both ends of each combined pipe segment. The end connecting steel plates are fixedly connected to the steel pipes of the combined pipe segment.

3. The high-performance offshore wind power steel-UHPC combined pipe structure according to claim 1 is characterized in that: The reinforcement mesh includes longitudinal reinforcements and transverse reinforcements. The longitudinal reinforcements are arranged along the length direction of the steel pipe, and the transverse reinforcements are arranged along the circumferential direction of the steel pipe to form annular reinforcements. The longitudinal reinforcements and the transverse reinforcements are tied and welded to form a mesh structure.

4. The high-performance offshore wind power steel-UHPC combined pipe structure according to claim 3 is characterized in that: The longitudinal reinforcements are arranged at intervals of 50 mm to 100 mm, and the transverse reinforcements are arranged at intervals of 50 mm to 100 mm.

5. The high-performance offshore wind power steel-UHPC combined pipe structure according to claim 3 is characterized in that: The longitudinal reinforcement and the transverse reinforcement are steel bars and / or FRP bars.

6. The high-performance offshore wind power steel-UHPC combined pipe structure according to claim 3 is characterized in that: A plurality of the studs are evenly arranged on the outer surface of the steel pipe along the length direction and the circumferential direction.

7. A method for manufacturing and constructing a high-performance offshore wind power steel-UHPC composite pipe structure as described in claims 1 to 6, characterized in that: The steps include: S1. The two ends of the steel pipe are welded to connect the steel plates; S2. Clean and pretreat the surface of the steel structure formed by connecting the steel pipe and the end connecting steel plate in step S1 to remove surface impurities, including oil stains and rust; S3. Studs are welded on the outer surface of the steel pipe; S4. Laying out the reinforcement mesh, connecting the reinforcement mesh to the studs by spot welding or tying; S5. A UHPC outer cladding is constructed on the outside of the steel pipe by pouring or spraying to obtain a combined pipe segment; S6. Maintaining the combined pipe segment; S7. The combined pipe segment is transported to the construction site by a vehicle and / or a ship, and the combined pipe segment is firmly fixed to the vehicle or ship to prevent displacement or sliding during transportation; S8. Use a lifting device to hoist the combined pipe segments, and sequentially connect the end connecting steel plates between adjacent combined pipe segments by welding and / or flange connection. The combined pipe segments are connected to form a steel-UHPC combined pipe structure.

8. The manufacturing and construction method of the high-performance offshore wind power steel-UHPC composite pipe structure according to claim 7 is characterized by: In the step S5, the UHPC outer cladding constructed by casting is constructed by using a structural formwork, and the structural formwork is removed after the UHPC outer cladding is constructed.

9. The manufacturing and construction method of the high-performance offshore wind power steel-UHPC composite pipe structure according to claim 7 is characterized by: In the step S6, the combined pipe segment is cured by high temperature steaming in the prefabrication plant, or the combined pipe segment constructed on site is cured by film coating.

10. The manufacturing and construction method of the high-performance offshore wind power steel-UHPC composite pipe structure according to claim 7 is characterized in that: The UHPC material of the UHPC outer cladding has an axial compressive strength of not less than 120 MPa, an axial tensile strength of not less than 7 MPa, and a fiber volume content of not less than 2%.

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