Improved corrugated steel cylinder fiber reinforced pipe and manufacturing method thereof

Abstract

The invention discloses an improved corrugated steel cylinder fiber reinforced pipe and a manufacturing method thereof, belongs to the field of pipeline and pressure vessel manufacturing, and comprises an improved corrugated steel cylinder fiber reinforced pipe structure, a prestressed fiber winding method and an improved corrugated steel cylinder fiber reinforced pipe manufacturing method. According to the improved corrugated steel cylinder fiber reinforced pipe, a spiral corrugated steel cylinder is adopted to replace an annular corrugated steel cylinder, a corrugated valley bottom is machined, a wire winding process is improved, then circumferential and longitudinal steel bars are welded to the steel cylinder, and then a novel corrugated steel cylinder composite pipe structure with smaller prestress loss and higher steel cylinder constraining force is obtained. According to the improved corrugated steel cylinder fiber reinforced pipe, the spiral corrugated steel cylinder and a prestressed fiber wire winding method are adopted, so that the prestress retaining capacity and the wire breakage resistance of the pipe are improved.

Description

Technical Field

[0001] The present invention belongs to the field of pipeline and pressure vessel manufacturing, in particular to a novel long-distance large-diameter water supply and drainage pipeline and manufacturing technology, and more particularly to an improved corrugated steel tube fiber reinforced pipe and a manufacturing method thereof. Background Art

[0002] In the field of high-pressure water pipelines, traditional pipeline materials and structures are susceptible to corrosion, wear and pressure fluctuations during long-term operation, resulting in pipeline rupture or leakage. As a new type of pipeline material, basalt fiber reinforced corrugated steel concrete composite pipe (BSCP) is widely used in hydraulic structures due to its excellent mechanical properties and corrosion resistance. However, during the manufacturing process of BSCP, especially in the fiber winding process, the fiber filaments are prone to slip and concentrate at the trough of the corrugated steel cylinder, resulting in uneven stress distribution, affecting the structural integrity and durability of the pipeline. The traditional fiber winding method has problems such as low winding efficiency, unstable quality, and difficulty in achieving automated control. In addition, due to the lack of effective fiber distribution control means, the problem of fiber slippage and wear at the trough is difficult to solve, which limits the application scope and service life of BSCP pipelines.

[0003] In view of the above problems, the present invention aims to propose an improved corrugated steel tube fiber reinforced pipe and its manufacturing method, by using a spiral corrugated steel tube instead of an annular corrugated steel tube, processing the corrugated valley and improving the wire winding process, and then welding the annular and longitudinal steel bars on the steel tube, thereby obtaining a new type of corrugated steel tube composite pipe structure with less prestress loss and stronger steel tube constraint. The prestressed fiber winding method involved in the present invention is efficient and feasible, and the new type of corrugated steel tube composite pipe structure involved has stronger resistance to wire breakage, which helps to overcome the problem of wire breakage and cracking in BSCP pipelines, and provides more reliable technical support for the safe operation of hydraulic structures.

[0004] After review, very few of the published patents involve BSCP pipeline structure innovation and prestressed fiber winding process optimization. Some related patents are as follows: CN117450330A discloses a large-diameter fiber-reinforced corrugated steel-concrete composite pipe and a preparation method thereof. The designed BSCP includes a high-strength concrete layer, a steel corrugated tube, a mixed layer, a fiber-reinforced layer pre-impregnated with resin and a high-density polyethylene outer protective layer arranged in sequence from the inside to the outside and compositely connected together. During the production process, the structure has stress relaxation and wear of the prestressed fiber wires, which may cause a decrease in product quality.

[0005] After review, a small number of published patents involve improved wire wrapping methods for non-BSCP pipes. Some of the relevant patents are as follows: CN219768637U discloses a pipe outer wall wire wrapping device, which can wrap steel wires around the outer surface of the pipe at a uniform speed and equal distance. After the wire wrapping, the steel wires wrapped up and down can fit together, thereby ensuring the compressive strength of the pipe after the wire wrapping; CN218664843U discloses a pipeline wire wrapping machine, which can fix pipes of different sizes and speed up the wire wrapping speed of the pipe; CN215445390U discloses a pipe core wire wrapping device for processing prestressed steel cylinder concrete pipes; the above patents cannot overcome the wire wrapping problem when the prestressed wires are stacked. Summary of the invention

[0006] According to the above-mentioned problems that the existing BSCP is difficult to wind with high quality and difficult to solve the problem of wire breakage and cracking, an improved corrugated steel tube fiber reinforced pipe and a manufacturing method thereof are provided to provide more reliable technical support for the optimization of BSCP structure and high-quality production.

[0007] The present invention provides an improved corrugated steel tube fiber reinforced pipe and a manufacturing method thereof, wherein the improved corrugated steel tube fiber reinforced pipe structure comprises fiber-mixed mortar, a spiral corrugated steel tube and basalt fiber filaments.

[0008] Furthermore, the basalt fiber filaments are wound on a spiral corrugated steel cylinder and covered with unsaturated resin.

[0009] Preferably, the unsaturated resin may also be replaced by a fast-curing AB glue or structural glue or other resin adhesive that can quickly develop strength.

[0010] Further, the fiber-mixed mortar is coated on the inner surface of the spiral corrugated steel tube, and the fiber-mixed mortar is allowed to solidify to form strength.

[0011] Preferably, the fibers in the fiber-blended mortar are basalt short fibers, which mainly prevent microcracks, but can also be replaced by microcapsule self-repairing concrete, shape memory alloy concrete and other concrete that prevents microcracks.

[0012] Furthermore, longitudinal steel bars and annular steel bars are welded to the spiral corrugated steel cylinder, and the surfaces of the longitudinal steel bars and annular steel bars are wrapped with PE protective sleeves.

[0013] Preferably, the longitudinal reinforcement and annular reinforcement welded on the spiral corrugated steel cylinder are threaded steel bars, but may also be reinforcement components such as steel cables and steel grid-type reinforcements.

[0014] Furthermore, the spiral corrugated steel cylinder includes crests and troughs, and a plurality of corrugations are arranged in the troughs.

[0015] Preferably, the depth of the corrugations arranged in the trough is not less than 1 / 3 of the original trough depth of the spiral corrugated steel cylinder.

[0016] Furthermore, a first layer of basalt fiber filaments is wound around the bottom of the corrugation, a first layer of unsaturated resin is covered on the first layer of basalt fiber filaments, a second layer of basalt fiber filaments is wound on the first layer of unsaturated resin, a second layer of unsaturated resin is covered on the second layer of basalt fiber filaments, a third layer of basalt fiber filaments is wound on the second layer of unsaturated resin, and a third layer of unsaturated resin is covered on the third layer of basalt fiber filaments.

[0017] Preferably, three layers of basalt fiber and unsaturated resin are arranged in the trough, but more layers may be added as required.

[0018] The present invention provides an improved method for manufacturing a corrugated steel tube fiber reinforced pipe, characterized in that the method comprises the following steps: S1: Making spiral corrugated steel cylinder; S2: Spraying fiber-mixed mortar on the inner surface of the spiral corrugated steel cylinder; S3: Wrapping basalt fiber filaments around the trough of the spiral corrugated steel cylinder; S4: Filling the trough of the spiral corrugated steel cylinder with unsaturated resin; S5: Welding longitudinal reinforcement and circumferential reinforcement on the spiral corrugated steel cylinder; S6: The outermost side of the corrugated steel fiber reinforced pipe is wrapped with a PE protective sheath.

[0019] Preferably, the step S3 and the step S4 further include a method for winding and curing prestressed basalt fiber filaments: winding a first layer of basalt fiber filaments at the bottom of the trough, ensuring that a basalt fiber filament is arranged in each corrugation, and ensuring that the prestress loss of the basalt fiber filaments is less than 5% during the winding process; using a first layer of unsaturated resin to completely cover the first layer of basalt fiber filaments, and its height reaches 1 / 3 of the height of the trough, and waiting for the first layer of unsaturated resin to be cured; winding a second layer of basalt fiber filaments on the cured first layer of unsaturated resin, and covering the second layer of basalt fiber filaments with a second layer of unsaturated resin, and its height reaches 2 / 3 of the height of the trough, and waiting for the second layer of unsaturated resin to be cured; winding a third layer of basalt fiber filaments on the cured second layer of unsaturated resin, and covering the third layer of basalt fiber filaments with a third layer of unsaturated resin, and its height completely fills the trough and is consistent with the height of the peak, and waiting for the third layer of unsaturated resin to be cured; Preferably, in the winding process in step S3 and step S4, unsaturated resin may be pre-coated on the basalt fiber filaments, and then the basalt fiber filaments may be wound on the spiral corrugated steel cylinder before they are solidified.

[0020] Preferably, step S5 also includes a method for arranging longitudinal steel bars and circumferential steel bars: the longitudinal steel bars are arranged at the crest position of the spiral corrugated steel cylinder by spot welding, and then the circumferential steel bars are arranged at the end of the spiral corrugated steel cylinder and connected to each longitudinal steel bar by spot welding.

[0021] Compared with the prior art, the advantages and positive effects of the present invention are: The present invention provides an improved corrugated steel tube fiber reinforced pipe and its manufacturing method. Compared with the prior art, the present invention increases the shear resistance of the product by replacing the annular corrugated steel tube with a spiral corrugated steel tube; processes the corrugated valley bottom and improves the wire winding process, thereby increasing the product's resistance to wire breakage; welds circumferential and longitudinal steel bars on the steel tube, thereby reducing the probability of stress concentration in the corrugated steel tube and the possibility of cracks at the end of the product; and finally obtains a new type of corrugated steel tube composite pipe structure with less prestress loss and stronger steel tube constraint. The prestressed fiber winding method involved in the present invention is efficient and feasible, and the new type of corrugated steel tube composite pipe structure involved has a stronger resistance to wire breakage, which helps to overcome the problem of wire breakage and cracking in BSCP pipelines and provides more reliable technical support for the safe operation of hydraulic structures. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings required for use in the description of the embodiments will be briefly introduced one by one below. Obviously, the accompanying drawings in the following description are some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without paying creative labor.

[0023] Figure 1 A schematic diagram of the structure of an improved corrugated steel tube fiber reinforced pipe provided in Example 2; Figure 2 A schematic diagram of the details of the trough winding of an improved corrugated steel tube fiber-reinforced pipe provided in Example 2; Figure 3 A schematic diagram of the wire wrapping and strengthening process of an improved corrugated steel tube fiber reinforced pipe provided in Example 2; In the above figures, 1. fiber-blended mortar; 2. spiral corrugated steel tube; 3. basalt fiber filaments; 4. unsaturated resin; 5. longitudinal steel bars; 6. circumferential steel bars; 7. PE protective sleeve; 8. wave crest; 9. wave trough; 10. corrugation; 11. first layer of basalt fiber filaments; 12. first layer of unsaturated resin; 13. second layer of basalt fiber filaments; 14. second layer of unsaturated resin; 15. third layer of basalt fiber filaments; 16. third layer of unsaturated resin. DETAILED DESCRIPTION

[0024] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the accompanying drawings in the embodiments of the present invention. It should be noted that the embodiments of the present application and the features in the embodiments can be combined with each other without conflict.

[0025] In the following description, many specific details are set forth to facilitate a full understanding of the present invention. However, the present invention may also be implemented in other ways than those described herein. Therefore, the present invention is not limited to the specific embodiments of the following disclosure.

[0026] Example 1: This example aims to implement a process for manufacturing a fiber-mixed mortar inner layer of an improved corrugated steel tube fiber-reinforced pipe. When manufacturing the fiber-mixed mortar inner layer, the following steps need to be followed to ensure the quality of the product: 1. Prepare materials: 350 kg / m³ cement, 650 kg / m³ river sand, 10 kg / m³ short basalt fiber (the selected fiber length is between 6-12mm), and 70 kg / m³ water.

[0027] 2. Mortar preparation: In a dry state, mix cement and fine aggregate thoroughly; disperse short basalt fibers evenly in the mixture of cement and fine aggregate, ensuring that the fibers are evenly distributed to avoid agglomeration; gradually add measured water while stirring until the mortar reaches appropriate consistency and fluidity.

[0028] 3. Spraying process: ensure that the inner surface of the spiral corrugated steel cylinder is clean, free of oil and dust to improve the adhesion of the mortar; use professional spraying equipment to evenly spray the prepared short basalt fiber-blended mortar on the inner surface of the spiral corrugated steel cylinder; control the pressure and speed of spraying to ensure the uniformity and thickness of the mortar layer; control the thickness of the mortar layer, generally 3-5mm, to ensure sufficient protection and strength.

[0029] 4. Curing and maintenance: After spraying, place the product in a standard curing room for 7-14 days, and wait for the inner layer of the fiber-added mortar to completely cure, and then check the micro-cracks of the finished product.

[0030] Example 2: This example aims to implement the design of an improved corrugated steel tube fiber reinforced pipe. Figures 1 to 3 When making a new type of corrugated steel tube composite pipe structure, you need to follow the following steps to ensure the correctness of the product: 1. The annular corrugated steel cylinder in the original BSCP structure is changed into a spiral corrugated steel cylinder. First, the wave crests (8) and wave troughs (9) of the thin steel plate are pressed out, and then the thin steel plate is rolled into a cylinder using a plate rolling machine and welded into a steel cylinder. It is necessary to ensure that the steel cylinder is fully welded on both sides along the splicing line and that there is no gap.

[0031] 2. The prepared fiber-mixed mortar (1) is sprayed on the spiral corrugated steel cylinder to form a basalt fiber reinforced concrete inner cushion layer.

[0032] 3. Wrap the first layer of basalt fiber (11) around the bottom of the trough (9), ensuring that a basalt fiber (3) is arranged in each corrugation (10), and maintaining the prestress loss less than 5% during the winding process.

[0033] 4. Using a first layer of unsaturated resin (12) to completely cover the first layer of basalt fiber filaments (11) to a height reaching 1 / 3 of the height of the trough (9), and waiting for the first layer of unsaturated resin (12) to solidify for at least 4 hours; winding a second layer of basalt fiber filaments (13) on the solidified first layer of unsaturated resin (12), and covering the second layer of basalt fiber filaments (13) with a second layer of unsaturated resin (14), and waiting for the second layer of unsaturated resin (14) to solidify for at least 4 hours.

[0034] 5. A third layer of basalt fiber (15) is wound on the cured second layer of unsaturated resin (14), and a third layer of unsaturated resin (16) is covered on the third layer of basalt fiber (15), with the height of the third layer of unsaturated resin (16) completely filling the wave valley (9) and being consistent with the height of the wave peak (8), and the third layer of unsaturated resin (16) is allowed to cure for at least 4 hours.

[0035] 6. The longitudinal steel bars (5) are arranged at the crest (8) of the spiral corrugated steel tube (2) by spot welding, and the diameter of the longitudinal steel bars is 12 mm; then the circumferential steel bars (6) are arranged at the ends of the spiral corrugated steel tube (2), and the diameter of the circumferential steel bars is 10 mm, and are connected to each longitudinal steel bar (5) by spot welding, and the distance between the welding points does not exceed 200 mm.

[0036] 7. Wrap the entire pipe with a PE protective sleeve (7), use PE tape to wrap the spiral corrugated steel cylinder wrapped with basalt fiber (3), and then heat the entire pipe section on a heating device to melt the PE tape into the entire PE protective sleeve (7). The thickness of the PE protective sleeve (7) is not less than 2 mm.

[0037] Embodiment 3: This embodiment aims to implement an installation method of an improved corrugated steel tube fiber reinforced pipe. When installing the improved corrugated steel tube fiber reinforced pipe, the following steps need to be followed to ensure the normal use of the product: 1. Make sure the installation site has been cleaned and there are no sharp obstacles at the installation site. Check whether the site is flat and solid to ensure the stability of the pipeline after installation.

[0038] 2. Before installation, conduct a comprehensive inspection of the improved corrugated steel tube fiber reinforced pipe to ensure that there is no damage, deformation or defect.

[0039] 3. Use a crane or forklift to slowly lift the pipe to the installation location, ensuring that the pipe is not twisted or violently impacted during the lifting process to avoid damage to the PE protective cover and internal structure.

[0040] 4. Connect both ends of the pipeline to adjacent pipelines or interfaces, ensure the sealing and stability of the connection, adjust the pipeline position, ensure that the pipeline axis is consistent with the design axis, and the pipeline slope meets the use requirements.

[0041] 5. After the pipeline is installed, a pressure test is performed to verify the tightness and strength of the pipeline.

[0042] 6. When the service life reaches 24 and 60 months, check whether the PE protective cover has signs of wear, aging or damage, and check whether there are leaks at the pipe joints.

Claims

1. An improved corrugated steel tube fiber reinforced pipe structure, characterized in that: The improved corrugated steel tube fiber reinforced pipe structure comprises a fiber-mixed mortar (1), a spiral corrugated steel tube (2) and basalt fiber filaments (3), wherein the basalt fiber filaments (3) are wound around the spiral corrugated steel tube (2) and covered with an unsaturated resin (4), and the fiber-mixed mortar (1) is coated on the inner surface of the spiral corrugated steel tube (2); longitudinal steel bars (5) and annular steel bars (6) are welded to the spiral corrugated steel tube (2), and the surfaces of the longitudinal steel bars (5) and the annular steel bars (6) are wrapped with a PE protective sleeve (7); the spiral corrugated steel tube (2) comprises a wave crest (8) and a wave trough (9) ), a plurality of corrugations (10) are arranged in the trough (9), a first layer of basalt fiber filaments (11) is wound around the bottom of the corrugations (10), a first layer of unsaturated resin (12) is covered on the first layer of basalt fiber filaments (11), a second layer of basalt fiber filaments (13) is wound around the first layer of unsaturated resin (12), a second layer of unsaturated resin (14) is covered on the second layer of basalt fiber filaments (13), a third layer of basalt fiber filaments (15) is wound around the second layer of unsaturated resin (14), and a third layer of unsaturated resin (16) is covered on the third layer of basalt fiber filaments (15).

2. A method for manufacturing an improved corrugated steel tube fiber reinforced pipe, characterized in that: The method comprises the following steps: S1: Making spiral corrugated steel cylinder; S2: Spraying fiber-mixed mortar on the inner surface of the spiral corrugated steel cylinder; S3: Wrapping basalt fiber filaments around the trough of the spiral corrugated steel cylinder; S4: Filling the trough of the spiral corrugated steel cylinder with unsaturated resin; S5: Welding longitudinal reinforcement and circumferential reinforcement on the spiral corrugated steel cylinder; S6: The outermost side of the corrugated steel fiber reinforced pipe is wrapped with a PE protective sheath.

3. The improved method for manufacturing a corrugated steel tube fiber reinforced pipe according to claim 2, characterized in that: The steps S3 and S4 also include a method for winding and curing prestressed basalt fiber filaments, the method comprising: winding a first layer of basalt fiber filaments (11) around the bottom of the trough (9), ensuring that a basalt fiber filament (3) is arranged in each corrugation (10), and ensuring that the prestress loss of the basalt fiber filaments (3) is less than 5% during the winding process; using a first layer of unsaturated resin (12) to completely cover the first layer of basalt fiber filaments (11), the height of which reaches 1 / 3 of the height of the trough (9), and waiting for the first layer of unsaturated resin (12) to cure; after curing, A second layer of basalt fiber filaments (13) is wound on a layer of unsaturated resin (12), and a second layer of unsaturated resin (14) is covered on the second layer of basalt fiber filaments (13), the height of which reaches 2 / 3 of the height of the trough (9), and the second layer of unsaturated resin (14) is waited for to be cured; a third layer of basalt fiber filaments (15) is wound on the cured second layer of unsaturated resin (14), and a third layer of unsaturated resin (16) is covered on the third layer of basalt fiber filaments (15), the height of which completely fills the trough (9) and is consistent with the height of the peak (8), and the third layer of unsaturated resin (16) is waited for to be cured.

4. The improved method for manufacturing a corrugated steel tube fiber reinforced pipe according to claim 2, characterized in that: The step S5 further comprises a method for arranging the longitudinal steel bars (5) and the circumferential steel bars (6), the method comprising: arranging the longitudinal steel bars (5) at the crests (8) of the spiral corrugated steel cylinder (2) by spot welding, and then arranging the circumferential steel bars (6) at the ends of the spiral corrugated steel cylinder (2) and connecting them to each longitudinal steel bar (5) by spot welding.

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