Plastic-Lined Concrete Sewer Joints for Sulfuric Acid Corrosion
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Solution Overview
Problem
Concrete sewer systems are prone to premature degradation due to sulfuric acid corrosion from H2S gas, leading to reduced service life, and existing solutions like polymer concrete linings are expensive and complex to implement.
Innovation Solution
Prefabricated composite concrete elements with a premolded corrosion-resistant inner plastic liner that lines the interior and connection details, preventing corrosive materials from reaching the concrete and allowing for easy assembly into a corrosion-resistant sewer system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If concrete sewer elements are used without lining, then the structure is simple and cost-effective, but the service life is reduced due to sulfuric acid corrosion
Solution Approach 1:
The patent applies preliminary action by incorporating the plastic liner into the concrete element during the manufacturing process before the element is installed. The liner is positioned and secured within the mold cavity while the concrete is being cast, ensuring the protective layer is already in place before the element exposes to corrosive environments. This pre-installation approach eliminates the need for complex field installation procedures and ensures complete coverage of interior surfaces.
Solution Approach 2:
The patent employs composite materials by combining conventional structural concrete with a plastic liner material to create a composite concrete element. The concrete provides structural strength and durability, while the plastic liner provides chemical resistance to sulfuric acid corrosion. This composite structure allows the element to benefit from both materials' properties, extending service life in corrosive sewer environments.
2Object-affected harmful factors
If a plastic liner is installed in the field after construction, then corrosion resistance is improved, but installation complexity and cost increase significantly
Solution Approach 1:
The patent applies preliminary action by incorporating the plastic liner into the concrete element during the manufacturing process before the element is installed. The liner is positioned and secured within the mold cavity while the concrete is being cast, ensuring the protective layer is already in place before the element exposes to corrosive environments. This pre-installation approach eliminates the need for complex field installation procedures and ensures complete coverage of interior surfaces.
Solution Approach 2:
The patent merges two separate processes - concrete casting and liner installation - into a single integrated manufacturing process. By combining these operations, the patent eliminates the need for separate field installation of liners, reducing installation complexity and cost while ensuring the liner is properly positioned and secured before the concrete sets.
3Object-affected harmful factors
If polymer concrete is used instead of conventional concrete, then chemical resistance is improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent applies local quality by providing corrosion protection only where it is needed - on the interior surfaces of the concrete element that contact corrosive wastewater. The plastic liner is applied locally to the interior cavity, while the exterior concrete structure maintains its conventional composition and properties. This localized approach provides chemical resistance where required without incurring the full cost of polymer concrete throughout the entire structure.
Solution Approach 2:
The patent employs composite materials by combining conventional structural concrete with a plastic liner material to create a composite concrete element. The concrete provides structural strength and durability, while the plastic liner provides chemical resistance to sulfuric acid corrosion. This composite structure allows the element to benefit from both materials' properties, extending service life in corrosive sewer environments.
4Ease of manufacture
If conventional concrete is used, then manufacturing cost is low, but the concrete degrades prematurely due to acid corrosion
Solution Approach 1:
The patent applies local quality by providing corrosion protection only where it is needed - on the interior surfaces of the concrete element that contact corrosive wastewater. The plastic liner is applied locally to the interior cavity, while the exterior concrete structure maintains its conventional composition and properties. This localized approach provides chemical resistance where required without incurring the full cost of polymer concrete throughout the entire structure.
Solution Approach 2:
The patent employs composite materials by combining conventional structural concrete with a plastic liner material to create a composite concrete element. The concrete provides structural strength and durability, while the plastic liner provides chemical resistance to sulfuric acid corrosion. This composite structure allows the element to benefit from both materials' properties, extending service life in corrosive sewer environments.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a cost-effective, reliable, and efficient method to protect concrete sewer elements from chemical degradation, extending their service life while minimizing field labor and expenses.
Implementation Method 1
a prefabricated composite concrete element includes a corrosion resistant plastic liner that lines an interior of the hollow concrete element
Implementation Method 2
The sulfuric acid in turn can come into contact with the interior wall of the hollow concrete pipes and other elements of the system and can then react with calcium carbonate, present in the concrete walls of the various elements, to form calcium sulfate and carbon dioxide
Data Source
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AI summary
A prefabricated composite concrete element for use in a corrosive sewer environment. The concrete element has a hollow reinforced cast concrete portion with at least one end having connection details, a premolded corrosion resistant inner plastic liner. The plastic liner lines an interior of the hollow concrete element and the connection details to provide abutting liner faces in an assembled joint to limit exposure through said joint of said concrete portion to corrosive materials arising in said sewer environment. At least two prefabricated composite concrete elements may be assembled end to end at a joint to form a concrete sewer system. Also disclosed are a method of prefabricating such a composite concrete element.