CN107721246B

CN107721246B - FRP reinforced prestressed steel cylinder concrete pressure pipeline manufacturing process

Info

Publication number: CN107721246B
Application number: CN201711092588.8A
Authority: CN
Inventors: 温振刚; 高晨晓; 吴青玉
Original assignee: Yiwu Super Strong Pipe Industry Co Ltd
Current assignee: Yiwu super strong pipe industry Co., Ltd
Priority date: 2017-11-08
Filing date: 2017-11-08
Publication date: 2020-07-17
Anticipated expiration: 2037-11-08
Also published as: CN107721246A

Abstract

A FRP reinforced prestressed steel cylinder concrete pressure pipeline manufacturing process belongs to the technical field of pipeline manufacturing, cement concrete is poured on the inner wall of a steel cylinder with a bell and spigot to prepare a pipe core or the steel cylinder is embedded in the middle of the concrete to prepare the pipe core, then annular prestressed steel wires are wound on the outer wall of the pipe core to prepare a PCCP pipe semi-finished product, an interface treating agent is coated on the outer surface of the PCCP pipe semi-finished product, then polymer concrete is wound on the outer wall of the PCCP pipe semi-finished product by adopting a gauze bag to form a polymer concrete layer, a layer of glass fiber is wound on the outer surface of the polymer concrete layer to prepare a glass fiber reinforced layer, and finally a surface resin-rich layer is prepared on the outer surface of the FRP fiber reinforced layer to prepare the FRP reinforced prestressed steel. The manufacturing process is simple, and the manufactured FRP reinforced prestressed concrete cylinder pressure pipeline has excellent performance in all aspects, and has the advantages of high sealing property, high strength, high impermeability, corrosion resistance and the like.

Description

FRP reinforced prestressed steel cylinder concrete pressure pipeline manufacturing process

Technical Field

The invention belongs to the technical field of pipeline manufacturing, relates to a prestressed concrete pipeline, and particularly relates to a manufacturing process of an FRP (fiber reinforced plastic) reinforced prestressed concrete cylinder pressure pipeline. The manufacturing process is simple, and the manufactured FRP reinforced prestressed concrete cylinder pressure pipeline has excellent performance in all aspects, and has the advantages of high sealing property, high strength, high impermeability, corrosion resistance and the like.

Background

In the 40 th of the 20 th century, development of the European and American competition was started, wherein the United states is the country which produces and uses the most prestressed steel cylinder concrete pipes, and the prestressed steel cylinder concrete pipes are adopted in 28000km and 7600mm in the United states until now, and about 90% of water supply projects of large and medium cities in North America. The two largest prestressed concrete cylinder pipe manufacturers in the united states, Price Brothers Co, and amacron Co, establish many plants around the world in addition to the local production of prestressed concrete cylinder pipes.

The production technology of the novel prestressed steel cylinder concrete pipe is introduced from the United states in the early 90 s of the last century in China. Mainly, a straight seam welding can manufacturing process of the Pulisi brother company and a spiral welding can manufacturing process of the Amaron company are taken as representative steel can manufacturing technologies. On the basis of the advanced technologies of digestion and absorption in China, more than ten pre-stressed steel cylinder concrete pipe production plants are built successively, and the products are widely applied to water conservancy, municipal administration and tap water supply main pipeline engineering.

However, the current PCCP pipe has the following disadvantages:

1. the outer protective layer is manufactured in a guniting vertical mode, large particles in cement mortar break or damage prestressed steel wires easily in the guniting process, and defects are caused.

2. In the process of manufacturing the outer protective layer by spraying, an uncompacted part is easily formed, the steel bar is not tightly protected, a cavity or a hollow drum is formed, and the hollow drum is collided during transportation and installation and damaged.

3. The cement concrete has high water absorption rate and poor seepage resistance, and when the pipeline is buried underground, water enters the cement concrete to cause reinforcement corrosion for a long time.

4. The bell and spigot is made of steel, and the working surface is exposed outside and is easy to corrode to cause leakage.

Disclosure of Invention

The invention provides a process for manufacturing an FRP (fiber reinforced plastic) reinforced prestressed concrete cylinder pressure pipeline to solve the problems. The process is simple to operate, and the prepared FRP reinforced prestressed steel cylinder concrete pressure pipeline has good performance and is safe and reliable in the operation of the whole pipeline system.

The technical scheme adopted by the invention for realizing the purpose is as follows:

a process for preparing the FRP reinforced prestressed concrete cylinder pressure pipeline includes pouring cement concrete on the inner wall of steel cylinder with spigot and socket to form tube core, embedding the steel cylinder in the concrete to form tube core, spirally winding hoop prestressed steel wire on the outer wall of tube core to form PCCP semi-finished product, coating interface treating agent on the outer surface of PCCP semi-finished product, winding polymer concrete on the outer wall of PCCP semi-finished product by gauze to form polymer concrete layer, winding a layer of glass fiber on the outer surface of polymer concrete layer to form glass fiber reinforced layer, and preparing resin-enriched surface layer on the outer surface of glass fiber reinforced layer.

The interface treating agent comprises, by weight, 70-75% of vinyl resin, 3-5% of flexible resin, 3-4% of styrene, 0.5-1% of a defoaming agent, 1-2% of a silane coupling agent, 1-3% of fumed silica, 4-6% of 200-mesh aluminum hydroxide, 6-8% of 70-100-mesh aluminum hydroxide and 0.5-1% of an accelerator.

Preferably, the interface treatment agent comprises 75% of vinyl resin, 5% of flexible resin, 3.5% of styrene, 0.5% of defoaming agent, 1% of silane coupling agent, 2% of fumed silica, 5% of 200-mesh aluminum hydroxide, 7% of 70-100-mesh aluminum hydroxide and 1% of accelerator by weight.

And spraying a layer of quartz sand particles with the number of 6-12 meshes on the outer surface of the interface treating agent, controlling the quartz sand particles 1/3 to be embedded into the interface treating agent, and fixing exposed 2/3 with the polymer concrete.

The polymer concrete comprises the following components in percentage by mass 84:16, wherein the aggregate comprises, by weight, 50-55% of 10-30 mesh quartz sand, 20-25% of 30-70 mesh quartz sand, 15-18% of 70-100 mesh quartz sand and 8-12% of 200-300 mesh quartz sand, and the auxiliary materials comprise, by weight, 80-85% of unsaturated resin, 4-6% of styrene, 8-12% of flexible resin, 0.1-0.3% of defoaming agent, 1-2% of silane coupling agent and 0.5-0.8% of accelerator.

Preferably, the aggregate comprises, by weight, 55% of 10-30 mesh quartz sand, 20% of 30-70 mesh quartz sand, 15% of 70-100 mesh quartz sand and 10% of 200-300 mesh quartz sand, and the auxiliary materials comprise, by weight, 83.3% of unsaturated resin, 5% of styrene, 10% of flexible resin, 0.2% of defoaming agent, 1% of silane coupling agent and 0.5% of accelerator.

The surface resin-rich layer is prepared by the following method:

A. preparing raw materials, by weight, 85-90% of vinyl resin, 2-2.5% of thixotropic agent, 0.1-0.3% of propylene glycol, 1-1.2% of ultraviolet absorbent, 0.1-0.3% of defoaming agent, 3-5% of 250-mesh quartz sand, 2-4% of color paste, 0.5-1% of accelerator and 1-1.5% of curing agent to prepare a resin-rich agent;

B. winding a surface felt on the outer surface of the glass fiber reinforced layer, and spraying a resin-rich agent while winding until the resin-rich agent content of the surface felt reaches 90-95%;

C. coating a layer of resin-rich agent with the thickness of 1.8-2.5mm on the outer surface of the surfacing mat to form a resin-rich layer;

D. winding a layer of polyester film on the surface of the resin-rich layer, curing at 40-50 ℃ for 30-60min, and removing the polyester film to finish the preparation of the resin-rich layer on the surface.

In the step B, the surface felt is 200mm wide, and during winding, the lapping treatment of 20-30mm is adopted between the felts; and D, adopting a polyester film with the thickness of 0.2mm and the width of 200mm as the polyester film in the step D, and adopting the lapping treatment of 20-30mm between the polyester film and the polyester film during winding.

The thickness of the polymer concrete layer is 6-10 mm.

The bell and spigot joint is subjected to the following antiseptic treatment:

a. preparing the following raw materials by weight percent into the anticorrosive paint: 85-88% of vinyl resin, 2-4% of thixotropic agent, 0.1-0.2% of defoaming agent, 0.5-0.8% of coupling agent, 5-10% of 250-mesh quartz sand, 0.5-0.8% of accelerator and 1-1.5% of curing agent;

b. polishing the outer wall of the spigot and the inner wall of the socket to remove rust, plugging the pressure test ports of two sealing rings of the spigot, and spraying the anticorrosive paint of the step a onto the outer wall of the spigot and the inner wall of the socket, wherein the spraying thickness is 0.6-0.8 mm;

c. and (4) smearing a water-blocking agent on the outer surface of the cement concrete wrapping the inner wall of the socket.

And b, coating the anticorrosive paint by adopting a multi-layer spraying method or a roll coating method, wherein each layer is 0.2mm, coating a layer on the surface of the anticorrosive paint after curing, and so on until the total coating thickness is 0.6-0.8 mm.

In the step c, the water-blocking agent adopts silane with the molecular structure size of 1 nm.

And spraying or rolling a layer of epoxy ceramic on the inner wall of the tube core.

The invention has the beneficial effects that:

the product is originated at home, is formed by compounding a glass fiber reinforced layer, prestressed reinforcements, a steel cylinder and concrete, fully exerts the technical characteristics and advantages of various materials, and has the following advantages:

(1) the designability is strong. Through the structural design of the invention, the mechanical property requirements of different pressure grades, rigidity grades, earthquake resistance grades and the like can be met, and the use requirements of different media and different temperatures can be met through the material selection of the invention.

(2) The mechanical property is excellent. Through the structural design of the invention, the highest pressure grade of the pipe can reach 3.0 MPa.

(3) The corrosion resistance is excellent. The corrosion resistance of the glass fiber reinforced layer is fully exerted in the product design process, and the requirements of various medium environments can be met.

(4) Excellent water conservancy performance and low pumping cost. Through the process design of the invention, the inner surface of the pipe is smooth and flat, the mirror surface effect can be achieved, the water conservancy flow resistance is small, the pumping efficiency is improved, and the pumping cost is reduced.

(5) The service life is long. The service life can reach 70 years.

(6) The product price is low. Compared with the prestressed steel cylinder concrete pipe and steel pipe with the same specification, the price is relatively lower.

(7) The construction cost is low: the composite pipe has good mechanical property and good anti-settling capacity, has low requirement on the foundation compared with other pipes, and reduces the construction cost.

(8) Maintenance is not required. Can resist various environmental conditions and does not need maintenance after long-term use.

(9) The shock resistance is strong: the pipe is formed by compounding steel and glass fiber reinforced materials, and has good shock resistance.

Detailed Description

The product has the characteristics of strong designability, good waterproof performance, chemical corrosion resistance, long service life and insulation, and is manufactured into a PCCP semi-finished product by manufacturing a steel cylinder with a bell and spigot on the basis of the traditional PCCP pipeline manufacturing process, pouring cement concrete on the inner wall of the steel cylinder, and then winding prestressed steel wires on the outer wall of the steel cylinder. The main technology of the invention is to use polymer concrete mortar and a glass fiber reinforced plastic winding process to replace a cement mortar spraying process to manufacture the PCCP pipeline outer protective layer. The present invention will be further described with reference to the following specific examples.

Example 1

The FRP reinforced prestressed steel cylinder concrete pressure pipeline is produced through pouring cement concrete into the inner wall of steel cylinder with spigot and socket to form pipe core or embedding steel cylinder in the middle of concrete to form pipe core, then spirally winding a circumferential prestressed steel wire on the outer wall of the pipe core to prepare a PCCP pipe semi-finished product, coating an interface treating agent on the outer surface of the PCCP pipe semi-finished product, winding polymer concrete on the outer wall of the PCCP pipe semi-finished product by using a gauze bag to form a polymer concrete layer with the thickness of 6-10mm, aiming at compacting and filling gaps between prestressed wires, the outer surface of the polymer concrete layer is wound with a layer of glass fiber to manufacture a glass fiber reinforced layer with the thickness of 2-5mm, and finally, a surface resin-rich layer is manufactured on the outer surface of the glass fiber reinforced layer, so that the composite strength of the glass fiber reinforced prestressed steel wire is ensured, the density between layers is improved, and the prestressed steel wire is prevented from being corroded to manufacture the FRP reinforced prestressed steel cylinder concrete pressure pipeline. The glass fiber reinforced layer can also improve the mechanical properties of the pipeline, such as compression resistance, tensile resistance and the like, prevent cracks and reduce the burden of a pipe core in the pipeline; meanwhile, the acting force of the polymer concrete on the annular reinforcing mesh is dispersed, the prestressed steel wires are prevented from breaking points and being broken, and the breakage rate of the annular reinforcing mesh is reduced.

Further, the interface treating agent comprises 75% of vinyl resin, 5% of flexible resin, 3.5% of styrene, 0.5% of defoaming agent, 1% of silane coupling agent, 2% of fumed silica, 5% of 200-mesh aluminum hydroxide, 7% of 70-100-mesh aluminum hydroxide and 1% of accelerator by weight. The interface treating agent has the function of bonding the metal matrix and the polymer concrete, improves the integrity of the pipeline, can also improve the compactness and the fire resistance of the pipeline simultaneously, further prevents the pipeline from cracking and bursting, selects the o-benzene type flexible resin, and the addition of the flexible resin is used for further solving the problem of dry cracking and can further improve the anti-fracture capability simultaneously. The vinyl resin, the flexible resin and the styrene are combined, so that a bridge bond is formed among all components of the interface treating agent, the internal stress is relieved, the formation of cracks is reduced, potential harm and chronic forced damage are avoided, the structure of a cured product can be improved, the crack expansion is resisted, and the microcrack initiation of an interface treating layer is prevented.

Further, a layer of quartz sand particles with the number of 6-12 meshes is sprayed on the outer surface of the interface treatment agent, the quartz sand particles 1/3 are controlled to be embedded into the interface treatment agent, and the exposed 2/3 is fixed with the polymer concrete. The quartz sand with the granularity can be better adhered to the interface treatment layer by spraying, the aim of coating the quartz sand layer is to prevent interlayer separation, the function of combining polymer concrete and the interface treatment layer into an integral structure is achieved, the compactness and the crack resistance of a formed pipeline are improved, cracking is prevented, the quartz sand is sprayed on the surface of the interface treatment layer, one part of the quartz sand is embedded into the interface treatment layer, the other part of the quartz sand is combined with the polymer concrete, and the function of enhancing the interlayer combination force is achieved.

Further, the polymer concrete comprises a mass ratio of 84:16, wherein the aggregate comprises 55% of 10-30 mesh quartz sand, 20% of 30-70 mesh quartz sand, 15% of 70-100 mesh quartz sand and 10% of 200-300 mesh quartz sand, and the auxiliary materials comprise 83.3% of unsaturated resin, 5% of styrene, 10% of flexible resin, 0.2% of defoaming agent, 1% of silane coupling agent and 0.5% of accelerator. The o-benzene type flexible resin is selected, and the flexible resin is added to further solve the problem of dry cracking and further improve the fracture resistance.

The design of the aggregate can improve the insulating property and the corrosion resistance of the polymer concrete material, the aggregate is fixed in a multiphase structure through the solidification of resin, and the toughness of the polymer concrete material is improved through the matching of the aggregate and a silane coupling agent, so that the polymer concrete has good impact resistance, wear resistance and durability. The control of the components, proportion and particle size of the aggregate also has the function of improving the compactness and strength of the polymer concrete. The polymer concrete disclosed by the invention belongs to a hole sealing structure, has good impermeability, prevents water from entering the structure, and avoids structural damage caused by repeated freezing and melting of the water entering the cement concrete at the temperature of minus 5 ℃. The polymer concrete hole sealing structure solves the special condition and the freeze-thaw resistance of cement concrete.

The addition of the accelerant can promote the curing reaction, has no influence on the performance of the cured product, and simultaneously forms a multiphase structure in the cured product by combining with the flexible resin, thereby further improving the toughness and the shock resistance of the cured product and playing roles of plasticizing and toughening.

The polymer concrete material can be applied to various aspects, such as seabed, can not be isolated and dispersed by adopting a gauze winding mode, has high curing speed and strong cohesiveness, has excellent compression resistance, shear resistance, impact strength and seawater corrosion resistance after curing, can not crack or fall off after being soaked in simulated seawater (3 percent NaCl solution) for 40 days, and meets the requirements of marine pipelines¹³。

Further, the surface resin-rich layer is prepared in the following way:

A. preparing raw materials, by weight, 86% of vinyl resin, 2.5% of thixotropic agent (fumed silica), 0.2% of propylene glycol, 1.1% of ultraviolet absorbent, 0.2% of defoaming agent, 5% of 250-mesh quartz sand, 3% of color paste, 0.5% of accelerator (0.1% of cobalt liquid) and 1.5% of curing agent to prepare a resin-rich agent; the vinyl resin adopts the resin with the viscosity of 1000-1500cps, has good corrosion resistance, water resistance and weather resistance, can be cured at normal temperature, and has excellent process performance; the thixotropic agent has the functions of preventing the resin-rich layer on the surface from sagging, reducing the viscosity of the resin in the rolling process, increasing the construction operation performance, increasing the viscosity of the resin after the roller coating is finished and standing, avoiding sagging and ensuring uniform and bright surface; the 250-mesh quartz sand plays a role in enhancing; through the selection of the raw materials and the matching of the proportion, the prepared resin-rich layer with the surface can not only beautify the product, but also protect the product from being damaged by surrounding media, improve the weather resistance, the water resistance and the corrosion resistance of the product, and have the function of prolonging the service life of the product.

B. Winding a surface felt on the outer surface of the glass fiber reinforced layer, wherein the surface felt is a surface felt with the width of 200mm, during winding, lapping treatment of 20-30mm is adopted between the felts, compression roller compaction is adopted for removing air bubbles, and resin rich agent is sprayed while the surface felt is soaked by resin and wound until the content of the resin rich agent in the surface felt reaches 90-95%;

D. spirally winding a layer of polyester film on the surface of the resin-rich layer, wherein the polyester film is 0.2mm thick and 200mm wide, so that the surface of the resin-rich layer is uniform and flat and is as smooth as the polyester film, and during winding, the polyester film and the polyester film are subjected to 20-30mm lap joint treatment, then curing is carried out for 30-60min at 40-50 ℃, and the polyester film is removed, so that the preparation of the resin-rich layer on the surface is finished.

Further, the faucet is subjected to the following anticorrosion treatment:

a. preparing the following raw materials by weight percent into the anticorrosive paint: 87.3 percent of vinyl resin, 3 percent of thixotropic agent, 0.2 percent of defoaming agent, 0.5 percent of coupling agent, 7 percent of 250-mesh quartz sand, 0.5 percent of accelerator and 1.5 percent of curing agent;

b. polishing the outer wall of the spigot and the inner wall of the socket to remove rust, plugging the pressure test ports of two sealing rings of the spigot, spraying the anticorrosive paint of the step a on the outer wall of the spigot and the inner wall of the socket, spraying the anticorrosive paint by adopting a multi-layer spraying method in the step b, spraying 0.2mm on each layer, spraying one layer on the surface of the anticorrosive paint after curing, and so on until the total spraying thickness is 0.6-0.8mm, and adopting a brush or brushing on a part which is not easy to treat;

c. and (3) coating a water-blocking agent on the outer surface of the cement concrete wrapping the inner wall of the socket, wherein the water-blocking agent adopts silane with the molecular structure of 1 nm. The silane of this structure can be sealed the tiny hole of concrete is whole, prevents that moisture from getting into concrete and contacting metal socket internal surface to prevent to rust.

The same operation is carried out on the outer wall of the socket and the whole outer part of the pipeline, namely the socket is integrally wrapped by winding glass fiber reinforced plastics, a resin-rich layer and the like and is formed in one step.

The bell and spigot carries out anticorrosive treatment, and the purpose is to prevent bell and spigot corruption, further prevents to corrode the indirect pipeline that causes because of bell and spigot corruption.

Furthermore, a layer of epoxy ceramic is sprayed or roll-coated on the inner wall of the manufactured pipeline (namely the cement concrete on the inner wall of the pipe core), so that the problems of water flow and water quality caused by poor porosity and seepage-proofing performance of the cement concrete and easy algae formation are solved. The design of the epoxy ceramic layer can form a smooth inner wall surface on the inner wall of the pipeline, and reduce the water supply resistance and the abrasion of substances such as gravel in water to the pipeline in the water supply process. Meanwhile, the arrangement of the epoxy ceramic layer can improve the surface smoothness of the pipeline, reduce the flowing water resistance and improve the apparent quality. Avoid the corrosion and the infiltration of water to the pipeline, prevent the pipeline fracture. On the other hand, the design of epoxy ceramic layer can reduce the effect of water pressure to the pipeline, plays the effect of buffering to polymer concrete layer, improves the shock resistance of pipeline. If the water quality safety requirement exists, a food-grade epoxy ceramic layer can be selected to meet the sanitary requirement of a water supply pipeline.

Example 2

1. Preparing an interface treating agent:

according to the weight percentage, the vinyl resin is 70.2 percent, the flexible resin is 5 percent, the styrene is 4 percent, the defoaming agent is 1 percent, the silane coupling agent is 2 percent, the fumed silica is 3 percent, the 200-mesh aluminum hydroxide is 6 percent, the 70-100-mesh aluminum hydroxide is 8 percent, and the accelerant (1 percent of cobalt solution) is 0.8 percent for standby.

Operating at 23-30 deg.C, adding methyl ethyl ketone peroxide 1.5 wt% of interface treating agent into the above interface treating agent, stirring, and uniformly coating on the surface of steel cylinder to form interface treating layer.

The existing vinyl resin has the problem of low bonding strength with concrete, most of the existing solutions are to modify the vinyl resin, supplement a bonding agent and the like, and the vinyl resin needs to be pretreated or reprocessed in the manner, so that the operation complexity is improved, the construction difficulty is increased, and the use is inconvenient. The invention abandons the conventional method, improves the defects of the prior vinyl resin by compounding the vinyl resin and the flexible resin and adding 200-mesh aluminum hydroxide, and improves the workability of the vinyl resin by the treatment of the invention, the durability is longer and the aging resistance is improved by 20-30 percent.

The vinyl resin, the flexible resin and the silane coupling agent are combined, particularly, the proportion of the vinyl resin, the flexible resin and the silane coupling agent is strictly controlled, the penetration and diffusivity of the vinyl resin, the flexible resin and the silane coupling agent to the polymer concrete is enhanced, the bonding performance between the vinyl resin and the polymer concrete is improved, and the adhesion and the bonding of the interface treatment layer and the polymer concrete layer are improved. The addition and proportion control of the fumed silica and the 70-100 mesh aluminum hydroxide solve the problem that the interface is not easy to bond caused by surface pulverization of the interface treatment layer or smooth surface of the steel cylinder, improve the bonding performance of the surface of the steel cylinder and prevent cracking and delamination.

The interface treating agent improves the flexibility by selecting each component and controlling the proportion of the whole components, reduces the surface shrinkage rate of concrete after being combined with polymer concrete, and avoids the problems of molecular chain fracture and reduction of the bonding strength of the interface treating agent and the polymer concrete caused by shrinkage after bonding.

2. Preparation of polymer concrete:

weighing aggregate according to the following weight percentage: 50% of 10-30 mesh quartz sand, 25% of 30-70 mesh quartz sand, 17% of 70-100 mesh quartz sand and 8% of 200-300 mesh quartz sand; weighing the following auxiliary materials in percentage by weight: 80% of unsaturated resin, 6% of styrene, 11% of flexible resin, 0.3% of defoaming agent, 2% of silane coupling agent and 0.7% of accelerator for later use. The mass ratio of the aggregate to the auxiliary materials is 84: 16.

The aggregate has the composition parameters of water content not more than 0.2%, mud content not more than 0.5%, silicon content not less than 95%, acid resistance not less than 98%, and hard and mellow texture. In the parameter control of each aggregate component, the water content is controlled to be less than or equal to 0.2 percent so as to improve the adhesion and prevent cracking caused by water diffusion during curing, and meanwhile, the control of the water content can improve the durability of the polymer concrete material and solve the problem of poor durability. The mud can wrap the surface of large particles, so that the resin soaking and bonding are influenced, the strength is reduced, and the mud content needs to be controlled to be less than or equal to 0.5 percent. The silicon content of the aggregate component of the invention is controlled to improve the corrosion resistance of the material. The acid resistance is controlled to improve the service life and reduce the overall cost. The hard and round aggregate is selected to improve the fluidity in the pouring process, and is not round, poor in fluidity and more in bubbles, so that the resin content is high finally.

3. Preparation of resin-rich agent

According to the weight percentage, 85.6 percent of vinyl resin, 2.3 percent of thixotropic agent (fumed silica), 0.1 percent of propylene glycol, 1.2 percent of ultraviolet absorbent, 0.3 percent of defoaming agent, 4 percent of 250-mesh quartz sand, 4 percent of color paste, 1 percent of accelerant (0.1 percent of cobalt liquid) and 1.5 percent of curing agent are weighed.

4. Preparation of anticorrosive paint

According to the weight percentage, 85 percent of vinyl resin, 3.2 percent of thixotropic agent, 0.15 percent of antifoaming agent, 0.8 percent of coupling agent, 9 percent of 250-mesh quartz sand, 0.8 percent of accelerant and 1.05 percent of curing agent are weighed.

The FRP reinforced prestressed steel cylinder concrete pressure pipeline manufacturing process comprises the following steps:

pouring cement concrete on the inner wall of a steel cylinder with a bell and spigot to prepare a pipe core, or embedding the steel cylinder in the middle of the concrete to prepare the pipe core, then winding a circumferential prestressed steel wire on the outer wall of the pipe core to prepare a PCCP pipe semi-finished product, coating an interface treatment agent on the outer surface of the PCCP pipe semi-finished product to form an interface layer, then spraying a layer of 10-mesh quartz sand particles on the interface layer, embedding the particles 1/3 into an adhesive, then curing, forming an interface layer capable of being tightly adhered with polymer concrete on the surface of the PCCP pipe semi-finished product, then winding the polymer concrete on the outer wall of the PCCP pipe semi-finished product by using pocket gauze to form a polymer concrete layer with the thickness of 10mm, winding a layer of glass fiber on the outer surface of the polymer concrete layer to prepare a glass fiber reinforced layer, and finally manufacturing the outer surface of the glass fiber reinforced layer according:

winding a surface felt on the outer surface of the glass fiber reinforced layer, wherein the surface felt is a surface felt with the width of 200mm, during winding, lapping treatment of 25mm is adopted between the felts, compression rollers are adopted for compacting and are used for removing air bubbles, and resin is sprayed while the surface felt is wound after being soaked by resin until the content of the resin-rich agent in the surface felt reaches 93%;

coating a layer of resin-rich agent with the thickness of 2mm on the outer surface of the surfacing mat to form a resin-rich layer;

spirally winding a layer of polyester film on the surface of the resin-rich layer, wherein the polyester film is 0.2mm thick and 200mm wide, so that the surface of the resin-rich layer is uniform and flat and is as smooth as the polyester film, during winding, lapping treatment of 25mm is adopted between the polyester film and the polyester film, then curing is carried out for 50min at 45 ℃, and the polyester film is removed, namely the outer surface of the glass fiber reinforced layer forms a surface resin-rich layer, taking resin non-sticking as the standard and the Babbitt hardness of not less than 35.

And finally, carrying out the following anticorrosive treatment on the bell and spigot:

polishing the outer wall of the spigot and the inner wall of the socket to remove rust, plugging the pressure test ports of two sealing rings of the spigot, spraying anticorrosive paint on the outer wall of the spigot and the inner wall of the socket, spraying the anticorrosive paint by adopting a multi-layer spraying method, spraying 0.2mm on each layer, spraying one layer on the surface of the coating after curing, and so on until the total spraying thickness is 0.6mm, and adopting a brush or brushing at a local position which is not well treated;

and (3) coating a water-blocking agent on the outer surface of the cement concrete wrapping the inner wall of the socket, wherein the water-blocking agent adopts silane with the molecular structure of 1 nm. The silane of this structure can be sealed the tiny hole of concrete is whole, prevents that moisture from getting into concrete and contacting metal socket internal surface to prevent to rust.

And spraying or rolling a layer of epoxy ceramic on the inner wall of the manufactured pipeline (namely the cement concrete on the inner wall of the pipe core).

Example 3

The difference from the embodiment 2 is that:

1. preparing an interface treating agent:

according to the weight percentage, 74.7 percent of vinyl resin, 4.5 percent of flexible resin, 3.5 percent of styrene, 0.8 percent of defoaming agent, 1.5 percent of silane coupling agent, 2.5 percent of gas-phase silicon dioxide, 4.5 percent of 200-mesh aluminum hydroxide, 7.5 percent of 70-100-mesh aluminum hydroxide and 0.5 percent of accelerator (1 percent of cobalt solution) are taken for standby.

2. Preparation of polymer concrete:

weighing aggregate according to the following weight percentage: 53 percent of 10-30 mesh quartz sand, 23 percent of 30-70 mesh quartz sand, 16 percent of 70-100 mesh quartz sand and 8 percent of 200-300 mesh quartz sand; weighing the following auxiliary materials in percentage by weight: 85% of unsaturated resin, 4% of styrene, 8.8% of flexible resin, 0.1% of defoaming agent, 1.6% of silane coupling agent and 0.5% of accelerator for later use.

3. Preparation of resin-rich agent

According to the weight percentage, 90 percent of vinyl resin, 2 percent of thixotropic agent (fumed silica), 0.3 percent of propylene glycol, 1 percent of ultraviolet absorbent, 0.2 percent of defoaming agent, 3 percent of 250-mesh quartz sand, 2 percent of color paste, 0.5 percent of accelerant (0.1 percent of cobalt liquid) and 1 percent of curing agent are weighed.

4. Preparation of anticorrosive paint

According to the weight percentage, 88 percent of vinyl resin, 2.1 percent of thixotropic agent, 0.1 percent of antifoaming agent, 0.7 percent of coupling agent, 7 percent of 250-mesh quartz sand, 0.7 percent of accelerating agent and 1.4 percent of curing agent are weighed.

Claims

The FRP reinforced prestressed steel cylinder concrete pressure pipeline manufacturing process is characterized in that an interface treating agent is coated on the outer surface of a PCCP pipe semi-finished product, then polymer concrete is wound on the outer wall of the PCCP pipe semi-finished product by adopting a gauze bag to form a polymer concrete layer, a layer of glass fiber is wound on the outer surface of the polymer concrete layer to manufacture a glass fiber reinforced layer, and finally a surface resin-rich layer is manufactured on the outer surface of the FRP fiber reinforced layer to manufacture the FRP reinforced prestressed steel cylinder concrete pressure pipeline;

the interface treating agent comprises, by weight, 70-75% of vinyl resin, 3-5% of flexible resin, 3-4% of styrene, 0.5-1% of a defoaming agent, 1-2% of a silane coupling agent, 1-3% of fumed silica, 4-6% of 200-mesh aluminum hydroxide, 6-8% of 70-100-mesh aluminum hydroxide and 0.5-1% of an accelerator.
2. The process for manufacturing the FRP reinforced prestressed concrete cylinder pressure pipe as claimed in claim 1, wherein a layer of quartz sand particles with 6-12 meshes is sprayed on the outer surface of the interface treatment agent, the quartz sand particles 1/3 are controlled to be embedded into the interface treatment agent, and the exposed 2/3 is fixed with the polymer concrete.
3. The process for manufacturing the FRP reinforced prestressed concrete cylinder pressure pipe as claimed in claim 1, wherein the polymer concrete comprises the following components in mass ratio of 84:16, wherein the aggregate comprises, by weight, 50-55% of 10-30 mesh quartz sand, 20-25% of 30-70 mesh quartz sand, 15-18% of 70-100 mesh quartz sand and 8-12% of 200-300 mesh quartz sand, and the auxiliary materials comprise, by weight, 80-85% of unsaturated resin, 4-6% of styrene, 8-12% of flexible resin, 0.1-0.3% of defoaming agent, 1-2% of silane coupling agent and 0.5-0.8% of accelerator.
4. The process for manufacturing the FRP reinforced prestressed concrete cylinder pressure pipe as claimed in claim 1, wherein the surface resin-rich layer is manufactured by the following method:

A. preparing raw materials, by weight, 85-90% of vinyl resin, 2-2.5% of thixotropic agent, 0.1-0.3% of propylene glycol, 1-1.2% of ultraviolet absorbent, 0.1-0.3% of defoaming agent, 3-5% of 250-mesh quartz sand, 2-4% of color paste, 0.5-1% of accelerator and 1-1.5% of curing agent to prepare a resin-rich agent;

B. winding a surface felt on the outer surface of the glass fiber reinforced layer, and spraying a resin-rich agent while winding until the resin-rich agent content of the surface felt reaches 90-95%;

C. coating a layer of resin-rich agent with the thickness of 1.8-2.5mm on the outer surface of the surfacing mat to form a resin-rich layer;

D. winding a layer of polyester film on the surface of the resin-rich layer, curing at 40-50 ℃ for 30-60min, and removing the polyester film to finish the preparation of the resin-rich layer on the surface.
5. The process for manufacturing the FRP reinforced prestressed concrete cylinder pressure pipeline according to claim 4, wherein the surfacing mat in the step B is a surfacing mat with the width of 200mm, and the lapping treatment of 20-30mm is adopted between the mats during winding; and D, adopting a polyester film with the thickness of 0.2mm and the width of 200mm as the polyester film in the step D, and adopting the lapping treatment of 20-30mm between the polyester film and the polyester film during winding.
6. The process for manufacturing the FRP reinforced prestressed concrete cylinder pressure pipeline according to claim 1, wherein the faucet is subjected to the following anticorrosion treatment:

a. preparing the following raw materials by weight percent into the anticorrosive paint: 85-88% of vinyl resin, 2-4% of thixotropic agent, 0.1-0.2% of defoaming agent, 0.5-0.8% of coupling agent, 5-10% of 250-mesh quartz sand, 0.5-0.8% of accelerator and 1-1.5% of curing agent;

b. polishing the outer wall of the spigot and the inner wall of the socket to remove rust, plugging the pressure test ports of two sealing rings of the spigot, and spraying the anticorrosive paint of the step a onto the outer wall of the spigot and the inner wall of the socket, wherein the spraying thickness is 0.6-0.8 mm;

c. and (4) smearing a water-blocking agent on the outer surface of the cement concrete wrapping the inner wall of the socket.
7. The process for manufacturing the FRP reinforced prestressed concrete cylinder pressure pipeline according to claim 6, wherein in the step b, a multilayer spraying method or a roll coating method is adopted to coat the anticorrosive paint, each layer is coated for 0.2mm, after the anticorrosive paint is cured, a layer is coated on the surface of the FRP reinforced prestressed concrete cylinder pressure pipeline, and the like until the total coating thickness is 0.6-0.8 mm.
8. The process for manufacturing the FRP reinforced prestressed concrete cylinder pressure pipe as claimed in claim 6, wherein in the step c, the water-blocking agent is silane with a molecular structure size of 1 nm.
9. The process for manufacturing the FRP reinforced prestressed concrete cylinder pressure pipe as claimed in claim 1, wherein a layer of epoxy ceramic is sprayed or roll-coated on the inner wall of the pipe core.