Method to manufacture protective weighting concrete coating of pipeline

FIELD: technological processes.

SUBSTANCE: invention relates to piping, namely, to materials applied onto the outer surface of pipes as a protective weighting coating. In the method to manufacture a protective weighting concrete coating of a pipeline, including mixing of cement, filler, plasticising additive and water, injection of the produced mix into the annular space created by the outer surface of the pipeline and a leave-in-place form installed on it with a gap, hardening of the produced coating, portland cement is supplied for mixing with account of its content in the mix from 8.8 wt % to 20.0 wt %, water is introduced in terms of water to cement ratio from 0.31 to 0.63, plasticising additive supplied for mixing is a plasticising agent and a defoaming agent in the amount of 1.0 kg/m3 to 3.0 kg/m3, the filler supplied for mixing with grain size not exceeding 10 mm is selected from barite or iron-containing ore, or gabbrodiabase, or granite in the mixture or separately, at the same time components are mixed to produce a mix having a flow index measured by flow equal to 55 - 75 cm, and the index of air content from 1% to 4% of the volume. The invention is developed in invention claims.

EFFECT: provision of density of a protective concrete material within 2600 - 3400 kg/m3.

3 cl, 2 tbl

 

The invention relates to pipeline engineering, namely to the materials deposited on the outer surface of the pipe as a protective concrete weight coating. Known method of preparing a ballast material for subsea pipeline, comprising mixing cement, aggregate, water and a plasticizer, wherein the filler used coarse aggregate from the group of: barite, iron or ore, or a mixture thereof, wherein the mixing is carried out in two stages: the first stage to the mixer serves from 10 wt. % to 20 wt. % specified coarse aggregate from its total, cement, water and plasticizing additive and mixing is carried out for from 10 seconds to 15 seconds, and in the second stage, the supply remaining the specified coarse aggregate in equal portions with an interval of 10 to 15 h with stirring and carry out the mixing of the components to obtain a homogeneous mixture (RU 2412393, 20.02.2011).

Known ballast material containing cement, barite ore, water and a plasticizer. As the plasticizer used polycarbamyl. In the manufacture of the ballast material use the following fractional composition of barite ore :

the coarse fraction from 5 mm to 25 mm - 8 wt. % to 16 wt. %,

the small fraction from 0.16 mm to 5 mm, from 70 wt. % to 84 wt. %,

very Melk�I fraction from 0.01 DM 160 DM from 8 wt. % to 14 wt. %

(EN 2399828, 20.09.2010).

Also known ballast material containing cement, filler, plasticizer and water. As the cement used sulphate-resistant Portland cement, as plasticizer - PCE RFE, and as filler - barite product, barite ore and ferromanganese concentrate. The material has the following ratio of components:

Portland cement - from 8.2 wt. % to 10.5 wt. %,

water - from 5.2 wt. % to 6.7 wt. %,

plasticizer, from 0.1 wt. % to 0.15 wt. %,

barite products - from 18 wt. % to 28 wt. % with a density of 3.78 kg/cm3to 3.82 kg/cm3and humidity from 0.9% to 2.1%,

barite ore - 18 wt. % to 28 wt. % with a density of 3.9 kg/cm3to 4.1 kg/cm3and humidity 2%,

iron-manganese concentrate from 25 wt. % to 45 wt. % with a density of 4.2 kg/cm3up to 4.5 kg/cm3and humidity of 4%.

The ratio of water to Portland cement is from 0.35 to 0.5.

Components of aggregate have the following particle size distribution:

to 0.16 cm - up to 5%,

from 0.16 cm to 1.0 cm, up to 25%,

from 1.0 cm to 2.5 cm to 35%

from 2.5 cm to 5.0 cm - else

(EN 2437020, 20.12.2011).

The disadvantages of the above technical solutions is not sufficiently high viscosity of the solution and the time of preservation of the mobility of the concrete mixture, which complicates the quality of the filling pipe �of prostranstva the design of pipe-in-pipe and causes the need for a process for controlling the humidity of the raw material to prevent rupture of the outer shell and delamination of the concrete mix is drenched inside the structure.

The closest to the proposed technical solution is a method of manufacturing a ballast coating on the pipeline, comprising mixing the starting components, namely, sulphate-resistant Portland cement, barite ore, a plasticizer based on polycarboxylate ether and water. To take mixing components in the following amounts:

sulphate-resistant Portland cement from 12 wt. % to 17 wt. %,

the water is from 4 wt. % to 10 wt. %,

plasticizer based on polycarboxylate ether from 0.1 wt. % to 0.25 wt. %,

barite ore - other.

And serves for mixing different fractions of barite ore in their next content (wt. %):

large from 3 mm to 25 mm - 18 wt. %,

small from 0.16 mm to 3 mm, from 70 wt. % to 85 wt. %,

very small from 0.01 mm to -0.16 mm - 7 wt. % to 16 wt. %.

Water for concrete mixes subjected to a preliminary treatment by passing it through a magnetic field, which support the tension value of from 120,000 vehicles up to 140,000 vehicles, with a speed of 0.5 m/s to 3.0 m/s, while water treatment time is not less than 2 hours (EN 2453515, 20.06.2012).

However, the known method is quite difficult to apply to obtain mixtures that tend to trap off, because the water is subjected to processing in a magnetic field, has a relatively small period of effective action that imposes things�governmental restrictions on the transit of the solution and also the behavior of such concrete mixtures with application of an external force (for example, flow of the mixture, concrete pump) subject to sharp changes.

The technical problem solved by the invention is to provide a method of manufacturing a protective concrete weight coating pipeline with high specified density with after hardening and aging of high compressive strength, which in turn allows to obtain a technical result, namely to reduce the outer diameter of pipes with protective coating ballast for underwater, underground and above-ground pads.

The claimed technical result is achieved by the claimed method of manufacturing a protective concrete weight coating pipeline, which comprises mixing cement, aggregates, plasticizer and water. The resulting mixture is injected into the annular space formed by the outer surface of the tubing and installed with a gap of a fixed timbering. The coating obtained leave to set. According to the proposed method serves for mixing Portland cement based its content in the mixture of 8.8 wt. % to 20.0 wt. %, water is injected from the calculation of the ratio of water to cement in the range of $ 0.31 to 0.63 and. As a plasticizer serves for mixing the plasticizer with the defoamer. Koli�the ETS used a plasticizer in the mixture is from 1 kg/m 3up to 3 kg/m3. Supplied to the mixing aggregate must contain a grain size not exceeding 10 mm. the Filler is selected from barium or iron-containing ore, or gabrodiabaz, or granite. The mixing of the components together or separately carried out on the basis of a mixture having the turnover rate, as measured by the blurring of the cone is equal to from 55 cm to 75 cm, and the air content from 1% to 4% by volume of the mixture. Filler applied to the mixture has the following particle size distribution:

to 0.16 mm - up to 8%,

from 0.16 mm to 1.25 mm up to 35%,

from 1.25 mm to 2.5 mm up to 37%,

from 2.5 mm to 10.0 mm - the rest.

Preferably, the plasticizer further comprises a lignosulfonate, melaninogenica and naphthalenesulfonate individually and in a mixture.

The number of plastificator must add up to 1% dry solids by weight of cement.

To obtain a mixture of the required mobility and sufficient viscosity and to avoid stratification of the amount of the plasticizer are chosen so that the resulting material, on the one hand, there was enough fluid, namely the blurring of the cone should be between 55 cm to 75 cm, and on the other hand, the air content should be between 1% to 4% by volume. Thus, the proposed method is applied� on a mixture of plasticizer, consisting of a plasticizer and a defoamer in an amount of from 1.0 kg/m3to 3.0 kg/m3mixture allows plastic concrete mass which fills all the space between the pipes and at the same time, after hardening of the concrete surface will have a high density. In plasticizing additive content of the antifoam should not exceed 50%. The increase in the content of the antifoam leads to a drastic decrease of fluidity of the concrete mix and the appearance of voids in the concrete coating that minimises the characteristics of the compressive strength of the concrete. Low content of antifoam less than 1% leads to an increase of air content in concrete mixtures and the resulting decline in the density of the concrete.

The ratio of water to cement, selected in the range of from 0.31 to 0.63 and necessary to achieve the required mobility and the strength of the concrete material. The use of water in a smaller number leads to a decrease in the mobility of the concrete and the appearance of air voids after curing, and the increase in water leads to delamination and loss of the compressive strength of the concrete.

In a further example implementation of the claimed method of manufacturing a protective concrete weight coating pipeline on the example of use as a filler barite ore, n� limits the scope of the present invention.

An example of a method

First prepare the initial components of the mixture. The process of preparation of the components of the concrete mix includes crushing of inert filler, such as barite ore to a size not exceeding 10 mm. the Use of larger fractions of filler lead to a reduction in the density of the coating. If necessary, barite ore is heated to 5°C (maximum), particularly following the melting stuck (frozen) pieces of rock to prevent separation of the ballast mixture during transportation. Then measure the humidity of barite ore. According to the results of moisture measurement specify the quantity of barite ore in the composition of the ballast material according to the formula:

m1=m2/(l-W/100),

where m1is the mass of barite ore with regard to humidity,

m2is the mass of barite ore in nominal recipe

W - water content, expressed as a percentage.

Barite ore is sifted through Borat for the separation of large impurities fraction. Then barite ore and Portland cement in the amount of its content in the mixture is from 8,8% to 20.0% via a system of conveyors and serves on the scales, where the components are weighed according to the specified composition. Granulometric composition of the filler are shown in Table 1, the selection of the ratios due to the reception of ballast cover with a given raft�awn.

To ensure the fluidity of the concrete mix when pouring it added plasticizing additive in an amount of from 1.0 kg/m3to 3.0 kg/m3. Plasticizer is a mixture of a plasticizer and a defoamer. And the amount of antifoam in plasticizing additive should be no more than 50%. As a defoamer can be used tributyl phosphate or anhydrous silicone semidisplacement antifoam brand Penta-4604. As the plasticizer can be any known plasticizer based on polycarboxylate or polyacrylate ester. Plasticizer may further comprise lignosulfonates, melaninogenica and naphthalenesulfonate. The above components can be used individually, in any combination that does not affect obtaining the claimed technical result. The amount of plasticizer should be no more than 1% dry matter by weight of cement.

The resulting mixture was added water from the calculation of the ratio of water to cement in the range of $ 0.31 to 0,63, and mix thoroughly. Stirring was continued until a homogeneous mixture with the blurring on the cone from 55 cm to 75 cm.

The resulting concrete mix is pumped with a concrete pump in the space between the conductive pipe and the installed fixed on�alupkoj. When assembled, the tube design is on the stand, installed at a certain angle. The injection solution is made using a special removable plugs on the end of the pipe. When you pour this design is inclined with one end lower than the other) and the fill is done from the end located below. Download concrete mix is a concrete pump to fill the entire design - to the exit of the mixture from the nozzle design cover above. After completion of the filling procedure the design of it is on display during the exposure time up to a strength of at least 5 MPa, and then stored up to the set of transport strength of not less than 22 MPa.

Depending on technological requirements in the casting of pipe construction may be used in various types of outdoor permanent formwork, for example, spiral steel shuttering may be made by the locks of outside and inside construction and can be painted or coated with various polymeric materials, which allows to obtain different characteristics of the products.

To enhance the design in the space between the pipe and fixed timbering possible location of the reinforcement (steel or polymer) in the form of bars or mesh, which is connected by welding or attached, as well as to enhance the strength �of etona perhaps the use of fibers (steel or polymer).

The inventive method allows high accuracy to provide the specified density protective concrete weight coating of the pipeline in the range from 2600 to 3400 kg/m3.

Determining the average density of the mixtures made in accordance with GOST 12730.1-78. The strength of concrete in compression was determined in accordance with GOST 10180-90.

To obtain coatings with different characteristics of density and strength can be used as placeholders not only barite, and iron ore, gardiasis, granite. These fillers can be used as separately from each other and in various combinations. Examples of compositions used in the protected way, and the resulting densities and compressive strength of the obtained coating are shown in Table 2.

When used in the composition of the combination of different fillers fractional number is crushed (prepared) for each component separately. With fine and coarse aggregate fractions are composed of the same component and in the proportions shown in Table 1.

Declared quantity supplied of initial components and, importantly, the characteristics of the resulting mixture were identified during numerous field experiments, the results of which are shown in Table 1 and Table 2. Table 1 shows the particle size distribution with�Tav fillers. The presence of small fractions of filler allows you to create conditions that reduce the delamination of the protective concrete weight of the material during the casting process.

Table 2 shows examples of various compositions of protective weight coating pipeline with the use of components of different density and the indexes of the compressive strength obtained ballast material for each composition, and provides data on the coating obtained in accordance with the prototype.

1. A method of manufacturing a protective concrete weight coating pipeline, comprising mixing cement, filler, a plasticizing component and water, the injection of the mixture into the space formed by the outer surface of the tubing and installed with a gap retained formwork, the solidification of the coating, characterized in that the mixing serves Portland cement based its content in the mixture of 8.8 wt. % to 20.0 wt. %, water is injected from the calculation of the ratio of water to cement in the range of $ 0.31 to 0.63 and, as a plasticizer additive used on the basis of polycarboxyl�atna or polyacrylate ester in an amount of from 1 kg/m 3up to 3 kg/m3the mixture serves for mixing the plasticizer defoamer supplied to mixing the filler with a grain size not exceeding 10 mm, is selected from barium or iron-containing ore, or gabrodiabaz, or granite, and the mixing of the components together or separately carried out on the basis of a mixture having the turnover rate, as measured by the blurring of the cone is equal to from 55 cm to 75 cm, and the air content of 1% to 4% vol., and fed to the mixing of the filler has the following particle size distribution:
to 0.16 mm - up to 8%,
from 0.16 mm to 1.25 mm up to 35%,
from 1.25 mm to 2.5 mm up to 37%,
from 2.5 mm to 10.0 mm - the rest.

2. A method according to claim 1, characterized in that the plasticizer further comprises a lignosulfonate, melaninogenica and naphthalenesulfonate individually and in a mixture.

3. A method according to claim 1, characterized in that the plasticizer is used in an amount up to 1% dry solids by weight of cement.



 

Same patents:

FIELD: chemistry.

SUBSTANCE: anticorrosive coating based on a cement composition with additives of plasticiser S-3 and sugar syrup is deposited on the inner surface of pipes by shotcreting or centrifuging. The mixture further contains chamotte marl flour and aqueous calcium nitrate solution. The composition of the mixture is given.

EFFECT: invention increases resistance of the pipeline coating to varying temperature of the heat carrier in a wide temperature range.

1 tbl

FIELD: chemistry.

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2 cl

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EFFECT: higher density of a concrete mixture and production of a concrete with increased strength.

6 cl, 2 tbl, 2 dwg

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FIELD: machine building.

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2 tbl

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3 cl, 4 tbl

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EFFECT: raised mechanical strength and density of ballast material.

6 cl, 1 tbl

Ballast material // 2399828

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EFFECT: increased density and strength.

6 cl, 1 ex, 2 tbl

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EFFECT: increased strength, reduced coefficient of heat conductivity, density.

1 tbl

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11 cl, 6 ex, 1 tbl

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25 cl, 2 ex

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10 cl, 6 tbl, 2 dwg

FIELD: chemistry.

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EFFECT: improvement of the concrete mixture self-levelling.

24 cl, 6 tbl

FIELD: chemistry.

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EFFECT: improvement of basic properties of concrete: increase of strength and reduction of moisture permeability.

1 dwg, 1 tbl

FIELD: chemistry.

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EFFECT: safe utilisation of mobile phones.

1 tbl

FIELD: chemistry.

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EFFECT: obtaining durable and ecologically safe artificial stone.

1 tbl

FIELD: chemistry.

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EFFECT: reducing dust formation, reducing the degree of release of organic compounds during storage and use of construction materials.

14 cl, 1 tbl

FIELD: chemistry.

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9 cl, 7 tbl

FIELD: construction.

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EFFECT: improving strength of concrete during the first day of hardening; increasing grade strength, freeze resistance and water resistance.

2 cl, 1 tbl

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