CN107379363B - Forming process of polymer concrete pipeline - Google Patents
Forming process of polymer concrete pipeline Download PDFInfo
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- CN107379363B CN107379363B CN201710823649.7A CN201710823649A CN107379363B CN 107379363 B CN107379363 B CN 107379363B CN 201710823649 A CN201710823649 A CN 201710823649A CN 107379363 B CN107379363 B CN 107379363B
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- 239000002986 polymer concrete Substances 0.000 title claims abstract description 116
- 238000000034 method Methods 0.000 title claims abstract description 24
- 230000008569 process Effects 0.000 title claims abstract description 22
- 229920005989 resin Polymers 0.000 claims abstract description 127
- 239000011347 resin Substances 0.000 claims abstract description 127
- 239000006004 Quartz sand Substances 0.000 claims abstract description 119
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 119
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 62
- 239000010959 steel Substances 0.000 claims abstract description 62
- 239000000853 adhesive Substances 0.000 claims abstract description 60
- 230000001070 adhesive effect Effects 0.000 claims abstract description 60
- 239000003795 chemical substances by application Substances 0.000 claims abstract description 53
- 239000011248 coating agent Substances 0.000 claims abstract description 47
- 238000000576 coating method Methods 0.000 claims abstract description 47
- 239000002245 particle Substances 0.000 claims abstract description 38
- 230000003014 reinforcing effect Effects 0.000 claims abstract description 28
- 238000005507 spraying Methods 0.000 claims abstract description 18
- 239000004744 fabric Substances 0.000 claims abstract description 8
- 239000010410 layer Substances 0.000 claims description 91
- 238000003756 stirring Methods 0.000 claims description 56
- 239000000463 material Substances 0.000 claims description 53
- 238000002156 mixing Methods 0.000 claims description 41
- 238000006116 polymerization reaction Methods 0.000 claims description 36
- 238000002360 preparation method Methods 0.000 claims description 23
- 239000003063 flame retardant Substances 0.000 claims description 19
- 239000007822 coupling agent Substances 0.000 claims description 18
- 239000003112 inhibitor Substances 0.000 claims description 18
- 239000012752 auxiliary agent Substances 0.000 claims description 17
- 239000011230 binding agent Substances 0.000 claims description 14
- 230000000670 limiting effect Effects 0.000 claims description 14
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 claims description 12
- 239000003365 glass fiber Substances 0.000 claims description 10
- 239000004567 concrete Substances 0.000 claims description 6
- 238000005266 casting Methods 0.000 claims description 2
- 239000003822 epoxy resin Substances 0.000 claims description 2
- 229920000647 polyepoxide Polymers 0.000 claims description 2
- 238000000465 moulding Methods 0.000 claims 2
- 239000002671 adjuvant Substances 0.000 claims 1
- 239000011247 coating layer Substances 0.000 claims 1
- 238000004519 manufacturing process Methods 0.000 abstract description 15
- 230000007797 corrosion Effects 0.000 abstract description 13
- 238000005260 corrosion Methods 0.000 abstract description 13
- 238000007789 sealing Methods 0.000 abstract description 4
- 230000003487 anti-permeability effect Effects 0.000 abstract 1
- 230000002787 reinforcement Effects 0.000 description 29
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 25
- 238000005336 cracking Methods 0.000 description 17
- 238000006243 chemical reaction Methods 0.000 description 13
- 229910001294 Reinforcing steel Inorganic materials 0.000 description 12
- 238000001879 gelation Methods 0.000 description 12
- 239000011229 interlayer Substances 0.000 description 12
- 238000011160 research Methods 0.000 description 9
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 8
- 230000006835 compression Effects 0.000 description 8
- 238000007906 compression Methods 0.000 description 8
- 238000013461 design Methods 0.000 description 8
- 230000000694 effects Effects 0.000 description 8
- 229910052710 silicon Inorganic materials 0.000 description 8
- 239000010703 silicon Substances 0.000 description 8
- 239000002253 acid Substances 0.000 description 7
- UHOVQNZJYSORNB-UHFFFAOYSA-N benzene Substances C1=CC=CC=C1 UHOVQNZJYSORNB-UHFFFAOYSA-N 0.000 description 7
- 230000006750 UV protection Effects 0.000 description 6
- 229920001688 coating polymer Polymers 0.000 description 6
- 230000007613 environmental effect Effects 0.000 description 6
- 230000004224 protection Effects 0.000 description 6
- 239000011521 glass Substances 0.000 description 5
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 238000007493 shaping process Methods 0.000 description 5
- 230000006378 damage Effects 0.000 description 3
- 238000009792 diffusion process Methods 0.000 description 3
- 238000012545 processing Methods 0.000 description 3
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 229920002748 Basalt fiber Polymers 0.000 description 2
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 2
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 description 2
- 239000004568 cement Substances 0.000 description 2
- FPAFDBFIGPHWGO-UHFFFAOYSA-N dioxosilane;oxomagnesium;hydrate Chemical compound O.[Mg]=O.[Mg]=O.[Mg]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O FPAFDBFIGPHWGO-UHFFFAOYSA-N 0.000 description 2
- 239000012796 inorganic flame retardant Substances 0.000 description 2
- 239000005011 phenolic resin Substances 0.000 description 2
- 229920001568 phenolic resin Polymers 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 239000013535 sea water Substances 0.000 description 2
- 238000000926 separation method Methods 0.000 description 2
- 238000010257 thawing Methods 0.000 description 2
- CNHDIAIOKMXOLK-UHFFFAOYSA-N toluquinol Chemical compound CC1=CC(O)=CC=C1O CNHDIAIOKMXOLK-UHFFFAOYSA-N 0.000 description 2
- QIGBRXMKCJKVMJ-UHFFFAOYSA-N 1,4-Benzenediol Natural products OC1=CC=C(O)C=C1 QIGBRXMKCJKVMJ-UHFFFAOYSA-N 0.000 description 1
- SPSSULHKWOKEEL-UHFFFAOYSA-N 2,4,6-trinitrotoluene Chemical compound CC1=C([N+]([O-])=O)C=C([N+]([O-])=O)C=C1[N+]([O-])=O SPSSULHKWOKEEL-UHFFFAOYSA-N 0.000 description 1
- WFUGQJXVXHBTEM-UHFFFAOYSA-N 2-hydroperoxy-2-(2-hydroperoxybutan-2-ylperoxy)butane Chemical group CCC(C)(OO)OOC(C)(CC)OO WFUGQJXVXHBTEM-UHFFFAOYSA-N 0.000 description 1
- 239000004114 Ammonium polyphosphate Substances 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- 239000006087 Silane Coupling Agent Substances 0.000 description 1
- YUWBVKYVJWNVLE-UHFFFAOYSA-N [N].[P] Chemical compound [N].[P] YUWBVKYVJWNVLE-UHFFFAOYSA-N 0.000 description 1
- 238000005903 acid hydrolysis reaction Methods 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- 235000019826 ammonium polyphosphate Nutrition 0.000 description 1
- 229920001276 ammonium polyphosphate Polymers 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000003139 buffering effect Effects 0.000 description 1
- 230000001684 chronic effect Effects 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical group [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000013329 compounding Methods 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 230000008014 freezing Effects 0.000 description 1
- 238000007710 freezing Methods 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- NWVVVBRKAWDGAB-UHFFFAOYSA-N hydroquinone methyl ether Natural products COC1=CC=C(O)C=C1 NWVVVBRKAWDGAB-UHFFFAOYSA-N 0.000 description 1
- 125000000687 hydroquinonyl group Chemical group C1(O)=C(C=C(O)C=C1)* 0.000 description 1
- 230000008595 infiltration Effects 0.000 description 1
- 238000001764 infiltration Methods 0.000 description 1
- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 description 1
- 239000000347 magnesium hydroxide Substances 0.000 description 1
- 229910001862 magnesium hydroxide Inorganic materials 0.000 description 1
- 239000005078 molybdenum compound Substances 0.000 description 1
- 150000002752 molybdenum compounds Chemical class 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 150000003961 organosilicon compounds Chemical class 0.000 description 1
- 230000003204 osmotic effect Effects 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000010865 sewage Substances 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 238000002791 soaking Methods 0.000 description 1
- 239000011780 sodium chloride Substances 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000000015 trinitrotoluene Substances 0.000 description 1
- BIKXLKXABVUSMH-UHFFFAOYSA-N trizinc;diborate Chemical compound [Zn+2].[Zn+2].[Zn+2].[O-]B([O-])[O-].[O-]B([O-])[O-] BIKXLKXABVUSMH-UHFFFAOYSA-N 0.000 description 1
- 229920006337 unsaturated polyester resin Polymers 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
- B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
- B29C39/10—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. casting around inserts or for coating articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
- B29C39/22—Component parts, details or accessories; Auxiliary operations
- B29C39/26—Moulds or cores
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
- C04B26/02—Macromolecular compounds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2023/00—Tubular articles
- B29L2023/22—Tubes or pipes, i.e. rigid
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Laminated Bodies (AREA)
- Sewage (AREA)
Abstract
A forming process of a polymer concrete pipeline belongs to the technical field of pipeline manufacturing, and comprises an inner lining mold and an outer mold, and comprises the following steps: A. coating a layer of release agent on the outer wall of the lining mold, then coating a fabric resin gel coat layer on the surface of the release agent, and spraying quartz sand particles; B. coating a layer of release agent on the inner wall of the outer die, then coating a layer of pure resin gel coat or fabric resin gel coat on the surface of the release agent, and spraying adhesive particles after curing; C. sequentially sleeving a lining mold, a steel bar net framework, a reinforcing net and an outer mold from inside to outside to form a pouring structure; D. and pouring polymer concrete into the pouring structure, and removing the lining mold and the outer mold after curing and forming to obtain the polymer concrete pipeline. The invention has simple process, and the prepared polymer concrete pipeline has excellent performance in all aspects, and has the advantages of high sealing performance, high strength, high anti-permeability, corrosion resistance and the like.
Description
Technical Field
The invention belongs to the technical field of pipeline manufacturing, designs a polymer concrete pipeline, and particularly relates to a forming process of the polymer concrete pipeline. The invention has simple forming process, and the prepared polymer concrete pipeline has excellent performance in all aspects, and has the advantages of high sealing property, high strength, high impermeability, freeze thawing resistance, corrosion resistance and the like.
Background
The pipeline used by the existing urban water supply and drainage system is mainly a concrete pipe, has the advantages of low cost, simple production and the like, but also has the defects of poor osmotic pressure resistance, poor corrosion resistance, low pipe body strength, large friction coefficient of the inner wall of the pipe and the like, and the service life is greatly influenced.
The existing polymer concrete pipeline is generally manufactured by the steps of firstly building an inner lining mould and an outer mould, then pouring polymer concrete into a formed cavity, and then removing the inner lining mould and the outer mould to obtain the polymer concrete pipeline. The polymer concrete pipeline obtained by the method has poor pressure bearing performance, is easy to crack, explode and corrode; in addition, the polymer concrete is selected from common concrete lifting materials, belongs to heterogeneous materials with porous structures, is a typical brittle material, has high elastic modulus and poor rupture resistance, freezing and thawing resistance, corrosion resistance and the like, and cannot meet the requirements of production practice. The properties of the polymer-concrete material such as PC are mainly determined by the type and performance of the polymer adhesive and the performance of the aggregate, the content of the resin controlled in the PC can only reach more than or equal to 12 percent and is generally 12 to 15 percent at present, and the content of the resin in the PC can not be further reduced, which becomes a great problem for controlling the development of the PC.
Disclosure of Invention
The invention provides a forming process of a polymer concrete pipeline for solving the problems, which not only solves the performance problem of the pipeline and enables the prepared pipeline to have excellent performance in all aspects, but also successfully reduces the content of resin in PC through innovative design, makes breakthrough progress and breaks through the impasse that the content of the resin in the existing PC can not be less than 8%.
The technical scheme adopted by the invention for realizing the purpose is as follows:
the forming process of the polymer concrete pipeline comprises an inner lining mould and an outer mould, and comprises the following steps:
A. internal mold pretreatment: coating a layer of release agent on the outer wall of the lining mold, coating a fabric resin gel coat layer on the surface of the release agent, coating a layer of structural adhesive, and spraying adhesive particles on the surface of the structural adhesive;
B. external mold pretreatment: coating a layer of release agent on the inner wall of the outer die, then coating a layer of pure resin gel coat or fabric resin gel coat on the surface of the release agent, and spraying adhesive particles after curing;
C. building a pouring structure: sequentially sleeving a lining mold, a steel bar net framework, a reinforcing net and an outer mold from inside to outside to form a pouring structure;
D. preparation of polymer concrete pipe: and pouring polymer concrete into the pouring structure, and removing the lining mold and the outer mold after curing and forming to obtain the polymer concrete pipeline.
The polymer concrete comprises 92-93.5% of aggregate, 6.5-8% of resin binder and auxiliary agent in total by mass percent, wherein the aggregate comprises 3/8-4 meshes of quartz sand, 4-10 meshes of quartz sand, 10-0 meshes of quartz sand, 30-70 meshes of quartz sand, 70-120 meshes of quartz sand and 120 meshes of 250 meshes of quartz sand which are in mass ratio of (20-30) to (30-40) to (12-16) to (5-10) to (3-8).
The auxiliary agent comprises a curing agent accounting for 1.0-2.5% of the mass of the resin adhesive, an accelerating agent accounting for 0.1-0.6% of the mass of the resin adhesive, a coupling agent accounting for 0.2-3% of the mass of the resin adhesive, a polymerization inhibitor accounting for 0.01-0.05% of the mass of the resin adhesive and a flame retardant accounting for 0.5-7% of the mass of the resin adhesive.
The polymer concrete was prepared as follows:
a. mixing the aggregate: conveying 3/8-4 meshes of quartz sand, 4-10 meshes of quartz sand, 10-30 meshes of quartz sand, 30-70 meshes of quartz sand, 70-120 meshes of quartz sand and 120-250 meshes of quartz sand to a mixer for mixing through an automatic batching machine.
b. Resin treatment: adding a coupling agent into a resin adhesive with the viscosity of 200-250cps, stirring and mixing, then adding a polymerization inhibitor, stirring and mixing, then adding a flame retardant, stirring and mixing, finally adding an accelerant, stirring and mixing for 3-5 min;
c. preparation of polymer concrete material: and C, adding the mixed resin into a metering tank, adding a curing agent into the metering tank, stirring for 3-5min, and uniformly stirring the resin in the metering tank and the mixed aggregate metered in the step A in a stirring tank to obtain the polymer concrete material.
The reinforcing mesh is an epoxy resin square grid.
The distance between the reinforcing mesh and the reinforcing mesh skeleton is 1/3.
The steel bar of the steel bar net framework is connected with a limiting snap ring in a clamping manner.
The fabric resin gel coat layer comprises a surface felt made on a resin layer, and the resin is food-grade resin.
The bonding particles are 2-4mm chopped glass fibers or quartz sand with the particle size of 10-30 meshes.
The invention has the beneficial effects that:
the pipeline prepared by the invention can achieve the following performances: the service life is more than 50 years, the compression strength is more than 80MPa, the breaking strength is 25MPa, and the maximum working pressure is 6 MPa.
The preparation method of the polymer concrete is designed, and the mixing uniformity among all the aggregate components can be enhanced through the mixing mode, so that the compactness can be further improved, and the adhesive force can be further improved. The invention adopts resin with the viscosity of 200-250cps, sequentially adds the coupling agent, the polymerization inhibitor, the flame retardant and the accelerator, mixes, and finally adds the curing agent, aiming at promoting the curing reaction and some chemical reactions to form a bridge bond, thereby relieving the internal stress, reducing the formation of microcracks, avoiding potential harm and chronic forced damage, improving the structure of a cured product, resisting crack expansion and preventing microcracks from cracking.
The invention reduces the dosage of the resin adhesive in the polymer concrete material PC to less than 8% through the collocation and design of the aggregate components, the aggregate grain diameter and the proportion of the aggregate components. The dosage of each component, the particle size of the aggregate and the selection of the material of the aggregate are obtained through research and practice. In the process of research, the content of resin is found to be influenced by the particle size of aggregate and the components and proportion of the aggregate, the type and the performance of the resin which are considered to be influence factors before are broken through, the key for solving the problem of resin dosage is the decisive factor for reducing the resin dosage, and due to the discovery of the essential influence factors, the dosage of the resin binder in the polymer concrete material PC is reduced to be less than 8% through the collocation and the design of the components of the aggregate, the particle size of the aggregate and the proportion of the components of the aggregate, so that the situation that the dosage of the resin in the polymer concrete material PC can not be less than 8% in the prior art is broken through.
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 curing 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 of the invention belongs to a hole sealing structure, has good impermeability, and prevents water from entering the structure. Avoid the water entering the cement concrete at the temperature of minus 5 ℃ to freeze and melt repeatedly to cause structural damage. 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 during pouring, has high curing speed and strong cohesiveness, has excellent compression resistance, shear resistance, impact strength and seawater corrosion resistance after curing, does not crack or fall off after being soaked in simulated seawater (3 percent NaCl solution) for 40 days, and meets the requirements of marine pipelines. Can be used for electric insulating pipeline, and has good insulating property and surface resistivity of 2.37 × 1013. It can also be used in water supply and drainage pipeline, sewage pipeline, FRP pipeline, PCCP pipeline, high-speed rail, acid hydrolysis tank, etc.
The invention greatly reduces the cost because of the reduction of the consumption of the resin, and the used aggregate is cheap and easy to obtain, thereby further reducing the cost. When the polymer concrete material is prepared, if the polymer concrete material has stronger impact resistance requirement, short fiber materials can be added into the raw materials, and the polymer concrete material prepared after the addition can be used in high impact force occasions. If the requirement of electrical conductivity exists, an electrical conductive material, such as graphite, can be added into the raw materials, and the polymer concrete material prepared after the addition can be used for electrical conductivity.
Detailed Description
The present invention will be further described with reference to the following examples.
The material of the steel bar mesh framework is selected from steel bars, glass fiber reinforced plastics or composite material steel bars.
Example 1
A. Internal mold pretreatment: coating a layer of release agent on the outer wall of the lining mold, then coating a layer of resin on the surface of the release agent, manufacturing a surface felt on the resin layer, coating polymer high-strength structural adhesive after the surface felt is cured, spraying quartz sand particles of 2mm-5mm, embedding half of the structural adhesive, exposing half of the structural adhesive to the outside, and using the structural adhesive as an inner lining layer, wherein if the requirement of water quality safety exists, a food-grade inner lining layer can be selected. Through this setting, accord with the sanitary requirement of water supply pipe, the coating of inner liner layer can form glossy inner wall surface at the inner wall of pipeline in addition, at the in-process that supplies water, reduces the wearing and tearing of substances such as water supply resistance and aquatic grit to the pipeline. Simultaneously, the setting of inner liner can improve the closely knit nature of pipeline, avoids water to the corruption, the infiltration of pipeline, prevents the pipeline fracture. On the other hand, the design of inner liner can reduce the effect of water pressure to the pipeline, plays the effect of buffering to polymer concrete layer, improves the impact resistance of pipeline. (ii) a
B. External mold pretreatment: coating a layer of release agent on the inner wall of the outer die, then coating a layer of pure resin gel coat on the surface of the release agent or manufacturing a surface felt layer on the resin layer, and spraying adhesive particles after curing; the gel coat layer or the surface felt layer has the functions of providing external protection, ultraviolet resistance and corrosion resistance, and simultaneously, after the gel coat layer is coated, the formed pipeline is attractive and smooth, and the outer wall is not easy to wear;
C. building a pouring structure: sequentially sleeving a lining mold, a steel bar net framework, a reinforcing net and an outer mold from inside to outside to form a pouring structure; the reinforcing net is arranged to improve the mechanical properties of the pipeline such as compression resistance, tensile resistance and the like, prevent cracks and reduce the burden of a reinforcing mesh framework in the pipeline; the reinforcing mesh is an epoxy square grid with the diameter of 2mm-4mm and the grid density of 50 x 50.
D. Preparation of polymer concrete pipe: and pouring polymer concrete into the pouring structure, vibrating at high frequency, curing and forming, and removing the lining mold and the outer mold to obtain the polymer concrete pipeline.
Furthermore, in the step B, quartz sand with the grain diameter of 10 meshes-30 meshes is adopted as the bonding particles. The quartz sand with the granularity is adopted for coating, so that the quartz sand can be better bonded with the gel coat layer or the surface felt layer, the quartz sand is coated for preventing the interlayer from separating, the polymer concrete and the gel coat layer are combined into an integral structure, the compactness and the crack resistance of a formed pipeline are improved, and the cracking is prevented;
furthermore, the steel bars of the steel bar mesh framework are clamped with limiting snap rings, so that the limiting effect on the steel bar mesh framework is achieved, and the interlayer combination and the support are enhanced. The steel bar net framework is a steel bar net with the diameter of 4mm-6mm and the grid density of 100mm (100mm-200mm) 200 mm.
The design is that the reinforcement mesh framework is a mesh reinforcement, the reinforcement mesh framework is deviated, twisted and deformed and is S-shaped or curved when being sleeved between a lining mold and an outer mold, the cast pipeline is unqualified in performance and extremely easy to crack, the reinforcement mesh framework is found to be cracked after the pipeline is disassembled, and in order to solve the problem ①, the conventional operation is shaping processing, but a problem ② is also caused when the polymer concrete is impacted during pouring, the reinforcement mesh is deviated, twisted and deformed, the serious direct cause and fracture of the reinforcement mesh framework is caused, so the conventional shaping processing solves the fundamental problem, a series of exploration and research are carried out, the reinforcement mesh framework which is welded on the reinforcement mesh framework at intervals is successfully solved, the reinforcement mesh framework which is protruded outside the reinforcement mesh framework is not deformed at one time, the reinforcement mesh framework which is protruded outside the reinforcement mesh framework is not deformed at least along the axial direction, the reinforcement mesh framework which is not deformed into a pipeline with an angle of 36 degrees, 539, the reinforcement mesh framework which is not deformed, and is set to be equal to two rows of the reinforcement mesh frameworks which are preferably equal to 36 and no angular points.
Further, the polymer concrete adopts 92.8% of aggregate, 7.2% of resin adhesive and auxiliary agent in total, wherein the aggregate comprises 3/8-4 meshes of quartz sand, 10 meshes of quartz sand, 30 meshes of quartz sand, 70 meshes of quartz sand and 120 meshes of quartz sand, 120 meshes of quartz sand and 250 meshes of quartz sand, and the mass ratio of the quartz sand to the resin adhesive to the auxiliary agent is 25:35:14:14:7: 5. The preparation of the polymer concrete is as follows:
a. mixing the aggregate: conveying 3/8-4 meshes of quartz sand, 4 meshes of quartz sand with the grain size less than or equal to 10 meshes, 10 meshes of quartz sand with the grain size less than or equal to 30 meshes, 30 meshes of quartz sand with the grain size less than or equal to 70 meshes, 70 meshes of quartz sand with the grain size less than or equal to 120 meshes and 120 meshes of quartz sand with the grain size less than or equal to 250 meshes to a mixer through an automatic batching machine for mixing.
b. Resin treatment: adding coupling agent into resin adhesive with viscosity of 200-250cps for improving adhesion between materials, stirring and mixing, then adding polymerization inhibitor, stirring and mixing, then adding flame retardant, stirring and mixing, finally adding accelerator, stirring and mixing for 5min, wherein the polymerization inhibitor is added to reduce the reaction process, in the process of research, the materials are subjected to a plurality of failed processes, the prepared materials have poor performance and are unqualified, and a series of research and research of the inventor finds that when the materials are gelled without adding a polymerization inhibitor, the temperature can reach 35-40 ℃, the reaction at the temperature is not easy to control, so that the prepared material has poor performance and is unqualified, and the problem can be solved by adding the polymerization inhibitor through subsequent exploration and analysis in many aspects, which is the progress obtained by practical exploration of people;
c. preparation of polymer concrete material: and C, adding the mixed resin into a metering tank, adding a curing agent into the metering tank, stirring for 3min, then carrying out gelation on the resin in the metering tank and the mixed aggregate metered in the step A in a stirring tank, and uniformly stirring for 60-90min to obtain the polymer concrete material. And during gelation, controlling the environmental temperature to be 18-25 ℃ and the humidity to be 50-55 percent to obtain the polymer concrete material. The gel environment temperature and the environment humidity are used for ensuring the stability of the gel, the stability of the gel directly influences the polymerization effect in the subsequent pouring, if the stability of the gel is poor, the polymerization temperature is too high in the later pouring polymerization, the reaction is not easy to control, and more seriously, the gel directly cracks and bursts, and a pipeline cannot be formed.
Furthermore, in the step b, before the coupling agent is added, the o-benzene flexible resin is added, stirred and mixed, and the flexible resin is added as an auxiliary agent, so as to further solve the problem of dry cracking. The addition amount of the flexible resin is 6-9% of the mass of the resin adhesive.
Furthermore, the parameters of the components of the aggregate are controlled to be that the water content is less than or equal to 0.2 percent, the mud content is less than or equal to 0.5 percent, the silicon content is more than or equal to 95 percent, the acid resistance is more than or equal to 98 percent, and the texture is hard and mellow. 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.
Furthermore, if the prepared pipeline is an open-air pipeline, an ultraviolet-proof agent, such as talcum powder, is added on the basis of the auxiliary agent, the ultraviolet-proof and radiation-proof capability of the pipeline can be improved by adding the talcum powder, and the adding amount of the ultraviolet-proof agent is 1-1.5% of the resin adhesive. The addition of the anti-ultraviolet agent can further improve the service life and the performance of the pipeline.
Further, in order to enable the prepared polymer concrete pipeline to have more excellent high strength, high temperature resistance and high performance, the resin adhesive is required to be compounded with high-temperature phenolic resin and basalt fiber according to the compounding ratio of 1:1:1, or the high-temperature phenolic resin and/or the basalt fiber are/is directly selected.
Example 2
A. Internal mold pretreatment: coating a layer of release agent on the outer wall of the lining mold, then coating a layer of resin on the surface of the release agent, manufacturing a surface felt on the resin layer, coating polymer high-strength structural adhesive after the surface felt is cured, spraying quartz sand particles with the particle size of 3-4 mm, embedding half of the structural adhesive and exposing half of the structural adhesive;
B. external mold pretreatment: coating a layer of release agent on the inner wall of the outer die, then coating a layer of pure resin gel coat on the surface of the release agent, and spraying adhesive particles after curing; the gel coat layer or the surface felt layer has the functions of providing external protection, ultraviolet resistance and corrosion resistance, and simultaneously, after the gel coat layer is coated, the formed pipeline is attractive and smooth, and the outer wall is not easy to wear;
C. building a pouring structure: sequentially sleeving a lining mold, a steel bar net framework, a reinforcing net and an outer mold from inside to outside to form a pouring structure; the reinforcing net is arranged to improve the mechanical properties of the pipeline such as compression resistance, tensile resistance and the like, prevent cracks and reduce the burden of a reinforcing mesh framework in the pipeline;
D. preparation of polymer concrete pipe: and pouring polymer concrete into the pouring structure, and removing the lining mold and the outer mold after curing and forming to obtain the polymer concrete pipeline.
Furthermore, in the step B, quartz sand with the particle size of 20 meshes-30 meshes is adopted as the bonding particles. The quartz sand with the granularity is adopted for coating, so that the quartz sand can be better bonded with the gel coat layer or the surface felt layer, the quartz sand is coated for preventing the interlayer from separating, the polymer concrete and the gel coat layer are combined into an integral structure, the compactness and the crack resistance of a formed pipeline are improved, and the cracking is prevented;
furthermore, the steel bars of the steel bar mesh framework are clamped with limiting snap rings, so that the limiting effect on the steel bar mesh framework is achieved, and the interlayer combination and the support are enhanced.
The reinforcement mesh framework is formed by binding metal reinforcement meshes or glass reinforcement meshes into a cylinder, the reinforcements are arranged in rows along the length direction of the reinforcement meshes, and at least 1 row is arranged, the design is that when the reinforcement mesh framework is sleeved between a lining mold and an outer mold by ①, the reinforcement mesh framework is shifted, twisted and deformed into an S shape or a curved shape, so that the performance of a cast pipeline is unqualified and easy to crack, and the reinforcement mesh framework is found to be cracked after the pipeline is disassembled, so that the problem ① is solved, the conventional operation is shaping treatment, but the problem ② is that when the pipeline is cast, the reinforcement mesh framework is shifted, deformed and seriously and directly cracked due to the cracking of the reinforcement mesh framework, the problem that when the pipeline is disassembled is solved, the problem that when the conventional operation is shaping treatment is carried out, the problem that when the pipeline is cast, the reinforcement mesh framework is not cracked, the problem that the reinforcement mesh framework is not separated, deformed and the problem that when the pipeline is disassembled, the pipeline is not disassembled, the problem that the reinforcement mesh framework is not successfully disassembled, the problem that the pipeline is finally solved by a series of the reinforcement mesh framework is solved by ①, the conventional shaping treatment, and the problem that the pipeline is not successfully researched.
Further, the polymer concrete adopts 92% of aggregate, 8% of resin binder and auxiliary agent in total, and the aggregate comprises 1-3 mesh quartz sand, 5-9 mesh quartz sand, 15-25 mesh quartz sand, 40-60 mesh quartz sand, 80-100 mesh quartz sand and 150-200 mesh quartz sand in a mass ratio of 20:30:12:12:5: 3. The preparation of the polymer concrete is as follows:
a. mixing the aggregate: conveying 1-3 meshes of quartz sand, 5-9 meshes of quartz sand, 15-25 meshes of quartz sand, 40-60 meshes of quartz sand, 80-100 meshes of quartz sand and 150-200 meshes of quartz sand to a mixer for mixing through an automatic batching machine.
b. Resin treatment: adding coupling agent into resin adhesive with viscosity of 200-250cps for improving adhesion among materials, stirring and mixing, then adding polymerization inhibitor, stirring and mixing, then adding flame retardant, stirring and mixing, adding accelerant, stirring and mixing for 5min, the addition of polymerization inhibitor is to reduce the reaction process, in the process of research, the materials are subjected to a plurality of failed processes, the prepared materials have poor performance and are unqualified, and a series of research and research of the inventor finds that when the materials are gelled without adding a polymerization inhibitor, the temperature can reach 35-40 ℃, the reaction at the temperature is not easy to control, so that the prepared material has poor performance and is unqualified, and the problem can be solved by adding the polymerization inhibitor through subsequent exploration and analysis in many aspects, which is the progress obtained by practical exploration of people;
c. preparation of polymer concrete material: and C, adding the mixed resin into a metering tank, adding a curing agent into the metering tank, stirring for 4min, then carrying out gelation on the resin in the metering tank and the mixed aggregate metered in the step A in a stirring tank, and uniformly stirring to obtain the polymer concrete material. And during the gelation, controlling the environmental temperature to be 18-21 ℃ and the humidity to be 52-53 percent to obtain the polymer concrete material. The gel environment temperature and the environment humidity are used for ensuring the stability of the gel, the stability of the gel directly influences the polymerization effect in the subsequent pouring, if the stability of the gel is poor, the polymerization temperature is too high in the later pouring polymerization, the reaction is not easy to control, and more seriously, the gel directly cracks and bursts, and a pipeline cannot be formed.
Furthermore, in the step b, before the coupling agent is added, the o-benzene flexible resin is added, stirred and mixed, and the flexible resin is added as an auxiliary agent, so as to further solve the problem of dry cracking. The addition amount of the flexible resin is 7-8% of the resin adhesive.
Furthermore, the parameters of the components of the aggregate are controlled to be that the water content is less than or equal to 0.2 percent, the mud content is less than or equal to 0.5 percent, the silicon content is more than or equal to 95 percent, the acid resistance is more than or equal to 98 percent, and the texture is hard and mellow. 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.
Example 3
A. Internal mold pretreatment: coating a layer of release agent on the outer wall of the lining mold, then coating a layer of resin on the surface of the release agent, manufacturing a surface felt on the resin layer, coating polymer high-strength structural adhesive after the surface felt is cured, spraying quartz sand particles of 2mm-3mm, embedding half of the structural adhesive and exposing half of the structural adhesive;
B. external mold pretreatment: coating a layer of release agent on the inner wall of the outer die, then coating a gel coat layer or manufacturing a surface felt layer on the surface of the release agent, and spraying adhesive particles after curing; the gel coat layer or the surface felt layer has the functions of providing external protection, ultraviolet resistance and corrosion resistance, and simultaneously, after the gel coat layer is coated, the formed pipeline is attractive and smooth, and the outer wall is not easy to wear;
C. building a pouring structure: sequentially sleeving a lining mold, a steel bar net framework, a reinforcing net and an outer mold from inside to outside to form a pouring structure; the reinforcing net is arranged to improve the mechanical properties of the pipeline such as compression resistance, tensile resistance and the like, prevent cracks and reduce the burden of a reinforcing mesh framework in the pipeline;
D. preparation of polymer concrete pipe: and pouring polymer concrete into the pouring structure, and removing the lining mold and the outer mold after curing and forming to obtain the polymer concrete pipeline.
Furthermore, in the step B, chopped glass fibers with the diameter of 2mm-4mm are adopted as the bonding particles. The chopped glass fiber with the granularity is adopted for coating, so that the chopped glass fiber can be better bonded with the gel coat layer or the surface felt layer, the purpose of coating the chopped glass fiber is to prevent interlayer separation, the function of combining polymer concrete and the gel coat layer into an integral structure is achieved, the compactness and the crack resistance of a formed pipeline are improved, and cracking is prevented;
furthermore, the steel bars of the steel bar mesh framework are clamped with limiting snap rings, so that the limiting effect on the steel bar mesh framework is achieved, and the interlayer combination and the support are enhanced.
Furthermore, the reinforcing steel bar mesh framework is welded with reinforcing steel bars protruding towards the outer side of the reinforcing steel bar mesh framework at intervals. The steel bar mesh framework is a cylindrical shape formed by bundling metal steel bar meshes or glass steel bar meshes, and the steel bars are arranged in a row along the length direction of the steel bar meshes and at least provided with 1 row.
Further, the polymer concrete adopts 93% of aggregate, 7% of resin binder and auxiliary agent in total, wherein the aggregate comprises 2-3 mesh quartz sand, 6-8 mesh quartz sand, 18-22 mesh quartz sand, 50-70 mesh quartz sand, 90-110 mesh quartz sand and 150-210 mesh quartz sand in a mass ratio of 30:40:16:16: 8. The preparation of the polymer concrete is as follows:
a. mixing the aggregate: conveying 2-3 meshes of quartz sand, 6-8 meshes of quartz sand, 18-22 meshes of quartz sand, 50-70 meshes of quartz sand, 90-110 meshes of quartz sand and 150-210 meshes of quartz sand to a mixer for mixing through an automatic batching machine.
b. Resin treatment: adding coupling agent into resin adhesive with viscosity of 200-250cps, stirring, adding polymerization inhibitor, stirring, adding flame retardant, stirring, adding accelerator, stirring and mixing for 4 min;
c. preparation of polymer concrete material: and C, adding the mixed resin into a metering tank, adding a curing agent into the metering tank, stirring for 3min, then carrying out gelation on the resin in the metering tank and the mixed aggregate metered in the step A in a stirring tank, and uniformly stirring to obtain the polymer concrete material. And during the gelation, controlling the environmental temperature to be 20-23 ℃ and the humidity to be 50-52 percent to obtain the polymer concrete material. The gel environment temperature and the environment humidity are used for ensuring the stability of the gel, the stability of the gel directly influences the polymerization effect in the subsequent pouring, if the stability of the gel is poor, the polymerization temperature is too high in the later pouring polymerization, the reaction is not easy to control, and more seriously, the gel directly cracks and bursts, and a pipeline cannot be formed.
Furthermore, in the step b, before the coupling agent is added, the o-benzene flexible resin is added, stirred and mixed, and the flexible resin is added as an auxiliary agent, so as to further solve the problem of dry cracking. The amount of the flexible resin is 8% of the resin binder.
Furthermore, the parameters of the components of the aggregate are controlled to be that the water content is less than or equal to 0.2 percent, the mud content is less than or equal to 0.5 percent, the silicon content is more than or equal to 95 percent, the acid resistance is more than or equal to 98 percent, and the texture is hard and mellow. 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 casting process, and is not round, poor in fluidity and more in bubbles, so that the resin content is high finally.
Example 4
A. Internal mold pretreatment: coating a layer of release agent on the outer wall of the lining mold, then coating a layer of resin on the surface of the release agent, manufacturing a surface felt on the resin layer, coating polymer high-strength structural adhesive after the surface felt is cured, spraying quartz sand particles with the particle size of 3-4 mm, embedding half of the structural adhesive and exposing half of the structural adhesive;
B. external mold pretreatment: coating a layer of release agent on the inner wall of the outer die, then coating a gel coat layer or manufacturing a surface felt layer on the surface of the release agent, and spraying adhesive particles after curing; the gel coat layer or the surface felt layer has the functions of providing external protection, ultraviolet resistance and corrosion resistance, and simultaneously, after the gel coat layer is coated, the formed pipeline is attractive and smooth, and the outer wall is not easy to wear;
C. building a pouring structure: sequentially sleeving a lining mold, a steel bar net framework, a reinforcing net and an outer mold from inside to outside to form a pouring structure; the reinforcing net is arranged to improve the mechanical properties of the pipeline such as compression resistance, tensile resistance and the like, prevent cracks and reduce the burden of a reinforcing mesh framework in the pipeline;
D. preparation of polymer concrete pipe: and pouring polymer concrete into the pouring structure, and removing the lining mold and the outer mold after curing and forming to obtain the polymer concrete pipeline.
Furthermore, in the step B, 3mm-4mm chopped glass fibers are adopted as the bonding particles. The chopped glass fiber with the granularity is adopted for coating, so that the chopped glass fiber can be better bonded with the gel coat layer or the surface felt layer, the purpose of coating the chopped glass fiber is to prevent interlayer separation, the function of combining polymer concrete and the gel coat layer into an integral structure is achieved, the compactness and the crack resistance of a formed pipeline are improved, and cracking is prevented;
furthermore, the steel bars of the steel bar mesh framework are clamped with limiting snap rings, so that the limiting effect on the steel bar mesh framework is achieved, and the interlayer combination and the support are enhanced.
Furthermore, the reinforcing steel bar mesh framework is welded with reinforcing steel bars protruding towards the outer side of the reinforcing steel bar mesh framework at intervals. The steel bar mesh framework is a cylindrical shape formed by bundling metal steel bar meshes or glass steel bar meshes, and the steel bars are arranged in a row along the length direction of the steel bar meshes and at least provided with 1 row.
Further, the polymer concrete adopts 94% of aggregate, 6% of resin binder and 6% of auxiliary agent, and the aggregate comprises 1-2 meshes of quartz sand, 6-8 meshes of quartz sand, 13-24 meshes of quartz sand, 50-65 meshes of quartz sand, 100-120 meshes of quartz sand and 160-230 meshes of quartz sand in a mass ratio of 23:31:13:13:6: 4. The preparation of the polymer concrete is as follows:
a. mixing the aggregate: conveying 1-2 meshes, 6-8 meshes, 13-24 meshes, 50-65 meshes, 100-120 meshes and 160-230 meshes of quartz sand to a mixer for mixing through an automatic batching machine.
b. Resin treatment: adding a coupling agent into a resin adhesive with the viscosity of 200-250cps, wherein the addition of the coupling agent can also improve the adhesion between different materials such as quartz sand and resin and improve the overall strength by more than 20%, stirring and mixing, then adding a polymerization inhibitor, stirring and mixing, then adding a flame retardant, stirring and mixing, adding an accelerant, and stirring and mixing for 4min in order to improve the processing efficiency;
c. preparation of polymer concrete material: and C, adding the mixed resin into a metering tank, adding a curing agent into the metering tank, stirring for 5min, then carrying out gelation on the resin in the metering tank and the mixed aggregate metered in the step A in a stirring tank, and uniformly stirring to obtain the polymer concrete material. And during the gelation, controlling the environmental temperature to be 22-24 ℃ and the humidity to be 51-53 percent to obtain the polymer concrete material. The gel environment temperature and the environment humidity are used for ensuring the stability of the gel, the stability of the gel directly influences the polymerization effect in the subsequent pouring, if the stability of the gel is poor, the polymerization temperature is too high in the later pouring polymerization, the reaction is not easy to control, and more seriously, the gel directly cracks and bursts, and a pipeline cannot be formed.
Furthermore, in the step b, before the coupling agent is added, the o-benzene flexible resin is added, stirred and mixed, and the flexible resin is added as an auxiliary agent, so that the problem of dry cracking is further solved, and the fracture resistance can be further improved. The addition amount of the flexible resin is 6-9% of the resin adhesive.
Furthermore, the parameters of the components of the aggregate are controlled to be that the water content is less than or equal to 0.2 percent, the mud content is less than or equal to 0.5 percent, the silicon content is more than or equal to 95 percent, the acid resistance is more than or equal to 98 percent, and the texture is hard and mellow.
Example 5
A. Internal mold pretreatment: coating a layer of release agent on the outer wall of the lining mold, then coating a layer of resin on the surface of the release agent, manufacturing a surface felt on the resin layer, coating polymer high-strength structural adhesive after the surface felt is cured, spraying quartz sand particles with the particle size of 3mm-5mm, embedding half of the structural adhesive and exposing half of the structural adhesive;
B. external mold pretreatment: coating a layer of release agent on the inner wall of the outer die, then coating a gel coat layer or manufacturing a surface felt layer on the surface of the release agent, and spraying adhesive particles after curing; the gel coat layer or the surface felt layer has the functions of providing external protection, ultraviolet resistance and corrosion resistance, and simultaneously, after the gel coat layer is coated, the formed pipeline is attractive and smooth, and the outer wall is not easy to wear;
C. building a pouring structure: sequentially sleeving a lining mold, a steel bar net framework, a reinforcing net and an outer mold from inside to outside to form a pouring structure; the reinforcing net is arranged to improve the mechanical properties of the pipeline such as compression resistance, tensile resistance and the like, prevent cracks and reduce the burden of a reinforcing mesh framework in the pipeline;
D. preparation of polymer concrete pipe: and pouring polymer concrete into the pouring structure, and removing the lining mold and the outer mold after curing and forming to obtain the polymer concrete pipeline.
Further, in the step B, 10-20 meshes of quartz sand is used as the bonding particles. The quartz sand with the granularity is adopted for coating, so that the quartz sand can be better bonded with the gel coat layer or the surface felt layer, the quartz sand is coated for preventing the interlayer from separating, the polymer concrete and the gel coat layer are combined into an integral structure, the compactness and the crack resistance of a formed pipeline are improved, and the cracking is prevented;
furthermore, the steel bars of the steel bar mesh framework are clamped with limiting snap rings, so that the limiting effect on the steel bar mesh framework is achieved, and the interlayer combination and the support are enhanced.
Furthermore, the reinforcing steel bar mesh framework is welded with reinforcing steel bars protruding towards the outer side of the reinforcing steel bar mesh framework at intervals. The steel bar mesh framework is a cylindrical shape formed by bundling metal steel bar meshes or glass steel bar meshes, and the steel bars are arranged in a row along the length direction of the steel bar meshes and at least provided with 1 row.
Further, the polymer concrete adopts 92.5% of aggregate and 7.5% of resin binder and auxiliary agent in total, and the aggregate comprises 2-4 mesh quartz sand, 7-9 mesh quartz sand, 20-28 mesh quartz sand, 60-70 mesh quartz sand, 85-110 mesh quartz sand and 160-200 mesh quartz sand in a mass ratio of 27:33:15:15:8: 6. The preparation of the polymer concrete is as follows:
a. mixing the aggregate: conveying 2-4 meshes of quartz sand, 7-9 meshes of quartz sand, 20-28 meshes of quartz sand, 60-70 meshes of quartz sand, 85-110 meshes of quartz sand and 160-200 meshes of quartz sand to a mixer for mixing through an automatic batching machine.
b. Resin treatment: adding coupling agent into resin adhesive with viscosity of 200-250cps, stirring, adding polymerization inhibitor, stirring, adding flame retardant, stirring, adding accelerator, stirring and mixing for 4 min;
c. preparation of polymer concrete material: and C, adding the mixed resin into a metering tank, adding a curing agent into the metering tank, stirring for 3min, then carrying out gelation on the resin in the metering tank and the mixed aggregate metered in the step A in a stirring tank, and uniformly stirring to obtain the polymer concrete material. And during the gelation, controlling the environmental temperature to be 20-22 ℃ and the humidity to be 53-54 percent to obtain the polymer concrete material. The gel environment temperature and the environment humidity are used for ensuring the stability of the gel, the stability of the gel directly influences the polymerization effect in the subsequent pouring, if the stability of the gel is poor, the polymerization temperature is too high in the later pouring polymerization, the reaction is not easy to control, and more seriously, the gel directly cracks and bursts, and a pipeline cannot be formed.
Furthermore, in the step b, before the accelerator is added, the o-benzene flexible resin is added, stirred and mixed, and the flexible resin is added as an auxiliary agent, so as to further solve the problem of dry cracking. The addition amount of the flexible resin is 6-9% of the resin adhesive.
Furthermore, the parameters of the components of the aggregate are controlled to be that the water content is less than or equal to 0.2 percent, the mud content is less than or equal to 0.5 percent, the silicon content is more than or equal to 95 percent, the acid resistance is more than or equal to 98 percent, and the texture is hard and mellow.
Example 6
A. Internal mold pretreatment: coating a layer of release agent on the outer wall of the lining mold, then coating a layer of resin on the surface of the release agent, manufacturing a surface felt on the resin layer, coating polymer high-strength structural adhesive after the surface felt is cured, spraying quartz sand particles with the particle size of 4-5 mm, embedding half of the structural adhesive and exposing half of the structural adhesive;
B. external mold pretreatment: coating a layer of release agent on the inner wall of the outer die, then coating a gel coat layer or manufacturing a surface felt layer on the surface of the release agent, and spraying adhesive particles after curing; the gel coat layer or the surface felt layer has the functions of providing external protection, ultraviolet resistance and corrosion resistance, and simultaneously, after the gel coat layer is coated, the formed pipeline is attractive and smooth, and the outer wall is not easy to wear;
C. building a pouring structure: sequentially sleeving a lining mold, a steel bar net framework, a reinforcing net and an outer mold from inside to outside to form a pouring structure; the reinforcing net is arranged to improve the mechanical properties of the pipeline such as compression resistance, tensile resistance and the like, prevent cracks and reduce the burden of a reinforcing mesh framework in the pipeline;
D. preparation of polymer concrete pipe: and pouring polymer concrete into the pouring structure, and removing the lining mold and the outer mold after curing and forming to obtain the polymer concrete pipeline. The pouring of the polymer concrete adopts layered pouring, and the polymer concrete is vibrated during pouring, a vibrator adopts a high-frequency vibrator or an attached pneumatic vibrator, and the working rotating speed is 8000r/min-12000 r/min; installing a vibrator every 0.5 m in the height direction, installing a vibrator every 1 m in the length direction, controlling the vibrators through a variable frequency control cabinet, pouring 1 ton of polymer concrete every 5min, and pouring layer by layer according to the feeding height.
Further, in the step B, 20-30-mesh quartz sand is used as the bonding particles. The quartz sand with the granularity is adopted for coating, so that the quartz sand can be better bonded with the gel coat layer or the surface felt layer, the quartz sand is coated for preventing the interlayer from separating, the polymer concrete and the gel coat layer are combined into an integral structure, the compactness and the crack resistance of a formed pipeline are improved, and the cracking is prevented;
furthermore, the steel bars of the steel bar mesh framework are clamped with limiting snap rings, so that the limiting effect on the steel bar mesh framework is achieved, and the interlayer combination and the support are enhanced.
Furthermore, the reinforcing steel bar mesh framework is welded with reinforcing steel bars protruding towards the outer side of the reinforcing steel bar mesh framework at intervals. The steel bar mesh framework is a cylindrical shape formed by bundling metal steel bar meshes or glass steel bar meshes, and the steel bars are arranged in a row along the length direction of the steel bar meshes and at least provided with 1 row.
Further, the polymer concrete adopts 93.5% of aggregate and 6.5% of resin binder and auxiliary agent in total, and the aggregate comprises 2-3 mesh quartz sand, 5-8 mesh quartz sand, 20-25 mesh quartz sand, 40-60 mesh quartz sand, 90-110 mesh quartz sand and 170-240 mesh quartz sand in a mass ratio of 26:34:14:14:9: 7. The preparation of the polymer concrete is as follows:
a. mixing the aggregate: conveying 2-3 meshes of quartz sand, 5-8 meshes of quartz sand, 20-25 meshes of quartz sand, 40-60 meshes of quartz sand, 90-110 meshes of quartz sand and 170-240 meshes of quartz sand to a mixer for mixing through an automatic batching machine.
b. Resin treatment: adding coupling agent into resin adhesive with viscosity of 200-250cps, stirring, adding polymerization inhibitor, stirring, adding flame retardant, stirring, adding accelerator, stirring and mixing for 4 min;
c. preparation of polymer concrete material: and C, adding the mixed resin into a metering tank, adding a curing agent into the metering tank, stirring for 3min, then carrying out gelation on the resin in the metering tank and the mixed aggregate metered in the step A in a stirring tank, and uniformly stirring to obtain the polymer concrete material. And during gelation, controlling the environmental temperature to be 24-25 ℃ and the humidity to be 54-55 percent to obtain the polymer concrete material. The gel environment temperature and the environment humidity are used for ensuring the stability of the gel, the stability of the gel directly influences the polymerization effect in the subsequent pouring, if the stability of the gel is poor, the polymerization temperature is too high in the later pouring polymerization, the reaction is not easy to control, and more seriously, the gel directly cracks and bursts, and a pipeline cannot be formed.
Furthermore, in the step b, before the coupling agent is added, the o-benzene flexible resin is added, stirred and mixed, and the flexible resin is added as an auxiliary agent, so as to further solve the problem of dry cracking. The addition amount of the flexible resin is 6-9% of the numerical adhesive.
Furthermore, the parameters of the components of the aggregate are controlled to be that the water content is less than or equal to 0.2 percent, the mud content is less than or equal to 0.5 percent, the silicon content is more than or equal to 95 percent, the acid resistance is more than or equal to 98 percent, and the texture is hard and mellow.
The resin adhesive used in the invention is selected from o-benzene type unsaturated polyester resin, the curing agent is selected from methyl ethyl ketone peroxide, the accelerator is selected from cobalt solution with the concentration of 1%, the coupling agent is selected from silane coupling agent and/or organosilicon compound, and the polymerization inhibitor is selected from hydroquinone or methyl hydroquinone. The flame retardant is selected from organic flame retardants and/or inorganic flame retardants, for example, the organic flame retardants are selected from brominated flame retardants, phosphorus-nitrogen flame retardants, nitrogen flame retardants and/or red phosphorus and compound flame retardants; the inorganic flame retardant is selected from the group consisting of trinitrotoluene, magnesium hydroxide, aluminum hydroxide, silicon-based flame retardants, red phosphorus ammonium polyphosphate, zinc borate and/or molybdenum compounds.
Claims (9)
1. The forming process of the polymer concrete pipeline comprises an inner lining mould and an outer mould, and is characterized by comprising the following steps of:
A. internal mold pretreatment: coating a layer of release agent on the outer wall of the lining mold, coating a fabric resin gel coat layer on the surface of the release agent, coating a layer of structural adhesive, and spraying adhesive particles on the surface of the structural adhesive;
B. external mold pretreatment: coating a layer of release agent on the inner wall of the outer die, then coating a layer of pure resin gel coat or fabric resin gel coat on the surface of the release agent, and spraying adhesive particles after curing;
C. building a pouring structure: the casting structure is formed by sequentially sleeving a lining mold, a steel bar net framework, a reinforcing net and an outer mold from inside to outside, wherein steel bars protruding towards the outer side of the steel bar net framework are welded on the steel bar net framework at intervals, 4 rows of steel bars are arranged along the axial direction of the steel bar net framework, and the included angle between every two adjacent rows of steel bars is 90 degrees;
D. preparation of polymer concrete pipe: and pouring polymer concrete into the pouring structure, and removing the lining mold and the outer mold after curing and forming to obtain the polymer concrete pipeline.
2. The process for molding a polymer concrete pipe as claimed in claim 1, wherein the polymer concrete comprises 92-93.5% of aggregate, 6.5-8% of resin binder and auxiliary agent, and the aggregate comprises 3/8-4 mesh quartz sand, 4-10 mesh quartz sand, 10-30 mesh quartz sand, 30-70 mesh quartz sand, 70-120 mesh quartz sand and 120-250 mesh quartz sand in the mass ratio of (20-30): 30-40): 12-16): 5-10): 3-8.
3. A process for forming a polymer concrete pipe as claimed in claim 2, wherein the adjuvant comprises, in mass percent, a curing agent in an amount of 1.0-2.5% of the mass of the resin binder, an accelerator in an amount of 0.1-0.6% of the mass of the resin binder, a coupling agent in an amount of 0.2-3% of the mass of the resin binder, a polymerization inhibitor in an amount of 0.01-0.05% of the mass of the resin binder, and a flame retardant in an amount of 0.5-7% of the mass of the resin binder.
4. A process for forming a polymeric concrete pipe according to claim 3, wherein the polymeric concrete is prepared by:
a. mixing the aggregate: conveying 3/8-4-mesh quartz sand, 4-10-mesh quartz sand, 10-30-mesh quartz sand, 30-70-mesh quartz sand, 70-120-mesh quartz sand and 120-250-mesh quartz sand into a mixer for mixing through an automatic batching machine;
b. resin treatment: adding a coupling agent into a resin adhesive with the viscosity of 200-250cps, stirring and mixing, then adding a polymerization inhibitor, stirring and mixing, then adding a flame retardant, stirring and mixing, finally adding an accelerant, stirring and mixing for 3-5 min;
c. preparation of polymer concrete material: and C, adding the mixed resin into a metering tank, adding a curing agent into the metering tank, stirring for 3-5min, and uniformly stirring the resin in the metering tank and the mixed aggregate metered in the step A in a stirring tank to obtain the polymer concrete material.
5. A process for forming a polymer concrete pipe as claimed in claim 1, wherein the reinforcing mesh is an epoxy resin square mesh.
6. The process for forming a polymer concrete pipe as claimed in claim 1, wherein the distance between the reinforcing mesh and the reinforcing mesh skeleton is 1/3.
7. The process for forming a polymer concrete pipe according to claim 1, wherein a limiting snap ring is snapped on a steel bar of the steel bar mesh framework.
8. The process for forming a polymer concrete pipe according to claim 1, wherein said fabric resin coating layer comprises a surfacing mat formed on a resin layer, and said resin is a food grade resin.
9. The process for molding a polymer concrete pipe as claimed in claim 1, wherein the bonding particles are chopped glass fibers of 2-4mm or quartz sand with a particle size of 10-30 meshes.
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Effective date of registration: 20200628 Address after: 322000 characteristic industrial community of Dachen Town, Yiwu City, Jinhua City, Zhejiang Province Patentee after: Yiwu super strong pipe industry Co., Ltd Address before: 510300 Room 1-302, Rear Seat 176 Xingang West Road, Xingang Street, Haizhu District, Guangzhou City, Guangdong Province Patentee before: Liang Xinye |