Cement Mortar Coated Steel Pipes for Corrosion Protection
Cement mortar coated steel pipes are designed with a layer of concrete inside, which provides excellent thermal insulation properties. This characteristic allows the pipe to absorb and retain significant heat during fire exposure, resulting in an uneven temperature distribution across the cross-section. As a result, the structural integrity of the steel column is maintained for a longer time, reducing the rate at which the steel heats up. When the steel begins to yield, the surrounding cement mortar can take on most of the axial load, preventing catastrophic failure of the structure. Similarly, composite beams benefit from this system as heat is transferred from the top flange to the concrete, lowering the overall temperature of the steel beam. Studies have shown that using this method can reduce the amount of fireproof coating needed by up to two-thirds or more while still meeting a 3-hour fire resistance standard.
The strength grades of cement mortar used in these pipes include M3, M5, M7.5, M10, M12.5, M15, M20, M25, M30, and M40. Depending on the intended use, the mortar can be categorized into masonry, plastering, and jointing. However, these classifications are not directly related to the grade numbers. After the application of cement mortar, it is essential to allow the material to air dry naturally for 2–3 days. This step helps prevent cracks caused by physical impacts during transportation and ensures long-term durability.
Steel components are also affected by external forces, which can influence their deformation, stability, and fatigue resistance. Hot-rolled steel products often face challenges in maintaining precise dimensions, especially in terms of thickness and side width. Thermal expansion and contraction are natural phenomena; even if the initial measurements meet standards, cooling after hot rolling can lead to dimensional changes. The greater the negative difference in width and thickness, the more pronounced the impact on performance. Therefore, for large steel sections, exact specifications for edge width, thickness, length, angles, and edges may not always be achievable.
Internal corrosion protection of steel pipes using cement mortar is a widely adopted technique. Some common methods include:
- Three-layer polyethylene (3PE) and two-layer polyethylene (2PE) coatings for oil and gas pipelines.
- Single-layer and double-layer fused epoxy (FBE) coatings for corrosion protection in oil and gas industries.
- IPN8710 macromolecular non-toxic coatings for water supply pipelines.
- High-density polyethylene polyurethane foam insulated steel pipes.
- Cement mortar lining for internal corrosion prevention in water supply systems.
- Epoxy coal tar fiberglass cloth coatings for additional protection.
These cement mortar coated steel pipes have a wide range of applications, including:
- Municipal Engineering: Suitable for high-rise building water supply systems, heating networks, tap water projects, gas transmission, and underground water pipelines.
- Petroleum and Chemical Industries: Used in pipelines transporting corrosive media, such as in chemical plants, pharmaceuticals, and textile processing.
- Sewage Treatment: Ideal for sewage discharge pipes, sewer lines, and anti-corrosion works in biological treatment tanks.
- Agriculture: Offers superior corrosion resistance compared to traditional steel structures, making it ideal for irrigation, deep well, and drainage systems, while also improving fire resistance and safety.
In summary, cement mortar coated steel pipes provide an effective solution for both corrosion and fire protection. Their versatility, durability, and cost-effectiveness make them a preferred choice in various industrial and infrastructure applications.
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