Cement Mortar Coated Steel Pipes for Corrosion Resistance
Cement mortar coated steel pipes are widely used in various engineering applications due to their excellent corrosion resistance and structural stability. These pipes are filled with a cement-based mortar, which not only provides protection against internal corrosion but also enhances the fire resistance of the structure. When exposed to high temperatures, the cement mortar absorbs a significant amount of heat, leading to an uneven temperature distribution within the pipe section. This uneven distribution helps delay the heating of the steel core, thereby increasing the fire endurance time and reducing the risk of structural failure.
Once the steel component begins to yield under fire conditions, the surrounding cement mortar can take over most of the axial load, preventing sudden collapse. Additionally, this coating system reduces the temperature of the steel beams by transferring heat from the top flange to the concrete, improving the overall fire performance of composite structures. According to experimental data, using cement mortar coatings can reduce the amount of fireproof paint needed by up to two-thirds, depending on the required fire resistance rating.
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 application, the mortar is categorized into masonry, plastering, or jointing, regardless of its grade. After the mortar work is completed, it's essential to allow the material to air dry naturally for 2–3 days. This step is crucial to prevent cracking caused by external impacts during transportation and handling.
Steel components subjected to external forces may experience some degree of deformation, instability, or fatigue, which can affect their long-term performance. Hot-rolled steel products often face challenges in maintaining consistent thickness and width, as thermal expansion and contraction can cause dimensional changes after cooling. The greater the negative deviation in width and thickness, the more pronounced the impact on performance. Therefore, for large steel sections, precise dimensions in terms of edge width, thickness, length, angle, and edges are difficult to achieve.
There are several common anti-corrosion methods for steel pipes, including:
- 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 corrosive environments.
- IPN8710 non-toxic macromolecular coatings for water supply pipelines.
- High-density polyethylene and polyurethane foam insulation systems.
- Cement mortar lining for internal corrosion protection in water supply systems.
- Epoxy coal tar fiberglass cloth coatings for industrial applications.
These cement mortar coated steel pipes are commonly used in:
- Municipal Engineering: For high-rise building water supply, heating networks, tap water projects, gas transmission, and underground water pipelines.
- Petroleum and Chemical Industries: For transporting corrosive media in pipelines, chemical processing, and industrial applications.
- Sewage Treatment: For sewage discharge lines, sewer pipes, and corrosion-resistant structures in biological pools.
- Agriculture: For irrigation, deep well, and drainage systems where corrosion resistance is critical.
Overall, cement mortar coated steel pipes offer a reliable and cost-effective solution for both internal and external corrosion protection while enhancing the fire resistance and structural integrity of steel components in various applications.
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