Note: Descriptions are shown in the official language in which they were submitted.
CA 2917067 2017-05-12
A.dorney docket No, A.A0961
METHOD FOR MANUFACTURING A PROTECTIVE CONCRETE WEIGHT
COATING FOR PIPELINES
FIELD OF Tim INVENTION
100011 The invention
relates to materials for application to the outer suitices
of pipes as a protective negative buoyancy coating.
RACKGROUND OF THE INVENTION
100021 There is a
known method of preparing a ballast material for underwater
1.0 pipelines,
comprising mixing cement, aggregates, water, and plasticizer, wherein coarse
aggregate from the group of barite, or iron-containing ore, or a mixture
thereof is used as a
aggregate. The mixing is carried out in two stages, as a first step the
mentioned, coarse
aggregate, cement, water and plasticizer are fed to a mixer in the amount of
10 wt. % to 20 wt.
% of its total amount, the mixing is peribtmcd of 10 to 15 seconds and as the
second step,
rest of the mentioned coarse aggregate is supplied in equal portions at
intervals of 10 to 15
seconds while stirring and mixing of the cornponents is carried out until a
homogeneous
MiNtLITC (RU 2.412393, 20,02.2011).
100031 There is a
known ballast material containing cement, barite ore, water
and a plasticizer. The following fractional composition of barite ore wt. % is
used in the
manufacture of ballast material: coarse fraction (from 5 mm to 25 mm) - 8 wt.%
to 16
fine fraction (from 0, 6 Min 1:0 5 rum) - 70 wt.% to 84 WI:. %, a very small
fraction (from 0,01
p.M to 160 itM) - 8 wt% to 14 wt% (R11 2399828, 20.09.2010).
100041 There is
also known ballast material, comprising cement, aggregate,
plastici.zer and water, The material has sulphate resistant Portland cement,
polycarboxylate
P(.7,E plasticizer, and barium product, barite and iron manganese ore
aggregate concentrate.
The material has the following component ratio, wt.%: 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
product - from 18 wt% to 28 wt.% with density of 3.78 kg / cm3 to 3,82 kg / cm
and a.
humidity' of 0.9% to 2,1%, barite ore - from 18 wt,% to 28 wt,% with density
of 3.9 kg / enf3
to 4.1 kg / cm3 and a moisture content of 2%, iron manganese concentrate -
from 25 wt.% to
45 wt% with density of 4,2 kg / eni3 to 4.5 kg ir cm.3 and moisture content of
4%,
100051 The ratio
of water to Portland cement is from 0,35 to 0.5. Aggregate
components have the following particle size distribution: up to 0.16 cm - up
to 5% from 0,16
CA 2917067 2017-05-12
Attorney docket No. AA0961
cm to 1,0 çtn - up to 25% from 1.0 cm to 2.5 cm - up to 35% from 2.5 cm to 5.0
cm - the rest
(R1.5 2437020, 20,12.2011).
100061
Disadvantages of the above-mentioned technical solutions, are
insufficient viscosity of the solution and time of preserving the mobility of
the concrete
mixture, making it difficult to fill the annulus of "pipe in pipe" structure
and making it
necessary for the control. of the operational raw materials humidity in order
to avoid rupture of
the outer shell and the bundle of concrete solution within the fulfilled
structure.
100071 The
closest to the proposed technical solution is a method for
manufacturing of the ballast coating on the pipe, comprising: mixing the
initial components,
namely, sulphate resistant. Portland cement, barite ore and plasticizer based
on
polyearboxylate ether and water. The components fOr mixture are taken in the
f011owing
amounts (wt.%): sulphate resistant Portland cement of 12 wt,% to 17 wt.%,
water of 4 wt.% to
10 wt.%, plasticizer based on polycarboxylate ether of 0.1 wt.% to 0.25 wt,%,
barite ore - the
rest, And different fractions of barite ore at the following content (wt.%)
are served for the
mixture: large 3 mm to 25 mm - 18 wt.%, fine 0,16 mm to 3 mm of 70 wt.% to 85
wt.%,
very small 0.01 mm to 0.16 mm - of 7 wt.% to 16 wt,%.
100081 Water
for concrete mixture is subject to pre-treatment by passing it:
through a magnetic field,, wherein the intensity is maintained at the value of
1.20 000 A / in to
140 000 A / in, at a. speed of 0,5 m ( sec to 3.0 m / see, the time of water
treatment: is not less
than 2 hours (Ali 2453515, 20.06.2012).
100091
However, the known method is rather difficult to apply to mixtures that
are prone to self..pa.cking, as the water treated in a magnetic field has a
relatively small period
of effective action, which imposes substantial limitations on the time of the
solution feeding,
and the behaviour cif such concrete mixes under external forces (lbr example
feeding of the
. 25 mix with a concrete pump) could change rapidly.
18UM.M.ARY OF THE INVENTION
1000101 'The
invention relates to materials for application to the outer surfaces
of pipes as a protective negative buoyancy coating. it allows achieving
accurately a desired
density of the concrete protective weight coating of the pipeline in the range
of 2600 to 3400
kg / m3 by claimed method of manuthcturing a protective concrete weight
coating for
pipelines which includes mixing cement, aggregate, a plasticizing additive and
water,
pumping the resultant mixture into an annular space formed by the, outer
surtac,e of a pipeline
and a permanent limn mounted with clearance thereon, and setting the resultant
coating. In
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CA 2917067 2017-05-12
Attorney docket No, AA0961
the method. Portland cement is supplied .for mixing in an amount such that the
'mixture
contains from 8.8 wt,% to 20,0 wt.% Portland cement, and water is added in an
amount such
that the ratio of water to cement is from 0.31 to 0.63. The plasticizing
additive, in the .form of
a plasticizer and a defoamer, is supplied for mixing in an amount of from 1.0
kglinl to 3,0
kglar), The aggregate supplied fbr mixing is selected from barium ore or an
iron-bearing ore,
or gabbro-dutbase, or granite with particle size not exceeding 10 min. The
resultant concrete
.inixture has a flow behaviour index, measured by the slump of a cone, which
is equal to from
55 cm to 75 cm, and an air content of from 1% to 4% of the volume.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[000 I 1) The technical advantage
of the claim is a method for manufacturing a
protective concrete weight coating of the pipeline with high set density and
with a high
compressive strength after curing and aging. This in turn allows improving the
technical
result, namely reducing or the outer diameter of the pipe with a protective
ballast coating tor
underwater, underground and ground use.
11100121 The claimed technical
advantage is achieved by the claimed method of
manufacturing a protective concrete weight coating of the pipeline, which
comprises mixing
cement, aggregate, plasticizing additive and. water, The resulting mixture is
injected into the
annular space formed by the outer surface of the pipe and mounted thereon with
a gap of
permanent shimming. The coat is left to age. Portland cement is supplied for
mixing in an
amount such that the mixture contains from 8,8 wt. % to 20.0 wt. %, water is
added in an
amount such that the ratio of water to cement is from 0,31 to 0.63. The
plasticizing additive,
in the form of a plasticizer and a defoan1Ct, is supplied for mixing in an
amount of from 1.0
kg/m3 to 3.0 The aggregate supplied
for mixing- should contain grain size not
exceeding 1() mm, The aggregate is selected, front barium ore or an iron-
bearing ore, or
gabbro-diabase, or granite. The resultant concrete mixture has a flow
behaviour index,
measured by the slump of a cone, which is equal to from 55 cm to 75 cm. and an
air content
of from 1% to 4% of the volume, For the best resulting density of the
protective concrete
weight coating it is pretrable that the aggregate supplied for mixture has the
following
particle size distribution: up to Or 16 mm - up to 8%, from 0.16 mm to 1.25 mm
- up to 35%,
from 1,25 turn to 2,5 min - up to 37%, from. 2.5 mm to 10,0 inm - the rest.
[00013) As a plasticizer for
mixture it is preferable to use ltgnosulfonates,
naphthalene sulfonates and melamine sultanates separately or in a mixture in
any
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CA 2917067 2017-05-12
Attorney docket No..A.A0961
combination. The plasticizer is used in an amount of up to 1% of dry matter by
weight of
cement.
1000141 It is
preferable that in the plasticizing additive the defoamer does not
comprise more than 50% of the insertion pla.sticizer.
1000151 in order to obtain
the necessary mobility and sufficient viscosity of
mixtures, and to avoid its separation, plasticizer 18 chosen so that the
resulting material on one
hand is sufficiently fluid, namely slump flow should be between .55 cm to 75
cm, and on the
other hand the content of air should be in the range from 1% to 4% of volume.
Thus, in the
claimed method the plasticizing additive supplied for -mixture consists of a
plasticizer and a
defoamer in the amount of 1.0 kg ni.2' to 3.0 kg / rn3 which allows obtaining
a plastic concrete
mass which fills the entire space between the pipes and also after hardening
concrete coating
will have a high density_ In. the plasticizing additive defoamer content shall
not exceed 50%.
The increase of the defoamer volume leads to a sharp decrease of fluidity of
the concrete mix
and the appearance of voids in the concrete coating, which hinders the.
characteristics of the
compressive strength of the concrete coating. Smaller volumes of the defoamer
of less than
1% increases the air content of the concrete mix resulting in reduced concrete
coating density.
The ratio of water to cement, selected in the range of 0.31 to 0,63 is
necessary to achieve the
desired mobility and strength of the concrete material, The decrease of water
volumes leads to
the reduction of mobility of the concrete and the appearance of air voids
after solidification,
and the increase of water volumes leads to the delamination and loss of
compressive strength
of concrete pavement,
10001.6,1 Below is
the example of the application of the claimed method of
pipeline protective concrete weight coating manufacturing by using barite ore
as aggregate
which does not limit the scope of the present claim,
1000171 An example of the
method application. At first the preparation, of the
starting components of the mixture shall be carried out. The process of
preparing the
components of the concrete mix comprises grinding of inert aggregate, such as
barite ore to a
size not exceeding 10 mm. The use of larger .fractiorts of a aggregate leads
to decrease in
density of the coating. If necessary, barite ore is heated to 5'(:: (max),
while closely observing
the melting of the pieces of rock stuck together (frozen together) to prevent
separation of the
ballast mixture during transportation. Then the, moisture content of ba.ritc
ore is measured.. As
a result of the humidity measurement the content of' barite ore in the
composition of ballast
material is calculated according to the formula.:
10001.81 in ¨ / - W/ 100)
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CA 2917067 2017-05-12
Attorney docket No. A.A.0961
10001.91 where jnj is the weight of barite ore accounting air
humidity,
1000201 - weight of barite ore in nominal recipe,
1000211 W - moisture content expressed as a percentage.
1000221 Barite ore
is sifted through dresser to separate coarse fraction
impurities. Then the barite ore and Portland cement in the amount of its
content in the mixture
of 8,8% to 20.0% is supplied to the scales through a conveyor system., where
the components
are weighed according to the specification of the structure. Particle size
distribution of the
aggregate is shown in Table 1, the selection of ratios is due to the
production of ballast
coating with a given density.
1000231 To ensure the
fluidity of the concrete mix during filling the plasticizing
additive is added in an amount of 1,0 kg / m to 3.0 kg / m3. Plasticizing
additive is a mixture
of pla.sticizer and defoamen Moreover, the amount of the delOamer in
plasticizing additive
should be. not more than. 50%. Tributyl phosphate or self-dispersing,,
anhydrous Penta.-46041m
silicone defoamer can be used as a d.efoamer, Any known plasticizers, such as
1.5
lignosulfonatcs, naphthalene sulfonates and melamine stdfonates can be used as
a plasticizer.
These plasticizers can be used separately or in any combination with no
influence on the
claimed technical result The amount of plasticizer should be no more than 1%
on dry matter
by weight of cement.
1000241 The
resulting mixture is added by water at the water to cement ratio
from 0.31 to 0,63, and mixed thoroughly. Stirring is continued until a uniform
homogeneous
mixture with thee breaking tapering from 55 cm to 75 cm. The resulting
concrete mixture is
pumped by concrete pump into the space between the carrier pipe and mounted
thereon.
permanent shuttering. This tubular structure i.s assembled on the stand, set
at a certain angle.
The injection solution is mode through a special removable plug at the end of
the pipe. This
design is inclined to fill in (one end lower than the other) and the tilling
is done through the
end located below. Pumping con.crete mix is carried out till the concrete pump
fulfilled the
structure - to yield a mixture from the nozzle of cover located above and.
opposite site. After
completion of the filling the structure it is displayed for a soaking time
until curing is not less
than 51v1Pa, and then stored to a set to achieve of transport strength of not
less than 22 M.Pa.
1000251 Depending on process
requirements various types of external.
permanent shuttering may be used during the filling of the pipe .construction,
for example,
spiral steel shuttering, locks may be performed inside and outside the
construction and can be
painted or coated with various polymeric materials, which allows to obtain
different
characteristics of products.
$
CA 2917067 2017-05-12
Attorney docket No. A.A.0961.
1000261 To
reinforce the structure the arrangement of the reinforcement (steel
or plastic) in the form of rods or mesh connected by welding or linked) is
possible in the
space between the pipe and the permanent shuttering, and to enhance the
strength of the
concrete it is possible to use fibers (steel or plastic).
1000271 The claimed method
allows achieving accurately a desired density of
the concrete protective weight coating of the pipeline in the range of 2600 to
3400 kg / m.
1000281
Determination of the average density of the mixture is made in
accordance with GOST 12730.1-78. The compressive strength is determined in
accordance
with GosT lot80-90.
1000291 A.ggregates can be
used to have coating with different characteristics in
density and strength not only barite, but iron ore, gabbro-diabase, granite.
These aggregates
can be used separately and in various combinations_ Examples of compounds used
in the
process and the resulting protected densities and compressive strength of the
obtained coating
are shown in Table 2. When used as part of a combination of different
aggregates fractional
content is crushed (in reparation) for each component separately. Thus, tine
aggregate and
coarse fractions are composed of the same components and in the proportions
shown in Table
1_
1000301 The stated
quantities of submitted Mitial components and the main.
characteristics of the resulting mixture have been identified in numerous
field experiments,
the results of which are shown in Table 1 and Table 2. Table 1 shows the
particle size
distribution of aggregates. The presence of the tines in the aggregate creates
conditions that
reduce stratification of the protective concrete weight of the material in the
process of
fuifiliing
1000311 Table 2
shows examples of various formulations of the protective
weight coating of the pipeline components with different densities and
provides compressive
strength obtained for each ballast material composition, as well as data on
the resulting
coating according to the prototype.
1000321 Table 1
Title of the component 7 Density kg / ern3 (irram size, tam.
Barite, ore from 3.7 to 4.1 1.1p to 0.16 up to 8%.
. ,
from 0.16 to 1.25 up to 35%
from 1.25 to 2.5 up to 37%
from 2.5 to 10,0 rest
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Iron-ore from 3.8 to 4.5 lip to 0.16 up to
8%; 1
from 0.16 to 1.25 up to 35% 1
from 1.25 to 2.5 up to 37%
from 2.5 to 10.0 rest
_____________ -
Gabbro-diabase from 3.01 to 3.06 Up to 0,16 up to 8%;
from 0.16 to 1.25 up to 35%
from 1.25 to 2.5 up to 37%
from. 2.5 to 10.0 rest
____________________ , - ....
Granite from 2.56 to 2.62 Up to 0.16 up to 8%;
from 0.16 to 1.25 up to :35%
from 1.25 to 2.5 up to 37%
from 2.5 to 10.0 rest
..a.
1000331 - Table 2.
Components 1 2 3 l 4 5 6 7T8
-
Cement, kg / rn"* 470 480 450 i 450 340 350 486t
350
Water, kg / in3 210 172.8 194 210 150 150 210
210
Plasticizing additive, 1.2 1.92 1.2 1.3 2.6 2.6 1.24
1.2
kg / IT13
Gravel* - .
Barite ore, kg / m3* .. - - 700 800 600 - 2560
____________________ .... ..
Iron-Containing ores, - - - 750 2060 2100 -
kg I, rni*
Ga.bbro-diabase, : 650 - 2230 950 2300 -
-
kg / tn34 !
! _,..õõ,.,,
Granite, kg / tn3 * 990 1979 - . I- i -
-
Sand* - - - - .
._
Water-cement ratio 0.45 0.36 0.43 ' 0.47 0.44 0,43
0.44 0.6
, ---,
The 'air content before 2.8 1.7 2.7 2.0 1.9 1.8 1..8
2.5
structure fulfilling, %
_. .. -
Blurred cone, cm 57 68 58 ' 60 62 64 55 62
DaLsity, kg / m3 2600 2450 2800 3000
3350 3400 2800 3150
Compressive strength, 48 74 48 Si 49 48 42 47
N4Pa
[QM 41
Continued Table 2 -- -
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Attorney docket No. .AA 096I
F-63Triponents 9 1 12 13 T 14 13 7 14 15 Prototype I
I content
7.,--
Cement, kg / m3* 430 430 430 i 450 460 460 420
__________________________________ -i 420
Water, kg / r&210 210 200 , 200 210 210 210 190
I ¨
Plasticizing additive, :1.3 2.1 cis-r-L, 2.1. L4 2.6 -
,
,
kg / tri3* i
..- - --.--
Gravel* 1140
....L...... ¨
Barite ore, kg / m3* 600 ' 500 500 500 -
1
,-
Iron-containing ores, 2050 2000 r-900 900 1500 -
kg / irt3* 1
,---
Ga.bbro-diabase, 560 I 650 1230 500
i
kg/mu 1
Granite, kg / rn3* 1.30U r 520 I 300 __ 800 300 370
H,¨ ________________________________________________ - ¨
Sand* 1 -
710
-I-----
Water-cement ratio 0,49 0,45
...... --,
The air content before 2,5 2.5 275-4- 2.5 2.5 2.5 2.5
1
,
structure fulfilling, % i
,
-r-
Blurred cone, cm 55 56 54 65 60 56 55 .
Density, kg / m3
2540 3250 3250 3000 2870 2700 3000
--1 2480
Compressive strength, 47 47 48 --jr 60 55 56 40 45
IVI.Pa
..µ.... . .... ... 1
...1 ..,.
[000351 * The presented data are shown in the table on a dry matter
basis,
, 1000361 . While the invention has been described with reference to
an exemplary
embodiment, it will be understood by those skilled in the art that various
changes may be
made and equivalents may be substituted for elements thereof without departing
from the
scope of the invention, in addition, many modifications ma.y be made to adapt
a particular
situation or material to the teachings of the invention without departing from
the essential
scope thereof_ Therefore, it is intended that the invention not be limited to
the particular
embodiment disclosed. as the best mode contemplated for carrying out this
invention, but that
the invention will include all embodiments falling within the scope of the
appended claims.
8
