Technology "Bazalt-Invest" LLC
The form-building body for the manufacture of composite pipes using continuous technology consists of self-supporting mandrels of different diameters. On the surface of the mandrels there are movable sectors (in the longitudinal direction) that perform back and forth motion in a certain way. Due to these movements, the composite material moves continuously in the specified direction, wound on the surface of the mandrel. The mandrel is connected to the machine of the continuous pipe production (MCPP), which drives the mandrel mechanisms in motion.
When working, an insulating fluoroplastic film is first wound onto the mandrel so that the epoxy binder does not get on the surface and inside the mandrel, then a fiberglass roving (basalt or other fiber) is wound onto the mandrel, part of which goes through an impregnating bath with an epoxy binder, the other part of the roving is wound onto the mandrel using a threading machine (in the figure). As it moves, the wound material passes through the polymerization furnace, where the binder hardens. This is how a single-layer composite pipe is obtained. Such a pipe is suitable, for example, for non-pressure pipelines or support-mast structures.
For pressure products, a multilayer pipe is mainly manufactured, i.e. the pipe goes through several stages of "winding-curing" sequentially during one manufacturing cycle. In addition, during the winding of the pipe, decorative or flame retardant coatings can be applied to the surface of the pipe.Further, when the pipe is manufactured, it is cut to the required length. The ends of the pipes are processed, creating the necessary surface profile, for example, smooth or threaded. Pressure pipes are undergoing hydraulic testing. Finished pipes are packed and sent to the customer.
When working, an insulating fluoroplastic film is first wound onto the mandrel so that the epoxy binder does not get on the surface and inside the mandrel, then a fiberglass roving (basalt or other fiber) is wound onto the mandrel, part of which goes through an impregnating bath with an epoxy binder, the other part of the roving is wound onto the mandrel using a threading machine (in the figure). As it moves, the wound material passes through the polymerization furnace, where the binder hardens. This is how a single-layer composite pipe is obtained. Such a pipe is suitable, for example, for non-pressure pipelines or support-mast structures.
For pressure products, a multilayer pipe is mainly manufactured, i.e. the pipe goes through several stages of "winding-curing" sequentially during one manufacturing cycle. In addition, during the winding of the pipe, decorative or flame retardant coatings can be applied to the surface of the pipe.Further, when the pipe is manufactured, it is cut to the required length. The ends of the pipes are processed, creating the necessary surface profile, for example, smooth or threaded. Pressure pipes are undergoing hydraulic testing. Finished pipes are packed and sent to the customer.
Competitive advantages of Perm Continuous Technology (PCT)
- High manufacturing productivity and relatively low cost of pipes.
- The widest technological capabilities in terms of the range of pipe diameters, types of products and operating conditions.
- The technology is most suitable for the manufacture of technological pipelines and pipelines of intra-quarter heating systems due to minimal material losses in the manufacture of short pipes.
- PCT is the only known technological method that allows you to control and manage the thickness and structure of reinforcement without stopping the manufacturing process.
- PCT is flexibly adapted to the manufacture of new pipe sizes. Preparation of new production is characterized by minimal time and costs.
- The organization of the multilayer structure of the pipe. It allows you to combine in each layer different types of reinforcing fiber and a polymer binder. At the same time, due to the layer-by-layer solidification, the flow of the binder between the layers is excluded.
- Layer-by-layer solidification in relatively thin layers of the pipe reduces internal stresses and reduces defects in the polymer matrix, which contributes to more reliable tightness.
- The technology is the least fastidious in terms of the quality of the raw materials used.
- PCT is distinguished by high environmental friendliness of production since the emissions of harmful substances are extremely localized in the volume of premises.
- PCT is a domestic technology containing intellectual property protected by patents for inventions.
