The conference Composites CIS 2012 Shaklein Oleg of September, 2012 Crimea, Sevastopol. Composite piles: Manufacture and Application

Transcription

1 The conference Composites CIS 2012 Shaklein Oleg of September, 2012 Crimea, Sevastopol Composite piles: Manufacture and Application

2 Composite Piles Content: 1. About the enterprise. 2. Construction, design calculation, R&D. 3. Manufacturing technologies. 4. Piles function. 5. Probations. 6. Equipment, fitting-out. 7. Normative documentation. 8. Conclusion.

3 Group of companies MASHSPECSTROY R&D PRODUCTION EQUIPMENT

4 Our experience - Equipment LLC LUKOIL-Perm CJSC Composite-Neft LLC LUKOIL- Kogalymneftegas Ltd AVANGARD CJSC Тubus-Holding CJSC Tubus-Plast АО Mangistaumunaigas LLP ЗСТ LLP AZST

5 Our experience - Equipment LLC Evrokhim-BMU LLC ChTsZ LLC SUMZ LLC ERALKALIY Ltd Burintech GK Integra LLC Stavropolneftegas

6 Construction, design calculation, R&D. Distribution of stress fields Distribution of stress fields in bush cut Distribution of displacement fields Distribution of displacement fields on the bush surface

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8 Design of pole, flange made of glass-nylon polymer Distribution of stress fields Distribution of stress fields on the bush Distribution of displacement fields Distribution of displacement fields on the bush surface

9 Design of fiberglass pole Distribution of stress fields Distribution of displacement fields

10 Manufacturing technologies 1 - Winding to axel on-the-mitre for receipt of necessary physicotechnical characteristics

11 Manufacturing technologies 2 - Formation in the exterior form

12 Manufacturing technologies 3 - Centrifugal formation in the exterior form

13 Manufacturing technologies 4 - Combined

14 Piles function Park poles Cylindrical poles Lighting poles (lower) Lighting poles (wire) Power transmission poles Transmission towers, flagpoles Utilities Basement details made of composites

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18 Series of pole tests in in joint stock company ORGRES The sample of flange bearing 8,5х254х15 endured limit loads in three design conditions : Scheme 1. Wind is maximal Pа; No ground surface icing; Cables are not broken Scheme 2. Wind is 250 Pa; ground surface icing is maximal 30mm; Cables are not broken Scheme 3. (Emergency state is 500 kg) No wind; No ground surface icing; One cable is broken Conclusion: Flange bearing 8,5х254х150 meets the durability requirements for steel poles. Aberrations of the top of the fiberglass pole acceptable value according to normative documentation for steel poles, but satisfy the requirements of AASHTO LTS-5

19 Pole tests in Research Center of Automotive Equipment Tests and Lapping

20 Isograde Pole Tests The isograde poles with various reinforcing materials were produced and tested within the R&D framework Y (mm) Изогрид Isograde стекло glass Изогрид Isograde ст.+ glass уг. + carbon fiber Изогрид Isograde ribbon лента Р, (kn) Buckle dependability on approximation loading) Y=f(P)

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22 Equipment, fitting Automated pipe winding line- LIST Particular items of equipment: benches, chambers Fitting, driftpins, instruments Fitting for fiber producers Devices of batching, machine work Reinforcement production line LISA

23 Line for reinforcement - LISA Item LISA-1 LISA-2 LISA-4 reinforcement Producible diameter (mm) reinforcement 4 16 reinforcement 4 32 profiles (max) 200х200 2 Efficiency (m/m)min 8 (Ø4) 2 (Ø16) 8 (Ø4) х2 2 (Ø20) х2 3 Энергопотребление (kvt) Polymerization furnace, number 4 х 1,5 5х1,5 4х1,5 of sections х length (m) 8 (Ø4) х4 2 (Ø32) х1 5 Line dimension 17,3х2,0х1,6 17,3х2,0х1,6 20,0х4,4х1,6 (LengthxWidthxHeight) m 6 Type of binder anhydride anhydride, amine anhydride, amine 7 Heat type TEN TEN+IFK IFK 8 Type of protract device roll track hydrointercepting device 9 Quantity of simultaneously produced items reinforcement or 1 - profile

24 Nature tests for climatic factors and ultraviolet radiation

25 Pole tests in manufacturer conditions, according to specifications Flange bearing test scheme Upright pole test scheme loading substructure superstructure

26 Table of test works CONTACT LINE MAST Binder Production method Reinforcement Height m, diameter mm Weight, kg Tests, p, kg; у, m 1 PE-05 Winding Roving 2400, glass fibre mat, АSP-6 2 ED-20 (analog) Winding, clip Roving 2400, glass fibre mat, АSP-6 3 PE-05 Computation Roving 2400, glass fibre mat, АSP-6, песок 4 PE Winding, Roving 2400, glasstape ORTEX grades PE Winding, Roving 2400, glasstape ORTEX grades PE Winding, Roving 2400, glasstape ORTEX grades ED-20 (analog) Winding, Roving 2400, glasstape ORTEX grades ED-20 (analog) Winding, Roving 2400, glasstape ORTEX grades ,5х280х р=210 у=0,51 10,5х280х р=210 у=0,42 10,5х280х р=210 у=0,99 8,5х260х р=300 у=0,77 8,5х260х р=300 у=0,87 8,5х260х р=300 у=0,94 8,5х260х р=300 у=0,55 8,5х350х р=300 у=0,28

27 Dependability of deflection Y=f(P) for flange bearing 8,5х260х Y, mm ED ПЭ град. 120 кг ED ПЭ град. 99 кг ED ПЭ град. 95 кг ED ЭД град. 95 кг ED grades 120kg grades 99kg grades 95kg grades 95kg grades 126kg ЭД град. 126 кг Р, kg

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29 Our opportunities and experience Strength and stiffness calculation Study of various manufacturing technologies Choice of optimal materials and reinforcement schemes Development of technical requirements Equipment production Pilot batch fabrication Test operations Serial products fabrication

30 Normative documentation Normative documentation of Russian Federation was developed for traditional material poles (wood, ferroconcrete, metal). State Standard The USSR climate. Regionalization and statistical characteristic of climatic factors for technical purposes. State Standard R Technical means for road traffic organization. All-Russian construction norms and rules: Construction norms and rules * Loadings and impact. Construction norms and rules * Buildings and structures foundations Construction norms and rules Pilings Construction norms and rules * Steel structures. Design standard. Construction norms and rules Concrete and ferroconcrete structures Construction norms and rules Tram and т trolleybus lines Departmental norms and rules: Electrical installation code-7 STN CE SO Instructions for arrangement of lightning protection of buildings, structures and industrial communications. (Ministry of Energetics of Russian Federation) SE -518 Instruction for protection of structures from corrosion with the help of stray current (1999). Normative documentation which is applicable abroad and which takes into account physical-mechanical properties of composite. EN passive safety of bearing structures for road equipment. ASTM D 4923 Load intensity of glass-fiber plastic correspond. AASHTO LTS-5 Standard specifications of lighting poles, road signs, guide signs and flashlight, section 8 Reinforced composites. Deflection values of fiberglass plastic poles. PN - EN 40 Group of European standards norms.

31 Ready for cooperation with: Institutes Complex companies Project companies Construction companies Service companies Investment organizations

32 Manufacture project

33 Technological line

34 The Conference Composites CiS 2012 Crimea, Sevastopol Thank you for attention! Group of companies MASHSPECSTROY, Russian Federation, Perm Shaklein Oleg of September, 2012 Conference-hall Admiral Tel mob