Inside Cement Mortor Lining (ICML) of M.S. Pipes

Spinning

This method is more effective one to apply ICMLby centrifugal method in which we can able to achieve uniformity and good finish surface.

ASpinning machine will be used in this process along with drive engine. Rollers mounted with two side belts.The Diesel engine will be variable speed having gear control and mounted rigid in the spinning bed with chain sprocket drive and other related accessories.

The pipes sizes from 100 mm to 3000 mm diameter pipes can be done the ICMLin this method.The T length of the pipe from 6 meter to 12 meter can be done.The spinning bed has to be made ready according to diameter and the length of other pipes.

The machine mainly contains of anengine, Drive Rollers1 Pair Connective Rollers -1 Pair and Idling Rollers cumAdjustable Rollers1 PairAll one side Rollers IE 3 Rollers will be connected by an Endless Rubber Belt Having 6 or 8 Ply and minimum 400 mm width.This belt will be placed 2 sides so that the pipe to be inlined will be rest over the belt between drive roller and connective roller. Normally Drive rollers and connective rollers are same diameter.The idling roller may be smaller than the drive roller.

The diameter of rollers are to be designed depends the diameter of pipes are to be inlined.

The cooling arrangement of belt both sides are to be arranged, the water will have poured to the belt continuously during spinning so that the heat generation in belt and roller can be avoided.

The first pipe will be run for at least 15 minutes to check the all alignment of the machine and balancing T w asell of smooth running of pipe in uniform manner

Two Engine mounted Concrete mixture will be placed both end to mix the cement and sand and the water facility also [to be arranged near the machine by pump

Astopper has to be provided both end by vertical so that the edge of the pipe should not come beyond certain limit during spinning.

Procedure

The belt and roller will be set in correct place and the bare pipe placed over it, now a rubber belt having 100 mm width and 15 mm thick has to be placed inside edge of the pipe in both ends so that in that area cement will not bond and this will facilitate the pipe jointing in field during Laying and start the engine to run the rated speed may be approx. 120Check the cooling water over the belt.

Check the mixture of mortar ready in mixture machine and the ratio of cement and aggregate and water.

Now pour few quantity of water inside the pipe and let it wash for some time and allow the water to come out from the pipe.

Now we can apply the mortar from the mixture machine by manually both sides of the pipe.The pouring of the mortar may be done automatically by installing a chute method i.e. the conveyer should travel entire the pipe length to pour the mortar. Now we can see the mortar deposits inside the pipe uniformly by centrifugal force.

The cement and fine aggregate ratio is normally 1: 2 and it may be as per the specification and client instructions only.Also thickness of mortar will be 12.5 mm.The thickness also will be as per the specifications and client suggestions only. So the quantity of mortar will be calculated per pipe and the wastage may be added 5% extra during mixing.

After pouring entire quantity of slurry both side spinning operators can level the slurry by means of a Blade connected with a Steel Rod. Now the surface become uniform and all water content will come out in this stage.

NRPM ow the speed can be raised to 200and again finishing done on both side by Blade around 10 Minutes.The level ofwill be up to the thickness of inside mounted belt and now the surface will be ICML uniform.

Few quantity of Raw Cement may be spreaded inside the pipe to achieve good finish and after 10 minutes running the engine can be neutralist the pipe can slow down the speed and come to stop.

Now we can lift the pipe by crane by using belt in outside of the pipe. we have lift the pipe gently and keep it in curing yard above two rails so that it can be rolled by manual easily.

Curing

a)The spun Pipe placed in curing yard, the both end will be covered byTar Paulin so that the atmospheric air will not go inside and like steam curing will be happened inside the pipe.
b)The next day we have to open theTar Paulin and start the curing by manual or sprinkler method at least 7 days continuously so that the surface becomes wet always.
c)The proper register will be maintained it should contain date and time of in lining, cement aggregate ratio, thickness, speed maintained and duration, curing period.The pipe number and date of in lining will be painted inside the pipe corner.

Procedure

The belt and roller will be set in correct place and the bare pipe placed over it, Now a rubber belt having 100 mm width and 15 mm thick has to be placed inside edge of the pipe in both ends so that in that area cement will not bond and this will facilitate the pipe jointing in field during Laying and start the engine to run the rated speed may be approx. 120RPM Check the cooling water over the belt.

Check the mixture of mortar ready in mixture machine and the ratio of cement and fine aggregate and water or normally 1:1.5 or 1:2 ratio.

Now pour few quantity of water inside the pipe and let it wash for some time and allow the water to come out from the pipe.

Now we can apply the mortar from the mixture machine by manually both sides of the pipe.The pouring of the mortar may be done automatically by installing a chute method i.e. the conveyer should travel entire the pipe length to pour the mortar. Now the mortar deposits inside the pipe uniformly by centrifugal force.

The cement and fine aggregate ratio is normally 1: 2 and it may be as per the specification and client instructions only.Also thickness of mortar will be 12.5 mm.The thickness also will be as per the specifications and client suggestions only. So the quantity of mortar will be calculated per pipe and the wastage may be added 5% extra during mixing.

After pouring entire quantity of slurry both side spinning operators can level the slurry by means of a Blade connected with a Steel Rod. Now the surface become uniform and all water content will come out in this stage.

Now the speed can be raised up to 200 RPM and again finishing done on both side by Blade around 10 Minutes.The level of ICMLwill be up to the thickness of inside mounted belt and now the surface will be uniform.

Few quantity of Raw Cement may be spreaded inside the pipe to achieve good finish and after 10 minutes running the engine can be neutralized the pipe can slow down the speed and come to stop.

Now we can lift the pipe by crane by using belt in outside of the pipe. we have lift the pipe gently and keep it in curing yard above two rails so that it can be rolled by manual easily or we provide ganetry.

Curing

The spun Pipe placed in curing yard, the both end will be covered byTar Paulin so that the atmospheric air will not go inside and like steam curing will be happened inside the pipe.
The next day we have to open theTar Paulin and start the curing by manual or sprinkler method at least 7 days continuously so that the surface becomes wet always.
The proper register will be maintained it should contain date and time of in lining, cement aggregate ratio, thickness, speed maintained and duration, curing period.The pipe number and date of in lining will be painted inside the pipe corner.
Mortar cubes will be casted daily and to be tested for strength in proper intervals.