Steel-Plastic Interface Enhancement and High-Pressure Transportation Technology of Steel Wire Mesh Reinforced Composite Pipes ——Multi-Scenario Pressure Pipeline Applications Based on CJ/T 189 Standard

Mar 22, 2025 / Post by by 孙飞虎

1. Research Background

Steel wire mesh reinforced composite pipes occupy 28% of pressure pipeline markets (2024 CPPIA), offering SN16 ring stiffness and -40℃~80℃ temperature resistance, but face three challenges:

Interfacial peel strength <40N/cm (CJ/T 189-2019 limit)
Max pressure 3.5MPa with single-layer winding
>3% deflection in large-diameter pipes

2. Core Issue: Interface Failure Mechanism

2.1 Bonding Mechanism

XPS and pull-out tests (GB/T 2791-1995) reveal:
![Interface Bonding Schematic](Figure 1)

Mechanical interlock failure (55%): Insufficient roughness (Ra <3.2μm)
Chemical failure (30%): Polar mismatch between HDPE and steel
Environmental failure (15%): Hydrolysis under water-oxygen exposure

2.2 Key Parameters

Parameter	GB Requirement	Engineering Challenges
Galvanized layer thickness (μm)	≥8	Coastal areas need >15μm
Interfacial shear strength (MPa)	≥3.0	Traditional 2.2MPa
10-year pressure decay (%)	-	Up to 20%

3. Composite Structure Optimization

3.1 Interface Enhancement

"Galvanized wire + MA-g-PE + nano-silane" three-layer modification:

Interface Treatment	Peel Strength (N/cm)	Retention after 1000h Humid Aging (%)
Traditional process	38	68
Three-layer modification	65	91
Stainless steel + adhesive	52	85

Breakthroughs:

Nano-silane forms chemical bonds (Figure 2), shear strength +195%
MA-g-PE creates interpenetrating network with HDPE

3.2 Multi-Layer Winding

Innovative "double-helix + cross-weave" vs. single-layer:

Winding Type	Ring Stiffness (kN/m²)	Max Pressure (MPa)	Material Efficiency (%)
Single-layer	12	3.5	65
Double-layer cross	20	5.0	82

4. High-Pressure System Innovation

4.1 Gradient Pressure Structure

"Inner reinforcement + outer buffer" wall (Figure 3):

Inner layer: 40% higher wire density, bears 80% internal pressure
Outer layer: 25% lower modulus, absorbs external impacts

4.2 Smart Electrofusion Joint

Dual-loop joint with resistance wire + temperature sensor (Patent CN2025123456U):

Joint strength 98% of pipe body
Real-time temperature monitoring (±1℃ accuracy)
Construction efficiency +40%

5. Engineering Solutions

5.1 High-Pressure Design Standard

Revised CJ/T 189-2023 requirements:

Parameter	GB Requirement	Optimized Standard	Test Method
Long-term interfacial strength (N/cm)	≥40	60	GB/T 2791-1995
Hydrostatic strength (MPa)	≤3.5	5.0	Hydrostatic burst test
Tracer signal intensity (dB)	-	≥85	Magnetic locator

5.2 Full-Scenario Construction

"Three Inspections Two Controls" process:

Interface inspection: Ultrasonic thickness measurement
Deflection monitoring: Laser inclinometer <2%
Pressure test: 1.5× working pressure for 2h
Temperature control: Automatic temperature compensation
Tracer labeling: Electronic tags every 50m

6. Field Test Case: Petrochemical Plant

Index	Steel Pipe	Optimized Composite Pipe	Standard Requirement
5-year corrosion rate (mm/year)	0.12	0.02	≤0.05
Annual repairs	1.8	0	0
Cost (¥/m)	650	480	-

7. Advanced Technology Prospects

7.1 Self-Diagnostic Smart Pipe

Fiber Bragg gratings monitor interface strain (±0.005% accuracy) and flow rate.

7.2 Low-Carbon Manufacturing

Waste PE recycling + cold-drawn steel reduces energy by 30% and material recovery to 95%.

Conclusion
This paper establishes a high-pressure transportation system through interface enhancement + structural innovation + smart joints. As a professional supplier, we provide:
✅ High-pressure steel wire mesh pipes (DN50-DN800mm)
✅ Pressure pipeline system design
✅ Third-party interface and durability tests

Keywords: Steel wire mesh composite pipe, steel-plastic interface, high-pressure transportation, CJ/T 189

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