EP3348712B1 - Method for manufacturing hot extruded polyethylene zinc-aluminium alloy-plated steel wire hauling cable - Google Patents

Method for manufacturing hot extruded polyethylene zinc-aluminium alloy-plated steel wire hauling cable Download PDF

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Publication number
EP3348712B1
EP3348712B1 EP16898333.6A EP16898333A EP3348712B1 EP 3348712 B1 EP3348712 B1 EP 3348712B1 EP 16898333 A EP16898333 A EP 16898333A EP 3348712 B1 EP3348712 B1 EP 3348712B1
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EP
European Patent Office
Prior art keywords
steel wire
wire cable
anchor
steel
length
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EP16898333.6A
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German (de)
English (en)
French (fr)
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EP3348712A1 (en
EP3348712A4 (en
Inventor
Jun Zhao
Shiwei NING
Huajuan Xue
Zhubing Zhou
Qiong Wu
Qiang QIANG
Kebin HUANG
Xiaoxiong ZHU
Weihong SHU
Jin Wang
Zhongmei LIANG
Pengcheng ZHAI
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Jiangsu Fasten Steel Cable Co Ltd
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Jiangsu Fasten Steel Cable Co Ltd
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Application granted granted Critical
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    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B1/00—Constructional features of ropes or cables
    • D07B1/16—Ropes or cables with an enveloping sheathing or inlays of rubber or plastics
    • D07B1/162—Ropes or cables with an enveloping sheathing or inlays of rubber or plastics characterised by a plastic or rubber enveloping sheathing
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B1/00—Constructional features of ropes or cables
    • D07B1/06—Ropes or cables built-up from metal wires, e.g. of section wires around a hemp core
    • D07B1/08—Ropes or cables built-up from metal wires, e.g. of section wires around a hemp core the layers of which are formed of profiled interlocking wires, i.e. the strands forming concentric layers
    • D07B1/10—Ropes or cables built-up from metal wires, e.g. of section wires around a hemp core the layers of which are formed of profiled interlocking wires, i.e. the strands forming concentric layers with a core of wires arranged parallel to the centre line
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B1/00—Constructional features of ropes or cables
    • D07B1/14—Ropes or cables with incorporated auxiliary elements, e.g. for marking, extending throughout the length of the rope or cable
    • D07B1/148—Ropes or cables with incorporated auxiliary elements, e.g. for marking, extending throughout the length of the rope or cable comprising marks or luminous elements
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B3/00—General-purpose machines or apparatus for producing twisted ropes or cables from component strands of the same or different material
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B5/00—Making ropes or cables from special materials or of particular form
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B5/00—Making ropes or cables from special materials or of particular form
    • D07B5/002—Making parallel wire strands
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B7/00—Details of, or auxiliary devices incorporated in, rope- or cable-making machines; Auxiliary apparatus associated with such machines
    • D07B7/02—Machine details; Auxiliary devices
    • D07B7/14—Machine details; Auxiliary devices for coating or wrapping ropes, cables, or component strands thereof
    • D07B7/145—Coating or filling-up interstices
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B9/00—Binding or sealing ends, e.g. to prevent unravelling
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01D—CONSTRUCTION OF BRIDGES, ELEVATED ROADWAYS OR VIADUCTS; ASSEMBLY OF BRIDGES
    • E01D11/00—Suspension or cable-stayed bridges
    • E01D11/04—Cable-stayed bridges
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01D—CONSTRUCTION OF BRIDGES, ELEVATED ROADWAYS OR VIADUCTS; ASSEMBLY OF BRIDGES
    • E01D19/00—Structural or constructional details of bridges
    • E01D19/16—Suspension cables; Cable clamps for suspension cables ; Pre- or post-stressed cables
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B2201/00—Ropes or cables
    • D07B2201/20—Rope or cable components
    • D07B2201/2001—Wires or filaments
    • D07B2201/201—Wires or filaments characterised by a coating
    • D07B2201/2011—Wires or filaments characterised by a coating comprising metals
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B2201/00—Ropes or cables
    • D07B2201/20—Rope or cable components
    • D07B2201/2015—Strands
    • D07B2201/2042—Strands characterised by a coating
    • D07B2201/2044—Strands characterised by a coating comprising polymers
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B2201/00—Ropes or cables
    • D07B2201/20—Rope or cable components
    • D07B2201/2015—Strands
    • D07B2201/2042—Strands characterised by a coating
    • D07B2201/2045—Strands characterised by a coating comprising multiple layers
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B2201/00—Ropes or cables
    • D07B2201/20—Rope or cable components
    • D07B2201/2083—Jackets or coverings
    • D07B2201/2087—Jackets or coverings being of the coated type
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B2201/00—Ropes or cables
    • D07B2201/20—Rope or cable components
    • D07B2201/2083—Jackets or coverings
    • D07B2201/2088—Jackets or coverings having multiple layers
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B2201/00—Ropes or cables
    • D07B2201/20—Rope or cable components
    • D07B2201/2083—Jackets or coverings
    • D07B2201/2089—Jackets or coverings comprising wrapped structures
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B2205/00—Rope or cable materials
    • D07B2205/20—Organic high polymers
    • D07B2205/201—Polyolefins
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B2205/00—Rope or cable materials
    • D07B2205/30—Inorganic materials
    • D07B2205/3021—Metals
    • D07B2205/3085—Alloys, i.e. non ferrous
    • D07B2205/3092—Zinc (Zn) and tin (Sn) alloys
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B2207/00—Rope or cable making machines
    • D07B2207/40—Machine components
    • D07B2207/4031—Winding device
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B2501/00—Application field
    • D07B2501/20—Application field related to ropes or cables
    • D07B2501/2015—Construction industries
    • D07B2501/203—Bridges
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B5/00—Making ropes or cables from special materials or of particular form
    • D07B5/005—Making ropes or cables from special materials or of particular form characterised by their outer shape or surface properties
    • D07B5/006—Making ropes or cables from special materials or of particular form characterised by their outer shape or surface properties by the properties of an outer surface polymeric coating
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B7/00—Details of, or auxiliary devices incorporated in, rope- or cable-making machines; Auxiliary apparatus associated with such machines
    • D07B7/02—Machine details; Auxiliary devices
    • D07B7/10—Devices for taking-up or winding the finished rope or cable
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B7/00—Details of, or auxiliary devices incorporated in, rope- or cable-making machines; Auxiliary apparatus associated with such machines
    • D07B7/02—Machine details; Auxiliary devices
    • D07B7/14—Machine details; Auxiliary devices for coating or wrapping ropes, cables, or component strands thereof

Definitions

  • the invention belongs to the technical field of bridge cable, and relates to a method for fabricating a steel wire cable comprising an extruded polyethylene and a zinc-aluminum alloy plating.
  • a cable-stayed bridge has one or more towers, from which cables support the bridge deck.
  • the cable-stayed bridge features light structure and strong applicability, and is able to form different systems by varying the combination of bridge deck, cables, and towers according to different geologic environment and terrains. Due to the addition of the stay cables, a bending moment of a main girder is significantly decreased. Compared with large-span bridges of other systems, the uses of the steel and the concrete of the main girder in the cable-stayed bridge are relatively saved. Under the action of the pre-tension of the cable-stayed bridge, an internal force of the main girder can be adjusted to make the distribution thereof uniform and therefore acquire better economic effect.
  • the main girder can be manufactured as a uniform girder, thus being convenient for manufacture and installation.
  • a horizontal component force of the stay cable is equivalent to a pre-pressure applied to the main girder, which further improves the crack resistance of the girder (especially the concrete girder) and fully presents the performances of the materials.
  • the world's first modern cable-stayed bridge was the Stro msund Bridge built in 1955 in Sweden, and was a steel cable-stayed bridge having a span of 182.6 m across the Strom Strait, marking the beginning of modern cable-stayed bridges.
  • the world's first concrete cable-stayed bridge was built in Venezuela (with a main span of 135 meters). At that time, the cable-stayed bridge had gained rapid development.
  • the Norman Bridge with a main span of 856 meters, had been built in France, and the Duo Luo Bridge, with a main span of 890 meters, had been built in Japan. Cables of all these bridges adopts hot galvanized stranded wire or steel wire.
  • a method for fabricating a steel wire cable comprising an extruded polyethylene and a zinc-aluminum alloy plating.
  • steel wires are arranged according to an arrangement rule at a cross section of the steel wire cable; a length of the overall cable is controlled by a length of a central standard wire; a bunch of the steel wires comprising a zinc-aluminum alloy plating are twisted with a torsion angle of between 2° and 4°; the steel wire bunch is then wrapped with a polyester wrapping bandage and covered with a double-layered protective polyethylene sheath by using double-cavity co-extrusion process for one-step formation, and an outer surface of the polyethylene sheath is provided with embossments for rain-wind induced vibration resistance; the two ends of the steel wire cable are fixed by anchors using fillers, coiled, and stored. And the coils of the steel wire cables are then transported to and respectively laid on a construction
  • the present inventon provides a method for fabricating an extrusion coated steel wire cable as described in claim 1 as well as some advantageous embodiments as described in dependent claims.
  • the method comprises the following steps:
  • the steel wire comprising the zinc-aluminum alloy plating is adopted because the zinc-aluminum alloy plating possesses much stronger anti-corrosive property, principle of which is as follows: a) as aluminum has very active chemical property, a dense layer of alumina is formed on a surface of the steel wire after hot dip of aluminum, and therefore the surface of the steel wire is easily inactivated to form a protective layer in corrosive environment. In a corrosive medium, a zinc-enriched surface layer, functioning as a positive electrode, is firstly eroded, the aluminum content continuously increases to make the alumina content increase, thus making the plating layer possessing stronger capability of preventing external toxic substances.
  • the addition of the aluminum also inhibits the formation of a zinc-aluminum transitional layer which has weaker anti-corrosion performance and loosen tissue, thus being helpful for improving the overall anti-corrosion performance of the plating layer.
  • the zinc-aluminum alloy plating is destructed and the steel is exposed, the plating functions as a positive electrode of an iron-zinc aluminum battery and is dissolved, and a steel substrate is therefore protected.
  • a corrosion potential of the zinc-aluminum alloy is slightly lower than a pure zinc layer and is approximately -0.87, but the corrosion current of the zinc-aluminum alloy is only 1/5 of the hot dipped pure zinc.
  • the zinc-aluminum alloy plating includes two types, Zn95AI5 5 having an aluminum content of between 4.2 and 7.2 wt. %, and Zn90Al10 having the aluminum content of between 9.2 and 12.2 wt. %.
  • a plating weight is equal to or larger than 300 g/m 2 .
  • a homogeneity indicator of the plating satisfies a time of copper sulfate of equal to or larger than 4 with each time lasting 60 s.
  • a steel wire having a standard length is prepared. Certain markers for cutting are made at two ends of the steel wire. Thereafter, the steel wire having the standard length is utilized as a reference, and the overall length of the steel wire cable is controlled by a transfer method. By using the above measurements, the length error of the stay cable can be greatly reduced.
  • the fabrication precision of the standard wire exceeds 1/30000, and the fabrication precision of the finished product of the steel wire cable is improved from the China's national standard of 1/5000 to 1/20000.
  • the steel wire cable is formed by multiple layers of steel wires.
  • the standard wire is positioned at a center position of a cross section of the steel wire cable.
  • All the steel wires in the bunch are twisted to the left with a torsion angle of between 2° and 4°.
  • the twisted steel wire bunch is wrapped by a wrapping bandage, wherein the wrapping bandage is right-handed twisted, to yield a steel wire cable as a semi-product.
  • An outer dimeter of the steel wire bunch i. e., the naked steel wire cable, after being twisted is measured. Because the cross section of the steel wire bunch is in a shape of hexagon or hexagon with missing angles, a circumscribed circle of the selected cross section of the steel wire bunch is directly the diameter of the naked steel wire cable.
  • the wrapping bandage is preferably a bandage made from a polyester fiber.
  • the wrapping bandage has a width of between 40 and 60 mm and a tensile strength of equal to or high than 500 N/25 mm 2 .
  • a double-layered protective polyethylene is prepared outside the steel wire cable, in which, the double-layered protective polyethylene has a density of between 0.942 and 0.978 g/cm 3 , environmental stress crack resistance property of ⁇ 5000 F 0 /h, and a melt index of ⁇ 0.45 g/10 min.
  • Specific operation is as follows: before extruding, a die aperture of an extruder and an extrusion velocity are preset according to an outer diameter of the steel wire cable and thicknesses of two layers of polyethylene. The double-cavity co-extrusion for one-step formation is adopted. The two layers of the polyethylene plastics simultaneously cover the steel wire cable during the requirements of anti-corrosion.
  • an outer surface of the double-layered protective polyethylene is provided with helical lines or embossments.
  • a drag coefficient is equal to or smaller than 0.8.
  • Original cutting positions of the steel wire cable are determined, the double-layered protective polyethylene is locally stripped, and the markers for cutting at two ends of the standard wire at the center position of the steel wire cable are found. Then, the steel wire cable is cut by using a non-liquid cutting machine and end faces of the steel wire cable are ensured perpendicular to an axis of the steel wire cable.
  • the double-layered protective polyethylene is stripped according to a preset length to expose the steel wires, during which, the plating of the steel wires is prevented from being destructed.
  • the anchor is a main connecting structure to transmit a tension of the steel wire cable to a tower and a girder.
  • the steel wire cable adopts anchor structures including nut-screwing type anchor, anchor plate gap adjusting type anchor, or a fork-ear pin joint type anchor at two ends.
  • the anchor is performed with hot galvanizing or paints coating for corrosion resistance.
  • a thickness of the hot galvanizing is equal to or larger than 90 ⁇ m, and a thickness of the paints coating is determined according to specifications and design requirements of a steel structure.
  • the types of the structures of the anchor is as follows:
  • the nut screwing type anchor comprises: an anchor cup, a screw nut, an anchor plate, and a sealing assembly of a connecting cylinder.
  • Such steel wire cable utilizes the end face of the nut to support the pressure and to transmit the load.
  • the nut and the anchor cup are in rotary joint via a trapezoidal thread having high strength to realize the continuous adjustment of the length of the steel wire cable.
  • the anchor cup is provided with tensional inner threads. In installation of the steel wire cable on the construction site, an installation force is applied on the steel wire cable by drawing the anchor.
  • the anchor plate primarily functions in dispersing the steel wires, steel wire holes are distributed on the anchor plate, and the steel wires pass through corresponding steel wire holes and are headed.
  • An external cone boss can be tightly attached to an internal conical cavity.
  • the end face-supporting type anchor comprises: an anchor cup, an anchor plate, and a sealing assembly of a connecting cylinder. End faces of such steel wire cable are directly supported on anchor plate, and different gap adjusting plates are utilized to regulate the length of the steel wire cable.
  • the gas adjusting plates have different thicknesses to satisfy the requirement of the construction site.
  • the anchor cup is provided with tensional inner threads. In installation of the steel wire cable on the construction site, an installation force is applied on the steel wire cable by drawing the anchor. Such kind of anchor does not necessitate nuts, and the anchor cup is not provided with external threads.
  • the anchor plate functions in dispersing the steel wires, the steel wire holes are distributed on the anchor plate, and the steel wires pass through corresponding steel wire holes and are headed. An external cone boss can be tightly attached to an internal conical cavity.
  • the fork-ear pin joint type anchor comprises: a fork ear, a pin shaft, an anchor cup, a nut, and a sealing assembly of a connecting cylinder.
  • One end of such steel wire cable is connected to the steel structure of the tower or the girder via the fork ear and the pin shaft, and the other end of the steel wire cable adopts an end face of a nut to bear pressure and to transmit the load, thus realizing the continuous adjustment of the length of the steel wire cable.
  • the anchor cup is provided with tensional inner threads. In installation of the steel wire cable on the construction site, an installation force is applied on the steel wire cable by drawing the anchor.
  • the anchor plate functions in dispersing the steel wires, the steel wire holes are distributed on the anchor plate, and the steel wires pass through corresponding steel wire holes and are headed.
  • An external cone boss can be tightly attached to an internal conical cavity.
  • the sealing assembly of the connecting cylinder in the above three structures all adopts the new type of cable end sealing technology, in which, an outer part of the connecting cylinder is firstly sealed by a sealing cover, and an inner wall of the connecting cylinder in the vicinity of a port is sealed again by an elastic sealing ring and a sealing press ring.
  • the two sealing measurements finally realizes the sealing of the two ends of the steel wire cable, that is, the sealing between the anchors and the interfaces of the polyethylene steel wire cable.
  • the sealing assembly has stronger strength, thus being difficult to be destructed, much longer service life, and much endurable sealing structure.
  • the sealing structure at the ends of the steel wire cable is a reliable mechanical sealing structure, configured to prevent the corrosion resulting from the water penetration into the PE cable.
  • the sealing structure as a substitute of a heat shrink sleeve, is utilized for sealing, thus overcoming the problem of damage of the heat shrink sleeve.
  • an endurable sealing structure at an end of the steel wire cable fits together with the connecting cylinder of the anchor and comprises: the elastic sealing ring, a sealing press ring, and a sealing cover.
  • the sealing press ring is disposed in the port of the connecting cylinder and an outer end of the sealing press ring is exposed outside the connecting cylinder.
  • a press surface is formed on the inner wall of the connecting cylinder relative to the inner end face of the sealing press ring.
  • the elastic sealing ring is disposed between the inner end face of the sealing press ring and the press surface. Under the press of the press surface, the elastic sealing ring is deformed and attached to the outer wall of the steel wire cable.
  • the sealing cover is disposed on a front end of the connecting cylinder and possesses a Harvard structure.
  • a front part of the sealing cover contacts and fits with the outer wall of the steel wire cable and a corresponding contact surface is provided with a sealing ring.
  • a rear part of the sealing cover contacts and fits with the sealing press ring or the connecting cylinder and a corresponding contact surface is provided with a sealing strip.
  • the casting of the anchor is carried out by chill casting of heading anchor or by hot casting of anchor, operations of which are as follows:
  • the hot casting anchor adopts a zinc alloy for casting, and a zinc-copper alloy and a zinc-copper-aluminum alloy are the common two alloys.
  • the zinc-copper alloy comprises 98 ⁇ 0.2 wt. % of zinc and 2 ⁇ 0.2 wt. % of copper, and the zinc-copper-aluminum alloy comprises 4 - 7 wt. % of aluminum, 1 - 2 wt. % of copper, and 91 - 95 wt. % of zinc.
  • the casting is performed as follows:
  • the tension detection or the top pressure detection are important means to detect the quality of the steel wire cable. According to fillers for the casting of the anchor, the tension detection is performed on the steel wire cable with chilled-casted anchor or the top pressure detection is performed on the steel wire cable with hot-casted anchor before leaving a plant, which is specifically as follows:
  • the steel wire cable is stretched by an overstretching force which is set to be between 1.1 and 1.5 folds of a designed tension of the steel wire cable and satisfies that a retraction value of a casting body inside the anchor cup after stretching is equal to or less than 6 mm.
  • the overstretching force is then unloaded to be 20% of the original overstretching force or to be the designed tension of the steel wire cable after the stretching.
  • Atop pressure is applied to the steel wire cable.
  • the top pressure is 1.25 folds of the designed tension of the steel wire cable and satisfies that a retraction value of the casting body inside the anchor cup after the top pressure detection is equal to or less than 6 mm.
  • the steel wire cable is coiled by a coil frame. Before the coiling, an outer surface of the steel wire cable is packed, and layers of the steel wire cables are successively coiled by using the coil frame. An inner diameter of a resulting coil is equal to or larger than 20 folds of an outer diameter of the steel wire cable and is equal to or larger than 1.6 m.
  • Finished product of the steel wire cable adopts indoor storage or outdoor storage.
  • indoor storage When the indoor storage is adopted, an oilcloth is used to cover the steel wire cable.
  • a storage site is equipped with ventilation and fire-proof facilities to ensure the quality and the safety of the stored steel wire cables.
  • the method for fabricating the steel wire cable comprising the extruded polyethylene and the zinc-aluminum alloy plating has the following advantages: the steel wires are arranged according to the arrangement rule at the cross section of the steel wire cable.
  • the length of the overall cable is controlled by the length of the central standard wire.
  • the bunch of the steel wires comprising the zinc-aluminum alloy plating are twisted with the torsion angle of between 2° and 4°.
  • the steel wire bunch is then wrapped with the polyester wrapping bandage and covered with the double-layered protective polyethylene sheath by using double-cavity co-extrusion process for one-step formation, and the outer surface of the polyethylene sheath is provided with embossments for rain-wind induced vibration resistance.
  • the two ends of the steel wire cable are fixed by anchors using fillers, coiled, and stored. And the coils of the steel wire cables are then transported to and respectively laid on the construction field.
  • the fabrication of the steel wire cable of the invention is not restricted by the construction site, and hardly affected by the climate factors. And the management of the industrialized production is easily controllable. All these satisfy the use requirements of long length, high accuracy, and endurance of the stay cable for the large-span bridge used in the marine environment.
  • Anchor plate 1. Anchor plate; 2. Anchor cup; 3. Sealing assembly of a connecting cylinder; 4. Steel wire cable; 5. Sealing structure at an end of a steel wire cable; 6. Nut; 7. Gap adjusting plate; 8. Pin shaft; and 9. Fork ear.
  • steel wires comprising a zinc-aluminum alloy plating are twisted together to form a naked steel wire cable, an outer layer of the naked steel wire cable is covered by a double-layered protective polyethylene by extrusion. Two ends of a resulting steel wire cable are then anchored by casting, coiled, transported to the construction site and laid respectively.
  • the steel wire comprising the zinc-aluminum alloy plating is adopted because the zinc-aluminum alloy plating possesses much stronger anti-corrosive property.
  • the zinc-aluminum alloy plating includes two types, Zn95AI5 5 having an aluminum content of between 4.2 and 7.2 wt. %, and Zn90Al10 having the aluminum content of between 9.2 and 12.2 wt. %.
  • a plating weight is equal to or larger than 300 g/m 2 .
  • a steel wire having a standard length is prepared. Certain markers for cutting are made at two ends of the steel wire. Thereafter, the steel wire having the standard length is utilized as a reference, and the overall length of the steel wire cable is controlled by a transfer method.
  • the steel wire cable is formed by multiple layers of steel wires.
  • the standard wire is positioned at a center position of a cross section of the steel wire cable.
  • a steel wire bunch is twisted to the left with a torsion angle of between 2° and 4°.
  • the twisted steel wire bunch is wrapped by a wrapping bandage, wherein the wrapping bandage is right-handed twisted, to yield a steel wire cable as a semi-product.
  • An outer diameter of the steel wire bunch, i. e., the naked steel wire cable, after being twisted is measured. Because the cross section of the steel wire bunch is in a shape of hexagon, a circumscribed circle of the selected cross section of the steel wire bunch is directly the diameter of the naked steel wire cable.
  • a double-layered protective polyethylene is prepared outside the steel wire cable. Before extruding, a die aperture of an extruder and an extrusion velocity are preset according to an outer diameter of the steel wire cable and thicknesses of two layers of polyethylene. The double-cavity co-extrusion for one-step formation is adopted. The two layers of the polyethylene plastics simultaneously cover the steel wire cable during the requirements of anti-corrosion.
  • an outer surface of the double-layered protective polyethylene is provided with helical lines or embossments.
  • a drag coefficient is equal to or smaller than 0.8.
  • Original cutting positions of the steel wire cable are determined, the double-layered protective polyethylene is locally stripped, and the markers for cutting at two ends of the standard wire at the center position of the steel wire cable are found. Then, the steel wire cable is cut by using a non-liquid cutting machine and end faces of the steel wire cable are ensured perpendicular to an axis of the steel wire cable.
  • the double-layered protective polyethylene is stripped according to a preset length to expose the steel wires, during which, the plating of the steel wires is prevented from being destructed.
  • the anchor is a main connecting structure to transmit a tension of the steel wire cable to a tower and a girder.
  • Anchor structures of the steel wire cable are as follows: two nut-screwing type anchors disposed at two ends of the steel wire cable, as shown in FIG. 1 , two anchor plate gap adjusting type anchors at two ends of the steel wire cable, as shown in FIG. 2 , and a fork-ear pin joint type anchor at one end of the steel wire cable and a nut-screwing type anchor at the other end of the steel wire cable, as shown in FIGS. 3-4 .
  • the nut screwing type anchor comprises: an anchor cup, a screw nut, an anchor plate, and a sealing assembly of a connecting cylinder.
  • Such steel wire cable utilizes the end face of the nut to support the pressure and to transmit the load.
  • the nut and the anchor cup are in rotary joint via a trapezoidal thread having high strength to realize the continuous adjustment of the length of the steel wire cable.
  • the anchor cup is provided with tensional inner threads. In installation of the steel wire cable on the construction site, an installation force is applied on the steel wire cable by drawing the anchor.
  • the anchor plate primarily functions in dispersing the steel wires, steel wire holes are distributed on the anchor plate, and the steel wires pass through corresponding steel wire holes and are headed.
  • An external cone boss can be tightly attached to an internal conical cavity.
  • the end face-supporting type anchor comprises: an anchor cup, an anchor plate, and a sealing assembly of a connecting cylinder. End faces of such steel wire cable are directly supported on anchor plate, and different gap adjusting plates are utilized to regulate the length of the steel wire cable.
  • the gas adjusting plates have different thicknesses to satisfy the requirement of the construction site.
  • the anchor cup is provided with tensional inner threads. In installation of the steel wire cable on the construction site, an installation force is applied on the steel wire cable by drawing the anchor. Such kind of anchor does not necessitate nuts, and the anchor cup is not provided with external threads.
  • the anchor plate functions in dispersing the steel wires, the steel wire holes are distributed on the anchor plate, and the steel wires pass through corresponding steel wire holes and are headed. An external cone boss can be tightly attached to an internal conical cavity.
  • the fork-ear pin joint type anchor comprises: a fork ear, a pin shaft, an anchor cup, a nut, and a sealing assembly of a connecting cylinder.
  • One end of such steel wire cable is connected to the steel structure of the tower or the girder via the fork ear and the pin shaft, and the other end of the steel wire cable adopts an end face of a nut to bear pressure and to transmit the load, thus realizing the continuous adjustment of the length of the steel wire cable.
  • the anchor cup is provided with tensional inner threads. In installation of the steel wire cable on the construction site, an installation force is applied on the steel wire cable by drawing the anchor.
  • the anchor plate functions in dispersing the steel wires, the steel wire holes are distributed on the anchor plate, and the steel wires pass through corresponding steel wire holes and are headed.
  • An external cone boss can be tightly attached to an internal conical cavity.
  • the sealing assembly of the connecting cylinder in the above three structures all adopts the new type of cable end sealing technology, in which, an outer part of the connecting cylinder is firstly sealed by a sealing cover, and an inner wall of the connecting cylinder in the vicinity of a port is sealed again by an elastic sealing ring and a sealing press ring.
  • the two sealing measurements finally realizes the sealing of the two ends of the steel wire cable, that is, the sealing between the anchors and the interfaces of the polyethylene steel wire cable.
  • the sealing assembly has stronger strength, thus being difficult to be destructed, much longer service life, and much endurable sealing structure.
  • the sealing structure at the ends of the steel wire cable is a reliable mechanical sealing structure, configured to prevent the corrosion resulting from the water penetration into the PE cable.
  • the sealing structure as a substitute of a heat shrink sleeve, is utilized for sealing, thus overcoming the problem of damage of the heat shrink sleeve.
  • an endurable sealing structure at an end of the steel wire cable fits together with the connecting cylinder of the anchor and comprises: the elastic sealing ring, a sealing press ring, and a sealing cover.
  • the sealing press ring is disposed in the port of the connecting cylinder and an outer end of the sealing press ring is exposed outside the connecting cylinder.
  • a press surface is formed on the inner wall of the connecting cylinder relative to the inner end face of the sealing press ring.
  • the elastic sealing ring is disposed between the inner end face of the sealing press ring and the press surface. Under the press of the press surface, the elastic sealing ring is deformed and attached to the outer wall of the steel wire cable.
  • the sealing cover is disposed on a front end of the connecting cylinder and possesses a Harvard structure.
  • a front part of the sealing cover contacts and fits with the outer wall of the steel wire cable and a corresponding contact surface is provided with a sealing ring.
  • a rear part of the sealing cover contacts and fits with the sealing press ring or the connecting cylinder and a corresponding contact surface is provided with a sealing strip.
  • the anchor is performed with hot galvanizing or paints coating for corrosion resistance.
  • a thickness of the hot galvanizing is equal to or larger than 90 ⁇ m, and a thickness of the paints coating is determined according to specifications and design requirements of a steel structure.
  • the casting of the anchor is carried out by chill casting of heading anchor or by hot casting of anchor, operations of which are as follows:
  • the hot casting anchor adopts a zinc alloy for casting, and a zinc-copper alloy and a zinc-copper-aluminum alloy are the common two alloys.
  • the zinc-copper alloy comprises 98 ⁇ 0.2 wt. % of zinc and 2 ⁇ 0.2 wt. % of copper, and the zinc-copper-aluminum alloy comprises 4 - 7 wt. % of aluminum, 1 - 2 wt. % of copper, and 91 - 95 wt. % of zinc.
  • the casting is performed as follows:
  • the tension detection or the top pressure detection are important means to detect the quality of the steel wire cable. According to fillers for the casting of the anchor, the tension detection is performed on the steel wire cable with chilled-casted anchor or the top pressure detection is performed on the steel wire cable with hot-casted anchor before leaving a plant, which is specifically as follows:
  • the steel wire cable is stretched by an overstretching force which is set to be between 1.1 and 1.5 folds of a designed tension of the steel wire cable and satisfies that a retraction value of a casting body inside the anchor cup after stretching is equal to or less than 6 mm.
  • the overstretching force is then unloaded to be 20% of the original overstretching force or to be the designed tension of the steel wire cable after the stretching.
  • a top pressure is applied to the steel wire cable.
  • the top pressure is 1.25 folds of the designed tension of the steel wire cable and satisfies that a retraction value of the casting body inside the anchor cup after the top pressure detection is equal to or less than 6 mm.
  • the steel wire cable is coiled by a coil frame. Before the coiling, an outer surface of the steel wire cable is packed, and layers of the steel wire cables are successively coiled by using the coil frame. An inner diameter of a resulting coil is equal to or larger than 20 folds of an outer diameter of the steel wire cable and is equal to or larger than 1.6 m.
  • Finished product of the steel wire cable adopts indoor storage or outdoor storage.
  • indoor storage When the indoor storage is adopted, an oilcloth is used to cover the steel wire cable.
  • a storage site is equipped with ventilation and fire-proof facilities to ensure the quality and the safety of the stored steel wire cables.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Bridges Or Land Bridges (AREA)
  • Ropes Or Cables (AREA)
EP16898333.6A 2016-04-13 2016-05-30 Method for manufacturing hot extruded polyethylene zinc-aluminium alloy-plated steel wire hauling cable Active EP3348712B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CN201610229109.1A CN105862592B (zh) 2016-04-13 2016-04-13 一种热挤聚乙烯锌铝合金镀层钢丝拉索的制作方法
PCT/CN2016/083894 WO2017177518A1 (zh) 2016-04-13 2016-05-30 一种热挤聚乙烯锌铝合金镀层钢丝拉索的制作方法

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EP3348712A1 (en) 2018-07-18
CN105862592B (zh) 2017-08-11
EP3348712A4 (en) 2018-12-12
WO2017177518A1 (zh) 2017-10-19
US20180100269A1 (en) 2018-04-12
CN105862592A (zh) 2016-08-17

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