Concrete pipe racks are structures placed under fluid-carrying pipes in various industries. These structures act as supports, holding the pipes at a certain height. Consequently, all the weight and various forces from the pipes are transferred to these structures. Given the importance of pipe racks, these structures play a key role in power plants, refineries, petrochemical facilities, and more. Damage or deterioration in these structures can disrupt production processes in these industries, leading to significant financial and safety risks.
In the design of these structures, buckling analysis in various modes must be performed carefully, and the structure must also be safe in terms of withstanding pressure and bending. Over time, pipe racks can corrode and deteriorate due to the forces exerted on them and environmental conditions such as moisture, water, fluid leakage, and more, requiring repairs.
With the introduction of composites into the field of concrete structure repair and strengthening, pipe racks are no exception. FRP and CFRP laminates play a significant role in repairing and strengthening these structures. Composites are highly resistant to corrosion.
The unique mechanical properties of composites, including high yield strength, low weight (with density up to one-seventh of metals), and more, have made them widely used in critical industries. The unique features of composites, such as enhanced strength in desired directions, integrity in application, no need for line shutdown, good adhesion to concrete, etc., make them an ideal choice for repairing and strengthening pipe racks.
Farasath Zarfam, with its extensive experience in composites and FRP, CFRP laminates, is capable of designing suitable composite systems for pipe racks.
Selecting the appropriate resin and fibers, designing and analyzing layers using finite element software such as Abaqus, choosing the right primer for adhesion to concrete, or employing mechanical methods for bonding with concrete are essential considerations for designers.
Carbon fibers offer higher strength compared to fiberglass but come at a higher cost. Therefore, optimizing the design can reduce repair costs, which designers should consider. By balancing parameters like mechanical properties, ease of application, and final cost, using composites for repairing and strengthening these structures becomes justifiable.
Once the composites are applied, verification tests such as the Holiday test can easily be performed using existing standards to ensure proper application of FRP and CFRP laminates.
Farasath Zarfam, with its experienced design and engineering team and skilled execution team, provides services from the initial design stages to the implementation of FRP, CFRP systems, final testing, and quality control of these systems.