The project is implemented within the framework of state-owned corporation in introducing innovative materials in the nuclear industry. The first enterprise of "Rosatom", where for the repair and reconstruction have been applied composite materials based on carbon fibers became Highland Mechanical Plant, which is part of "fuel elements".
The company is engaged in the production of gas centrifuges to enrich uranium, which is necessary for the operation of nuclear reactors, nuclear power plants. In fact, it is the production of gas centrifuges 30 years ago claimed the development of the industry uglekompozitov. Ultracentrifugation for the separation of uranium isotopes with a speed of more than 100 thousand a minute could only be manufactured from carbon fiber.
Meanwhile, if 30 years ago the use of uglekompozitov limited space and nuclear industries, but now the scope of their use of an unusually broad. One of the most promising applications — construction and reconstruction of virtually any engineering structures.
Last summer, the Director General of the State Corporation "Rosatom" Sergey Kiriyenko signed a program for implementation of polymer composite materials based on carbon fibers in the nuclear industry. Implementation of the project, it was decided to start with just building applications of composite materials based on carbon fiber.
"At this plant was required to gain slabs covering one of the shops. Because of the systematic leaking roof has undergone substantial corrosion of reinforcement of roof slabs, plates are no longer required to carry the load, the question was to strengthen and restore the bearing capacity of structures ", — told the head of the introduction of PCM in the nuclear industry Eugene Rafailov.
According to him, a "substantial challenge was that the department — acting, you can not stop production, respectively, it was necessary to combine the performance of production and repair work."
"Repairs carried out by innovative technologies — through external reinforcement of damaged beams and slabs strips of carbon fiber. This type of repair is called a system of external reinforcement. This technology allows to carry out repair work, first, virtually without interruption, and secondly, with a significant reduction in time and labor costs ", — Rafailov said.
The reinforcement system is designed for the repair and strengthening of building structures in order to eliminate the consequences of the destruction of concrete and reinforcement corrosion due to prolonged exposure to the elements and hostile environments in the operation of buildings.
During the construction and operation of The reinforcement system to accomplish the following objectives: to eliminate design errors or execution of the work, increase the carrying capacity of structures with an increase in design loads, as well as eliminate the effects of damage to the load-bearing structures encountered during the operation.
Repair work on the Kovrov Mechanical Plant will be completed at the end of March. In general, repair of composite materials take more than 2 months. Currently, more than half of the work done.
Repair work leads a team of six people. All employees as the selection: tall, slim, athletic. Team leader Stanislav Trifonov says that his subordinates were a real casting: "We work in secret facilities where required different degrees of tolerance, so the reputation of staff should be flawless".
In the shops Kovrovskogo mechanical plant maintenance staff actually have to be constantly under the roof at a height of 6 meters. Typically used for work at height scaffolding. However, they would impede the work of the shop.
"In order not to interfere with the production process, our engineers have designed a special suspended structures, which have the span length of 15 meters. They are height adjustable and can be moved from the ceiling all over the shop. Below is a working process, and we do not actually intersect with the employees of the plant ", — Trifonov said.
He also said that one of the conditions of repair in running the shop was the lack of dust, which can negatively affect the performance of high-precision equipment:
"In order to meet this condition, we purchased a stripping machine for concrete with exhaust air, and industrial vacuum cleaners. This allowed us to achieve the complete absence of dust. "
Trifonov said that the process of repairing surfaces using uglekompozitov involves several steps. First — this is stripping the old, concrete, surface treatment pronimayuschim rust inhibitor, which is necessary for resuscitating corrosive reinforcement. The purified concrete primed with a special compound is applied to the surface of a high-quality polymer concrete.
To achieve the standard necessary to strengthen the adhesion layer of concrete by impregnating connecting to 30-40 millimeters. The next step — the alignment of surfaces, their primer and adhesive application of the binder, which is glued to the carbon tape. A final point — a protective coating. According to Trifonov, the process of bonding carbon ribbons — spends a minimal amount of time. For example, a 15-foot frame side can be pasted carbon fiber in just 15 minutes, and the repair does not need over the next 15 years.
Meanwhile, if the decision was made to repair shop Kovrovskogo Mechanical plant by traditional methods, production would have been suspended for 8-10 months, says Trifonov. According to him, all the equipment in the shop would have to be removed, and then crane beams and columns to hang additional I-beams, weighing 10-15 tons each: "This would strengthen the columns and foundations".
"Without interruption, otherwise repair shop would have been impossible", — confirmed by the head of construction and architectural department Kovrovskogo Mechanical Plant Sergei Manakin.
In addition Kovrovskogo Mechanical Plant, innovative materials holding "Composite" in 2012, will be renovated over 50 properties in the nuclear industry.