Ceramic patch-lined pipe, also known as a mining mosaic pipe, is a composite pipe formed by attaching wear-resistant ceramic sheets to the inner wall of a steel pipe using a special adhesive. The ceramic sheets are typically made of high-Alumina ceramic, such as 95% alumina ceramic, which offers high hardness and wear resistance. The steel pipe, serving as the base, provides strength and toughness, typically made of Q235 or Q355.

Features 

High wear resistance: The high alumina content of the ceramic sheets results in a microhardness of HV1000-1500, making them extremely wear-resistant and effectively resistant to erosion and wear from materials such as ores. 

Corrosion resistance: Ceramics are inorganic materials that resist oxidation and rust, and are resistant to corrosion from acids, alkalis, and other chemicals.

Easy installation: The ceramic sheets are lightweight and low-density, making them easy to install and transport. They can also be cut and spliced to suit site conditions, making them suitable for various custom-shaped parts. ·Application areas: Mainly used in mining, electric power, metallurgy, chemical industry and other industries, for conveying sand, gravel, coal powder, ash, slurry and other highly abrasive materials.

Transportation Notes

1. Packaging and Protection: Layered protection is required, with particular emphasis on edge and corner protection.

2. Pipe End Protection: The flanges/ends of a single pipe must be protected with thickened plastic caps (≥5mm thick) or wooden plugs to prevent dust and stones from entering the pipe during transportation and scratching the Ceramic Lining. Pipe ends without flanges must be wrapped with waterproof canvas and securely tied.

Overall Packaging: First, wrap the pipe with 2-3 layers of bubble wrap (for cushioning and scratch protection), then cover with a high-strength woven bag (load-bearing capacity ≥500kg). Areas with dense ceramic tiles/mosaic tiles (such as elbows and reducers) should be covered with additional 5mm thick cardboard and secured with tape to prevent localized damage from pressure. · Bundling: Bundle 5-8 pipes together (adjusted by diameter; pipes DN500 and above are recommended to be individually packaged). Use steel strapping or nylon rope with a width of 50mm or greater. Tie at the pipe ends at 1/3 of its length (avoiding ceramic joints). Place 3mm thick rubber pads where the strapping points contact the pipes to prevent deformation caused by compression from the steel straps.

3. Loading Requirements: Ensure stable loading; avoid stacking and overloading.

4. Transport Method: Flatbed or low-sided trucks are preferred. The truck bed must be flat and free of protrusions. Dump trucks are prohibited (they can easily cause pipes to slide and collide due to tilting).

· Substrate Bedding: Lay 100mm thick wooden pallets in the truck bed (pallet spacing ≤1.5m). Place 5mm thick rubber sheets on the pallets to reduce hard contact between the pipes and the truck bed and cushion transportation vibrations. · Stacking Specifications:

· Straight pipes must be stacked ≤ 3 layers high, with 10mm thick rubber spacers between layers (this must be applied at the corresponding locations on each pipe to prevent the upper pipe from crushing the ceramic lining of the lower layer).

· Elbows, tees, and other special-shaped pipes (commonly used in mining systems) must be placed individually and flat. Stacking is prohibited, and wooden blocks must be used at both ends to prevent rolling and collision.

5. Securement Measures: Multiple stoppers to prevent slippage and vibration.

6. Horizontal Securement: Secure each pipe group with wooden blocks (height ≥ 1/2 the pipe diameter) on both sides. Rubber pads should be placed where the blocks meet the pipes to prevent them from sliding.

· Longitudinal Securement: Secure the pipe group to the truck guardrail with steel wire rope (covered with rubber tubing), with one anchor point every 2 meters. The wire rope tension should be sufficient to prevent noticeable movement of the pipes and avoid excessive squeezing. · Vibration Protection: When transporting large-diameter mining pipes (DN800 and above), a 20mm thick elastic rubber pad can be placed between the bottom of the pipe and the pallet to absorb vibrations caused by road bumps and prevent the ceramic pieces from falling off due to long-term vibration.

7. Environmental and Route Requirements: Avoid moisture and high temperatures, and choose a stable route.

1· Weather Protection: During rainy days, cover the pipe with a thickened tarpaulin (the edges of the tarpaulin should be allowed to hang down to the bottom of the vehicle and compacted with sandbags). Prevent rainwater from entering the pipe or soaking the adhesive. During high temperatures (≥35°C), cover with a sunshade to prevent direct sunlight from prematurely aging the adhesive between the ceramic and steel pipes.

· Route Selection: Prefer asphalt or concrete roads, avoiding potholes and steep slopes. During transportation, maintain a speed of 40-60 km/h. Slow down when turning and braking to reduce inertial impact on the pipe.

 2.Unloading Procedures: Lift and place with care. Rough handling is prohibited.

3.Unloading Equipment: Use a crane or forklift for unloading. The crane must be equipped with a dedicated lifting strap (capacity ≥ 1.5 times the weight of the pipe). Do not use wire rope to tie the pipe directly (this may scratch the steel pipe and squeeze the ceramic).

Lifting Method: Use the "two-point lifting method." Wrap the lifting strap around each end of the pipe at 1/3 of its length (contacting only the outer steel pipe, not the ceramic lining). Keep the pipe level during lifting to avoid tilting, which could cause uneven stress on the ceramic.

Falling Protection: When dropping pipes, lower them slowly, first onto a pre-placed wooden pallet. Do not drop them directly onto the ground. After unloading, stack them separately (straight pipes and special-shaped pipes). The stacking area must be flat, dry, and free of sharp objects. Installation Operation Process

1.Preliminary Preparation: Working Condition Verification + Site Cleanup

2· Material Verification: Check that the pipe specifications (diameter, length, wall thickness), ceramic tile type (tile/mosaic), and alumina content (≥92% for mining applications) meet design requirements. Specifically, check that the ceramic tiles are free of cracks and peeling, and that the flange sealing surfaces are free of scratches.

· Site Cleanup: Clear the installation area of ore debris and accumulated water, and level the ground. Build a temporary support (the height should match the designed elevation of the pipe), placing a rubber sheet on the top of the support to prevent direct contact between the pipe and the metal support.

· Tool Preparation: Prepare a torque wrench (range 0-1000 N·m), a level (accuracy 0.02 mm/m), a compressed air gun (for cleaning the pipe interior), a special sealant (high-temperature and slurry-resistant), and welding equipment (for flangeless pipes only; requires a cooling device). 

3.Pipeline Pretreatment: Cleaning + Trial Docking

4· Inner Wall Cleaning: Use compressed air (pressure 0.6MPa) to blow the inner wall of the pipe to remove dust and ceramic debris. If the inner wall is oily, wipe it clean with acetone to ensure that no impurities can interfere with material transportation.

· Trial Docking: Lift the pipe to be installed onto a temporary support. Adjust the position so that the adjacent pipe flange holes align. Use a spirit level to calibrate the pipe axis (deviation ≤ 2mm/m). The flange parallelism error should be ≤ 0.3mm. Do not force the connection to avoid crushing the ceramic.

5.Interface Connection: Sealing + Step-by-Step Tightening

6. Flange Connection (Mainstream Method):

a. Evenly apply specialized sealant (1-2mm thick) to the flange sealing groove and insert a slurry-resistant sealing gasket (nitrile rubber gasket or spiral wound gasket, 3-5mm thick is recommended).

b. Install bolts (use 8.8-grade high-strength bolts, matching the flange specifications) using the "diagonal step-by-step tightening method": First, tighten to 1/3 of the design torque (e.g., for a DN300 pipe with a design torque of 350 N·m, tighten to 120 N·m in the first step), then to 2/3, and finally to the design value in the third step. Allow 5 minutes between each step to avoid localized stress and flange deformation.

· Welding Connection (only for large-diameter flangeless pipes):

a. Use the "low current, low heat input" welding process, using E4303 electrodes, controlling the welding current to 80-120A, and the arc voltage to 100V. 20-24V;

b. During welding, place a damp asbestos cloth on the ceramic lining inside the pipe (to reduce the temperature) to prevent the welding temperature from exceeding 200°C (to prevent adhesive failure). Stop welding every 100mm and wait until the temperature returns to room temperature before continuing.

7.Fixation and Pressure Testing: Support and Hanger Installation + Pressure Testing

8.Support and Hanger Fixing: Install the supports and hangers at the designed spacing (typically 3-4m for mining pipelines). Place 5mm thick rubber pads where the supports and hangers contact the pipeline and secure with U-bolts (bolt tightness should be appropriate to prevent up-and-down movement of the pipeline) to prevent vibration caused by slurry impact.

·Pressure Testing: After the pipeline system is installed, perform a hydraulic pressure test (test pressure 1.25 times the working pressure; mining pipeline working pressure is typically 0.8-1.6 MPa, test pressure 1.0-2.0 MPa). Maintain pressure for 30 minutes. A pressure drop of ≤0.05 MPa and no leakage are considered acceptable. If transporting slurry, a "clean water test" (flow rate 2-3 m/s) is also required to check for abnormal wear on the pipeline wall and leaks at the joints.