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Fire hose
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==Manufacturing process== Fire hose is usually manufactured in a plant that specializes in providing hose products to municipal, industrial, and forestry fire departments. Here is a typical sequence of operations used to manufacture a double jacket, rubber-lined fire hose.<ref name=FireHose>"Fire Hose." How Products are Made. Ed. Stacey L. Blachford. Gale Cengage, 2002. eNotes.com. 2006. 22 November 2009 [http://www.enotes.com/how-products-encyclopedia/ Fire-hose] {{Webarchive|url=https://web.archive.org/web/20111028075438/http://www.enotes.com/how-products-encyclopedia |date=28 October 2011 }}</ref> ;Preparing the yarn * There are two different fiber yarns that are woven together to form a hose jacket. The yarns that run lengthwise down the hose are called warp yarns and are usually made from spun [[polyester]] or filament [[nylon]]. They form the inner and outer surfaces of the jacket and provide abrasion resistance for the hose. The yarns that are wound in a tight spiral around the circumference of the hose are called the filler yarns and are made from filament polyester. They are trapped between the crisscrossing warp yarns and provide strength to resist the internal water pressure. The spun polyester warp yarns are specially prepared by a yarn manufacturer and are shipped to the hose plant. No further preparation is needed. * The continuous filament polyester fibers are gathered together in a bundle of 7-15 fibers and are twisted on a twister frame to form filler yarns. The plied and twisted yarn is then wound onto a spool called a filler bobbin.<ref name=FireHose/> ;Weaving the jackets * The warp yarns are staged on a creel, which will feed them lengthwise down through a circular [[loom]]. Two filler bobbins with the filler yarn are put in place in the loom. * As the loom starts, the filler bobbins wind the filler yarn in a circle through the warp yarns. As soon as the bobbins pass, the loom crisscrosses each pair of adjacent warp yarns to trap the filler yarn between them. This weaving process continues at a high speed as the lower end of the jacket is slowly drawn down through the loom, and the bobbins continue to wrap the filler yarns around the circumference of the jacket in a tight spiral. The woven jacket is wound flat on a take-up reel. * The inner and outer jackets are woven separately. The inner jacket is woven to a slightly smaller diameter so that it will fit inside the outer jacket. Depending on the expected demand, several thousand feet of jacket may be woven at one time. After an inspection, the two jackets are placed in storage. * If the outer jacket is to be coated, it is drawn through a dip tank filled with the coating material and then passed through an oven where the coating is dried and cured.<ref name=FireHose/> ;Extruding the liner * Blocks of softened, sticky, uncured rubber are fed into an extruder. The extruder warms the rubber and presses it out through an opening between an inner and outer solid circular piece to form a tubular liner. * The rubber liner is then heated in an oven where it undergoes a chemical reaction called vulcanizing, or curing. This makes the rubber strong and pliable. * The cured liner passes through a machine called a rubber calender, which forms a thin sheet of uncured rubber and wraps it around the outside of the liner.<ref name=FireHose/> ;Forming the hose * The jackets and liner are cut to the desired length. The inner jacket is inserted into the outer jacket, followed by the liner. * A steam connection is attached to each end of the assembled hose, and pressurized steam is injected into the hose. This makes the liner swell against the inner jacket and causes the thin sheet of uncured rubber to vulcanize and bond the liner to the inner jacket. * The metal end connections, or couplings, are attached to the hose. The outer portion of each coupling is slipped over the outer jacket and an inner ring is inserted into the rubber liner. A tool called an expansion [[mandrel]] is placed inside the hose and expands the ring. This squeezes the jackets and liner between the ring and serrations on the outer portion of the coupling to form a seal all the way around the hose.<ref name=FireHose/> ;Pressure testing the hose * Standards set by the [[National Fire Protection Association]] require that each length of new double jacket, rubber-lined attack hose must be pressure tested to {{convert|600|psi|bar kPa|sigfig=3|abbr=on}}, but most manufacturers test to {{convert|800|psi|bar kPa|sigfig=3|abbr=on}}. Subsequent to delivery, the hose is tested annually to {{convert|400|psi|bar kPa|sigfig=3|abbr=on}} by the fire department. While the hose is under pressure, it is inspected for leaks and to determine that the couplings are firmly attached. * After testing the hose is drained, dried, rolled, and shipped to the customer.<ref name=FireHose/> ;Quality control In addition to the final pressure testing, each hose is subjected to a variety of inspections and tests at each stage of manufacture. Some of these inspections and tests include visual inspections, [[ozone]] resistance tests, accelerated aging tests, adhesion tests of the bond between the liner and inner jacket, determination of the amount of hose twist under pressure, dimensional checks, and many more.<ref name=FireHose/> ===Future=== The trend in fire hose construction over the last 20 years has been to use lighter, stronger, lower maintenance materials. This trend is expected to continue in the future as new materials and manufacturing methods evolve. One result of this trend has been the introduction of lightweight supply hoses in diameters never possible before. Hoses up to {{convert|12|in|cm|1|abbr=on}} in diameter with pressure ratings up to {{convert|150|psi|bar kPa|sigfig=3|abbr=on}} are now available. These hoses are expected to find applications in large-scale industrial [[firefighting]], as well as in disaster relief efforts and military operations.<ref name=FireHose/> Fire hoses come in a variety of diameters. Lightweight, single-jacket construction, {{frac|3|4}}, 1, and {{frac|1|1|2}} inch diameter hose lines are commonly used in [[wildfire suppression]] applications. Heavy duty double, double-jacket, {{frac|1|1|2}}, {{frac|1|3|4}}, 2, {{frac|2|1|2}}, and on occasion 3-inch lines are used for structural applications. Supply lines, used to supply [[firefighting apparatus]] with water, are frequently found in {{frac|3|1|2}}, 4, {{frac|4|1|2}}, 5 and 6-inch diameters. There are several systems available for repairing holes in fire hoses, the most common being the [[Stenor Merlin]], which offer patching materials for Type 1, 2, and 3 hoses. The patches come in two different sizes and two different colours (red and yellow). The patches are [[Vulcanization|vulcanised]] onto the hose and usually last the lifetime of the hose.
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