A method for manufacturing a UHPC component

Abstract

The present invention discloses a method for manufacturing UHPC components, which includes the following steps: (1) CNC foam mold carving: using CNC carving technology to realize the production of two foam molds in a 1:1 ratio of the template, one piece is processed to achieve a smooth surface of the foam mold, including visible seam strips, and is used for bottom mold remaking. The other piece is processed to achieve a smooth surface and is used for closing the cover plate; (2) cement board seed mold production: because the front texture of the template is a fine lychee surface (rough surface), the cement board is produced on the foam mold that requires bottom mold remaking using GRC technology, and after demoulding, the surface texture is achieved by sandblasting technology to achieve a rough surface effect. This method can ensure the accuracy and aesthetics of the component thickness and obtain a good double-sided effect. The surface texture is achieved through a silicone texture mold, the component is formed in one step, and the durability of the surface is guaranteed, solving the problems of insufficient compressive strength of UHPC, uneven settlement of the incorporated steel fiber, cracking of prefabricated products, and poor working performance of UHPC.

Description

Technical Field

[0001] The present invention belongs to the technical direction of UHPC components, and specifically relates to a method for manufacturing UHPC components. Background Art

[0002] Ultra-High Performance Concrete (UHPC), also known as Reactive Powder Concrete (RPC), is the most innovative cement-based engineering material in the past three decades, achieving a major leap in the performance of engineering materials.

[0003] UHPC has excellent mechanical properties such as compression, tension, and flexural strength, as well as good durability and self-cleaning properties. Since entering China in 2018, it has developed rapidly. Common UHPC components on the market include: flat hollow UHPC, flat plate UHPC, curved UHPC components, etc. However, there are currently no UHPC components that combine multiple elements such as hyperbolic surfaces, high hollowing rates, and surface sandblasting textures. The present invention mainly focuses on the construction technology and quality control of UHPC components with hyperbolic special-shaped hollow rough surfaces. Summary of the Invention

[0004] The purpose of the present invention is to provide a method for manufacturing UHPC components for existing devices to solve the problems raised in the above background technology.

[0005] In order to solve the above technical problems, the present invention provides the following technical solution: a method for manufacturing a UHPC component, comprising the following steps:

[0006] (1) CNC foam mold carving: Use CNC carving technology to make two foam molds with a 1:1 ratio of the sample. One piece is processed to achieve a smooth surface with visible seams for the bottom mold. The other piece is processed to achieve a smooth surface for the cover plate.

[0007] (2) Cement board mold making: Because the front texture of the sample is a fine lychee surface (rough surface), the cement board is made using GRC technology on a foam mold that needs to be turned into a bottom mold. After demoulding, the surface texture is made into a rough surface effect by sandblasting technology. After sandblasting, if the sandblasting is not in place in some parts or the open seams are cracked, they need to be repaired;

[0008] (3) Silicone membrane production: After the cement board mold is sandblasted to complete the surface texture, it is then partially repaired. After the repair is completed, silicone oil is prepared to make a silicone mold;

[0009] (4) Fiberglass mold remaking: including the following steps:

[0010] S1 bottom mold remaking: remake the fiberglass mold on the silicone and place the steel frame for welding and fixing;

[0011] S2 closed cover plate mold remaking: directly remake the fiberglass mold on the foam mold, place the steel frame and weld it to fix;

[0012] (5) Production of side guard formwork: Use wooden formwork splicing technology to produce side guard formwork;

[0013] (6) Mold assembly: Place the bottom mold (fiberglass mold) on the table mold, fix the side rib mold to the bottom mold, check the overall mold size during assembly, fill the embedded holes with soft objects, and check the embedded size at the same time, finally close the closed cover mold and install it, and check the mold gap after installation;

[0014] (7) Anti-expansion measures: Use simple steel pipes for surrounding reinforcement, and fix the steel pipe joints with electric welding. The spacing between each layer of reinforcement shall not be greater than 300mm. At the same time, vent holes shall be set on the closed cover mold;

[0015] (8) UHPC grouting: Set a grouting port and fix it on the upper side. Pour the UHPC mixture into the mold. Turn on the switch and slowly discharge the material. Observe the slurry discharge from the bottom of the mold. When the slurry comes out of the vent hole, use a rubber hammer to hit the bottom mold side and then plug the vent hole with a plug in time. Repeat this process until all the vent holes have slurry. Then plug the vent holes with a plug. Stop grouting when the grouting material no longer sinks during the grouting process.

[0016] (IX) UHPC demoulding and lifting: When the strength of the UHPC finished product meets the lifting strength requirements, the UHPC finished product can be lifted to a temporary stacking area, and then the UHPC finished product can be turned over and lifted to the shelf for placement;

[0017] (10) Repair of UHPC finished panels: If the front surface has a rough surface texture and there are defects on the surface, such as bubbles, dense pores, and open seam defects, fill them with repair slurry and lightly grind them manually; if there are bubbles, dense pores, or missing edges on the back surface, grind them with an air grinder equipped with 80-120 mesh sandpaper, scrape and fill them with repair slurry, and then grind them with an air grinder equipped with 400-600 mesh sandpaper;

[0018] (11) Spraying protective agent on the surface of UHPC finished board: Use a W71 caliber spray bottle to fill with water-based protective agent and spray the surface of UHPC finished product. The number of spraying times shall not exceed 2 times.

[0019] The present invention further illustrates that, during the step (ii) of making the cement board mold, the rough surface is repaired with mortar, and the exposed joints are repaired with cement paste.

[0020] The present invention further illustrates that during the mold assembly process of step (six), the error of the mold size is controlled within ±2 mm, and the error of the embedded size is controlled within ±2 mm.

[0021] The present invention further illustrates that during the step (seven) of preventing the membrane from expanding, the size of the steel pipe is 50*50mm.

[0022] Compared with the existing technology, the present invention has the following beneficial effects: it can ensure the accuracy and aesthetics of the thickness of the component, obtain a better double-sided effect, the surface texture is achieved through the silicone texture mold, the component is formed in one step, the durability of the surface is guaranteed, and the problems of insufficient compressive strength of UHPC, uneven settlement of the incorporated steel fiber, cracking of the prefabricated product, and poor working performance of UHPC are solved.

[0023] (1) Through the use of CNC foam mold carving → cement board mold making → silicone mold making → fiberglass mold remaking → sidewall mold making → mold assembly → anti-expansion membrane measures → UHPC grouting → UHPC demoulding and lifting → UHPC finished board repair → UHPC finished board surface spraying protective agent, and using double-sided closed mold to ensure the accuracy and aesthetics of the component thickness, vertical casting can obtain better double-sided effects, the surface texture is achieved through the silicone texture mold, the component is formed in one time, and the durability of the surface is guaranteed. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation of the present invention. In the accompanying drawings:

[0025] Figure 1 It is a schematic diagram of the foam template structure of the present invention;

[0026] Figure 2 It is a schematic structural diagram of a cement mold of the present invention;

[0027] Figure 3 Schematic diagram of the structure of the silica gel membrane of the present invention;

[0028] Figure 4 This is a schematic diagram of the glass fiber reinforced plastic mold remaking process of the present invention;

[0029] Figure 5 It is a schematic diagram of the edge touch structure of the present invention;

[0030] Figure 6 It is a schematic diagram of the mold assembly process of the present invention;

[0031] Figure 7 This is a schematic diagram of the process of the anti-expansion membrane measure of the present invention;

[0032] Figure 8This is a schematic diagram of the UHPC grouting process of the present invention;

[0033] Figure 9 It is a schematic diagram of the UHPC demoulding and lifting process of the present invention. DETAILED DESCRIPTION

[0034] The following is a non-limiting detailed description of the technical solutions of the present invention in conjunction with preferred embodiments and the accompanying drawings. Obviously, the embodiments described are only some of the embodiments of the present invention, not all of them. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without inventive effort are also within the scope of protection of the present invention.

[0035] See also Figure 1-9 The present invention provides a technical solution: a method for manufacturing a UHPC component, comprising the following steps:

[0036] (1) CNC foam mold engraving: see Figure 1 As shown, two foam molds are made from a 1:1 sample using CNC engraving technology. One piece is processed to achieve a smooth surface with visible seams for bottom mold remaking. The other piece is processed to achieve a smooth surface for closing the cover.

[0037] (2) Cement board mold making: see Figure 2 As shown, because the front texture of the sample is a fine lychee surface (rough surface), the cement board is made by GRC technology on the foam mold that needs to be turned into a bottom mold. After demoulding, the surface texture is made into a rough surface effect by sandblasting technology. After sandblasting, if the sandblasting is not in place in some parts and the cracks in the open seams are broken, they need to be repaired;

[0038] (3) Silicone membrane production: see Figure 3 As shown, the cement board mold is sandblasted to complete the surface texture, and then local repair is carried out. After the repair is completed, silicone oil is prepared to re-make the silicone mold;

[0039] (4) Fiberglass mold remaking: see Figure 4 As shown, the following steps are included:

[0040] S1 bottom mold remaking: remake the fiberglass mold on the silicone and place the steel frame for welding and fixing;

[0041] S2 closed cover plate mold remaking: directly remake the fiberglass mold on the foam mold, place the steel frame and weld it to fix;

[0042] (5) Production of retaining edge mold: see Figure 5 As shown, the side formwork of the retaining wall is made by using the wooden formwork splicing technology;

[0043] (6) Mold assembly: see Figure 6As shown, place the bottom mold (glass fiber reinforced plastic mold) on the table mold, fix the side rib mold to the bottom mold, check the overall mold size during assembly, fill the embedded holes with soft objects, and check the embedded size at the same time. Finally, close the closed cover mold and install it. After installation, check the mold gap.

[0044] (VII) Measures to prevent film expansion: see Figure 7 As shown, simple steel pipes are used for surrounding reinforcement, and the steel pipe joints are fixed by electric welding. The interval between each layer of reinforcement shall not be greater than 300mm, and exhaust holes shall be set on the closed cover plate mold;

[0045] (8) UHPC grouting: see Figure 8 As shown, a grouting port is set and fixed on the upper side. The UHPC mixture is poured into the mold. The switch is turned on to slowly discharge the material. The slurry discharge at the bottom of the mold is observed. When the slurry comes out of the vent hole, the bottom mold side can be hit with a rubber hammer and the vent hole can be blocked with a plug in time. The cycle is repeated until all the vent holes have slurry, and then the vent holes are blocked with plugs. When the grouting material no longer sinks during the grouting process, the grouting is stopped.

[0046] (IX) UHPC demoulding and lifting: see Figure 9 As shown in the figure, if the strength of the UHPC finished product meets the lifting strength, the UHPC finished product can be lifted to a temporary stacking place, and then the UHPC finished product can be turned over and lifted to be placed on the shelf;

[0047] (10) Repair of UHPC finished panels: If the front surface has a rough surface texture and there are defects on the surface, such as bubbles, dense pores, and open seam defects, fill them with repair slurry and lightly grind them manually; if there are bubbles, dense pores, or missing edges on the back surface, grind them with an air grinder equipped with 80-120 mesh sandpaper, scrape and fill them with repair slurry, and then grind them with an air grinder equipped with 400-600 mesh sandpaper;

[0048] (11) Spraying protective agent on the surface of UHPC finished board: Use a W71 caliber spray bottle to fill it with water-based protective agent and spray the surface of UHPC finished product. The number of spraying times shall not exceed 2 times.

[0049] During the process of making the cement board mold in step (2), the rough surface is repaired with mortar, and the exposed joints are repaired with cement paste.

[0050] During the mold assembly process of step (six), the error of the mold size is controlled within ±2mm, and the error of the embedded size is controlled within ±2mm.

[0051] During the step (seven) of the anti-expansion membrane measures, the size of the steel pipe is 50*50mm.

[0052] In the description of the present invention, it should be understood that the terms "up", "down", "front", "back", "left", "right", etc., indicating directions or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore should not be understood as a limitation on the present invention.

[0053] Finally, it should be noted that the above embodiments are intended only to illustrate the technical solutions of the present invention and are not intended to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art will appreciate that modifications may be made to the technical solutions described in the aforementioned embodiments, or that some of the technical features may be replaced with equivalents. Such modifications or replacements do not deviate from the spirit and scope of the technical solutions of the various embodiments of the present invention.

Claims

1. A method for manufacturing a UHPC component, characterized in that: The following steps are involved: (1) CNC foam mold carving: Use CNC carving technology to make two foam molds of 1:1 sample. One piece is processed to make the foam mold surface flat and include visible seam strips for bottom mold remaking. The other piece is processed to make the surface flat and is used to close the cover plate. (2) Cement board mold making: Because the front texture of the sample is a fine lychee surface, the cement board is made using GRC technology on a foam mold that needs to be turned into a bottom mold. After demoulding, the surface texture is made rough by sandblasting technology. After sandblasting, if the sandblasting is not in place in some places or the open seams are cracked, they need to be repaired; (3) Silicone membrane production: After the cement board mold is sandblasted to complete the surface texture, it is then partially repaired. After the repair is completed, silicone oil is prepared to make a silicone mold; (4) Fiberglass mold remaking: including the following steps: S1 bottom mold remaking: remake the fiberglass mold on the silicone and place the steel frame for welding and fixing; S2 closed cover plate mold remaking: directly remake the fiberglass mold on the foam mold, place the steel frame and weld it to fix; (5) Production of side guard formwork: Use wooden formwork splicing technology to produce side guard formwork; (6) Mold assembly: Place the bottom mold on the table mold, fix the side rib mold to the bottom mold, check the overall mold size during the assembly process, fill the embedded holes with soft objects, and check the embedded dimensions at the same time. Finally, close the closed cover mold and install it. Check the mold gap after installation; (7) Anti-expansion measures: Use simple steel pipes for surrounding reinforcement, and fix the steel pipe joints with electric welding. The spacing between each layer of reinforcement shall not be greater than 300mm. At the same time, vent holes shall be set on the closed cover mold; (8) UHPC grouting: Set a grouting port and fix it on the upper side. Pour the UHPC mixture into the mold. Turn on the switch and slowly discharge the material. Observe the slurry discharge from the bottom of the mold. When the slurry comes out of the vent hole, use a rubber hammer to hit the bottom mold side and then plug the vent hole with a plug in time. Repeat this process until all the vent holes have slurry. Then plug the vent holes with a plug. Stop grouting when the grouting material no longer sinks during the grouting process. (IX) UHPC demoulding and lifting: When the strength of the UHPC finished product meets the lifting strength requirements, the UHPC finished product can be lifted to a temporary stacking area, and then the UHPC finished product can be turned over and lifted to the shelf for placement; (10) Repair of UHPC finished panels: If the front surface has a rough surface texture and there are defects on the surface, such as bubbles, dense pores, and open seam defects, fill them with repair slurry and lightly grind them manually; if there are bubbles, dense pores, or missing edges on the back surface, grind them with an air grinder equipped with 80-120 mesh sandpaper, scrape and fill them with repair slurry, and then grind them with an air grinder equipped with 400-600 mesh sandpaper; (11) Spraying protective agent on the surface of UHPC finished board: Use a W71 caliber spray bottle to fill it with water-based protective agent and spray the surface of UHPC finished product. The number of spraying times shall not exceed 2 times.

2. The method for manufacturing a UHPC component according to claim 1, wherein: During the step (2) of making the cement board mold, the rough surface is repaired with mortar, and the exposed joints are repaired with cement paste.

3. The method for manufacturing a UHPC component according to claim 1, wherein: During the mold assembly process of step (six), the error of the mold size is controlled within ±2 mm, and the error of the embedded size is controlled within ±2 mm.

4. The method for manufacturing a UHPC component according to claim 1, wherein: During the step (seven) of taking measures to prevent the membrane from expanding, the size of the steel pipe is 50*50mm.

Images