Steel wire concrete and preparation method thereof

Abstract

The present invention relates to the field of building materials, and specifically to a steel wire concrete and a preparation method thereof. The steel wire reinforced concrete adopts cement-based fine aggregate concrete material as base material and steel wire material as reinforcing and modifying material, and eliminates the mixing process of steel wire material and base material. The concrete is prepared by paving the steel wire material and grouting or grouting the high-fluidity base material. The composite process of the steel wire material and the base material of the present invention adopts a mixing-free composite concrete process of laying (or layered laying) of the steel wire material, grouting or grouting pouring, infiltration, and vibration technology. The base material is filled in the gaps between the steel wires, and each steel wire is wrapped to form a homogeneous (or layered) composite steel wire concrete. This is based on the fact that the present invention adopts a high-performance, high-fluidity base material and grouting (or grouting) technology, and the molding process is convenient and efficient.

Description

Technical Field

[0001] The invention relates to the field of building materials, and in particular to steel wire concrete and a preparation method thereof. Background Art

[0002] Ordinary cement concrete and mortar have high compressive strength, but their tensile strength, crack resistance, bending resistance, impact resistance and toughness are relatively poor. Adding fibers to them can effectively improve and enhance the above properties to form fiber concrete. Commonly used fibers are low elastic modulus fibers (such as nylon fibers, polyethylene fibers, polypropylene fibers, etc.) and high elastic modulus fibers (steel fibers, carbon fibers, glass fibers, etc.). Generally speaking, low elastic modulus fibers can improve the impact toughness of concrete, but have no obvious effect on tensile strength. High elastic modulus fibers can significantly improve toughness and tensile strength. For example, adding 1.2-2% volume ratio of steel fibers to concrete can increase its bending strength by 1.5-3 times, toughness by more than 3-10 times, and tensile strength by 20%-50%.

[0003] Since the late 1970s, my country has adopted chopped steel fibers in straight, indented, corrugated, end-groove, big-headed and irregular pockmarked shapes made of carbon steel, alloy steel and stainless steel. Steel fibers with a length of 20 to 60 mm, an equivalent diameter of 0.3 to 0.9 mm and an aspect ratio of 30 to 80 are commonly used in engineering and are mixed into concrete to form composite steel fiber concrete. The application of steel fiber concrete in structural engineering is increasing, such as the surface structure of the bridge deck, road surface, runway, bridge deck pavement, tunnel lining, shield segment engineering and concrete components. However, in practical applications, there are also certain problems that limit its use, such as poor workability of concrete during construction, fiber agglomeration and uneven dispersion during mixing, pouring and vibration tamping, and bonding performance needs to be improved. The fiber price is also high, which affects the promotion and application of steel fiber concrete. my country already has corresponding fiber concrete technical regulations, such as JGJ / T221-2010 fiber concrete application technical regulations, GB / T38901--2020 fiber concrete shield segment, etc. At present, there are four major types of steel fibers widely used at home and abroad, high-strength steel wire cutting type, thin plate shearing type, ingot milling type and melt extraction type. my country's fiber reinforced concrete technology is mainly short-cut fiber (short-cut steel fiber and polymer fiber) reinforced cement concrete and steel mesh (sheet woven steel bar, wire mesh or welded steel mesh) reinforced cement concrete and mortar (both called fiber concrete).

[0004] In order to overcome the shortcomings of the prior art and give concrete different application purposes and application scopes, the present invention proposes steel wire concrete (SWC) with a different concept from the existing steel fiber modified concrete, which uses steel wire material (forming random felt, net, cloud shape) to reinforce and modify concrete and a preparation method thereof. Summary of the invention

[0005] The present invention proposes a steel wire reinforced modified steel wire concrete prepared by using high-performance, high-fluidity cement-based fine aggregate concrete as a base material and steel wire material (random felt, net or cloud-like) formed by steel wires as a reinforcing and modified material through a stirring-free grouting or grouting process.

[0006] The purpose of the present invention is achieved by the following technical solutions:

[0007] In the first aspect, the present invention proposes a steel wire concrete, wherein the steel wire reinforced concrete uses cement-based fine aggregate concrete material as a base material and steel wire material as a reinforcing and modified material, eliminating the mixing process of the steel wire material and the base material, and is prepared by paving the steel wire material and grouting or grouting of a high-fluidity base material.

[0008] Preferably, the cement-based fine aggregate concrete material contains high-performance mortar, lightweight aggregate concrete material and the like.

[0009] Preferably, the material is a steel wire reinforced concrete material, that is, a steel wire concrete material, or a steel wire mortar material, or a steel wire lightweight aggregate concrete material, or a layered composite material with reinforced concrete or lightweight aggregate concrete.

[0010] Preferably, the steel wire material is a felt-shaped, mesh-shaped or cloud-shaped steel wire material made of steel wire with a diameter or equivalent diameter of 0.3 to 0.9 mm.

[0011] Steel wire concrete can be used for various assembled composite plate components, shock-absorbing composite components or thin-walled concrete structures, decorative components, port roads, bridge deck pavement, etc. For example, components with high seismic performance requirements, building energy-saving lightweight exterior wall panels, anti-collision composite components and other concrete products. Steel wire concrete can also be combined with steel bars to form steel wire reinforced concrete components.

[0012] Preferably, the steel wire concrete is composed of the following raw materials in parts by volume: 0.25% to 1.20% of the modified component steel wire material; 99.75% to 98.80% of the base material component.

[0013] If the content of modified component steel wire material is too high or the amount of steel wire used is too large, the gaps between the wires will be reduced, which is not conducive to the penetration of the base material. At the same time, it will increase the dispersion of the base material and reduce the overall continuity of the base material.

[0014] Preferably, the steel wire used in the modified component steel wire material is a non-linear steel wire with a diameter (or equivalent diameter) of 0.3 to 0.9 mm and a length greater than 500 mm.

[0015] Preferably, the steel wire material is in a cloud-like, felt-like, or mesh-like shape, depending on the molding requirements of the concrete, the steel content, etc.; a layer thickness of 20-100 mm is usually selected, the voids between the wires are not less than 5 mm, and the distribution is controlled to be basically uniform.

[0016] Preferably, the slump of the base material component is not less than 180 mm, the compressive strength is not less than 20 MPa, and the expansion of pumped concrete is not less than 450 mm.

[0017] More preferably, the base material components are divided according to mass composition (Kg / m 3 ) includes: 380-880 parts of cement, 200-1400 parts of sand, 0-520 parts of light aggregate, 60-1300 parts of admixture, 1-6 parts of admixture, and 170-220 parts of water.

[0018] Preferably, the light aggregate includes at least one of ceramsite (ceramic sand) and EPS light beads; the particle size of the light aggregate is not greater than 5 mm, and 2.5 mm is generally used; the density of the ceramsite is 900 kg / m 3 The cylinder pressure strength is above 3.5Mpa, and the density of EPS light beads is flame retardant at 3-7Kg / m 3 The purpose of lightweight aggregate is to prepare steel wire concrete with lower density, which is used in building components or parts with requirements of light weight and energy saving.

[0019] Preferably, the admixture includes at least one of mineral powder, silica ash, fly ash, ceramic polishing slag powder, and composite stone powder (including ultrafine powdery materials).

[0020] Preferably, the admixture is at least one of a polycarboxylic acid high-efficiency water reducing agent and a silane redispersible latex powder.

[0021] In a second aspect, the present invention provides a process for preparing steel wire concrete, comprising the following steps:

[0022] Step 1, under closed conditions, according to the measured ingredients, first add sand, light aggregate, then cement, admixture, additive and water, and stir well;

[0023] Step 2, laying and pouring the modified component steel wire material and the base material component, and the steel wire material should not be laid more than two layers at a time;

[0024] Step 3: After the steel wires are laid in layers and the base material is poured, a vibrator is used to compact the steel wires;

[0025] Preferably, in step 1, when configuring the high-performance base material, first grind and disperse part of the cement, ultrafine powder admixture, admixture and water into a slurry (such as a colloid mill) according to the measurement of the ingredients, and then add sand, light aggregate and the remaining materials into a mixer and stir them evenly.

[0026] Preferably, in step 2, when pouring the base material, pump pouring or machine sprinkling is adopted; when preparing uniform steel wire concrete, a mortar pump grouting or grouting scheme is adopted to slowly press the mortar into the feed hole below the mold, or pour it into the gaps of the steel wire from the top, filling the gaps, wrapping each steel wire, and expelling bubbles with vibration.

[0027] Preferably, in step 2, depending on the type of steel wire material, the thickness of the base material should not exceed 400 mm when grouting is performed from the top, and the thickness should not exceed 500 mm when grouting is performed from the bottom.

[0028] Preferably, in step 3, no jumping, delamination or segregation of the wire mesh should occur during vibration.

[0029] The beneficial effects of the present invention are:

[0030] The present invention starts with the structural construction of concrete materials, the principle of composite modification of materials and the manufacturing process, adopts high-fluidity fine aggregate concrete and mortar (including ultra-high performance concrete, high-performance mortar, etc.) as base materials; adopts elastic multi-dimensional (random space felt, net, cloud-like) steel wire material made of steel wire (diameter 0.3-0.9 mm, long steel wires of different lengths (generally not less than 500 mm) as tensile, crack-resistant, bending-resistant, impact-resistant, toughening and reinforcing materials; eliminates the mixing process of steel wire material and base material; and forms a composite cement-based steel wire modified concrete isotropic homogeneous material with high crack resistance, bending resistance and toughness, namely steel wire concrete, or a layered composite material of steel wire homogeneous material and reinforced concrete or lightweight aggregate concrete through the paving of steel wire material, grouting or grouting of high-fluidity base material, penetration and vibration molding.

[0031] The steel wire concrete prepared by the present invention can be used for construction, transportation, water conservancy engineering structures, etc., as well as assembled composite plate components, shock-absorbing composite components or thin-walled concrete structures, such as: building energy-saving lightweight exterior wall panels, shock-absorbing components and plates with high seismic performance requirements, anti-collision enclosure components, and concrete products composited with elastic polyurethane seismic isolation materials, etc. Steel wire concrete SWC (steel wire concrete) can also be combined with steel bars to form reinforced concrete components.

[0032] The composite process of steel wire material and base material of the present invention adopts a non-stirring composite concrete process of steel wire material laying (or layered laying), grouting or grouting pouring, infiltration, and vibration technology. The base material fills the gaps between the steel wires and wraps each steel wire to form a uniform or layered composite steel wire concrete. This is based on the fact that the present invention adopts a high-performance, high-fluidity base material and grouting or grouting technology, and the molding process is convenient and efficient. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The present invention is further described using the accompanying drawings and embodiments, but the accompanying drawings and embodiments do not constitute any limitation to the present invention. A person skilled in the art can obtain other drawings based on the following drawings without creative work.

[0034] Figure 1 The cloud-like steel wire material prepared in the present invention.

[0035] Figure 2 The present invention relates to a felt-like steel wire material prepared in the present invention. DETAILED DESCRIPTION

[0036] In order to more clearly illustrate the present invention and have a clearer understanding of the technical features, purposes and beneficial effects of the present invention, the technical solution of the present invention is now described in detail below, but it should not be construed as limiting the applicable scope of the present invention.

[0037] Unless otherwise specified, the raw materials, reagents or devices used in the following examples can be obtained from conventional commercial sources or by existing known methods.

[0038] The present invention is further described in conjunction with the following examples.

[0039] Example 1

[0040] The steel wire concrete (sand wire) in this example is composed of the following volume ratios: the steel wire component with an equivalent diameter of 0.40 mm accounts for 0.20%, and the base material (mortar) component accounts for 99.80%.

[0041] The base material is composed of the following raw materials in parts by weight: 42.5 silicate cement (580), sand with a particle size not greater than 2.5 mm (1300), fly ash (120), mineral powder (60), porcelain slag powder (80), fine stone powder (80), polycarboxylic acid high-efficiency water reducing agent (5), and water (170). The steel wire is evenly distributed in the concrete.

[0042] First, lay the steel wire evenly in the mold. Then, mix and measure the cement, admixtures, additives, water and fine aggregate, disperse the fine powder fully, stir evenly to form a high-fluidity mixture, and then use a mortar pump to evenly pour it into the mold until the slurry fills the gaps between the steel wires and the mold, and use a vibrator to vibrate appropriately to expel bubbles.

[0043] Example 2

[0044] The steel wire concrete (sand wire) in this example is composed of the following volume ratios: the steel wire component with an equivalent diameter of 0.40 mm accounts for 0.50%, and the base material (mortar) component accounts for 99.50%.

[0045] The base material is composed of the following raw materials in parts by weight: 42.5 silicate cement (600), sand with a particle size not greater than 1.25 mm (1200), fly ash (120), mineral powder (80), silica fume (60), quartz sand powder (120), polycarboxylate high-efficiency water reducing agent (6), and water (180). The steel wire is evenly distributed in the concrete.

[0046] First, the steel wire is evenly laid in the mold with a feed hole at the bottom. Cement, admixtures, additives, water, and sand are batched and measured, and the fine powder is fully dispersed, and then fully stirred and evenly mixed to form a high-fluidity mixture. Then a mortar pump is used to slowly press the slurry into the mold through the feed hole at the bottom of the mold until the slurry fills the gaps between the steel wires and the mold, and then it is properly vibrated to eliminate bubbles and perform maintenance.

[0047] Example 3

[0048] The steel wire concrete (ceramsite wire) of this example is composed of the following volume ratios: the steel wire component with an equivalent diameter of 0.60 mm accounts for 0.25%, and the base material (ceramsite concrete) component accounts for 99.75%.

[0049] The base material is composed of the following raw materials by weight: 42.5 silicate cement (580), sand (560), maximum particle size 3.5mm, density 700Kg / m 3 ceramsite (450), fly ash (80), mineral powder (60), polycarboxylic acid high-efficiency water reducing agent (4), silane redispersible latex powder (0.5), water (170). Steel wire is evenly distributed in ceramsite concrete.

[0050] First, cement, admixtures, additives, water, ceramsite (ceramsite sand) and sand are batched, measured and stirred to form a high-fluidity ceramsite concrete mixture. The mixture and steel wire material are laid in layers in the mold, with each layer thickness not exceeding 40 mm. At the same time, appropriate vibration is applied until the mixture fills the gaps in the steel wire and the mold, and then curing is carried out. The dry density is not more than 1950Kg / m 3 Lightweight steel wire concrete.

[0051] Example 4

[0052] The steel wire concrete (beaded wire) in this example is composed of the following volume ratios: the steel wire component with a diameter of 0.45 mm accounts for 0.20%, and the base material (light beaded concrete) component accounts for 99.80%.

[0053] The base material is composed of the following raw materials by weight: 42.5 silicate cement (480), sand (880) with a particle size not greater than 2.5 mm, and a density of 5 kg / m 3 EPS light beads (3), fly ash (80), mineral powder (40), polycarboxylic acid high-efficiency water reducing agent (4), water (170), and steel wire are evenly distributed in the light bead concrete.

[0054] First, cement, admixtures, additives, water, light beads and sand are mixed under batching, metering and closed conditions to form a high-fluidity light bead concrete mixture. The mixture and steel wire are laid in layers in the mold, with each layer being about 30 mm thick, and appropriate vibration is used until the slurry fills the gaps between the steel wires and the mold, and then curing is carried out. The dry density is not more than 1650Kg / m 3 Lightweight steel wire concrete.

[0055] Example 5

[0056] The steel wire concrete (high-strength sand wire) in this example is composed of the following volume ratios: the steel wire component with an equivalent diameter of 0.6 mm accounts for 0.60%, and the base material (high-performance mortar) component accounts for 99.40%.

[0057] The base material is composed of the following raw materials in parts by weight: 52.5 parts of silicate cement (790 parts), quartz sand with a particle size not greater than 2.5 mm (1200 parts), silica fume (60 parts), mineral powder (60 parts), ceramic polishing slag powder (60 parts), polycarboxylic acid high-efficiency water reducing agent (6 parts), and water (172 parts). The steel wire is evenly distributed in the concrete. The preparation process of the steel wire concrete is as follows:

[0058] The steel wire is evenly laid in the mold with a feed hole at the bottom. First, cement, ultrafine powder, admixture and water are batched, measured and stirred, and then fully dispersed and evenly mixed by a colloid mill, and then mixed with fine aggregate quartz sand by a mixer to form a high-fluidity mixture. A mortar pump is used to slowly press the slurry into the mold through the feed hole at the bottom of the mold until the slurry fills the gaps between the steel wires and the mold, and then vibrates appropriately to eliminate bubbles and perform maintenance.

[0059] The density of the part prepared by the present invention is 2118~2176Kg / m 3 , the mechanical properties test results of steel wire concrete with a steel content of 0.2-0.45% are in the following ranges:

[0060] (1) 400×100×100mm specimen, flexural strength is 5.1~6MPa, flexural failure load is 17~20KN, axial tensile strength is 5.1~6.7MPa;

[0061] (2) For 100 mm cubic specimens, the compressive strength is between 35 and 41 MPa, and the splitting tensile strength is between 6.0 and 7.9 MPa.

[0062] At the same time, the present invention also detects the destructive crack conditions of steel wire concrete flexural test specimens with a size of 400mm×100mm×100mm (length×width×height): as the steel content increases, the cracks decrease. When the steel content is equal to 0%, the specimen breaks brittlely under the destructive load; when the steel content is 0.25%, the flexural concrete specimen does not break brittlely under the destructive load, the maximum crack width is 1.5mm, and the crack height is 60% of the specimen height; when the steel content is 0.45%, the maximum crack width of the flexural concrete specimen under the destructive load is 0.01mm, and the crack height is about 20% of the specimen height, which is difficult to distinguish with the naked eye.

[0063] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present invention, rather than to limit the scope of protection of the present invention. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solution of the present invention can be modified or replaced by equivalents without departing from the essence and scope of the technical solution of the present invention.

Claims

1. A steel wire concrete, characterized in that: The base material of the steel wire concrete is a fine aggregate concrete composed of silicate cement, sand, fly ash and mineral powder, with steel wire material as a reinforcing and modifying material, eliminating the mixing process of the steel wire material and the base material, and is prepared by paving the steel wire material and grouting or grouting the high-fluidity base material; The steel wire material is a felt-shaped, mesh-shaped or cloud-shaped steel wire material made of steel wire; the base material components include, by mass: 380-880 parts of cement, 200-1400 parts of sand, 0-520 parts of light aggregate, 60-1300 parts of admixture, 1-6 parts of admixture, and 170-220 parts of water; the steel wire concrete is composed of the following raw materials in volume parts: 0.25%-1.20% of modified component steel wire material; 99.75%-98.80% of base material component; the steel wire used in the modified component steel wire material is non-linear, with a diameter or equivalent diameter of 0.3-0.9 mm and a length greater than 500 mm.

2. The steel wire concrete according to claim 1, characterized in that: The shape of the steel wire material depends on the molding requirements and steel content of the concrete; the layer thickness is selected in the range of 20 to 100 mm, the voids between the wires are not less than 5 mm, and the distribution is controlled to be uniform.

3. The steel wire concrete according to claim 1, characterized in that: The slump of the base material component is not less than 180 mm, the compressive strength is not less than 20 MPa, and the expansion of the pumped concrete is not less than 450 mm.

4. The steel wire concrete according to claim 1, characterized in that: The light aggregate includes at least one of ceramsite, ceramic sand and EPS light beads; the particle size of the light aggregate is not greater than 5mm; the density of the ceramsite is 900kg / m 3 The cylinder pressure strength is above 3.5MPa, and the density of EPS light beads is 3-7kg / m 3 The admixture includes at least one of mineral powder, silica ash, fly ash, ceramic polishing slag powder and composite stone powder; the admixture is at least one of polycarboxylic acid high-efficiency water reducing agent and silane redispersible latex powder.

5. A process for preparing a steel wire concrete according to any one of claims 1 to 4, characterized in that: The following steps are involved: Step 1: Under closed conditions, add sand and light aggregate first, then cement, admixture, additive and water according to the measured ingredients, and stir them evenly; or first grind and disperse part of the cement, ultrafine powder admixture, additive and water into slurry, and then add sand, light aggregate and the remaining materials with a mixer and stir them evenly; Step 2, laying and pouring the modified component steel wire material and the base material component, with the steel wire material being laid in no more than two layers each time; Step 3: After the steel wires are laid in layers and the base material is poured, a vibrator is used to compact the steel wires.

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