A method for grouting vertical joints of prefabricated components

Abstract

The present invention discloses a method for grouting vertical joints of prefabricated components, comprising the following steps: S1, hoisting prefabricated components to form a prefabricated assembled wind turbine foundation, providing rubber strips along the contours of adjacent surfaces between each prefabricated component, and opening grouting openings at the top to form vertical joint cavities; S2, performing a water filling test on the vertical joint cavities to check the sealing of the rubber strips and ensure that the vertical joint cavities are watertight; S3, preparing, transporting, and storing slurry; S4, performing four rounds of grouting on all vertical joint cavities, with the grouting volume in each round of grouting in a single vertical joint cavity being 1 / 4 of the total grouting volume of the single vertical joint cavity, and the same amount of slurry being grouted in all vertical joint cavities in each round of grouting; S5, immediately performing surface maintenance after the grouting operation is completed. The present invention adopts a segmented cyclic grouting method, and during the grouting process, the grouting pressure of each vertical joint is balanced, thereby preventing lateral movement of the component.

Description

Technical Field

[0001] The present invention relates to the technical field of onshore wind power foundations, and in particular to a method for grouting vertical joints of prefabricated components. Background Art

[0002] With the continuous advancement of wind power technology, the capacity of individual wind turbines is increasing, and the foundations required are also becoming larger and more expensive. Traditional wind turbine foundations are large reinforced concrete structures, requiring large amounts of concrete and steel, resulting in low material efficiency. Traditional wind turbine foundations are cast-in-place, resulting in long construction times and challenging quality control. Prefabricated foundations, on the other hand, can save material and shorten construction times, and are expected to be widely adopted in the future.

[0003] Prefabricated foundations are assembled from several prefabricated components, with the joints filled with grout. Ensuring dense grouting is crucial for prefabricated foundations. However, due to the large vertical joints, the traditional grouting method involves fully grouting each vertical joint before proceeding to the next. However, this grouting process exerts significant lateral pressure on the components. Filling each vertical joint at once can lead to lateral shifting of the components, compromising accuracy.

[0004] Therefore, the applicant believes that it is necessary to propose a vertical joint grouting method that can avoid lateral displacement of components. Summary of the Invention

[0005] The present invention aims to solve one of the technical problems in the related art at least to a certain extent.

[0006] To achieve the above object, the present invention proposes a method for grouting vertical joints of prefabricated components, comprising the following steps:

[0007] S1. Prefabricated components are hoisted to form a prefabricated assembled wind turbine foundation. Rubber strips are set along the contours of adjacent surfaces between each prefabricated component, and grouting openings are opened at the top to form vertical joint cavities.

[0008] S2. Perform a water filling test on the vertical seam cavity to check the sealing of the rubber strip to ensure that the vertical seam cavity is leak-proof;

[0009] S3, slurry preparation, transportation and storage;

[0010] S4. Perform four rounds of grouting on all vertical joint cavities. The grouting volume in each round of grouting in a single vertical joint cavity is 1 / 4 of the total grouting volume of the single vertical joint cavity. In each round of grouting, the same amount of grouting material is used in all vertical joint cavities.

[0011] S5. Carry out surface maintenance work immediately after the grouting operation is completed.

[0012] The present invention adopts a segmented cyclic grouting method. During the grouting process, the grouting pressures of the vertical joints are balanced with each other, which can prevent the components from shifting sideways.

[0013] Optionally, in S3, the cement content in the grouting material is not less than 30%, the quartz content is not higher than 60%, the amorphous silicon content should be less than 15%, the amorphous calcium aluminum silicate content should be less than 20%, and the alumina content should be less than 20%.

[0014] Furthermore, when preparing the slurry, drinking purified water should be used for stirring the high-strength grouting material, and the amount of water added should be weighed using a precision electronic meter, and the accuracy of the electronic meter should be at least accurate to grams.

[0015] Furthermore, the amount of water added per ton of high-strength grouting material dry powder does not exceed 130 kg.

[0016] Furthermore, the compressive strength of the slurry is not less than 80 MPa.

[0017] Furthermore, the slurry material is stirred by mechanical stirring, and the minimum speed of the mixer is not less than 30 rpm. When mixing, first add 2 / 3 of the total water volume and mix for 3 minutes, then add the remaining 1 / 3 of the water volume and mix until the consistency is uniform. The stirred grouting material needs to be left to stand for 2 to 3 minutes before use to discharge the bubbles in the grouting material slurry. The total stirring time is generally not less than 6 minutes.

[0018] Furthermore, the S4 specifically includes the following steps:

[0019] S41. Arrange a grouting conduit and extend it into the vertical joint cavity. Place the bottom of the conduit at the bottom of the portion to be grouted in the vertical joint cavity. Install a funnel at the top of the conduit to facilitate grouting.

[0020] S42. After the grouting conduit is arranged, a pumping machine is used to deliver the slurry to the top of the prefabricated component through the pumping pipe. The slurry enters the grouting conduit from the funnel to perform the grouting operation.

[0021] S43, after completing the grouting operation of 1 / 4 of the total grouting volume in a single vertical joint cavity, sequentially move the pumping pipe in a clockwise or counterclockwise direction to the next adjacent vertical joint cavity to perform the grouting operation of 1 / 4 of the total grouting volume of the current vertical joint cavity, until the grouting operation of 1 / 4 of the total grouting volume in all vertical joint cavities is completed;

[0022] S44: According to step S43, the grouting operation is repeated for three rounds until all vertical joint cavities are completely grouted.

[0023] Furthermore, the highest point of the pumping pipeline is 500 mm higher than the height of the upper opening of the vertical slot cavity and is directly above the funnel.

[0024] Furthermore, in said S5, after the grouting is completed, the exposed part should be promptly sprayed with curing liquid or covered with plastic film to keep condensed water in the plastic film, and covered with a wet quilt or wet straw bag to prevent the water on the surface of the grouting layer from evaporating too quickly, reduce the temperature difference between the center of the grouting layer and the surface of the grouting layer, and control the temperature difference within 25°C.

[0025] Furthermore, 2 to 6 hours after the grouting operation is completed, the surface of the grouting layer is smoothed with a trowel to reduce the risk of temperature cracks and early shrinkage cracks.

[0026] Additional aspects and advantages of the present invention will be set forth in part in the description which follows and, in part, will be obvious from the description which follows, or may be learned through practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the following description of the embodiments in conjunction with the accompanying drawings, in which:

[0028] Figure 1 1. It is a schematic diagram of the steps of a vertical joint grouting method of a prefabricated component according to the present invention;

[0029] Figure 2 3. This is a schematic diagram of a specific step S4 of a method for grouting vertical joints of a prefabricated component according to the present invention;

[0030] Figure 3 2. It is a schematic structural diagram of a vertical joint cavity formed by a prefabricated component according to a method for grouting vertical joints of a prefabricated component of the present invention;

[0031] Figure 4 yes Figure 3 The cross-sectional structure diagram of the AA section is intended to show the structure of the vertical slit cavity;

[0032] Figure 5 The present invention is a schematic diagram of a slurry pumping process of a vertical joint grouting method for prefabricated components. DETAILED DESCRIPTION

[0033] The following describes embodiments of the present invention in detail, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, and are not to be construed as limiting the present invention.

[0034] The present invention provides a method for grouting vertical joints of prefabricated components. Figures 1 to 5 Elaborate in detail.

[0035] A method for grouting vertical joints of prefabricated components comprises the following steps:

[0036] S1. Prefabricated components are hoisted to form a prefabricated assembled wind turbine foundation. Rubber strips are set along the contours of adjacent surfaces between each prefabricated component, and grouting openings are opened at the top to form vertical joint cavities.

[0037] S2. Perform a water filling test on the vertical seam cavity to check the sealing of the rubber strip to ensure that the vertical seam cavity is leak-proof;

[0038] S3, slurry preparation, transportation and storage;

[0039] S4. Perform four rounds of grouting on all vertical joint cavities. The grouting volume in each round of grouting in a single vertical joint cavity is 1 / 4 of the total grouting volume of the single vertical joint cavity. In each round of grouting, the same amount of grouting material is used in all vertical joint cavities.

[0040] S5. Carry out surface maintenance work immediately after the grouting operation is completed.

[0041] Due to the large height of the vertical joints, the grouting will exert a large lateral pressure on the component during grouting. If each vertical joint is filled at once, it will cause the component to shift laterally, affecting the accuracy. Therefore, the present invention adopts a segmented cyclic grouting method. During the grouting process, the grouting pressure of each vertical joint is balanced, which can prevent the component from shifting laterally.

[0042] In S1, the prefabricated and assembled foundation consists of a total of 16 prefabricated components. A certain gap is formed between adjacent prefabricated components. At the same time, this gap is formed by the inner rubber strip, outer rubber strip and bottom rubber strip set at the adjacent surfaces of the prefabricated components near the contour position to form a vertical seam cavity with an upper opening.

[0043] In S2, after all 16 prefabricated components are hoisted into place and the inner rubber strip, outer rubber strip and bottom rubber strip are installed, a water filling test is performed on the vertical seam cavity to ensure that the vertical seam cavity is leak-proof.

[0044] In S3, the cement content of the grouting material must be no less than 30%, the quartz content no more than 60%, the amorphous silicon content less than 15%, the amorphous calcium aluminum silicate content less than 20%, and the alumina content less than 20%. Furthermore, when preparing the slurry, use purified drinking water for mixing the high-strength grouting material. The amount of water added should be measured using a precision electronic meter with an accuracy of at least gram. The amount of water added per ton of dry high-strength grouting material powder should not exceed 130kg. The compressive strength of the slurry should be no less than 80MPa.

[0045] When stirring the slurry, mechanical stirring should be used. In this embodiment, a stirrer is used for stirring, and the minimum speed of the stirrer is not less than 30 rpm. When stirring, first add 2 / 3 of the total water volume and stir for 3 minutes, then add the remaining 1 / 3 of water and stir until the consistency is uniform. The stirred grouting material needs to be left to stand for 2 to 3 minutes before use to discharge the bubbles in the grouting material slurry. The total stirring time is generally not less than 6 minutes.

[0046] After mixing, transport the grouting material to the construction site. Once transported to the construction site, the grouting material should be stacked on moisture-proof mats and covered with waterproof membrane to prevent rainwater intrusion. In summer, when temperatures are high (greater than 35°C), avoid direct sunlight and store the material in a cool, well-ventilated location. In winter, when temperatures are low (less than 5°C), keep the material warm.

[0047] In S4, the specific method of the grouting operation includes the following steps:

[0048] S41. Arrange a grouting conduit and extend it into the vertical joint cavity. Place the bottom of the conduit at the bottom of the portion to be grouted in the vertical joint cavity. Install a funnel at the top of the conduit to facilitate grouting.

[0049] S42. After the grouting conduit is arranged, a pumping machine is used to deliver the slurry to the top of the prefabricated component through the pumping pipe. The slurry enters the grouting conduit from the funnel to perform the grouting operation.

[0050] S43, after completing the grouting operation of 1 / 4 of the total grouting volume in a single vertical joint cavity, sequentially move the pumping pipe in a clockwise or counterclockwise direction to the next adjacent vertical joint cavity to perform the grouting operation of 1 / 4 of the total grouting volume of the current vertical joint cavity, until the grouting operation of 1 / 4 of the total grouting volume in all vertical joint cavities is completed;

[0051] S44: According to step S43, the grouting operation is repeated for three rounds until all vertical joint cavities are completely grouted.

[0052] In this embodiment, the self-weight grouting method is adopted, and the slurry is pumped to a certain height through the pumping pipe by using a grouting machine, a pumping machine external to the grouting machine, and a pumping pipe, and then the slurry is allowed to fall into the vertical seam cavity. The height of the highest point of the pumping pipe is 500mm higher than the height of the upper opening of the vertical seam cavity, and is directly above the funnel. A bracket for fixing the pumping pipe is provided on the prefabricated component, so that the pumping pipe can maintain a predetermined height.

[0053] After grouting is completed, in S5, the exposed areas should be promptly sprayed with curing fluid or covered with plastic film to maintain condensation within the film. A wet blanket or wet straw bag should be added to prevent rapid evaporation of moisture from the surface of the grouting layer. The temperature difference between the center and surface of the grouting layer should be reduced to within 25°C. Furthermore, 2 to 6 hours after grouting, the surface of the grouting layer should be smoothed with a spatula to reduce the risk of temperature cracks and early shrinkage cracks.

[0054] In the description of this specification, the reference terms "one embodiment," "some embodiments," "example," "specific example," or "some examples" mean that the specific features, structures, materials, or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described can be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art can combine and combine different embodiments or examples described in this specification and features of different embodiments or examples without contradiction.

[0055] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of the technical features being referred to. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature. In the description of the present invention, "plurality" means at least two, such as two, three, etc., unless otherwise specifically defined.

[0056] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to the embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the claims and their equivalents.

Claims

1. A method for grouting vertical joints of prefabricated components, characterized in that: The following steps are involved: S1. Prefabricated components are hoisted to form a prefabricated assembled wind turbine foundation. Rubber strips are set along the contours of adjacent surfaces between each prefabricated component, and grouting openings are opened at the top to form vertical joint cavities. S2. Perform a water filling test on the vertical seam cavity to check the sealing of the rubber strip to ensure that the vertical seam cavity is leak-proof; S3, slurry preparation, transportation and storage; In said S3, the cement content in the grouting material is not less than 30%, the quartz content is not higher than 60%, the amorphous silicon content should be less than 15%, the amorphous calcium aluminum silicate content should be less than 20%, and the alumina content should be less than 20%; S4. Perform four rounds of grouting on all vertical joint cavities. The grouting volume in each round of grouting in a single vertical joint cavity is 1 / 4 of the total grouting volume of the single vertical joint cavity. In each round of grouting, the same amount of grouting material is used in all vertical joint cavities. Described S4 specifically comprises the following steps: S41. Arrange a grouting conduit and extend it into the vertical joint cavity. Place the bottom of the conduit at the bottom of the portion to be grouted in the vertical joint cavity. Install a funnel at the top of the conduit to facilitate grouting. S42. After the grouting conduit is arranged, a pumping machine is used to deliver the slurry to the top of the prefabricated component through the pumping pipe. The slurry enters the grouting conduit from the funnel to perform the grouting operation. The highest point of the pumping pipe is 500mm higher than the upper opening of the vertical slot cavity and is directly above the funnel; S43, after completing the grouting operation of 1 / 4 of the total grouting volume in a single vertical joint cavity, sequentially move the pumping pipe in a clockwise or counterclockwise direction to the next adjacent vertical joint cavity to perform the grouting operation of 1 / 4 of the total grouting volume of the current vertical joint cavity, until the grouting operation of 1 / 4 of the total grouting volume in all vertical joint cavities is completed; S44, according to step S43, repeat the grouting operation for three rounds again until all vertical joint cavities are completely grouted; S5. Carry out surface maintenance work immediately after the grouting operation is completed.

2. A method for grouting vertical joints of prefabricated components according to claim 1, characterized in that: When preparing the slurry, drinking purified water should be used for mixing high-strength grouting materials, and the amount of water added should be weighed using a precision electronic meter, and the accuracy of the electronic meter should be at least accurate to grams.

3. A method for grouting vertical joints of prefabricated components according to claim 2, characterized in that: The amount of water added per ton of high-strength grouting material dry powder shall not exceed 130kg.

4. A method for grouting vertical joints of prefabricated components according to any one of claims 1 to 3, characterized in that: The compressive strength of the slurry shall not be less than 80MPa.

5. A method for grouting vertical joints of prefabricated components according to any one of claims 1 to 3, characterized in that: The grouting material is mixed using mechanical stirring, and the minimum speed of the mixer is not less than 30 rpm. When mixing, first add 2 / 3 of the total water volume and mix for 3 minutes, then add the remaining 1 / 3 of water and mix until the consistency is uniform. The mixed grouting material needs to be left to stand for 2 to 3 minutes before use to expel the bubbles in the grouting material slurry. The total stirring time is generally not less than 6 minutes.

6. A method for grouting vertical joints of prefabricated components according to claim 1, characterized in that: In said S5, after the grouting is completed, the exposed part should be promptly sprayed with curing liquid or covered with plastic film to keep condensed water in the plastic film, and covered with a wet quilt or wet straw bag to prevent the water on the surface of the grouting layer from evaporating too quickly, reduce the temperature difference between the center of the grouting layer and the surface of the grouting layer, and control the temperature difference within 25°C.

7. A method for grouting vertical joints of prefabricated components according to claim 6, characterized in that: 2 to 6 hours after completing the grouting operation, use a spatula to smooth the surface of the grouting layer to reduce the risk of temperature cracks and early shrinkage cracks.

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