A 3D printed concrete reinforcement template and reinforcement method

Abstract

This invention discloses a 3D-printed concrete reinforcement template and reinforcement method. The template unit of the reinforcement template is a 3D-printed ultra-high performance concrete unit. Adjacent template units are assembled through a seamlessly fitting combination structure. Fastening holes are provided through the corresponding parts of the combination structure of the two template units. Fastening structural components are connected to the fastening holes to secure the two template units and seal the fastening holes to prevent concrete leakage during subsequent pouring of the ultra-high performance concrete bonding reinforcement layer. The template reinforcement method involves inserting reinforcing bars into the surface of the structure to be reinforced and erecting a reinforcing mesh. Template units are then spliced ​​at the parts of the structure to be reinforced to form a reinforcement template. A cavity layer is left between the reinforcement template and the part of the structure to be reinforced. Ultra-high performance concrete is poured into the cavity layer to form a bonding reinforcement layer. The method features excellent durability, simple and quick construction, high reinforcement strength, high environmental adaptability, and adaptability to various irregularly shaped structural components.

Description

Technical Field

[0001] This invention belongs to the field of concrete building technology, and particularly relates to a concrete reinforcement formwork and reinforcement method. Background Technology

[0002] Over time, many engineering structures in my country have developed cracks, defects, or insufficient load-bearing capacity, especially those located in areas prone to corrosion or erosion. Meanwhile, my country's construction industry is undergoing a transformation from traditional construction to industrialized construction, with increasingly advanced technologies being introduced. Among these, 3D printing technology has made zero-wood and zero-steel-formwork construction possible.

[0003] Commonly used formwork for concrete includes plywood formwork for timber beams, 50mm thick wooden boards, all-steel decorative formwork, cast aluminum decorative formwork, and plywood decorative formwork. However, the diverse forms of engineering reinforcement structures and the high difficulty of formwork erection lead to resource waste during the formwork erection and dismantling process. Traditional engineering structure reinforcement methods often employ external concrete encasing, external prestressing reinforcement, carbon fiber bonding reinforcement, steel bonding reinforcement, and reinforced mesh composite mortar reinforcement. However, all of these methods have drawbacks in engineering practice: for example, encasing the structure in ordinary concrete can affect its appearance and clearance; external prestressed reinforcement, i.e., steel reinforcement, involves complex stress distribution in the joint areas, making structural treatment quite difficult, and its corrosion resistance is poor; carbon fiber reinforced components have poor fire resistance; steel bonding reinforcement is only suitable for components subjected to static loads and in normal humidity environments; the reinforcement method using steel mesh composite mortar has limitations in increasing the load-bearing capacity of components; and the prestressed reinforcement method requires high-level construction technology and large-scale construction equipment, thus having limitations and is not suitable for reinforcing concrete structures in high humidity environments or concrete structures with large shrinkage and creep.

[0004] Even if the existing reinforcement methods meet the requirements of engineering practice, different reinforcement methods have unsatisfactory defects in terms of reinforcement cost, construction efficiency, construction difficulty, reinforcement strength or durability. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention aims to provide a 3D-printed concrete reinforcement template and reinforcement method that combines excellent durability, simple and quick construction, high reinforcement strength, high environmental adaptability, and adaptability to various irregular structural components.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] The 3D-printed concrete reinforcement formwork comprises several formwork units, each a 3D-printed ultra-high performance concrete unit. The ultra-high performance concrete has a strength of no less than 100 MPa, a rheological range of 150 mm to 200 mm, an initial setting time of no less than 20 minutes, and a final setting time of no more than 150 minutes. Adjacent formwork units are assembled using a seamlessly fitting combination structure. Corresponding parts of the combination structure of the two formwork units are provided with through-hole fastening holes. Fastening structural components connect to these holes, securely linking the two formwork units and sealing the holes to prevent concrete leakage during subsequent pouring of the ultra-high performance concrete bonding reinforcement layer.

[0008] As an optional solution, the fastening hole is a screw hole, the fastening structure is a bolt assembly, and the bolt assembly contains a washer that covers the screw hole, which can prevent concrete leakage.

[0009] As an optional solution, the fastening hole is a threaded hole. The fastening structure includes a sealing bolt connected to the fastening hole and fixing the two template units in series at the combined structure, and a plugging bolt connected to the sealing bolt. The sealing bolt has an externally threaded rod connected to the fastening hole. The sealing bolt has an injection cavity extending from its bolt head end to the free end of the externally threaded rod. The injection cavity does not penetrate the free end of the externally threaded rod, making the free end of the externally threaded rod a closed end. The outer wall of the externally threaded rod is provided with longitudinally extending guide grooves that lead to the injection cavity. After the externally threaded rod is threadedly connected to the fastening hole, thermoplastic polyurethane rubber is injected into the injection cavity through the injection port. The thermoplastic polyurethane rubber fills the injection cavity and overflows through the guide grooves to fill the threaded hole section corresponding to the guide grooves. The plugging bolt is connected to the injection port to seal. This method provides better structural strength for the assembled template units and better sealing for leak-proof grouting of the fastening hole.

[0010] 3D-printed concrete formwork reinforcement methods include:

[0011] Template units are 3D printed and their surfaces are coated and cured. The template units adopt the above-mentioned form.

[0012] The adjacent surfaces of the structure to be reinforced and the template unit are roughened and cleaned.

[0013] Reinforcing bars are inserted into the surface of the structure to be reinforced, and a reinforcing mesh is erected.

[0014] The template units are spliced ​​together at the part of the structure to be reinforced to form a reinforcing template, and a cavity layer is left between the reinforcing template and the part of the structure to be reinforced.

[0015] Ultra-high performance concrete is poured into the cavity layer to reinforce and bond the structure to be reinforced and the reinforcement template, and then fully vibrated to form a bonded reinforcement layer.

[0016] The present invention has the following beneficial effects:

[0017] This invention relates to a 3D-printed concrete reinforcement template and reinforcement method. Each template unit of the reinforcement template is 3D printed with ultra-high performance concrete, which has excellent durability, high environmental adaptability, simple and quick construction, and high strength. It can also print various irregularly shaped concrete structures, and the connection is simple and quick while the connection structure has high strength. The 3D-printed concrete template reinforcement method forms a bonding reinforcement layer with the advantages of high reinforcement strength, excellent durability, and simple and quick construction. Attached Figure Description

[0018] Figure 1 This is a top view of the template unit connection of the 3D printed concrete reinforcement template of the present invention;

[0019] Figure 2 This is a front view of the template unit connection of the 3D printed concrete reinforcement template of the present invention;

[0020] Figure 3 This is a simplified schematic diagram of the 3D-printed concrete formwork reinforcement method of the present invention;

[0021] Figure 4 This is a schematic diagram of another embodiment of the template unit connection of the 3D printed concrete reinforcement template of the present invention;

[0022] Figure 5 for Figure 4 Schematic diagram of the fastening structure in the embodiment;

[0023] Figure 6 This is a schematic diagram of another embodiment of the template unit connection of the 3D printed concrete reinforcement template of the present invention;

[0024] Figure 7 for Figure 6 A schematic diagram of an optimized embodiment of the example scheme. Detailed Implementation

[0025] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, so as to better understand the technical concept claimed by the present invention.

[0026] like Figure 1-2The 3D-printed concrete reinforcement template shown includes several template units 1. Template unit 1 is a 3D-printed ultra-high performance concrete unit. The ultra-high performance concrete has a strength of not less than 100MPa, a rheological range of 150mm-200mm, an initial setting time of not less than 20min, and a final setting time of not more than 150min to ensure the structural strength requirements and the speed of printing. Template unit 1 has very good compactness and durability, which can significantly improve the corrosion resistance of concrete structures. It has excellent durability, high environmental adaptability, simple and quick construction, high strength, and can realize the printing of various irregular-shaped concrete structures.

[0027] Adjacent template units 1 are assembled by a seamlessly fitting combination structure 2. Each template unit 1 has a through-hole 3 corresponding to a portion of the combination structure 2. A fastening component 4 connects to the fastening holes 3, securely connecting the two template units 1 and sealing the fastening holes 3 to prevent concrete leakage during subsequent pouring of the ultra-high performance concrete bonding reinforcement layer. The connection is simple, quick, and the structure boasts high strength. In this embodiment, the combination structure 2 uses a seamless fit of protrusions and grooves. Other fitting methods can also be used to achieve quick assembly into a complete template. The fastening holes 3 are preferably screw holes, and the fastening component 4 is preferably a bolt assembly. The bolt assembly also includes a washer 40 covering the screw hole, which helps prevent concrete leakage. In this embodiment, the bolt assembly is easier to obtain and the connection is simple and effective.

[0028] like Figure 3 As shown, the 3D-printed concrete formwork reinforcement method includes the following steps:

[0029] Based on the information of the structure to be reinforced, determine the size, shape, and quantity parameters of template unit 1;

[0030] Select the ultra-high performance concrete mix proportion based on the requirements of the engineering project and the pumpability and extrudability required for 3D printing;

[0031] Prepare concrete materials;

[0032] 3D printing of template unit 1 is performed based on the determined shape of template unit 1;

[0033] Each template unit 1 surface shall be covered with a film and cured for no less than 7 days;

[0034] Roughen and clean the adjacent surfaces of the structure to be reinforced 5 and template unit 1.

[0035] Reinforcing bars are inserted into the surface of the structure to be reinforced 5 and a reinforcing mesh 6 is erected;

[0036] According to the five parts of the structure to be reinforced. Figure 1-2The template unit 1 is spliced ​​in the manner shown to form a reinforced template 10, and a cavity layer 7 is left between the reinforced template 10 and the part of the structure 5 to be reinforced.

[0037] Ultra-high performance concrete is poured into the cavity layer 7 to reinforce and bond the structure to be reinforced 5 and the reinforcement template 10, and fully vibrated to form a bonded reinforcement layer 8. The bonded reinforcement layer 8 is embedded with steel mesh 6, which has the advantages of high reinforcement strength, excellent durability, and simple and quick construction.

[0038] A curing agent is applied to the surface of the bonded reinforcement layer 8 formed by pouring for curing.

[0039] like Figure 4 and Figure 5 As shown, the fastening structure 4 can also take this form, with the fastening hole 3 still taking the form of a screw hole. The fastening structure 4 includes a sealing bolt 41 connected to the fastening hole 3 and fixing the two template units 1 in series at the part of the combined structure 2, and a plugging bolt 42 connected to the sealing bolt 41. The sealing bolt 41 has an externally threaded rod 43 connected to the fastening hole 3, i.e., the screw hole. The sealing bolt 41 extends from its bolt head end to the free end of the externally threaded rod 43 and is provided with a filling cavity 44. The filling cavity 44 does not penetrate the free end of the externally threaded rod 43, so that the free end of the externally threaded rod 43 forms a closed end. The outer wall of the externally threaded rod 43 is provided with longitudinally extending guide grooves 45, which lead to the filling cavity 44. The inner wall of the filling port 47 of the filling cavity 44 is provided with internal threads. After the sealing bolt 41 is threaded into the fastening hole 3 via the external threaded rod 43, thermoplastic polyurethane rubber 46 is injected into the injection cavity 44 through the injection port 47. The thermoplastic polyurethane rubber 46 overflows through the guide groove 45 during injection into the injection cavity 44, filling the threaded hole section corresponding to the guide groove 45. After the thermoplastic polyurethane rubber 46 fills to the vicinity of the injection port 47, the sealing bolt 42 is connected to the injection port 47 to seal it. This thermoplastic polyurethane rubber 46 has high strength, excellent wear resistance, chemical resistance, hydrolysis resistance, and high and low temperature resistance. After curing, it can strengthen the connection strength between the external threaded rod 43 and the fastening hole 3, and simultaneously seal the fastening hole 3 from the inside, preventing concrete grout leakage. It provides better structural strength for the assembled template unit 1 and better sealing of the fastening hole 3 to prevent leakage.

[0040] like Figure 6As shown, the sealing bolt 41 can also be configured with a coarse threaded rod 411 near the bolt head and a fine threaded rod 412 on the bolt body. A threaded hole 31, which mates with the coarse threaded rod 411, is provided at the outer end of the fastening hole 3 on one side of the grooved template unit 1. The sealing bolt 41 is installed in the fastening holes 3 of the two template units 1 through the connection and mating of the coarse threaded rod 411 and the threaded hole 31. Thermoplastic polyurethane rubber is injected into the fastening hole 3 on the other side of the grooved template unit 1, and the two template units 1 are connected by locking the connection to the fine threaded rod 412 with a nut 413, achieving the same effect. Furthermore, it can also be configured as follows... Figure 7 As shown, when the combined structure 2 is assembled, a filling gap 32 is formed between the side walls of the protrusion and the groove. Corresponding grooves 33 are set on the side walls of the protrusion and the groove. A steel mesh is implanted in the groove 33. Thermoplastic polyurethane rubber is injected into the fastening hole 3, which flows into and fills the filling gap 32 and is embedded with the steel mesh in the groove 33. This can further enhance the structural strength of the connection between the two template units 1.

[0041] For those skilled in the art, various other corresponding changes and modifications can be made based on the technical solutions and concepts described above, and all such changes and modifications should fall within the protection scope of the claims of this invention.

Claims

1. A 3D-printed concrete reinforcement formwork, comprising several formwork units, characterized in that, The template unit is a 3D-printed ultra-high performance concrete unit. The ultra-high performance concrete has a strength of not less than 100MPa, a rheological range of 150mm-200mm, an initial setting time of not less than 20min, and a final setting time of not more than 150min. The two adjacent template units are assembled by a seamlessly fitting combination structure, and the two template units are respectively provided with fastening holes through the parts of the combination structure. The fastening structure is connected to the fastening holes to fasten the two template units and seal the fastening holes. The fastening structure includes a sealing bolt connected to the fastening hole and fixing the two template units in series at the combined structure. The combined structure adopts a seamless fit of protrusions and grooves. The sealing bolt has a coarse thread near the bolt head and a fine thread on the bolt body. A threaded hole that mates with the coarse thread is provided at the outer end of the fastening hole on one side of the template unit with grooves. The sealing bolt is installed in the fastening holes of the two template units through the connection and mating of the coarse thread and the threaded hole. Thermoplastic polyurethane rubber is injected into the fastening hole on the other side of the template unit with grooves, and the two template units are assembled and connected by locking the nut to the fine thread. A filling gap is formed between the sidewalls of the protrusion and the groove of the combined structure, and thermoplastic polyurethane rubber is injected into the fastening hole to fill the filling gap; The protrusions and grooves of the combined structure are respectively provided with grooves, and steel mesh is implanted in the grooves. The thermoplastic polyurethane rubber is injected into the fastening hole to fill the filling gap and is embedded with the steel mesh in the groove.

2. A method for reinforcing 3D-printed concrete formwork, comprising: The template unit is 3D printed and its surface is coated and cured. The template unit is the template unit described in claim 1. The adjacent surfaces of the structure to be reinforced and the template unit are roughened and cleaned. Reinforcing bars are inserted into the surface of the structure to be reinforced, and a reinforcing mesh is erected. The template units are spliced ​​together at the part of the structure to be reinforced to form a reinforcing template, and a cavity layer is left between the reinforcing template and the part of the structure to be reinforced. Ultra-high performance concrete is poured into the cavity layer to reinforce and bond the structure to be reinforced and the reinforcement template, and then fully vibrated to form a bonded reinforcement layer.

3. The 3D-printed concrete formwork reinforcement method as described in claim 2, characterized in that, Before 3D printing the template unit, the following steps are also included: (1) Determine the size, shape, and quantity parameters of the template unit based on the information of the structure to be reinforced; (2) Select the ultra-high performance concrete mix proportion according to the requirements of the project and the pumpability and extrudability required for 3D printing; (3) Prepare concrete materials according to steps (1) and (2).

4. The 3D-printed concrete formwork reinforcement method as described in claim 2, characterized in that, The template unit surface is cured with a film for no less than 7 days.

5. The 3D-printed concrete formwork reinforcement method as described in claim 2, characterized in that, A curing agent is applied to the surface of the bonded reinforcement layer formed by the casting for curing.

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