A long-life anti-wear repair technology

Abstract

The present invention discloses a long-life anti-abrasion repair technology for hydraulic discharge structures. It adopts strain-strengthened inorganic metal anti-abrasion materials and is combined with two innovative auxiliary materials: hydrophilic low-viscosity polyurethane modified interface glue TG and high thixotropic rheology modifier TV. Through innovative structural design and construction technology, the repaired anti-abrasion surface layer structure has excellent anti-abrasion properties such as high strength and toughness, high crack resistance, high impact resistance and abrasion resistance, and high aging resistance. It can also coordinate deformation with the foundation concrete, eliminate common interface problems such as staggered layers, debonding, and hollowing in traditional repair technologies, and achieve a long service life. The service life of the 3cm thick anti-abrasion surface layer reaches more than 7 years, and no secondary maintenance is required during this period, saving a lot of manpower and material resources that traditional technologies need to invest due to repeated abrasion damage, significantly improving the full life economy of the anti-abrasion structure, and better ensuring the safety of dam operations.

Description

Technical Field

[0001] The invention relates to a long-life anti-abrasion repair technology, belonging to the technical field of anti-abrasion of hydraulic discharge structures. Background Art

[0002] Existing anti-abrasion repair technologies fall into two main categories: one, exemplified by C50 silica fume concrete, enhances concrete strength to improve abrasion resistance; the other, exemplified by epoxy mortar, enhances abrasion resistance by coating the base concrete surface with various organic polymer-based materials, such as epoxy mortar. The advantages of the former are cost-effectiveness, ease of construction, and inherent aging resistance. However, the disadvantages are brittleness, susceptibility to cracking, low tensile strength, and poor impact toughness, resulting in insufficient abrasion and cavitation resistance. The latter offers significant improvements in erosion resistance, but due to the significant difference in linear expansion coefficient (approximately three times) between the organic polymer material and the base concrete, the misaligned deformation under ambient temperature loads (thermal expansion and contraction) can lead to defects such as dislocation, hollowing, and detachment at the interface, shortening its service life. Furthermore, the relatively high cost, demanding construction environment, and complex construction processes are also challenging. Furthermore, when used for surface protection, organic polymer materials exhibit poor aging resistance, hindering their longevity.

[0003] In summary, although the anti-abrasion repair technology for hydraulic discharge structures has made great progress with scientific development, existing technologies still have their limitations. It is necessary to develop a new anti-abrasion repair technology with a long service life, good life-cycle economic efficiency, and convenient construction. Summary of the Invention

[0004] The purpose of this invention is to provide a long-life anti-abrasion repair technology for hydraulic discharge structures, addressing the shortcomings of existing anti-abrasion repair technologies, such as short service life, repeated maintenance requirements, and high operation and maintenance costs. This technology combines the advantages of existing technologies while effectively overcoming their respective shortcomings, achieving a long service life and reducing operation and maintenance costs.

[0005] The technical solution of the present invention is a long-life anti-wear repair technology, which is applied on the flow surface of hydraulic discharge structures according to the coating amount of 2-3m 2 / Kg is coated with a hydrophilic low-viscosity polyurethane modified interface glue TG, and then a strain-strengthened inorganic metal anti-impact and wear material is poured thereon. When the base surface is an inclined surface and the inclination angle is greater than 15°, a high thixotropic rheology modifier TV is added to the strain-strengthened inorganic metal anti-impact and wear material; the strain-strengthened inorganic metal anti-impact and wear material is composed of a high-strength and dense matrix powder USC, a special coated metal fiber and water, and the weight ratio of the three is: 1000:93~95:88~101, and the addition amount of the high thixotropic rheology modifier TV is 0.02%~0.2% of the weight of the high-strength and dense matrix powder USC.

[0006] In the aforementioned long-life anti-impact and wear repair technology, the strain-strengthened inorganic metal anti-impact and wear material is developed and produced by Shanghai Tongyang Chemical Co., Ltd.

[0007] In the aforementioned long-life anti-impact and abrasion repair technology, the hydrophilic low-viscosity polyurethane-modified interface adhesive TG is formed by uniformly mixing component A - hydrophilic low-viscosity polyurethane-modified epoxy resin PUE and component B - aliphatic amine curing agent HD, with the mixing ratio of component A: component B = 2-3:1. The hydrophilic low-viscosity polyurethane-modified epoxy resin PUE is obtained by graft copolymerization of liquid bisphenol A with 5-20% by weight of a polyurethane prepolymer.

[0008] In the aforementioned long-life anti-impact repair technology, the high thixotropic rheology modifier TV is composed of one or more of the following materials in a weight ratio of 1:0-1:0-1: hydroxypropyl methylcellulose ether + fumed silica + intercalated attapulgite.

[0009] In the aforementioned long-life anti-impact repair technology, the casting of strain-strengthened inorganic metal anti-impact materials adopts compartmentalized construction, and the maximum construction area of ​​each compartment is length × width = 30m × 30m. A transverse tooth groove structure is set at the structural joint perpendicular to the water flow direction, and inserted reinforcement is set inside the tooth groove. Then, according to the base surface construction process, the hydrophilic low-viscosity polyurethane modified interface glue TG is applied and the strain-strengthened inorganic metal anti-impact material is cast. When the construction surface is an inclined surface and the inclination angle is greater than 15°, a high thixotropic rheology modifier TV is also added to the strain-strengthened inorganic metal anti-impact material.

[0010] In the aforementioned long-life anti-impact repair technology, the tooth groove excavation width × depth is 15-20cm × 5-20cm, and Φ10 dowel bars are arranged in a plum blossom shape in the groove. The dowel bars are implanted to a depth of 10cm, the top is flush with the base surface, and are arranged at intervals of 20cm. The casting thickness in the tooth groove is the same as the casting thickness of the base surface.

[0011] In the aforementioned long-life anti-impact and wear repair technology, two rows of Φ10 dowel bars are arranged in a plum blossom shape on the base surface of the foundation concrete slab 25 cm behind the tooth groove, with a front-to-back and left-to-right interval of 25 cm. The dowel bars are implanted to a depth of 10 cm and exposed to 2.5 cm from the base surface. During pouring, the pouring is completed at one time within a range of 50 cm between the tooth groove and the two rows of dowel bars arranged at the rear. When the base surface of the construction surface is an inclined surface and the inclination angle is greater than 15°, the dowel bars are fully arranged in a plum blossom shape on the base surface of the foundation concrete slab behind the tooth groove. The dowel bars are made of Φ10 or larger steel bars, with a dowel bar implantation depth of 10d, where d is the diameter of the dowel bar, and a front-to-back and left-to-right interval of 50 cm.

[0012] In the aforementioned long-life anti-impact and wear repair technology, the thickness of the strain-hardened inorganic metal anti-impact and wear material cast on the base surface is at least 3 cm.

[0013] In the aforementioned long-life anti-impact and wear repair technology, the strain-strengthened inorganic metal anti-impact and wear material is stirred by a vertical shaft forced, high-power precision mixer. The gap between the mixer blade and the cylinder wall should be less than 2mm, the motor power of 500L capacity is greater than 7.5KW, and the speed is greater than 60rpm.

[0014] In the aforementioned long-life anti-wear repair technology, the surface is immediately covered with a film for maintenance after pouring is completed.

[0015] Beneficial effects of the present invention: Compared with the existing technology, the repair technology of the present invention has the following advantages:

[0016] 1. The present invention adopts a new type of strain-strengthened inorganic metal anti-impact material, and uses two auxiliary materials, innovative low-viscosity and high-permeability polyurethane modified interface glue TG and high thixotropic rheology modifier TV, in combination with innovative tooth groove structure design and targeted new mixing parameters and construction technology, to achieve a service life of more than 7 years after the anti-impact repair of hydraulic drainage structures (casting thickness 3cm), without the need for further maintenance during this period. Not only is the one-time cost low (saving about half the cost of typical epoxy mortar), but it also greatly saves a lot of manpower and material resources that traditional technology often needs to repeatedly repair, and the full life economy is significant. The long-life anti-impact repair technology of the present invention has outstanding innovation and advancement from materials (main materials, auxiliary materials) to structure, and then to construction parameters and construction technology.

[0017] 2. The strain-hardened inorganic metal anti-impact and wear material used has outstanding material mechanical properties and anti-impact and wear application performance. Its compressive, flexural, tensile strength and tensile strain reach 150MPa, 40MPa, 10MPa and 2000 microstrain (10 -6 ) and above, significantly higher than the existing typical technologies (C50 silica fume concrete and organic polymer-based anti-wear materials represented by epoxy) by several times or even more than ten times. This new material has the characteristics of "high strength and high toughness". It has not only high strength but also good toughness. Therefore, its impact toughness and anti-wear strength performance are very outstanding, reaching 20KJ / m 2 and 200h / (kg / m 2 ), significantly exceeding most existing impact and abrasion resistance technologies by several or even dozens of times. Furthermore, its linear expansion coefficient is identical to that of the base concrete. Therefore, under the influence of thermal expansion and contraction, they can coordinate deformation, avoiding interface defects such as debonding, misalignment, and hollowing, thereby ensuring a long service life.

[0018] 3. The innovative hydrophilic low-viscosity polyurethane modified interface adhesive TG designed by the present invention has significant advantages over existing typical interface adhesives: 1) Superior performance. The hydrophilic low-viscosity polyurethane modified interface adhesive TG has low surface tension, fine particle size, and low viscosity. It has better wetting and penetration properties on the interface of the foundation concrete, can penetrate into the foundation concrete to a certain depth, and play a better anchoring and reinforcement role. Therefore, it can provide higher interface bonding strength, with an increase of 30%-100% or even higher (related to the bonding strength of the surface material itself), which is significantly higher than traditional interface agents / glue. This is because traditional interface agents / glue generally have a large molecular weight, coarse particle size, and high surface energy (high surface tension), so they have poor permeability and are not easy to penetrate into the foundation concrete to play a reinforcing and anchoring role. Moreover, due to the harsh use conditions of some traditional interface agents / glue products (such as the need for a dry base surface for construction), once the actual construction conditions deviate, it will cause negative effects. The bonding strength between the strain-strengthened inorganic metal anti-impact material used in the present invention and C50 plain concrete (without interface glue) is 3.0 MPa. After adopting the hydrophilic low-viscosity polyurethane modified interface glue TG, the interface bonding strength is increased to more than 4.0 MPa, and the increase is more than one-third. 2) Green and environmentally friendly. The hydrophilic low-viscosity polyurethane modified interface glue TG is a hydrophilic solvent-free design, without volatile solvents, non-toxic and pollution-free, and very friendly to the environment. Solvent-based products will volatilize a large amount of toxic organic solvents when applied, which not only harms the health of construction workers, but also pollutes the surrounding environment. 3) Good aging resistance. The hydrophilic low-viscosity polyurethane modified interface glue TG is a polymer modified with polyurethane through advanced graft copolymerization technology, and therefore has better aging resistance than traditional epoxy interface glues, and can significantly improve its service life. 4) Easy to use. Because of its hydrophilic design, it can be used on a wet base surface, overcoming the disadvantage that traditional solvent-based interface agents / glue require a dry base surface for construction, reducing construction difficulty, improving work efficiency, and shortening construction period.

[0019] 4. The innovative high-thixotropic rheology modifier TV designed by the present invention has the following outstanding advantages compared to conventional tackifiers and thickeners: 1) Better construction performance. High-thixotropic rheology modifier TV has extremely high low-shear viscosity, while simultaneously controlling medium-shear and high-shear viscosities to relatively low levels. Therefore, while imparting good thixotropic properties to the casting material, it can also effectively reduce the internal viscosity of the material. In terms of construction performance, it is a new cast surface anti-abrasion material that can stay on the inclined surface without flowing, meeting the requirements of inclined surface construction. It can also be "easily" spread and smoothed without sticking or effort, reducing labor intensity. This effectively overcomes the disadvantages of epoxy materials such as high viscosity (high viscosity) that make it difficult to spread and smooth, and the labor intensity is high. 2) Ease of use. High-thixotropic rheology modifier TV is packaged as a solid powder and can be easily added directly to the material during mixing, eliminating the trouble of conventional liquid thickeners that require adjusting the mixing ratio during use due to the addition of solvents and water. Due to its high thixotropic index and sensitive viscosity adjustment, only a small amount is needed to meet the construction requirements of different slopes. 3) It has little effect on the mechanical properties of the casting material. Traditional viscosity enhancers, due to their low thixotropic index, often require a large addition amount (1-5%) to meet the construction performance requirements of different working conditions, and the addition of such external admixtures will reduce the mechanical properties of the added material itself to a certain extent. The innovative high thixotropic rheology modifier TV designed by the present invention has a high thixotropic index and is particularly sensitive to viscosity adjustment, so the dosage is extremely small. Generally, a dosage of 0.02-0.2% (weight ratio) can meet the construction requirements of slopes with an inclination of 10-90 degrees, so the impact on the mechanical properties of the material can be ignored.

[0020] 5. The innovative structural design of this invention cleverly utilizes the simple principle of a tooth-groove structure at the structural joints. This scientifically and economically eliminates the structural weakness that can arise from the horizontal structural joints perpendicular to the water flow direction, which are susceptible to damage from direct hydraulic impact. This significantly reduces the potential damage of "lifting" by high-speed water flow and improves the reliability and service life of the impact-resistant structure. This new structural design is innovative, reliable, practical, convenient, and economical.

[0021] 6. The innovative construction technology of this invention offers the following benefits: 1) By adjusting the parameters of the mixing equipment, the strain-hardened inorganic metal anti-wear material can be efficiently and thoroughly mixed, achieving self-leveling and self-compacting performance at extremely low water-to-cement ratios. This overcomes common drawbacks of conventional equipment, such as long mixing times, low efficiency, uneven mixing, and fiber clumping, which often severely impact material performance. 2) Through innovative supporting materials, the bond strength between the new and old surfaces is increased by over 30%, while the shrinkage rate is zero, ensuring that the new and old surfaces remain free of interfacial issues throughout their service life. This eliminates the debonding, misalignment, and hollowing common with conventional adhesives, laying a key foundation for the long-term service life of anti-wear repair technology. Furthermore, the technology is environmentally friendly and can be applied on damp surfaces, significantly reducing construction difficulty and effectively shortening construction time. The highly thixotropic rheology modifier TV makes it possible to apply the self-leveling material on inclined surfaces, significantly reducing the construction difficulty and facilitating project progress. 3) Through the innovative “surface-collecting and coating at the same time” process, the shortcomings of USC materials due to extremely low water-cement ratio and easy water loss on the surface are overcome, ensuring construction quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a three-dimensional schematic diagram of the tooth groove structure;

[0023] Figure 2 It is a plan view of the tooth groove structure;

[0024] Figure 3 This is a schematic diagram of the arrangement of inclined reinforcement bars. DETAILED DESCRIPTION

[0025] The present invention will be further described below with reference to the accompanying drawings and examples, but they are not intended to limit the present invention.

[0026] Example 1 of the present invention: In August 2015, the dam bottom plate of the No. 5 dam section of the Wanjiazhai Water Conservancy Project in Shanxi Province was 800m high. 2 The test section (plane) was repaired for the first time using the technology of the present invention.

[0027] The strain-strengthened inorganic metal anti-impact material is uniformly stirred by an innovative mixer according to the following weight ratio: 1000 (high-strength and dense inorganic matrix powder USC) + 94 (special coated metal fiber) + 101 (water).

[0028] The mixer parameters are as follows: 500L capacity vertical shaft forced mixer, 2mm gap between mixing blade and cylinder wall, 7.5KW motor power, 60rpm speed.

[0029] The foundation concrete (C50) damaged by high-speed sand-laden water flow is roughened on the surface (the roughening depth is about 1cm) to remove the loose structure. After washing with a high-pressure water gun, apply hydrophilic low-viscosity polyurethane modified interface glue TG with a coating amount of 2-3m 2 / Kg. The hydrophilic, low-viscosity polyurethane-modified interface adhesive TG is a hydrophilic two-component adhesive, prepared by mixing component A and component B in a 3:1 ratio. Component A is a hydrophilic, low-viscosity polyurethane-modified epoxy resin (PUE), and component B is an aliphatic amine curing agent (HD). The polyurethane modification ratio in component A is 8% (by weight, graft copolymerization).

[0030] Then, the strain-hardened inorganic metal anti-wear material was cast to a thickness of 3 cm according to the innovative construction technology of the present invention, and the material was covered with a film for moisture preservation and cured for two weeks. The test properties of the materials are shown in Table 1.

[0031] After seven years of flood discharge and erosion resistance, the strain-hardened inorganic metal anti-wear material layer maintained its integrity as of 2022, showing no signs of cracking or hollowing, with only a gradual, uniform thinning (layer-by-layer, year-by-year, wear). In contrast, traditional technologies, such as epoxy, used during the same period, experienced localized cracking, hollowing, and detachment of the anti-wear surface layer almost every year after the flood season, requiring repeated repairs.

[0032] The repair technology of this invention has an initial cost of approximately half that of a typical epoxy mortar. Combined with the seven-year maintenance costs of epoxy, the lifecycle economics of this invention are highly significant. This seven-year practice demonstrates that compared to existing anti-abrasion repair technologies, this invention offers significant technical advantages and economic value, fully demonstrating its innovative and advanced nature.

[0033] Example 2 of the present invention: In May 2021, the Wanjiazhai Water Conservancy Project was 800m high six years ago. 2 Based on the good results obtained in the test section, the application was expanded and the technology of the present invention was used to repair the 6-8 dam section with a total area of ​​3400m 2 The tank bottom plate was repaired to resist impact and wear on a large area, including 1200m 2 It is an inclined surface (ridge), and the rest are flat surfaces.

[0034] The weight ratio of strain-strengthened inorganic metal anti-impact material is 1000 (high-strength and dense inorganic matrix powder USC) + 93.5 (special coating metal fiber) + 90 (water).

[0035] The mixture was stirred evenly using a 500L vertical shaft forced mixer (gap between stirring blade and cylinder wall 2mm, motor power 7.5KW, speed 60rpm).

[0036] After the foundation concrete (C50) is roughened (depth of about 1cm), apply hydrophilic low viscosity polyurethane modified interface glue TG, with a coating amount of 2-3m 2 / Kg. Hydrophilic low-viscosity polyurethane modified interface adhesive TG is a hydrophilic two-component adhesive, mixed evenly in a ratio of 3:1. Component A is a hydrophilic low-viscosity polyurethane modified epoxy resin PUE, and component B is an aliphatic amine curing agent HD. The polyurethane modification ratio of component A is 8% (by weight, graft copolymerization).

[0037] According to the innovative structural design of the present invention, transverse trough structures are installed at the transverse joints, with dimensions of 15cm x 10cm (width x depth). Concrete is poured in compartments corresponding to the foundation's dimensions of 20m x 19m (length x width). Using the innovative construction technology of the present invention, a strain-hardened inorganic metal anti-impact material is poured to a thickness of 3cm, then covered with a film for two weeks of moisture-retention curing.

[0038] 1200m 2 During the construction of the slope (cantilever), according to the slope structure design and construction method of the present invention, the base surface is reinforced with Φ10 dowel bars, and the dowel bars are spaced 50cm in front, back, left and right, and arranged in a plum blossom shape. Figure 3 Schematic diagram.

[0039] The strain-strengthened inorganic metal anti-impact material is mixed with a high thixotropic rheology modifier TV during stirring. The high thixotropic rheology modifier TV is composed of a single-component hydroxypropyl methylcellulose ether (HPMC).

[0040] The slope of the ridge varies from high to low, roughly divided into three sections: the highest section with an inclination of over 60 degrees (reaching approximately 75 degrees at the top), the middle section with an angle of approximately 40-60 degrees, and the lower section with an angle of approximately 20-40 degrees. Field tests determined the dosage of rheology modifier TV to be 0.12%, 0.10%, and 0.05% (relative to the weight of the high-strength, dense inorganic matrix powder USC) for these three inclinations, achieving satisfactory construction results.

[0041] After nearly three years of flood discharge and scour resistance testing, the erosion-resistant surface layer has maintained excellent integrity, with no cracking, debonding, misalignment, or hollowing defects. This demonstrates the advanced materials, scientific structure, and rational process of the repair technology presented in this invention, and its large-scale application has achieved good results. Relevant material test properties are shown in Table 1.

[0042] Example 3 of the present invention: In June 2022, Wanjiazhai Water Conservancy Project continued to use the technology of the present invention to repair the remaining 1100m of the No. 5 dam section. 2 The tank bottom plate is repaired to resist impact and wear, of which about 1 / 3 (~370m 2 ) is a slope (ridge), the rest are flat, and about 100m 2The overflow surface (curved surface) is used for process test application.

[0043] The weight ratio of strain-strengthened inorganic metal anti-impact material is 1000 (high-strength and dense inorganic matrix powder) + 93.5 (special coating metal fiber) + 88-95 (water).

[0044] The concrete is mixed evenly with a 500L vertical shaft forced mixer (the gap between the mixing blade and the cylinder wall is 2mm, the motor power is 7.5KW, and the speed is 60rpm). The base concrete (C50) is roughened (depth is about 1cm) and then coated with hydrophilic low viscosity interface glue TG with a coating amount of 2-3m 2 / Kg. Hydrophilic low-viscosity interface adhesive TG is a hydrophilic two-component adhesive, mixed evenly in a ratio of 3:1. Component A is a hydrophilic, low-viscosity polyurethane-modified epoxy resin PUE, and component B is an aliphatic amine curing agent HD. The polyurethane modification ratio of component A is 8% (by weight, graft copolymerization).

[0045] According to the innovative structural design of the present invention, transverse tooth groove structures are installed at the horizontal joints of the structure, with dimensions of 15cm × 10cm (width × depth). The concrete is poured in compartments corresponding to the foundation's dimensions of 20m × 19m (length × width). Using the innovative construction technology of the present invention, strain-hardened inorganic metal anti-impact material is poured to a thickness of 5cm, and then covered with a film for two weeks of moisture retention and curing.

[0046] 370m 2 During the construction of the slope, the base surface is reinforced with Φ10 dowel bars, and the dowel bars are spaced 50cm in front, back, left and right, in a plum blossom shape. Figure 3 Schematic diagram.

[0047] The strain-strengthened inorganic metal anti-impact material is mixed with a high thixotropic rheology modifier TV during stirring. The TV is composed of a single-component hydroxypropyl methylcellulose ether (HPMC).

[0048] The slope is divided into three sections from high to low. The highest section has an inclination of more than 60 degrees (the top reaches about 75 degrees), the middle section is about 40-60 degrees, and the lower section is about 20-40 degrees. For these three inclinations, field tests determined that the dosage of rheology modifier TV from high to low is 0.1%, 0.08%, and 0.06% (relative to the weight ratio of high-strength and dense inorganic matrix powder). 2 The construction technology of the overflow surface (curved surface) test section is the same as that of the inclined surface, and both achieved satisfactory construction results.

[0049] After the summer flood discharge and scouring in 2022, the USC abrasion-resistant surface layer remained intact, with no cracking, debonding, misalignment, or hollowing defects observed. The project achieved its intended results. See Table 1 for relevant material test properties.

[0050] Table 1 Main performance test data of Examples 1-3

[0051]

[0052] The strain-hardened inorganic metal anti-wear material in the above-mentioned embodiment was developed and produced by Shanghai Tongyang Chemical Co., Ltd. Details can be found in Chinese patent CN114956723A. Its key components include high-strength, dense inorganic matrix powder (USC), special-coated metal fibers, and water. The preparation of the high-strength, dense inorganic matrix powder (USC) and special-coated metal fibers is described in detail in the patent.

[0053] The long-life anti-abrasion repair technology used in the above embodiment uses a patented product - strain-strengthened inorganic metal anti-abrasion material, combined with an innovative hydrophilic low-viscosity polyurethane modified interface glue TG and a high thixotropic rheology modifier TV. Through innovative enhanced structural design and construction technology, it achieves the purpose of long-term anti-abrasion after the damaged flow surface is repaired, reducing a large amount of manpower and material resources and ensuring the safety of dam operation. The anti-abrasion strength reaches 200 [h / (Kg / m 2 )], several or even dozens of times greater than most existing repair technologies. It also deforms synergistically with the foundation concrete, overcoming the common drawbacks of organic polymer-based repair technologies, including numerous interface issues (such as peeling and hollowing), high costs, and difficult construction. The 3cm-thick, strain-hardened, inorganic metal anti-abrasion repair layer boasts a service life of over seven years, eliminating the need for repeated repairs. This significantly reduces the operation and maintenance costs of spillway structures, resulting in significant lifespan economic benefits.

[0054] The hydrophilic, low-viscosity polyurethane-modified interface adhesive TG in the above-mentioned embodiment is formed by uniformly mixing a hydrophilic, low-viscosity polyurethane-modified epoxy resin PUE (Component A) and an aliphatic amine curing agent HD (Component B) in a ratio of 2-3:1. The hydrophilic, low-viscosity polyurethane-modified epoxy resin PUE (Component A) is obtained by dropwise adding 5-20% by weight of a polyurethane prepolymer to liquid bisphenol A in a reaction kettle and then graft-copolymerizing it. The isocyanate (-NCO) groups in the polyurethane prepolymer react with epoxy groups to form an alkanone polymer, forming an interpenetrating polyurethane network (IPN). This improves the interfacial bond strength, impact toughness, permeability, and aging resistance of the TG interface adhesive, while also reducing shrinkage during curing. Using this hydrophilic, low-viscosity polyurethane-modified interface adhesive TG can increase interfacial bond strength by over 30%. The strain-hardened inorganic metal anti-abrasion material used in this invention has a plain interfacial bond strength (without interfacial adhesive) of 3 MPa with C50 concrete. After application of the hydrophilic, low-viscosity polyurethane-modified interfacial adhesive (TG), the bond strength increases to over 4 MPa, an improvement of more than one-third, further ensuring the interfacial connection between the new and old materials. TG, a hydrophilic, low-viscosity polyurethane-modified interfacial adhesive, is environmentally friendly and contains no volatile solvents. It also offers low viscosity, excellent fluidity, and strong permeability, high bond strength, and no shrinkage after curing. It also exhibits excellent chemical and aging resistance. Furthermore, it is easy to apply and cure on damp surfaces, and can be rolled, brushed, or sprayed.

[0055] The highly thixotropic rheology modifier TV in the above-mentioned embodiment is a rheology modifier with high low-shear viscosity, low medium- and high-shear viscosity, and excellent thixotropic properties. It is composed of one or two of the following materials in a weight ratio of 1:(0-1):(0-1):hydroxypropyl methylcellulose ether (HPMC) + fumed silica + intercalated attapulgite. This highly thixotropic rheology modifier TV features easily adjustable thixotropic index and minimal impact on mechanical properties. Its dosage is 0.02% to 0.2% by weight of the high-strength, dense inorganic matrix powder. When applied on inclined surfaces, the self-leveling material will flow on the slope, requiring the addition of this highly thixotropic rheology modifier TV to adjust the appropriate fluidity and workability.

[0056] In the above embodiment, a transverse tooth groove structure is provided at the structural joint in the direction perpendicular to the water flow, which can strengthen the structural weakness of the water-facing surface of the transverse joint caused by the impact of the frontal high-speed water flow. Once the old and new interfaces at this location are damaged by the impact of water, the high-speed water flow will gradually penetrate into the interior of the interlayer along the interface, causing further damage, and in severe cases, a "lifting plate" effect. The present invention innovatively proposes to excavate tooth grooves with a width × depth of (15-20) cm × (5-20) cm at the transverse structural joint (perpendicular to the direction of water flow), and arrange Φ10 dowels in a plum blossom shape in the groove. The dowels are implanted to a depth of 10 cm, exposing 5-20 cm of the groove bottom (level with the base surface), with an interval of 20 cm, see Figure 1 、 Figure 2 At the same time, on the foundation concrete slab 25cm behind the tooth groove (along the water flow direction), two rows of Φ10 inserted bars are arranged in a plum blossom shape, with the front and back and left and right intervals of 25cm. Figure 2 As shown, the dowels are embedded 10 cm deep, with 2.5 cm exposed above the base. When pouring the strain-hardened inorganic metal anti-abrasion surface layer, the entire 50 cm area between the tooth grooves and the two rows of dowels arranged behind them is poured at once, forming a complete structure. This significantly improves the ability of transverse structural joints to resist damage from direct hydraulic impacts, eliminates weak links in the anti-abrasion structure, and extends its service life.

[0057] Additionally, when the construction surface is inclined and the inclination angle is greater than 15 degrees, the base concrete interface is expanded to further enhance the interface connection performance on the inclined surface. The inserted rebars should be Φ10 or larger, with a depth of 10d (d is the diameter of the inserted rebar), protruding 2.5cm from the base surface and spaced 50cm apart in a plum blossom pattern.

[0058] The innovative construction technology in the above embodiment is characterized by:

[0059] 1) The new and old interfaces are reinforced with a hydrophilic low-viscosity polyurethane modified interface adhesive TG, which is characterized by low surface tension and high permeability. It can penetrate into the foundation concrete to a certain depth, thereby improving the interface bonding strength by more than 30%. After adopting the hydrophilic low-viscosity polyurethane modified interface adhesive TG technology of the present invention, the interface bonding strength between the strain-hardened inorganic metal anti-impact material and the C50 foundation concrete is increased from 3.0MPa to more than 4.0MPa, an increase of more than one third. TG coating amount 2-3m 2 / Kg, can be used on dry or wet surfaces, but no visible water is allowed.

[0060] 2) Using a highly thixotropic rheology modifier, TV, offers the advantage of conveniently adjusting the fluidity of strain-hardened inorganic metal anti-wear materials to meet the construction conditions of varying slopes, while also ensuring excellent workability, ensuring "easy spreading and plastering without sticking." The core technology lies in the rational combination of low, medium, and high shear viscosities. High low-shear viscosity imparts excellent thixotropy (allowing the material to stay on the slope without flowing); however, high medium and high shear viscosities make construction extremely laborious (high sticking forces) and difficult to spread and plaster. Therefore, to achieve the excellent workability of "staying on the slope without slacking effort" on slopes, the material requires high low-shear viscosity and low medium and high shear viscosities.

[0061] 3) Adjust the mixing parameters. The gap between the mixer blade and the cylinder wall should be less than 2mm. The motor power of 500L capacity should be greater than 7.5KW and the speed should be greater than 60rpm.

[0062] 4) During pouring, an innovative “surface collecting and coating at the same time” process is adopted to overcome the disadvantage of surface defects caused by easy water loss due to the extremely low water-binder ratio of USC materials.

Claims

1. A long-life anti-wear repair technology, characterized by: Apply hydrophilic low-viscosity polyurethane modified interface glue TG on the flow surface of the hydraulic discharge structure at a coating amount of 2-3m2 / Kg, and then cast the strain-strengthened inorganic metal anti-impact material on it. When the base surface is an inclined surface with an inclination angle greater than 15°, add a high thixotropic rheology modifier TV to the strain-strengthened inorganic metal anti-impact material; The strain-strengthened inorganic metal anti-impact material is composed of high-strength and dense matrix powder USC, special coating metal fiber and water. The weight ratio of the three is 1000:93-95:88-101. The addition amount of high thixotropic rheology modifier TV is 0.02%-0.2% of the weight of the high-strength and dense matrix powder USC. The hydrophilic low-viscosity polyurethane modified interface adhesive TG is formed by uniformly mixing component A, a hydrophilic low-viscosity polyurethane modified epoxy resin PUE, and component B, an aliphatic amine curing agent HD, with a mixing ratio of component A:component B = 2-3:

1. The hydrophilic low-viscosity polyurethane modified epoxy resin PUE is obtained by graft copolymerization of liquid bisphenol A with a polyurethane prepolymer at a weight ratio of 5-20%. The high thixotropic rheology modifier TV is composed of one or more of the following materials in a weight ratio of 1:0-1:0-1: hydroxypropyl methylcellulose ether+fumed silica+intercalated attapulgite.

2. The long-life anti-wear repair technology according to claim 1 is characterized in that: The strain-strengthened inorganic metal anti-impact and wear material is developed and produced by Shanghai Tongyang Chemical Co., Ltd.

3. The long-life anti-wear repair technology according to claim 1 is characterized in that: The casting of strain-strengthened inorganic metal anti-impact and wear materials adopts compartmentalized construction. The maximum construction area of ​​each compartment is length × width = 30m × 30m. A transverse groove structure is set at the structural joint perpendicular to the water flow direction, and inserted reinforcement is set inside the groove. Then, according to the base surface construction process, hydrophilic low-viscosity polyurethane modified interface glue TG is applied and the strain-strengthened inorganic metal anti-impact and wear materials are cast. When the construction surface is an inclined surface with an inclination angle greater than 15°, a high thixotropic rheology modifier TV is also added to the strain-strengthened inorganic metal anti-impact and wear material.

4. The long-life anti-wear repair technology according to claim 3 is characterized in that: The excavation width and depth of the tooth groove are 15-20cm×5-20cm, and Φ10 dowel bars are arranged in a plum blossom shape in the groove. The dowel bars are implanted to a depth of 10cm, the top is flush with the base surface, and are arranged at intervals of 20cm. The casting thickness in the tooth groove is the same as the casting thickness of the base surface.

5. The long-life anti-wear repair technology according to claim 3 is characterized in that: On the base surface of the foundation concrete slab 25 cm behind the tooth groove, two rows of Φ10 dowel bars are arranged in a plum blossom shape, with a front-back and left-right interval of 25 cm. The dowel bars are embedded to a depth of 10 cm and are exposed to 2.5 cm from the base surface. During pouring, the tooth groove and the area within 50 cm of the two rows of dowel bars at the rear are poured at one time; when the base surface of the construction surface is an inclined surface and the inclination angle is greater than 15°, the dowel bars are fully arranged in a plum blossom shape on the base surface of the foundation concrete slab behind the tooth groove. The dowel bars are made of Φ10 or larger steel bars, with a depth of 10d, where d is the diameter of the dowel bar, and the front-back and left-right intervals are all 50 cm.

6. The long-life anti-wear repair technology according to claim 1 is characterized in that: The thickness of the base surface cast strain-hardened inorganic metal anti-impact and wear material is at least 3 cm.

7. The long-life anti-wear repair technology according to claim 1 is characterized in that: The strain-hardened inorganic metal anti-impact material is stirred by a vertical shaft forced, high-power precision mixer. The gap between the mixer blade and the cylinder wall should be less than 2mm. The motor power of 500L capacity is greater than 7.5KW and the speed is greater than 60rpm.

8. The long-life anti-wear repair technology according to claim 1 is characterized in that: After pouring is completed, the surface is immediately covered with film for maintenance.

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