A concrete layer for support or wall thickening and its decomposition-based preparation method

Abstract

A concrete layer for support or wall thickening and its decomposition-based preparation method are disclosed. The concrete layer includes a crushed stone mesh hung at the construction site and a mortar layer disposed on the crushed stone mesh. The mortar layer fills the gaps in the crushed stone mesh, together forming a cast-in-place concrete structural layer. The decomposition-based preparation method includes the following steps: 1) preparing the crushed stone mesh, which is a metal mesh sheet with crushed stones fixed in a preset arrangement; 2) hanging the crushed stone mesh at the construction site where concrete needs to be poured; 3) setting up a template and injecting mortar into the template; or, directly pressing or spraying mortar onto the crushed stone mesh. This invention avoids the problem of crushed stone clogging during the pouring of ultra-thin concrete structures, while improving the strength, crack resistance, flexural strength, and shear strength of the concrete layer. Furthermore, it is simple, efficient, and low-cost to construct.

Description

Technical Field

[0001] This invention relates to a concrete structure and its preparation method, particularly a concrete layer for support or wall thickening and its decomposition-based preparation method, belonging to the field of building construction technology. Background Technology

[0002] Concrete is widely recognized as one of the most representative building materials in modern society. Due to its exceptionally high strength, long lifespan, good plasticity, and reasonable price, it has become the most widely used, primary, and indispensable material for building structures. The three main components of concrete are cementitious materials (primarily cement), aggregates (coarse aggregates, mainly crushed stone), and fillers (fine aggregates, mainly sand). Aggregates (such as crushed stone) play a crucial role in providing structural support, reducing costs, and ensuring strength due to their low cost, high strength, and stable performance. Fillers (such as sand) fill the voids in the aggregates and ensure the fluidity of the concrete. Cementitious materials bind the aggregates, lubricate, and facilitate setting. Traditional concrete production methods involve mixing cementitious materials, aggregates, and fillers in a container with water. All materials are thoroughly mixed to achieve the necessary performance for pouring building structures.

[0003] Currently, the prepared concrete is directly applied to areas such as wall thickening, tunnel initial support, and slope protection through spraying or troweling. After solidification, it can form a concrete layer or a similar concrete effect. Due to its small thickness, between 60-100mm, it is referred to here as an ultra-thin structure.

[0004] However, the concrete pouring process for such ultra-thin structures often suffers from drawbacks, such as the difficulty in the flow of aggregate in small cross-sectional areas or densely reinforced spaces, affecting construction quality. For example, in the reinforcement of many old residential buildings, it is necessary to add 60 to 100 mm of reinforced concrete to both sides of the old brick walls. Due to the small thickness of the added concrete layer and the presence of a large amount of steel mesh in the middle, the aggregate prepared by the above-mentioned traditional methods is prone to getting stuck between the steel bars and the wall during pouring, thus forming voids and causing defects such as honeycomb and holes that reduce quality.

[0005] In addressing this defect, using other chemical grouting materials would result in costs far exceeding those of ordinary concrete; while using cement mortar, although it can ensure density, would lead to reduced strength due to the lack of aggregate, and would also make it prone to shrinkage cracking. Summary of the Invention

[0006] To overcome the above-mentioned shortcomings of related technologies, the present invention provides a concrete layer for support or wall thickening and its decomposition preparation method, which can avoid the problem of stone debris blockage during the pouring of ultra-thin concrete structures, and at the same time improve the strength, crack resistance, flexural strength, shear resistance and other mechanical properties of the concrete layer, and the construction is simple, efficient and low cost.

[0007] One technical solution adopted by the present invention to solve its technical problem is:

[0008] A concrete layer for support or wall thickening includes a crushed stone mesh hung at the construction site and a mortar layer disposed on the crushed stone mesh. The mortar layer fills the gaps in the crushed stone mesh to form a cast concrete structural layer.

[0009] Optionally, the crushed stone mesh includes a double-layer metal mesh and crushed stone fixed between the double-layer metal mesh; the double-layer metal mesh includes a first metal mesh and a second metal mesh stacked on top of each other, and the first metal mesh and the second metal mesh are respectively provided with first wire mesh holes and second wire mesh holes, both with a diameter smaller than that of the crushed stone; a single crushed stone is fixed to the double-layer metal mesh through the first wire mesh hole and / or the second wire mesh hole, eliminating the single installation method in which all crushed stones are fixed to the first wire mesh hole or the second wire mesh hole.

[0010] Optionally, the first wire mesh and the second wire mesh are arranged in a preset pattern.

[0011] Optionally, the outer side of the double-layer metal mesh is further provided with several reinforcing bars.

[0012] Optionally, the reinforcing bars include a first reinforcing bar fixedly connected to a first metal mesh and a second reinforcing bar fixedly connected to a second metal mesh, wherein the first and second reinforcing bars are spatially staggered and arranged in parallel.

[0013] Using the above technical solution, this invention is used for supporting or thickening concrete layers. It innovatively divides the main components of traditional concrete structural layers into crushed stone and mortar, and uses metal mesh to fix the crushed stone to form a crushed stone mesh. Then, the mortar layer and the crushed stone mesh are fused together to form a new concrete structural layer. In this way, the new concrete structural layer avoids the problem of crushed stone getting stuck during traditional concrete pouring, and improves the role of crushed stone in the concrete, thereby increasing the strength of the concrete layer. At the same time, the metal mesh of the crushed stone mesh can act as reinforcement in the concrete, further improving the mechanical properties of the concrete layer such as crack resistance, flexural resistance, and shear resistance.

[0014] Another technical solution adopted by the present invention to solve its technical problem is:

[0015] A decomposition method for preparing a concrete layer for support or wall thickening includes the following steps:

[0016] 1) Prepare a crushed stone mesh, wherein the crushed stone mesh is a metal mesh sheet in which crushed stones are fixed in a preset arrangement;

[0017] 2) Hang the crushed stone mesh at the construction site where concrete needs to be poured;

[0018] 3) Set up the formwork and inject mortar into the formwork; or, directly press or spray mortar onto the crushed stone mesh.

[0019] Optionally, the preparation of the crushed stone mesh includes the following specific steps:

[0020] First, fix the crushed stone onto the double-layer metal mesh according to the preset arrangement; then, place several steel bars at intervals on the two outer sides of the double-layer metal mesh.

[0021] Optionally, the mortar in step 3) can be replaced with putty or plaster.

[0022] Compared to related technologies, this invention provides a decomposition-based preparation method for concrete layers used in support or wall thickening. It innovatively improves upon traditional concrete preparation methods by pre-fixing crushed stone onto a double-layered metal mesh in a predetermined arrangement. During the construction of ultra-thin structures, the crushed stone mesh is then hung on the areas where concrete needs to be poured. Subsequently, formwork is erected, mortar is poured, or mortar is directly applied. On one hand, the crushed stone is fixed by the double-layered metal mesh; on the other hand, the mortar maintains good fluidity, allowing it to fill the voids and ultimately achieve the effect of poured concrete. This avoids the drawbacks of traditional concrete where crushed stone is difficult to move in small cross-sections or densely reinforced spaces, ensuring the construction quality of ultra-thin structures. It can be widely applied in areas such as wall thickening, initial tunnel support, and slope protection. Attached Figure Description

[0023] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0024] Figure 1 This is a perspective view of a crushed stone mesh used in a concrete layer for supporting or thickening a wall, according to an embodiment of the present invention.

[0025] Figure 2 This is a front view of a concrete layer containing crushed stone mesh used for supporting or thickening walls, according to an embodiment of the present invention.

[0026] Figure 3 This is a schematic diagram of the construction effect of a concrete layer used for support or wall thickening in wall processing according to an embodiment of the present invention, wherein the mortar layer is shown in perspective.

[0027] Explanation of the symbols in the attached diagram: 100-crushed stone mesh; 101-double-layer metal mesh; 102-crushed stone; 103-reinforcing steel; 200-mortar layer; 300-wall. Detailed Implementation

[0028] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of the present invention.

[0029] Figures 1 to 3 The diagram shows a preferred embodiment of the present invention. A concrete layer for supporting or thickening a wall 300 includes a crushed stone mesh 100 hung on the construction site and a mortar layer 200 disposed on the crushed stone mesh 100. The mortar layer 200 fills the gaps in the crushed stone mesh 100 and together they form a cast concrete structural layer.

[0030] To address the common problem of crushed stone 102 getting stuck during traditional concrete pouring, this embodiment is used for supporting or thickening the concrete layer of the wall 300. Since it can be decomposed into crushed stone mesh 100 and mortar layer 200, it can ensure that the crushed stone 102 is fixed and the mortar has good fluidity. Therefore, during pouring, the crushed stone 102 will not get stuck between the reinforcing steel 103 and the wall 300, forming gaps and causing honeycomb, dog holes and other quality reductions.

[0031] In this embodiment, the crushed stone 102 in the crushed stone mesh 100 can be arranged in a specific and fixed position based on the metal mesh, which further fully utilizes the role of the crushed stone 102 in the concrete, thereby effectively improving the strength of the concrete on the existing working surface. The metal mesh used to fix the crushed stone 102 is not found in traditional concrete components. The metal mesh can act as reinforcement in the concrete, thereby further optimizing the mechanical properties of the concrete, such as crack resistance, flexural resistance, and shear resistance.

[0032] As a further optional embodiment of the present invention, the gravel mesh 100 includes a double-layer metal mesh 101 and gravel 102 fixed between the double-layer metal mesh 101; the double-layer metal mesh 101 includes a first metal mesh and a second metal mesh stacked together, and the first metal mesh and the second metal mesh are respectively provided with first wire mesh holes and second wire mesh holes, both with a diameter smaller than the diameter of the gravel 102. Individual gravel 102 is fixed to the double-layer metal mesh 101 through the first wire mesh hole and / or the second wire mesh hole; however, in order to make the gravel mesh 100 an integrated structure, the gravel 102 therein serves to connect the first metal mesh and the second metal mesh, so it is necessary to exclude the single installation method where all gravel 102 are fixed to either the first wire mesh hole or the second wire mesh hole.

[0033] In specific implementation, the first and second metal meshes are sieve structures used to tighten and fix the crushed stone 102. The first and second wire mesh holes on them can be evenly or unevenly distributed, and their sizes can also be different. The position of the crushed stone 102 can be set as needed. Setting the hole diameter at that location to be smaller than the crushed stone 102 will allow the crushed stone 102 to be arranged at the position of the double-layer metal mesh 101.

[0034] As a further optional embodiment of the present invention, the first wire mesh and the second wire mesh are arranged in a preset pattern. Compared with the traditional mixed concrete structure, where the crushed stone 102 is arranged irregularly in concrete, this embodiment utilizes the first and second wire meshes to fix the crushed stone 102 in concrete according to a more scientific and mechanically consistent scheme, thereby further enhancing the reinforcing value of the crushed stone 102 in concrete.

[0035] As a further optional embodiment of the present invention, the outer side of the double-layer metal mesh 101 is further provided with a plurality of steel bars 103. The steel bars 103 on the surface of the double-layer metal mesh 101 are mainly used to improve the deformation resistance of the double-layer metal mesh 101, and the steel bar mesh 100 is also convenient for transportation by being made into a whole.

[0036] As one of the further optional embodiments of the present invention, the reinforcing bar 103 includes a first reinforcing bar fixedly connected to a first metal mesh and a second reinforcing bar fixedly connected to a second metal mesh, wherein the first reinforcing bar and the second reinforcing bar are spatially staggered and arranged in parallel.

[0037] The steel bars 103 in the diagram are multiple longitudinally arranged steel bars 103, but it is not limited to this. The amount of steel bars 103 can be increased or decreased and the arrangement direction and position of steel bars 103 can be changed according to actual design needs, in order to ensure the final structural strength.

[0038] Another technical solution adopted by the present invention to solve its technical problem is:

[0039] A decomposition method for preparing a 300mm thick concrete layer for support or wall construction includes the following steps:

[0040] 1) Prepare a crushed stone mesh 100, wherein the crushed stone mesh 100 is a metal mesh sheet in which crushed stones 102 are fixed in a preset arrangement;

[0041] 2) Hang the 100mm crushed stone mesh at the construction site where concrete needs to be poured;

[0042] 3) Set up the formwork and inject mortar into the formwork; or, directly press or spray mortar onto the crushed stone mesh 100.

[0043] As a further optional embodiment of the present invention, the preparation of the crushed stone mesh 100 includes the following specific steps:

[0044] First, the crushed stone 102 is fixed onto the double-layer metal mesh 101 according to the preset arrangement; then, several steel bars 103 are arranged at intervals on the two outer sides of the double-layer metal mesh 101.

[0045] As a further optional embodiment of the present invention, the mortar in step 3) is replaced by putty or plaster. When the mortar is replaced by putty or plaster, it can also be combined with crushed stone mesh to form another ultra-thin structure, such as a wall plaster layer.

[0046] The present invention provides a decomposition method for preparing a 300mm thick concrete layer for supporting or reinforcing walls. Overall, this method has the advantages of relatively easy construction and wide applicability, as specifically demonstrated below:

[0047] 1. In structural reinforcement applications, by pre-installing crushed stone mesh 100, mortar can be injected using a template to quickly form concrete, which is simple, efficient, and low-cost.

[0048] 2. In applications where thicker plastering is required on walls (i.e., exceeding 30mm), by pre-installing a 100mm gravel mesh, materials such as mortar, putty, and plaster can be manually applied to create a concrete effect. This avoids the need for multiple layers of traditional thicker plastering, saving both construction time and costs.

[0049] 3. In scenarios where shotcrete is used for initial tunnel support and slope protection, compared to traditional shotcrete which has lower overall strength due to the lack of coarse aggregate, this invention can improve the strength of shotcrete by pre-installing crushed stone mesh 100. Unlike traditional shotcrete where the crushed stone mesh 100 has a large number of gaps that make it easy for the shotcrete mortar to adhere, this invention can significantly reduce rebound, thereby reducing material waste, saving costs, and speeding up construction.

[0050] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Any simple modifications and equivalent changes made to the above embodiments based on the technical essence of the present invention shall fall within the protection scope of the present invention.

Claims

1. A concrete layer for support or wall thickening, characterized in that: It includes a crushed stone mesh hung at the construction site and a mortar layer set on the crushed stone mesh. The mortar layer fills the gaps in the crushed stone mesh and together they form a poured concrete structure layer. The crushed stone mesh includes a double-layer metal mesh sheet and crushed stone fixed between the double-layer metal mesh sheet; the double-layer metal mesh sheet includes a first metal mesh and a second metal mesh stacked on top of each other, and the first metal mesh and the second metal mesh sheet are respectively provided with first wire mesh holes and second wire mesh holes, both with a diameter smaller than the diameter of the crushed stone; a single crushed stone is fixed to the double-layer metal mesh sheet through the first wire mesh hole and / or the second wire mesh hole, excluding the single installation method in which all crushed stones are fixed to the first wire mesh hole or the second wire mesh hole; The decomposition method for preparing the concrete layer used for support or wall thickening includes: Step 1) Prepare a crushed stone mesh, wherein the crushed stone mesh is a metal mesh sheet in which crushed stones are fixed in a preset arrangement; Step 2) Hang the crushed stone mesh on the construction area where concrete needs to be poured; Step 3) Set up the formwork and inject mortar into the formwork; or, directly press or spray mortar onto the crushed stone mesh; The preparation of the crushed stone mesh in step 1) further includes the following specific steps: First, fix the crushed stone onto the double-layer metal mesh according to the preset arrangement; then, place several steel bars at intervals on the two outer sides of the double-layer metal mesh.

2. A concrete layer for support or wall thickening according to claim 1, characterized in that: The first wire mesh and the second wire mesh are arranged in a preset pattern.

3. A concrete layer for support or wall thickening according to claim 1 or 2, characterized in that: The outer side of the double-layer metal mesh is also provided with several reinforcing bars.

4. A concrete layer for support or wall thickening according to claim 3, characterized in that: The reinforcing bars include a first reinforcing bar fixedly connected to a first metal mesh and a second reinforcing bar fixedly connected to a second metal mesh, wherein the first and second reinforcing bars are spatially staggered and arranged in parallel.

5. A concrete layer for support or wall thickening according to claim 1, characterized in that: The mortar in step 3) is replaced by putty or plaster.

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