A rapidly installable flexible reinforced ultra high performance concrete pavement panel module

Abstract

This invention proposes a rapidly paved flexible reinforced ultra-high performance concrete road panel module, comprising unit panels and connectors. Multiple unit panels have coplanar upper surfaces, with gaps between adjacent unit panels filled with a first sealing and insulating filler. Adjacent unit panels are connected by at least one connector. Each unit panel consists of a concrete substrate and a fixed shaft. The upper surface of the concrete substrate is covered with metal edging on all four sides, and the edges of the metal edging have first stepped grooves filled with a second sealing and insulating filler. This invention features a simple structure, clear function, precise force transmission, and reliable stress distribution. It can be rapidly deployed for temporary pavement construction, addressing engineering needs in specific situations. It can be repeatedly disassembled and reused, demonstrating promising application prospects.

Description

Technical Field

[0001] This invention relates to precast concrete pavement, specifically a flexible reinforced ultra-high performance concrete road panel module that can be quickly paved. Background Technology

[0002] Typically, concrete pavement slabs for permanent or temporary traffic directly bear the vertical, horizontal, and vibrational impacts of aircraft and vehicle loads, and are directly affected by natural factors such as atmospheric precipitation, temperature, and humidity changes. They are generally constructed using on-site casting with formwork. Their pavement structure typically includes, from top to bottom, a pavement layer, a base layer, a subbase, and a foundation, resulting in a complex structure with multiple layers and a long construction period.

[0003] In existing technology, patent CN114960326A discloses a prefabricated ultra-high performance concrete pavement panel and its construction method. The panel structure is relatively thick and rigid, and cannot bend or deform to adapt to changes in flatness based on the foundation surface. Therefore, precise and flexible leveling of the pavement panel is achieved through pre-set leveling screw holes and post-installed leveling screws. Grouting is then performed on the bottom of the panel through pre-embedded grouting holes to achieve a tight fit between the pavement panel and the foundation. The panel units are connected by force transmission rods and post-cast high-strength tenons, involving wet construction. This invention has a complex structure and construction process, low installation efficiency, and high cost.

[0004] Patent CN111041923A discloses a prefabricated steel fiber reinforced concrete road connection structure and its road, comprising a connection structure and components. The connection structure includes a pre-clamping rod, a clamping sleeve, and a locking assembly. The clamping sleeve has an L-shaped cross-section with an open top. The L-shaped clamping sleeve includes a vertically arranged guide channel and a clamping groove located at the bottom end. The clamping rod fits into the clamping groove. The outer lateral side of the clamping rod is a third clamping slope, which slopes outward from top to bottom and extends into the guide channel. The locking assembly includes a locking block and a locking element. The bottom lateral side of the locking block is provided with a fourth clamping slope that cooperates with the third clamping slope. This design can effectively improve the connection strength between prefabricated steel fiber reinforced concrete road slabs, ensure good road integrity, facilitate assembly and disassembly, and improve construction efficiency.

[0005] Patent CN219010845U discloses a prefabricated steel fiber pavement panel, including a panel body with a pre-embedded steel mesh skeleton. Male and female connectors are fixedly connected to the panel body on opposite sides, forming an expansion joint structure during assembly. This prefabricated steel fiber pavement panel effectively improves the mechanical properties of the pavement panel. The connectors at the ends of the panel body effectively prevent damage caused by stress concentration at the prefabricated joints. The connector structure ensures the stability of the expansion joints, preventing detachment and minimizing damage during later dismantling. It is also easy to reuse, allowing for rapid on-site construction and immediate traffic opening after completion, significantly shortening the construction period.

[0006] The prefabricated concrete road slabs proposed in the above-mentioned existing technologies all suffer from significant drawbacks. The first two types rely on fixed connections between panels and between the panels and the foundation, resulting in long construction periods. Furthermore, in areas with large diurnal temperature variations, thermal expansion and contraction can easily cause cracking between the panels. The latter type uses movable expansion joints between panels, which can lead to unevenness between adjacent panels due to vehicle traffic, causing them to loosen and form large gaps, damaging the road surface and foundation, and resulting in poor product durability. Under the requirements of rapid repair and deployment for temporary road surfaces in airports and highways, all of the above-mentioned existing technologies have significant shortcomings. Summary of the Invention

[0007] In response to the problems raised in the background technology, the purpose of this invention is to propose a flexible reinforced ultra-high performance concrete road panel module that can be quickly laid. The panels are connected by a flexible connection method and structurally sealed. No additional roadbed treatment is required during paving. The prefabricated panel units are reinforced with ultra-high performance concrete and edge-wrapped, resulting in good structural strength and resistance to damage when the edges are subjected to loads. It is suitable for rapid repair and deployment of temporary pavement projects for airports and highways.

[0008] To achieve the above objectives, the present invention provides the following technical solution:

[0009] A flexible, reinforced, ultra-high performance concrete road panel module for rapid installation includes unit panels and connectors. The upper surfaces of multiple unit panels are coplanar, and gaps exist between adjacent unit panels. These gaps are filled with a first sealing and insulating filler. Adjacent unit panels are connected by at least one connector. Each unit panel consists of a concrete substrate and a fixed shaft. The concrete substrate has a quadrilateral structure with evenly distributed openings on its four sides, each opening containing a fixed shaft. The connectors extendably connect to the corresponding fixed shafts between adjacent unit panels at both ends. The upper surface of the concrete substrate is covered with metal edging on all four sides. The edges of the metal edging have first stepped grooves filled with a second sealing and insulating filler.

[0010] The fixed shaft is horizontally fixed to one side wall of the opening groove. The connector is a rectangular plate structure. Both ends of the connector are provided with waist-shaped through holes. The fixed shaft passes through the middle of the corresponding waist-shaped through holes. A fastening nut is provided on the fixed shaft to press and fix the connector to the side wall of the opening groove.

[0011] The fixed shaft is also fitted with a flat washer and a spring washer. The flat washer is located on both sides of the connector to facilitate the sliding of the connector, and the spring washer is used to maintain the clamping force of the fastening nut.

[0012] The fixed shaft is also provided with a pin hole, and a locking pin is provided in the pin hole to prevent the fastening nut from falling off.

[0013] The opening groove penetrates the upper and lower surfaces of the concrete substrate. The upper opening of the opening groove is provided with a second stepped groove, and a sealing plate is fixedly installed on the second stepped groove, the sealing plate covering the upper opening of the opening groove.

[0014] The bottom surface of the second step groove is provided with a fixing member, and the fixing member has an internal thread. The sealing plate is connected to the internal thread of the fixing member by a countersunk bolt.

[0015] The concrete substrate is made of ultra-high performance concrete, with a steel mesh underneath and hoisting components built into the four corners of its upper surface.

[0016] The beneficial effects of this invention are as follows: The unit panels of this invention are made of ultra-high performance concrete and reinforced with steel mesh. They are relatively thin, and while meeting traffic load-bearing requirements, they possess a certain degree of bending deformation capacity to adapt to foundations or subgrades with poor flatness. The unit panels are lightweight and suitable for centralized industrial manufacturing, conventional truck / train / ship transportation, and on-site mechanical lifting and installation. The unit panels can be directly laid on the foundation or subgrade without the need for a base course. The connection method ensures reliable connection between adjacent unit panels and allows for a certain degree of expansion and contraction in both two dimensions. Flexible sealing and insulating filler is used between the unit panels, improving the overall integrity of the pavement and preventing damage to the foundation or base course due to water immersion. This invention has a simple structure, clear function, clear force transmission, and reliable stress distribution. It can be quickly deployed for temporary pavement construction, solving engineering needs in specific situations. It can be repeatedly disassembled and reused, showing good application prospects. Attached Figure Description

[0017] Figure 1 This is a top view of the overall structure of the present invention;

[0018] Figure 2 This is a top view of the entire unit panel;

[0019] Figure 3 This is a top view of the connection points between unit panels;

[0020] Figure 4 This is a side view of the connection points between unit panels;

[0021] Figure 5 This is a schematic diagram showing the filling position of the second sealing and insulation filler.

[0022] Figure 6 This is a partial 3D view of the corner area of ​​the unit panel;

[0023] Figure 7 A partial 3D view of the corner of the unit panel from another perspective;

[0024] Figure 8 This is a schematic diagram of the locking pin.

[0025] In the figure, 1 is a unit plate, 2 is a connector, 11 is a concrete base plate, 12 is a fixed shaft, 13 is an open slot, 14 is a waist-shaped through hole, 15 is a fastening nut, 16 is a flat washer, 17 is a spring washer, 18 is a pin hole, 19 is a metal edging, 20 is a first step groove, 21 is a second step groove, 22 is a sealing plate, 23 is a fastener, 24 is a second sealing and insulation filler, and 25 is a first sealing and insulation filler. Detailed Implementation

[0026] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments.

[0027] like Figure 1-8 As shown, this invention proposes a flexible reinforced ultra-high performance concrete road panel module that can be quickly laid, including unit panels 1 and connectors 2. The upper surfaces of multiple unit panels 1 are coplanar, and there are gaps between adjacent unit panels 1. In one embodiment of this invention, the gap is 5-30 mm, and the gap is filled with a first sealing and heat-insulating filler 25. Adjacent unit panels 1 are connected by at least one connector 2. The unit panel 1 is composed of a concrete substrate 11 and a fixing shaft 12. The concrete substrate 11 is a quadrilateral structure with evenly distributed opening slots 13 on its four sides, and a fixing shaft 12 is provided in each opening slot 13. The two ends of the connector 2 are telescopically connected to the corresponding fixing shafts 12 between adjacent unit panels 1. The upper surface of the concrete substrate 11 is covered with metal edging 19 on all four sides. The edges of the metal edging 19 are provided with first stepped grooves 20, and the stepped grooves 20 are filled with a second sealing and heat-insulating filler 24.

[0028] The fixed shaft 12 is horizontally fixed to one side wall of the opening groove 13. The connector 2 is a rectangular plate structure. Both ends of the connector 2 are provided with waist-shaped through holes 14. The fixed shaft 12 passes through the middle of the corresponding waist-shaped through holes 14. A fastening nut 15 is provided on the fixed shaft 12 to press and fix the connector 2 to the side wall of the opening groove 13. In one embodiment of the present invention, the connector 2 is made of Q235 or Q345 steel plate, which is rectangular. Its thickness is 15mm-20mm, and its length is 10-20cm shorter than the splicing length of the two opening slots 13, which facilitates installation and provides a certain amount of expansion and contraction space. Two oblong through holes 14 are symmetrically opened at both ends of its length direction. The width of the oblong through hole 14 is 2-3mm larger than the diameter of the fixed shaft 12, and the length is 5-10mm larger than the diameter of the fixed shaft 12. The geometric parameters of the oblong through hole 14 can be adjusted according to the stress requirements at the joint position. The connector 2 restricts the vertical and horizontal displacement of adjacent unit plates 1. When the unit plate 1 undergoes thermal expansion and contraction, it has a certain sliding buffer with the fixed shaft 12, which can effectively maintain a firm connection between adjacent unit plates 1. If the sealing structure between the gaps is damaged, it can be detected and repaired on the spot in time due to the presence of the connector 2.

[0029] The fixed shaft 12 is also fitted with a flat washer 16 and a spring washer 17. The flat washer 16 is located on both sides of the connector 2 to facilitate the sliding of the connector 2. The spring washer 17 is used to maintain the clamping force of the fastening nut 15.

[0030] The fixed shaft 12 is also provided with a pin hole 18, and a locking pin is provided in the pin hole 18 to prevent the fastening nut from falling off.

[0031] The opening groove 13 penetrates the upper and lower surfaces of the concrete substrate 11. A second stepped groove 21 is provided at the upper opening of the opening groove 13. A sealing plate 22 is fixedly installed on the second stepped groove 21, covering the upper opening of the opening groove 13. A fixing member 23 is provided on the bottom surface of the step of the second stepped groove 21. The fixing member has internal threads, and the sealing plate 22 is connected to the internal threads of the fixing member 23 by countersunk bolts. The installation of the sealing plate 22 also maintains a seal, preventing rainwater from entering below the road surface.

[0032] The concrete substrate 11 is made of ultra-high performance concrete, with a steel mesh inside and four corners on its upper surface.

[0033] In one embodiment of the present invention, the unit plate 1 is the main functional structure that directly bears the service load, and its shape is a rectangular plate structure. The length of the unit plate 1 is between 3000mm and 7000mm, the width is between 2000mm and 3500mm, and the length-to-width ratio is between 1:1 and 2:1. The unit plate 1 is cast from ultra-high performance concrete with a compressive strength of not less than 120MPa, and the plate thickness is between 50mm and 80mm. The unit plate 1 has a two-way steel mesh arranged inside it near the bottom to improve the bending strength and deformation capacity of the plate. The steel mesh uses ordinary ribbed steel bars with a diameter of 6mm-8mm, arranged in both directions, and the spacing between the steel bars is 50mm-100mm. The upper surface of the unit plate 1 is provided with anti-slip embossing to improve tire friction. The embossing depth and density are in accordance with the engineering standards of the corresponding pavement project.

[0034] In one embodiment of the present invention, the unit panel 1 has pre-reserved opening grooves 13 at the edges where splicing is required. The opening grooves 13 penetrate the panel structure, are 80mm-120mm long, 40mm-60mm wide, and spaced 1500mm-3000mm apart. The unit panel 1 uses a 1mm thick steel edging. A second stepped groove 21 is provided on the top surface of the steel edging edge, with a width of 5-10mm and a height of 5-10mm. When spliced ​​with adjacent unit panels 1, a combined groove can be formed on the splice joint. The combined groove has a small upper opening and a large lower opening to prevent the second sealing and insulation filler 24 from falling off. The second sealing and insulation filler 24 filled in the combined groove is polyurethane rubber, which can achieve overall sealing of the road surface, giving the road surface waterproof and water-stopping functions, and preventing rainwater from seeping into the bottom of the unit panel 1 through the splice joint during use and thus eroding the foundation. The steel edging can make the unit panel 1 less prone to damage under large loads, maintain its integrity, and help prevent the second sealing and insulation filler 24 from falling off.

[0035] In one embodiment of the present invention, the lifting component is a nut made of metal material with a single-sided closed opening, which is built into the lifting holes reserved at the four corners of the upper surface of the unit plate 1. The inner diameter of the nut is between 16mm and 26mm, and the bottom of the lifting hole is closed.

[0036] In one embodiment of the present invention, the fixed shaft 12 is made of Q235 or Q345 steel and is cylindrical. It is embedded in the opening groove 13 of the unit plate 1 during prefabrication. Its diameter is selected based on the structural stress of the pavement project, generally 20mm-30mm, and its length meets the concrete pull-out requirements, generally being 10 times the diameter. One end is pre-embedded in the concrete during the fabrication of the unit plate 1, and the other end protrudes from one side wall of the opening groove 13, with an exposed length of 25-40mm. A pin hole 18 is provided on the outer side of the exposed end. One fixed shaft 12 is provided in each opening groove 13, and their relative positions are fixed. Vertically, it is located at the center of the plate thickness, and horizontally, it is located at the center of the side wall of the opening groove 13. The pin hole 18 of the fixed shaft 12 faces upwards to allow for the insertion of a cotter pin.

[0037] In one embodiment of the present invention, the locking pin is as follows: Figure 7 As shown, it is made of high-quality steel with good elasticity. Standard products can be ordered from the market, and their specifications and models match the pin hole 18. Insert it into the pin hole 18 and pry open the locking pin to prevent the cotter pin from loosening and falling off.

[0038] In one embodiment of the present invention, the first sealing and heat-insulating filler 25 between the gaps of the unit plates 1 is a flexible waterproof material such as asphalt sealant or butyl sealant; after the unit plates 1 are connected and fixed, the first sealing and heat-insulating filler 25 fills the gaps between adjacent unit plates 1 to form a seal, which can be waterproof and heat-insulating.

[0039] This invention proposes a flexible, reinforced, ultra-high performance concrete road panel module that can be rapidly installed. The fabrication of the unit panels can be organized and carried out in parallel with the foundation construction, ensuring that the foundation meets the technical quality requirements for installation before the road panel installation begins, thus saving construction time. The unit panels are prefabricated in factories or centralized production areas with complete supporting production resources and a high degree of specialization and industrialization, ensuring production efficiency and quality. During the fabrication of the unit panels, the pre-embedded work of fixing shafts, metal edging, fasteners, and hoisting components is completed simultaneously. The assembly of the panel modules is completed on the construction site.

[0040] The beneficial effects of this invention are as follows:

[0041] 1. The present invention has a simple structure, clear function, clear force transmission, and reliable force bearing. It does not have high requirements for the flatness of the foundation and can be laid directly.

[0042] 2. This invention uses ultra-high performance concrete material with a small thickness of load-bearing structure, which can be quickly constructed using prefabricated construction methods, greatly reducing the construction period.

[0043] 3. The present invention can be prefabricated industrially, with high manufacturing precision, and the on-site assembly construction has a high degree of mechanization, making it safe and reliable.

[0044] 4. The on-site assembly and construction process of this invention is simple, highly operable, has high installation accuracy, and low labor intensity.

[0045] 5. This invention allows for rapid construction, with prefabrication production proceeding simultaneously with foundation construction. Multiple parallel operations can be carried out during the installation phase, resulting in a short on-site assembly period. It offers significant advantages in terms of construction time for temporary traffic road facilities that require rapid deployment.

[0046] 6. This invention uses advanced ultra-high performance concrete materials, which greatly improves the service life of buildings, which is expected to reach more than 100 years. It can be repeatedly disassembled and reused.

[0047] 7. This invention consumes few materials and wastes little, which is in line with the concept of low-carbon and environmentally friendly development.

[0048] 8. The components and installation tools of this invention are simple, making them easy to purchase and operate.

[0049] 9. This device can be applied in temporary engineering projects such as airport engineering, road engineering, square engineering, and temporary road construction, and has good application prospects.

[0050] The parts of this invention not described in detail are prior art.

Claims

1. A flexible reinforced ultra-high performance concrete road panel module that can be quickly laid, comprising unit plates (1) and connectors (2), wherein the upper surfaces of multiple unit plates (1) are coplanar, and there are gaps between adjacent unit plates (1), the gaps being filled with a first sealing and heat-insulating filler (25), and adjacent unit plates (1) are connected by at least one connector (2); characterized in that: The unit plate (1) is composed of a concrete substrate (11) and a fixed shaft (12). The concrete substrate (11) is a quadrilateral structure with evenly distributed opening slots (13) on its four sides. Each opening slot (13) is provided with a fixed shaft (12). The connector (2) is telescopically connected to the corresponding fixed shafts (12) between adjacent unit plates (1). The upper surface of the concrete substrate (11) is covered with metal edging (19) on all four sides. The edges of the metal edging (19) are provided with a first stepped groove (20). The first stepped groove (20) is filled with a second sealing and heat-insulating filler (24). The fixed shaft (12) is horizontally fixed to one side wall of the opening groove (13). The connector (2) is a rectangular plate structure. The two ends of the connector (2) are respectively provided with waist-shaped through holes (14). The fixed shaft (12) passes through the middle of the corresponding waist-shaped through hole (14). A fastening nut (15) is provided on the fixed shaft (12) to press and fix the connector (2) to the side wall of the opening groove (13). The opening groove (13) penetrates the upper and lower surfaces of the concrete substrate (11). The upper opening of the opening groove (13) is provided with a second step groove (21). A sealing plate (22) is fixedly installed on the second step groove (21), and the sealing plate (22) covers the upper opening of the opening groove (13). The bottom surface of the second step groove (21) is provided with a fixing member (23), the fixing member (23) has an internal thread, and the sealing plate (22) is connected to the internal thread of the fixing member (23) by a countersunk bolt.

2. The flexible reinforced ultra-high performance concrete road panel module that can be quickly laid according to claim 1, characterized in that: The fixed shaft (12) is also fitted with a flat washer (16) and a spring washer (17). The flat washer (16) is located on both sides of the connector (2) to facilitate the sliding of the connector (2). The spring washer (17) is used to maintain the clamping force of the fastening nut (15).

3. The flexible reinforced ultra-high performance concrete road panel module that can be quickly laid according to claim 1, characterized in that: The fixed shaft (12) is also provided with a pin hole (18), and a locking pin is provided in the pin hole (18) to prevent the fastening nut (15) from falling off.

4. The flexible reinforced ultra-high performance concrete road panel module that can be quickly laid according to claim 1, characterized in that: The concrete substrate (11) is made of ultra-high performance concrete, with a steel mesh inside and four corners on its upper surface.

5. The flexible reinforced ultra-high performance concrete road panel module that can be quickly laid according to claim 1, characterized in that: The first sealing and heat-insulating filler (25) is asphalt sealant, and the second sealing and heat-insulating filler (24) is polyurethane rubber.

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