Steel bridge deck pavement pothole defect repairing structure and repairing method

Abstract

The present application relates to the field of steel bridge deck pavement maintenance and repair, a kind of steel bridge deck pavement pit disease repair structure and repair method. Its structure bottom is orthotropic steel plate, the lower layer is 1.5-2.0cm thick perfusion type resin concrete pavement, the upper layer is 3.0-4.0cm thick cast resin concrete pavement, and the surface is embedded with anti-skid gravel. Cold-mixed high-toughness resin is used as binder in both upper and lower layers of pavement. The low viscosity of cold-mixed high-toughness resin is used to infiltrate the delamination area at the bottom of the surrounding pavement around the pit, preventing the surrounding pavement from cracking. The porosity of both perfusion type resin concrete and cast resin concrete is less than 3%, and there are no interconnected voids inside, with good compactness and excellent waterproof effect. Both construction processes are normal temperature mixing, reducing the generation of harmful gases and waste. The curing time of the pit disease repair structure of the present application depends on the air temperature, which is 6h at 23℃. When there is sunlight or the air temperature is above 30℃, the curing time is significantly shortened, and the time of closing traffic is greatly reduced compared with the traditional pit repair scheme.

Description

Technical Field

[0001] This invention relates to the field of steel bridge deck pavement maintenance and repair, specifically to a repair structure and method for potholes and other defects in steel bridge deck pavement. Background Technology

[0002] Steel box girders are increasingly used in bridge construction due to their good strength and relatively light weight. my country currently has nearly one hundred medium- and large-span steel box girder bridges built and in use. Due to the harsh service environment, including high temperatures, heavy loads, and heavy rainfall, steel bridge deck pavement requires maintenance after 2-3 years of service. Bridge deck pavement is prone to defects such as cracks, rutting, bulging, and alligator cracking, with cracking being the most common. If cracks are not repaired promptly, they will further develop into serious defects such as potholes. Potholes will severely affect the bridge's traffic function, impacting driving safety, comfort, and the durability of the pavement.

[0003] The pavement construction of orthotropic steel box girder bridge decks has always been a global engineering challenge. Cracks and potholes are among the most prevalent forms of damage faced by existing long-span steel bridge decks. Compared to newly constructed pavement layers, the maintenance and repair of steel bridge decks faces numerous constraints. For example, after pothole repair, a construction joint exists between the filler and the original pavement. During service, this joint is a weak point, as significant differences in the properties of new and old materials can easily lead to secondary cracking under thermal expansion and contraction, load, and environmental influences. Furthermore, the small scale of pothole repair work and the limited compaction power of small rollers make conventional graded resin concrete prone to secondary cracking due to insufficient compaction. Additionally, traffic pressure may necessitate opening the bridge to traffic before sufficient curing time for the materials. These are all key and challenging aspects of steel bridge deck pavement maintenance and repair.

[0004] As the service life of pavement increases, the occurrence of pavement defects is often unavoidable under the combined effects of traffic loads and environmental factors. To ensure traffic safety and pavement durability, various defects should be maintained and treated promptly. In view of this, it is necessary to invent a repair structure and method for pothole defects in steel bridge pavement to solve the above problems. Summary of the Invention

[0005] The main objective of this invention is to provide a repair structure and method for potholes in steel bridge decks, so as to effectively solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a repair structure for potholes in steel bridge deck pavement, the bottom of which is an orthotropic steel plate. After grinding and rust removal, a double-layer pavement structure is adopted, the lower layer is a 1.5~2.0cm thick cast-in-place resin concrete pavement, and the upper layer is a 3.0~4.0cm thick cast-in-place resin concrete pavement. Anti-slip gravel is embedded on the surface. Both the upper and lower pavement layers use cold-mixed high-toughness resin as the binder.

[0007] This bridge deck pavement pothole repair structure utilizes cast-in-place resin concrete, which possesses excellent high and low temperature performance and fatigue resistance. It also features self-flowing molding and requires no compaction, significantly improving workability and simplifying the construction process while reducing the difficulty of quality control. The cast-in-place resin concrete leverages the low viscosity of cold-mixed high-toughness resin to penetrate into the delamination area at the bottom of the pavement surrounding the pothole, preventing cracking of the surrounding pavement. Simultaneously, it enhances the adhesion between the cast-in-place resin concrete and the steel plate and surrounding pavement interfaces, preventing secondary cracking at the interfaces. During construction, both types of resin concrete are mixed at room temperature, requiring no heating equipment, greatly reducing the generation of harmful gases and waste, resulting in excellent environmental performance. Furthermore, both cast-in-place and poured-in-place resin concrete have a porosity of less than 3%, with no interconnected voids, thus the pothole repair structure possesses good density and excellent waterproofing.

[0008] A repair method for potholes in steel bridge deck pavement includes the following steps:

[0009] Step 1: Select raw materials: including cold-mixed high-toughness resin, coarse aggregate, fine aggregate, etc.

[0010] Step 2: Design of the mixing ratio for infused resin mixtures.

[0011] Step 3: Design of the mixing ratio for cast-in-place resin mixtures.

[0012] Step 4: Pre-construction preparation: This includes preparing construction equipment, storing raw materials, removing existing paving, treating surfaces, cleaning the work surface, and protecting non-work areas.

[0013] Step 5: Construction of cast-in-place resin concrete.

[0014] Step Six: Construction of Cast-in-Place Resin Concrete.

[0015] Step Seven: Health Preservation.

[0016] Preferably, in step one, the cold-mixed high-toughness resin is a cured product obtained by mixing two components, A and B, in a certain proportion and reacting them chemically at room temperature. Component A is a high-elastic epoxy resin, and component B is a curing agent. The mass ratio (A:B) is 10:8~10:10, the tensile strength (23℃) is not less than 3.0MPa, the elongation at break (23℃) is not less than 100%, and the working time (23℃) is not less than 30min.

[0017] Preferably, in step two, the gradation requirements for the cast-in-place resin concrete are shown in Table 1, and the gradation should be as close as possible to the median value. Its curing conditions are: 6 hours at room temperature; porosity should be less than 3.0%; dynamic stability (60℃) greater than 30,000 cycles / mm; flexural strength (-10℃, 50mm / min) greater than 10MPa; and flexural strain (-10℃, 50mm / min) greater than 3000με.

[0018] Table 1. Gradation requirements for cast-in-place resin concrete

[0019]

[0020] Preferably, in step three, the gradation requirements for the cast-in-place resin concrete are shown in Table 2, and should be as close as possible to the median value. The curing conditions for the cast-in-place resin concrete are: curing at room temperature for 6 hours. After curing, the porosity of the specimen should be less than 3.0%, the dynamic stability (60℃) should be greater than 30,000 cycles / mm, the flexural strength (-10℃, 50mm / min) should be greater than 20MPa, and the flexural strain (-10℃, 50mm / min) should be greater than 3000με.

[0021] Table 2. Gradation requirements for cast-in-place resin concrete

[0022]

[0023] Preferably, in step four, the main construction equipment includes one blower, two electronic scales, one electric mixer, one cutting machine, several material buckets, several shovels, several wooden scrapers, several wire brushes, several brooms, and several spades.

[0024] Preferably, in step four, the storage requirements for raw materials are as follows: before construction, cold-mixed high-toughness resin components A and B are placed in a cool place, the aggregates are pre-mixed according to the design gradation, and all raw materials are transported to the site before construction.

[0025] Preferably, in step four, the requirement for removing the original paving is that, before backfilling with resin concrete, the original paving within the damaged area must be cut off with a cutting machine according to the principle of "round hole, square patch", with a cutting angle of 90°.

[0026] Preferably, in step four, the interface treatment requires that the damaged steel plate be ground and rust removed, and the treated interface should be flat and free from unevenness or residual oil stains, rust spots or other impurities.

[0027] Preferably, in step four, cleaning the work surface requires thorough cleaning. A wire brush is used to scrape off any cracked, loose, or weak trench walls or impurities. Then, a blower and broom are used to remove dust, debris, and moisture, ensuring the work surface is dry, clean, and free of contamination. Only after these conditions are met can the injection-type resin concrete be applied.

[0028] Preferably, in step four, the protection requirements for the non-working area are as follows: to prevent the existing paving in the non-working area from being contaminated, tape can be used to stick the paving surface around the pothole before construction to avoid contaminating the adjacent road paving, and at the same time to prevent resin from flowing along the longitudinal or transverse direction of the bridge, so as to ensure that the pothole has a straight and beautiful appearance after repair.

[0029] Preferably, in step five, the construction of the cast-in-place resin concrete is as follows: ① The cast-in-place resin concrete is applied in a single layer with a thickness of 1.5~2.0cm; ② The cast-in-place resin concrete should be completed within 30 minutes after the cold-mixed high-toughness resin is prepared, and the construction should be continuous; ③ After preparing the aggregate according to the requirements of Table 1, pour it directly into the pit with a thickness of 1.5~2.0cm, and level it using a shovel and scraper; ④ Pour the prepared cold-mixed high-toughness resin into the aggregate, allowing it to penetrate the aggregate through its fluidity, and then manually mix it with tools such as shovels and spades to ensure that any areas that have not been penetrated are completely covered with the cold-mixed high-toughness resin. Finally, smooth it with a wooden scraper. It is required that the top layer be covered by at least 2 / 3 of the cold-mixed high-toughness resin, and the interface between the pit and the surrounding paving must be completely covered with the cold-mixed high-toughness resin.

[0030] Preferably, in step six, the construction of the cast-in-place resin concrete is as follows: ① The cast-in-place resin concrete is constructed in a single layer, with the thickness determined by the difference between the top surface of the cast-in-place resin concrete and the surrounding paving surface, generally 3.0~4.0cm; ② A forced concrete mixer is used to mix the coarse and fine aggregates for 20~30s, then cold-mixed high-toughness resin is added and mixed for 1~2min until fully mixed. The mixed cast-in-place resin concrete should be uniform, with all aggregate particles completely coated with cold-mixed high-toughness resin, free from white spots, dead material (i.e., solidified cast-in-place resin concrete), clumps, or segregation of coarse and fine aggregates, and the asphalt-aggregate ratio is 8~10%; ③ The mixed cast-in-place resin concrete is poured into the work area, smoothed and tamped with a wooden scraper to make its surface level with the surrounding paving, and the corners are compacted with a thin steel rod. The construction joints should be full, without gaps or cracks, and each batch of concrete should be completed within 30min.

[0031] Preferably, in step seven, curing: it is essential to ensure that the cast-in-place resin concrete and the poured resin concrete undergo sufficient curing after construction. No vehicles are allowed to pass through during the curing period. The curing time depends on the temperature. At 23°C, it is 6 hours. When there is sunlight or the temperature is above 30°C, the curing time is significantly shortened.

[0032] The beneficial effects of this invention are: by utilizing the excellent high and low temperature performance and fatigue resistance of cast-in-place resin concrete, and by its self-flowing and compaction-free characteristics, it significantly improves the workability of construction, simplifies the construction process, and reduces the difficulty of quality control.

[0033] Cast-in-place resin concrete utilizes the low viscosity of cold-mixed high-toughness resin to penetrate into the delamination area at the bottom of the pavement around the pit, preventing cracking of the surrounding pavement; at the same time, it enhances the bonding performance between the cast-in-place resin concrete and the steel plate and the surrounding pavement interface, preventing secondary cracking of the interface.

[0034] During construction, both types of resin concrete are mixed at room temperature, requiring no heating equipment, which greatly reduces the generation of harmful gases and waste, resulting in excellent environmental performance. Furthermore, both the cast-in-place and poured-in-place resin concrete have a porosity of less than 3%, with no interconnected voids, thus the pothole repair structure possesses excellent density and waterproofing. The curing time for the pothole repair structure of this invention depends on the temperature; it takes 6 hours at 23°C. The curing time is significantly shortened under sunlight or when the temperature is above 30°C, greatly reducing the time spent closing traffic compared to traditional pothole repair methods. Attached Figure Description

[0035] Appendix Figure 1 This is a schematic diagram of a steel bridge deck pavement pothole repair structure proposed in one embodiment of the present invention.

[0036] Appendix Figure 1 In the middle, there are orthotropic steel plates 1, cast-in-place resin concrete 2, cast-in-place resin concrete 3, and anti-slip crushed stone 4. Detailed Implementation

[0037] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0038] See appendix Figure 1A repair structure for potholes in steel bridge deck pavement is provided. The bottom layer is an orthotropic steel plate 1. After grinding and rust removal, a double-layer pavement structure is adopted. The lower layer is a 2.0cm thick cast-in-place resin concrete 2 pavement, and the upper layer is a 3.5cm thick cast-in-place resin concrete 3 pavement. Anti-slip gravel 4 is embedded on the surface. Both the upper and lower pavement layers use cold-mixed high-toughness resin as the binder.

[0039] A repair method for potholes in steel bridge deck pavement includes the following steps:

[0040] Step 1: Select raw materials: including cold-mixed high-toughness resin (composed of high-elastic epoxy resin component A and curing agent component B), coarse aggregate, fine aggregate, etc., and design the mix proportions for injection-type resin mixtures and casting-type resin mixtures.

[0041] ① Preparation of cold-mixed high-toughness resin: The cold-mixed high-toughness resin for both grouting and casting resin concrete can be prepared together. Weigh component A and component B separately and mix them at a mass ratio of 10:8. Use an electric mixer equipped with mixing blades to mix thoroughly for 50 seconds. The technical requirements are shown in Table 3.

[0042] Table 3 Technical Requirements for Cold-Mixed High-Toughness Resins

[0043]

[0044] ② The gradation requirements for cast-in-place resin concrete are shown in Table 1, and the gradation should be as close to the median value as possible. The curing conditions for cast-in-place resin concrete are 6 hours at room temperature. The technical properties of the cured specimens should meet the requirements of Table 4.

[0045] Table 4 Technical requirements for cast-in-place resin concrete (cured specimens)

[0046]

[0047] ③ The gradation requirements for cast-in-place resin concrete are shown in Table 2, and the gradation should be as close to the median value as possible. The curing conditions for cast-in-place resin concrete are 6 hours at room temperature, and the technical properties of the cured specimens should meet the requirements in Table 5.

[0048] Table 5 Technical requirements for cast-in-place resin concrete (cured specimens)

[0049]

[0050] Step Two: Pre-construction preparation: This includes preparation of construction equipment, storage of raw materials, removal of existing paving, surface treatment, cleaning of the work surface, and protection of non-work areas.

[0051] ① The main construction equipment is shown in Table 6.

[0052] Table 6 Main Construction Equipment and Tools

[0053]

[0054] ② The storage requirements for raw materials are as follows: before construction, cold-mixed high-toughness resin components A and B should be placed in a cool place, the aggregates should be pre-mixed according to the design gradation, and all raw materials should be transported to the site before construction.

[0055] ③ The original paving removal requirement is that, before backfilling with resin concrete, the original paving within the damaged area must be cut off with a cutting machine according to the principle of "round hole, square patch", with a cutting angle of 90°.

[0056] ④ The interface treatment requirements are as follows: the damaged steel plate should be ground and rust removed. The treated interface should be flat and free from unevenness or residual oil stains, rust spots or other impurities.

[0057] ⑤ The work surface must be thoroughly cleaned. Use a wire brush to scrape off any cracked, loose, or weak trench walls or impurities. Then, use a blower, broom, or other tools to remove dust, debris, and moisture, ensuring the work surface is dry, clean, and free of contamination. Only after these conditions are met can the injection-type resin concrete be applied.

[0058] ⑥ The protection requirements for non-working areas are as follows: In order to prevent the existing paving in non-working areas from being contaminated, tape can be used to stick the paving surface around the pothole before construction to avoid contaminating the adjacent road paving, and at the same time prevent resin from flowing along the longitudinal or transverse direction of the bridge, so as to ensure that the pothole has a straight and beautiful appearance after repair.

[0059] Step 3: Construction of Cast-in-Place Resin Concrete: ① Cast-in-place resin concrete is applied in a single layer with a thickness of 2.0cm; ② The casting-in-place resin concrete should be constructed within 30 minutes of the preparation of the cold-mixed high-toughness resin, and construction should be continuous; ③ After preparing the aggregate according to the requirements in Table 1, pour it directly into the pit to a thickness of 2.0cm, and level it using a shovel and scraper; ④ Pour the prepared cold-mixed high-toughness resin into the aggregate, allowing it to penetrate the aggregate through its fluidity, and then manually mix it with tools such as shovels and spades to ensure that any areas not yet penetrated are completely covered with the cold-mixed high-toughness resin. Finally, smooth it with a wooden scraper. The top layer should be covered by at least 2 / 3 of the cold-mixed high-toughness resin, and the interface between the pit and the surrounding paving must be completely covered with cold-mixed high-toughness resin.

[0060] In step four, the construction of cast-in-place resin concrete is as follows: ① The cast-in-place resin concrete is applied in a single layer with a thickness of 3.5cm; ② A forced concrete mixer is used to mix the coarse and fine aggregates for 25 seconds, then cold-mixed high-toughness resin is added and mixed for 2 minutes until fully combined. The mixed cast-in-place resin concrete should be uniform, with all aggregate particles completely coated with cold-mixed high-toughness resin, free from white spots, dead material (i.e., already cured cast-in-place resin concrete), clumps, or segregation of coarse and fine aggregates. The asphalt-aggregate ratio is 9%; ③ The mixed cast-in-place resin concrete is poured into the work area, smoothed and tamped with a wooden scraper to ensure its surface is level with the surrounding paving. The corners are compacted with a thin steel rod, and the construction joints are full, without gaps or cracks. Each batch of concrete must be completed within 30 minutes.

[0061] In step five, curing: It is essential to ensure that the cast-in-place resin concrete and the poured resin concrete are fully cured after construction. No vehicles are allowed to pass through during the curing period. The curing time depends on the temperature. At 23℃, it is 6 hours. When there is sunlight or the temperature is above 30℃, the curing time will be significantly shortened.

[0062] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A repair structure for potholes in steel bridge deck pavement, characterized in that: Its bottom is an orthotropic steel plate. After grinding and rust removal, it adopts a double-layer paving structure. The lower layer is a 1.5~2.0cm thick cast-in-place resin concrete paving, and the upper layer is a 3.0~4.0cm thick cast-in-place resin concrete paving. Anti-slip gravel is embedded on the surface. Both the upper and lower paving layers use cold-mixed high-toughness resin as the binder.

2. A repair method for a steel bridge deck pavement pothole repair structure as described in claim 1, characterized in that: Specifically, the following steps are included: Step 1: Select raw materials: including cold-mixed high-toughness resin, coarse aggregate, fine aggregate, etc. Step 2: Design of the mixing ratio for injection-type resin mixture; Step 3: Design of the mix proportions for cast-in-place resin mixtures; Step 4, Pre-construction preparation: This includes preparation of construction equipment, storage of raw materials, removal of existing paving, surface treatment, cleaning of the work surface, and protection of non-work areas. Step 5: Construction of cast-in-place resin concrete; Step Six: Construction of Cast-in-Place Resin Concrete; Step Seven: Health Preservation.

3. The repair method according to claim 2, characterized in that: In step one, the cold-mixed high-toughness resin is a cured product obtained by mixing two components, A and B, in a certain proportion and reacting them chemically at room temperature. Component A is a high-elastic epoxy resin, and component B is a curing agent. The mass ratio (A:B) is 10:8~10:

10. The tensile strength (23℃) is not less than 3.0MPa, the elongation at break (23℃) is not less than 100%, and the working time (23℃) is not less than 30min. In step two, the gradation requirements for the cast-in-place resin concrete are shown in Table 1: Table 1. Gradation requirements for injected resin concrete The curing conditions are 6 hours at room temperature. After curing, the technical performance of the specimen should meet the following requirements: porosity less than 3.0%, dynamic stability (60℃) greater than 30,000 times / mm, flexural strength (-10℃, 50mm / min) greater than 10MPa, and flexural strain (-10℃, 50mm / min) greater than 3000με.

4. The repair method according to claim 2, characterized in that: In step three, the gradation requirements for cast-in-place resin concrete are shown in Table 2: Table 2. Gradation requirements for cast-in-place resin concrete The curing conditions are 6 hours at room temperature. After curing, the technical performance of the specimen should meet the following requirements: porosity less than 3.0%, dynamic stability (60℃) greater than 30,000 times / mm, flexural strength (-10℃, 50mm / min) greater than 20MPa, and flexural strain (-10℃, 50mm / min) greater than 3000με.

5. The repair method according to claim 2, characterized in that, In step five, the construction of the cast-in-place resin concrete includes: ① The cast-in-place resin concrete is a single-layer construction with a thickness of 1.5~2.0cm; ② The cast-in-place resin concrete should be constructed within 30 minutes after the cold-mixed high-toughness resin is prepared, and the construction should be continuous; ③ After preparing the aggregate according to the requirements of Table 1, pour it directly into the pit with a thickness of 1.5~2.0cm, and level it with a shovel and scraper; ④ Pour the prepared cold-mixed high-toughness resin into the aggregate, allowing it to penetrate into the aggregate through its fluidity, and manually mix it with tools such as shovels and spades to ensure that the areas where the resin has not penetrated are completely covered with the cold-mixed high-toughness resin, and finally smooth it with a wooden scraper; the top layer of aggregate should be covered by more than 2 / 3 of the cold-mixed high-toughness resin, and the interface between the pit and the surrounding paving should be completely covered with the cold-mixed high-toughness resin.

6. The repair method according to claim 2, characterized in that, In step six, the construction of the cast-in-place resin concrete includes: ① The cast-in-place resin concrete is constructed in a single layer, with the thickness determined by the difference between the top surface of the cast-in-place resin concrete and the surrounding paving surface, generally 3.0~4.0cm; ② A forced concrete mixer is used to mix the coarse and fine aggregates for 20~30s, and then cold-mixed high-toughness resin is added and mixed for 1~2min until fully mixed; the mixed cast-in-place resin concrete should be uniform, all mineral particles should be completely coated with cold-mixed high-toughness resin, without any white spots, clumps, or segregation of coarse and fine aggregates, and the asphalt-aggregate ratio should be 8~10%; ③ The mixed cast-in-place resin concrete is poured into the work area, leveled and tamped with a wooden scraper to make its surface level with the surrounding paving, and the corners are compacted with a thin steel rod. Each batch of cast-in-place resin concrete must be completed within 30min.

7. The repair method according to claim 2, characterized in that, In step seven, curing: it is essential to ensure that the cast-in-place resin concrete and the poured resin concrete undergo sufficient curing after construction. No vehicles are allowed to pass through during the curing period. The curing time depends on the temperature. At 23℃, it is 6 hours. When there is sunlight or the temperature is above 30℃, the curing time is significantly shortened.

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