One-step formed composite material flood prevention and rescue large block stone and preparation method thereof

Abstract

The present invention discloses a one-step-molded composite flood prevention and rescue block stone and its preparation method. The flood prevention block stone is composed of concrete, a steel cage, a support plate, a ton bag, and a sand and gravel core. The block stone has a regular quadrangular pyramidal shape, good integrity, high density, large size, good durability, is difficult to be washed away by water, and can be well stuck in the root stone pile. The preparation method is simple, one-time molding, good integrity, and convenient for mass production. The preparation method and steps include: first using a ton bag to prepare a compacted sand and gravel core; lowering the steel cage and pouring bottom concrete to the top surface of the pad; hoisting the ton bag and the compacted sand and gravel core; covering with a steel cage cover, pouring concrete on the side walls and top; demolding the outer formwork, and then curing to complete the preparation.

Description

Technical Field

[0001] The invention relates to the technical field of flood control engineering, in particular to a one-step formed composite material flood control and emergency rescue large block stone and a preparation method thereof. Background Art

[0002] During extreme weather, rivers experience large flows, rapid flow rates, and sudden rises in water levels during flood season, leading to erosion of dam banks and river embankments, severe loss of soil and rock, and consequently landslides. Throwing flood control stones is a commonly used method for river regulation and disaster relief in flood control projects. After being thrown, flood control stones can form root stones, thereby reinforcing the foundations and subgrades of dam banks and river embankments. The greater the density and size of the flood control stones, the better the management effect. However, in the past, flood control stones were usually small in size, and when being thrown, they relied on wire cages to gather small pieces of flood control stones into a whole before being thrown, which was time-consuming, labor-intensive, and uneconomical.

[0003] With the national environmental protection policy of closing mountains and reforesting, stone mining has been further restricted, the source of natural flood-control stone is dwindling, and its price is rising. Currently, artificial flood-control stone is mainly divided into two categories: one is small concrete flood-control stone made from mud, sand, and cement as the main materials, mixed with various chemical reagents, and then fired or extruded into a mold; the other is shell concrete flood-control stone made from flexible materials and concrete as the shell, and mud, sand, steel slag, and other materials as the core. The former has the disadvantages of polluting the environment and wasting energy during firing, or the poor water resistance and easy disintegration of extruded materials. Moreover, the artificial flood-control stone, whether fired or extruded, is relatively small in size. The latter has the disadvantage of being a shell material, which is difficult to prepare the core material, resulting in a smaller density and smaller size. Therefore, seeking artificial flood-control stone to replace natural flood-control stone has become an urgent matter.

[0004] Chinese patent publication number CN107059791A discloses a steel slag core concrete defense stone and its manufacturing method. The defense stone is designed with a reinforced concrete shell of a steel-plastic geogrid, and the core material is an artificial stone made of a steel slag mixture. However, it has the following defects: the geogrid consists of 6 pieces connected together (no instructions are given on how to connect them), the integrity is poor, and the overall tensile performance cannot be effectively improved; due to the insufficient rigidity of the geogrid, the positioning of the geogrid during construction is difficult; the steel slag core is complicated to manufacture, and the steel slag must first be crushed and screened, and then a binder is added and compressed into shape using a cold pressing method; the size of the defense stone is small, with a volume of only 0.074m 3 .

[0005] Chinese patent publication number CN204238179A discloses a cubic concrete-encased earth-filled defense stone. The defense stone uses a steel fiber mesh concrete shell, and the filling materials are mud, clay, water and straw. However, there are the following defects: the connection of the steel fiber mesh relies on welding, and the top steel fiber mesh needs to be placed last after the soil core is loaded, so the connection between this part and other parts is not good; due to the insufficient rigidity of the steel fiber mesh, it is difficult to position the steel fiber mesh during construction, and the steel fiber mesh is easy to deviate from its original position when the vibrating screen is vibrating; the soil core production process is complicated, and clay and straw are needed to bond the mud, and because the country protects arable land, the source of clay is limited; the finished body is small, with a volume of only 0.125m 3 ; The soil core density is small and the overall mass is relatively small.

[0006] The composite flood control block stone provided by the present invention has an outer shell made of highly impermeable reinforced concrete, and the core material is not restricted, making full use of waste materials. It adopts a one-time molding process, has good integrity, and can achieve a higher density of flood control stone. The outer shape adopts a unique square pyramid shape, and the size is huge, up to 1.06m. 3 , is a new design with great practical value. Summary of the Invention

[0007] The technical problem to be solved by the present invention is to provide a one-time formed composite material flood prevention and rescue large block stone and a preparation method. The flood prevention large block stone requires good integrity, high density, large size, good durability, an appearance that is difficult to be washed away by water and can be well stuck in the root stone pile; the preparation method is simple and convenient for batch production.

[0008] In order to solve the above technical problems, the present invention adopts the following technical means:

[0009] A one-time formed composite material large stone structure for flood prevention and rescue, including concrete and a steel cage, wherein the concrete and the steel cage constitute a concrete shell; the steel cage is located in the middle part of the concrete shell, and the steel cage is divided into a steel cage cover, a steel cage body, an auxiliary steel mesh and a steel cage bottom mesh; the auxiliary steel mesh is arranged above the steel cage bottom mesh, and the auxiliary steel mesh is connected to the steel cage body by binding; a pad is provided between the auxiliary steel mesh and the steel cage bottom mesh; the upper and lower parts of the pad are respectively bound and fixed to the auxiliary steel mesh and the steel cage bottom mesh; the ton bag is arranged in the concrete shell, the top of the ton bag is open, and a support plate is laid on the bottom of the ton bag; the ton bag is filled with a sand and gravel core and then wrapped with the sand and gravel core, and a compaction interval of 160 mm is provided between the tailings in the sand and gravel core and between the tailings and the side of the ton bag, and the compaction interval is filled with Yellow River sediment.

[0010] Further preferred solutions are as follows:

[0011] The concrete shell has the shape of a regular quadrangular pyramid. The specific dimensions of the outer surface of the shell are: the lower bottom side is 700mm long, the upper bottom side is 1200mm long, the height is 1147mm, and the concrete shell is 80mm thick; the dimensions of the inner surface are the same as those of the outer surface of the sand and gravel core.

[0012] Both ends of each steel bar on the steel bar cage cover are provided with hooks, which are directly clamped on the steel bar cage body at the lower part.

[0013] The compaction interval between the tailings is 160 mm, and there is a compaction interval between the tailings and the side of the ton bag. The thickness of the tailings is 90 mm, and the compaction interval between the tailings and the side of the ton bag is not less than 90 mm.

[0014] The pad is a cuboid of 40mm×40mm×160mm. The pad can bear the weight of the upper sand and stone core, and the pads on the edge can bear the weight of the inner mold.

[0015] The pads are evenly spaced and arranged on the bottom mesh of the steel cage and the auxiliary steel mesh.

[0016] A method for preparing a one-step-molded composite flood prevention and rescue large block stone comprises the following steps:

[0017] Prepare the outer formwork of the sand and gravel core;

[0018] (2) Place the outer template of the sand and gravel core on the flat bottom plate, place the pallet on the inner bottom surface of the ton bag, and then place the ton bag into the outer template of the sand and gravel core; turn the part of the ton bag that is higher than the outer template of the sand and gravel core over the outer surface of the outer template;

[0019] (3) After filling the gravel core in the ton bag, the gravel core is wrapped. There are compaction intervals between the tailings and the tailings in the gravel core and between the tailings and the side of the ton bag. The compaction intervals are filled with Yellow River mud. They are laid from the bottom surface upwards. After laying each layer of Yellow River mud, it is compacted until the gravel core reaches the required height. Continue to fill the ton bag with Yellow River mud. Use the compaction system to further compact the mud until the gravel core reaches the required density.

[0020] (4) The compaction system is equipped with a loading plate, a jack, and a reaction frame. The Yellow River silt is filled to the top of the ton bag. The reaction frame provides the reaction force. The loading plate compacts the Yellow River silt through the extension of the jack. The compaction stops when the silt is compacted to the designed top surface of the sand and gravel core and the sand and gravel core reaches the designed density.

[0021] (5) Prepare the outer shell template;

[0022] (6) Place the outer shell formwork on the flat bottom plate; lower the steel cage with pads to the designed concrete center position, pour concrete to the top surface of the pads, and the pads and the auxiliary steel mesh of the steel cage form a casting bottom surface with good integrity, which relies on the pads to support the inner formwork;

[0023] (7) Insert outer support rods and inner support rods inside and outside the steel cage respectively, and insert four inner formworks inside the inner support rods. The inner formworks are provided with winged inner formworks and non-winged inner formworks. The size of the internal space formed by the winged inner formworks and non-winged inner formworks is the same as the size of the ton bag. The inner formworks are made of high-rigidity steel plates; the steel plates are supported on pads; but in order to prevent the side wall concrete from overflowing, the height of the inner formworks must be greater than the height of the sand and gravel core;

[0024] (8) Place a bracket on the top of the sand and gravel core in the ton bag so that the bracket is against the four sides of the ton bag to prevent the sand and gravel core from deforming when it is lifted; use lifting equipment to lift the ton bag and place the ton bag in the inner formwork. After placing it, remove the bracket and pour concrete between the inner formwork and the outer formwork of the outer shell. Vibrate while pouring. After the pouring reaches the height of the steel cage, use a cantilever crane to pull out the outer support rod, pull out the inner support rod, pull out the inner formwork, continue pouring concrete and vibrate until the concrete completely fills the gaps left by the outer support rods, inner support rods and inner formwork and is in close contact with the ton bag;

[0025] (9) Cover the steel cage cover to form a closed steel cage with the steel cage body, and continue pouring concrete until the upper concrete shell reaches 80mm to form a complete concrete shell;

[0026] (10) The outer shell template is demoulded and then cured, and the final preparation is completed.

[0027] The ton bag is a regular quadrangular pyramid, the same shape as the sand and gravel core, but the height and the size of the open top surface are larger than the sand and gravel core and the outer template of the sand and gravel core, and is used to wrap the sand and gravel core. The support plate is square, and its internal area is the same as the bottom area of ​​the sand and gravel core; it is placed under the bottom surface of the sand and gravel core, inside the ton bag, and on the bottom surface of the ton bag; it is made of a 10mm thick mold plate. The lower bottom surface of the sand and gravel core has a side length of 606mm, the upper bottom surface has a side length of 1001mm, and the height is 908mm; preferably, the sand and gravel core is a mixture of Yellow River sediment and tailings, and the mixing method is layered, that is, first laying a layer of 160mm Yellow River sediment, and then laying a layer of 90mm tailings. The tailings are not less than 90mm away from the side on all sides, and are laid in sequence from the lower bottom surface of the ton bag upwards.

[0028] The space enclosed by the outer formwork of the sand and gravel core is a hexahedron without upper and lower bottom surfaces. The internal space dimensions are 606mm in side length of the lower bottom surface, 1001mm in side length of the upper bottom surface, and 1008mm in height. High-strength connecting bolts are set on the 90° bent side wings in the middle of the outer formwork, with 3 on each side.

[0029] The sand and gravel core is filled in the ton bag. After compaction, the tailings serve as the skeleton, supplemented by the support plate at the bottom of the ton bag and the bracket on the top, so the shape of the ton bag can be better maintained during lifting. Moreover, when it is lifted into the inner template, slight changes in the shape can be corrected.

[0030] The pallet supports the tonnage bags during the installation of the sand and gravel cores, preventing them from bulging at the bottom. When the sand and gravel cores are hoisted onto the inner formwork, the pallet evenly distributes the weight of the sand and gravel cores onto the pads, preventing uneven stress on the sand and gravel cores and causing an uneven bottom surface. After pouring, the pallet and tonnage bags are not removed and remain directly in the flood control stone.

[0031] The space enclosed by the outer formwork of the concrete shell is a hexahedron without upper and lower bottom surfaces. The internal space dimensions are 700mm in side length of the lower bottom surface, 1243mm in side length of the upper bottom surface, and 1247mm in height. High-strength connecting bolts are set on the 90° bent side wings in the middle of the outer formwork, with 3 on each side.

[0032] Because the sand and gravel core outer formwork and the outer shell outer formwork are both extremely heavy, they can fit tightly to the bottom surface by their own weight alone, so there is no need to make any connection between the outer formwork and the base plate; to facilitate demoulding, a release agent should be applied to the inner side of the outer formwork and the base plate.

[0033] The concrete uses self-mixed C30 concrete, and the maximum particle size of the coarse aggregate should meet the requirements of the minimum cross-section and the minimum steel bar spacing, and the maximum particle size does not exceed 20mm; in addition, the concrete should undergo freeze-thaw tests and anti-penetration tests to meet the durability requirements; the concrete pouring area needs to be cured for 7 days, and then the sand and gravel core is compacted on it. This is because after 7 days of curing, the strength of the concrete used in the experiment of the present invention can reach 50% of its strength, so that the sand and gravel core will not be crushed when it is made; if concrete of other strengths or different mix ratios is used, a uniaxial compressive test should be carried out to determine the demolding time.

[0034] The concrete inner formwork consists of two pieces of winged inner formwork and two pieces of non-winged inner formwork. The side wings of the winged inner formwork can restrain the non-winged inner formwork. The enclosed space is a hexahedron without upper and lower bottom surfaces. The internal space dimensions are 606mm in length for the lower bottom surface, 1001mm in length for the upper bottom surface, and 1008mm in height. A circular steel hook is welded to the center of the upper end of each piece of inner formwork, which can be easily lifted out with a cantilever crane. The lower part of the inner formwork is supported on pads.

[0035] The pad is a rectangular block with the size of 40mm×40mm×160mm. It is fixed by tying to the auxiliary steel mesh and the bottom mesh of the steel cage and is made of 42.5 cement mortar. The pad can bear the weight of the upper sand and gravel core, and the edge pads can bear the weight of the inner mold.

[0036] The support rod is a U-shaped rod, and the inner and outer support rods are of different heights, which is convenient for insertion and withdrawal; the bending degree of the steel cage is small, which will not affect the insertion and withdrawal of the inner and outer support rods; because the steel bars are slightly bent, the inner and outer support rods will not slide into the lower concrete after insertion; the opening distance of the inner support rod is 370mm, the straight section is 1200mm high, and the radius of the arc section is 260mm; the opening distance of the outer support rod is 370mm, the straight section is 1500mm high, and the radius of the arc section is 260mm; the thickness of the inner and outer support rods is both 32mm, and the thickness of the steel bars tied with the steel bars is 16mm, which just fills the distance of 80mm between the inner and outer formwork.

[0037] The sand and gravel core is compacted by a double compaction method using a rammer and a compaction system, with a maximum dry density of 1.62g / m 3 To control the compaction degree of the Yellow River sediment, 0.84t of dry sand was weighed and the density was 2.6g / m 3 Calculate and weigh 0.27t of tailings; compact according to the method in step (5) to press all the sand and gravel into the inner template so that the average density of the sand and gravel core reaches 1.86g / m 3 .

[0038] Each steel bar on the steel cage cover is provided with hooks at both ends, which can be directly clamped on the steel cage body at the bottom to form a steel cage with good integrity.

[0039] The working principle of the present invention is as follows:

[0040] The shape of the concrete flood prevention boulders was determined based on the river scouring test. The simulation showed that after the flood prevention boulders were thrown, they rolled down the underwater rock pile slope at a certain flow rate. After comparison, it was found that under the same density and volume, the underwater rolling distance of the tetrahedron was the shortest compared with the cylinder, triangular pyramid, cube and cuboid, indicating that it had the best scouring resistance. When C30 concrete was used, the concrete shell thickness was determined to be at least 60mm based on the similar scale model collision test and equal volume collision numerical simulation to meet the force requirements. However, for the convenience of construction, the thickness was finally determined to be 80mm. The specific size of the tetrahedron was the optimal solution given after combining the test and numerical simulation for the convenience of construction. The spacing between the steel bars was set according to the force conditions of the numerical simulation. The reason why the steel bars were slightly bent toward the inside of the tetrahedron was that the flood prevention boulders When colliding with other blocks of stone, the outer side of the concrete shell is under pressure and the inner side is under tension, and the inward bending of the steel bars can make the concrete on the inner side less likely to crack; the degree of inward bending of the steel bars is that the center position of the length of the steel bars is offset inward by 10mm, which can be completed using a steel bar bending machine; the role of the auxiliary steel mesh is to fix the pads, facilitate construction, and increase the strength of the concrete shell; the sand and gravel core adopts a layered structure, first laying a layer of Yellow River mud on the bottom of the shell, using a small rammer to compact it, and then laying a layer of tailings, and then laying a layer of Yellow River mud, and so on. When it reaches the top of the sand and gravel core, a press is used to compact it; when compacting the sand and gravel core, the optimal water content of the Yellow River mud should be used; the ton bag and pallet are set up for lifting the sand and gravel core and are no longer removed.

[0041] The advantages of the present invention are:

[0042] (1) The sand core uses Yellow River silt and tailings as raw materials, which are abundant and extremely cheap. The utilization and treatment of these wastes can turn waste into treasure, reduce ore mining, and contribute to environmental protection.

[0043] (2) The composite structure of the sand and gravel core is reasonably designed, which enables the Yellow River sediment and tailings to be well combined together to form a "strong core" with high density.

[0044] (3) The concrete shell has a reasonable structural design, which can meet the load-bearing requirements and save materials. It is formed in one go and has no joints, which ensures the integrity of the concrete shell. The construction process is simple and easy to mass produce, which greatly reduces the production cost of large flood control stones.

[0045] (4) The shape of the large flood control stone is a regular quadrangular pyramid, which is different from the common cube and rectangular parallelepiped, which is beneficial to the anti-scouring of the stone; when combined with flood control stones of other shapes, it can form a better gradation.

[0046] (5) When the steel cage is made, the steel bars are slightly bent toward the inside of the tetrahedron to form a certain curvature, so that the concrete shell of the flood control large stone is not easy to resist collision and its ability to resist collision is improved.

[0047] (6) The integrity of the large flood control stones is good. The concrete shell ensures sufficient anti-collision ability, and the compacted sand and gravel core ensures sufficient quality. The construction technology enables the concrete shell and the sand and gravel core to be tightly combined.

[0048] (7) The flood control boulders are huge, with a volume of up to 1.06m 3 , with a total mass of 2.3t, it is very beneficial to flood control and rescue work and has extremely high practical value. BRIEF DESCRIPTION OF THE DRAWINGS

[0049] Figure 1 It is a structural diagram of the flood prevention large block stone of the present invention.

[0050] Figure 2 It is an overall three-dimensional diagram of the flood prevention large-block stone reinforcement cage of the present invention.

[0051] Figure 3 It is a detailed view of the reinforcement cage cover of the flood prevention large block stone reinforcement cage of the present invention.

[0052] Figure 4 It is a three-dimensional diagram of the placement of ton bags when the flood prevention large stone and sand core is compacted according to the present invention.

[0053] Figure 5 It is an overall stereoscopic diagram of the hoisting of large flood prevention stone ton bags of the present invention.

[0054] Figure 6 It is a structural diagram of the flood prevention large stone ton bag support of the present invention.

[0055] Figure 7 It is a structural diagram of the flood prevention large stone and sand core of the present invention.

[0056] Figure 8 This is a diagram of the compaction of sand and gravel cores during the preparation of large flood control stones of the present invention.

[0057] Figure 9 An overall view of the outer mold during the preparation of the flood control large stone sand core of the present invention.

[0058] Figure 10 Detail of the outer mold during the preparation of the flood control large stone sand core of the present invention.

[0059] Figure 11 It is a three-dimensional diagram of the arrangement of large stone pads for flood control of the present invention.

[0060] Figure 12 It is a plan view of the arrangement of the flood control large stone pads of the present invention.

[0061] Figure 13 It is a plan view of the preparation process of the flood control large block stone of the present invention.

[0062] Figure 14 It is a three-dimensional diagram of the preparation process of the flood control large block stone of the present invention.

[0063] Figure 15 Overall view of the outer formwork for pouring the flood control massive stone concrete shell of the present invention.

[0064] Figure 16 Detailed view of the outer formwork for pouring the flood control massive stone concrete shell of the present invention.

[0065] Figure 17 It is an overall diagram of the inner mold during the preparation process of the flood control large block stone of the present invention.

[0066] Figure 18 This is a detailed view of the inner mold with wings during the preparation process of the flood control large block stone of the present invention.

[0067] Figure 19 This is a detailed view of the inner mold without wings during the preparation process of the flood control large block stone of the present invention.

[0068] Figure 20 It is a three-dimensional diagram of the support rods in the process of preparing the flood control large block stone of the present invention.

[0069] Explanation of the accompanying reference numerals: 1-concrete, 2-rebar cage, 2.1-rebar cage cover, 2.2-rebar cage body, 2.3-auxiliary steel mesh, 2.4-rebar cage bottom mesh, 3-support plate, 4-ton bag, 5-sand and gravel core, 5.1-Yellow River sediment, 5.2-tailings, 5.3-designed top surface of the sand and gravel core, 6-pad, 7-bracket, 8-external support rod, 9-inner support rod, 10-outer formwork of the outer shell, 10.1-outer formwork of the outer shell with wings, 10.2-bolts of the outer formwork of the outer shell, 11-inner formwork, 11.1-inner formwork with wings, 11.2-inner formwork without wings, 12-bottom plate, 13-outer formwork of the sand and gravel core, 13.1-outer formwork of the sand and gravel core with wings, 13.2-bolts of the outer formwork of the sand and gravel core, 14-loading plate, 15-jack, 16-reaction frame. DETAILED DESCRIPTION

[0070] The following description is an example and is intended to provide further detailed description of the present application. The terms used are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application.

[0071] See also Figure 1-7It can be seen that the composite material flood prevention and rescue large stone structure formed in one step of the present invention is composed of concrete 1, steel cage 2, support plate 3, ton bag 4 and sand and gravel core 5; the concrete 1 and steel cage 2 constitute the concrete shell; the steel cage 2 is located in the middle part of the concrete shell, and the steel cage 2 is divided into a steel cage cover 2.1, a steel cage body 2.2, an auxiliary steel mesh 2.3 and a steel cage bottom mesh 2.4; the auxiliary steel mesh 2.3 is arranged above the steel cage bottom mesh 2.4, and the auxiliary steel mesh 2.3 is tied and connected to the steel cage body 2.2; the auxiliary steel A spacer 6 is provided between the reinforcement mesh 2.3 and the reinforcement cage bottom mesh 2.4; the top and bottom of the spacer 6 are respectively tied and fixed to the auxiliary reinforcement mesh 2.3 and the reinforcement cage bottom mesh 2.4; the ton bag 4 is arranged in the concrete shell, the top of the ton bag 4 is open, and a support plate 3 is laid on the bottom of the ton bag 4; the ton bag 4 is filled with a sand and gravel core 5 and then wrapped with the sand and gravel core 5, and a compaction interval of 160 mm is provided between the tailings 5.2 in the sand and gravel core 5 and between the tailings 5.2 and the side of the ton bag 4, and the compaction interval is filled with Yellow River sediment 5.1.

[0072] See also Figure 1 It can be seen that the concrete 1 and the steel cage 2 form a concrete shell, which has a regular quadrangular pyramid shape. The specific dimensions of the shell are a lower bottom side length of 700 mm, an upper bottom side length of 1200 mm, a height of 1147 mm, and a concrete shell thickness of 80 mm.

[0073] See also Figure 1-3 It can be seen that the steel cage 2 is located in the middle part of the concrete shell, with a lower bottom side length of 635mm, an upper bottom side length of 1105mm, a height of 1067mm, a steel bar diameter of 8mm, a steel bar spacing of 150mm, and two rows of steel bars are arranged horizontally on the side as stirrups, which are 240mm away from the upper bottom and 380mm away from the lower bottom respectively; the steel bars of the steel cage 2 are slightly bent toward the inside of the tetrahedron to form a certain curvature; the steel cage 2 is divided into a steel cage cover 2.1, a steel cage body 2.2, an auxiliary steel mesh 2.3 and a steel cage bottom mesh 2.4. Both ends of each steel bar on the steel cage cover 2.1 are provided with hooks, which can be directly stuck on the lower steel cage body 2.2, and the connection between the steel bars is made by binding; the steel cage is provided with an auxiliary steel mesh 2.3 80mm above the steel cage bottom mesh 2.4, and the steel bars of the auxiliary steel mesh are no longer bent.

[0074] See also Figure 4-6 The ton bag 4 is arranged in the concrete shell, and the top of the ton bag 4 is open. The sand and gravel core 5 is filled in the ton bag 4 and then wrapped. As shown in the figure, the ton bag 4 is a regular quadrangular pyramid, and its shape is the same as the sand and gravel core 5, but the height of its top opening and the size of the top surface of the opening are larger than the sand and gravel core 5 and the sand and gravel core outer template 13, so that the sand and gravel core 5 can be wrapped after filling it.

[0075] See also Figure 7 It can be seen that the sand and gravel core 5 is a mixture of Yellow River silt 5.1 and tailings 5.2, which are mixed in layers. That is, a 160mm layer of Yellow River silt 5.1 is laid first, followed by a 90mm layer of tailings 5.2. The tailings 5.2 are laid at a distance of at least 90mm from the sides, and are laid in sequence from the bottom of the ton bag 4 upwards. The bottom side of the sand and gravel core 5 is 606mm long, the top side is 1001mm long, and the height is 908mm. The compaction interval here refers to the thickness after compaction by a compactor when laying in layers. Compactors generally have difficulty compacting to a very dense state. Therefore, after filling, the compaction system, i.e., the jack 15, is required to compact the sand and gravel further until all the weighed soil and rock are filled in and the designed density is achieved.

[0076] See also Figure 13 As can be seen, a spacer 6 is placed between the auxiliary reinforcement mesh 2.3 and the cage bottom mesh 2.4. The top and bottom of the spacer 6 are respectively tied to the auxiliary reinforcement mesh 2.3 and the cage bottom mesh 2.4. The top of the spacer 6 extends upward from the auxiliary reinforcement mesh 2.3, while the bottom of the spacer 6 extends downward from the cage bottom mesh 2.4. This facilitates the tying and fixing, increases the overall strength of the auxiliary reinforcement mesh 2.3, and helps position the cage 2. After tying according to the design, the cage 2 with the spacer can be directly placed to ensure that the cage 2 is in the designed position.

[0077] See also Figure 4-20 A method for preparing a one-step-molded composite flood prevention and rescue large block stone comprises the following steps:

[0078] See also Figure 4-6 A pair of high-rigidity steel plates with a thickness of more than 5 mm are used as the sand and gravel core outer template 13. The winged sand and gravel core outer template 13.1 is provided with 90° bent side wings, and 3 pairs of opening holes are provided on the side wings, which are connected using 3 pairs of sand and gravel core outer template bolts 13.2.

[0079] (2) See Figure 6 , place the sand and gravel core outer template 13 on the flat bottom plate 12, place the pallet 3 on the inner bottom surface of the ton bag 4, and then place the ton bag 4 into the sand and gravel core outer template 13; turn the part of the ton bag 4 higher than the sand and gravel core outer template 13 over the outer surface of the outer template.

[0080] (3) See Figure 6 、 Figure 7, after filling the sand and gravel core 5 in the ton bag 4, the sand and gravel core 5 is wrapped, and compaction intervals are provided between the tailings 5.2 in the sand and gravel core 5 and between the tailings 5.2 and the side of the ton bag 4, and the compaction intervals are filled with Yellow River mud 5.1; it is laid according to the structure of a layer of 160mm Yellow River mud 5.1 and then a layer of 90mm tailings 5.2. The distance between the tailings 5.2 and the side of the ton bag 4 is not less than 90mm as the compaction interval, and it is laid from the bottom surface to the top; after laying each layer of Yellow River mud 5.1, it needs to be compacted with a small rammer until the sand and gravel core 5 reaches the required height, and then continue to fill the Yellow River mud 5.1 to the ton bag 4, and use the compaction system to further compact the mud until the sand and gravel core 5 reaches the required density.

[0081] (4) See Figure 8 The compaction system consists of a loading plate 14, a jack 15, and a reaction frame 16. The Yellow River sediment 5.1 is filled to the top of the ton bag 4. The reaction frame 16 provides a reaction force, which is extended by the jack 15. The loading plate 14 compacts the Yellow River sediment 5.1 and stops compacting when it is compacted to the designed top surface 5.3 of the sand and gravel core. If there is any remaining Yellow River sediment 5.1 after one compaction, it will be filled into the top of the ton bag 4 and continued to be compacted to the designed top surface 5.3 of the sand and gravel core. This cycle is repeated until all the weighed sand and gravel are pressed in, so that the sand and gravel core 5 reaches the density required by the design.

[0082] (5) See Figure 15 、 Figure 16 The outer shell formwork 10 is provided with a winged outer shell formwork 10.1 and an outer shell formwork bolt 10.2. The outer shell formwork 10 adopts a pair of high-rigidity steel plates with a thickness of more than 5 mm. The winged outer shell formwork 10.1 is provided with a 90° bent side wing, and 3 pairs of opening holes are provided on the side wing. 3 pairs of high-strength outer shell formwork bolts 10.2 are used to connect the winged outer shell formwork 10.1.

[0083] (6) See Figure 11-16 , place the outer shell formwork 10 on the flat bottom plate 12; lower the steel cage 2 with the pad 6 to the designed center position of the concrete 1, pour concrete to the top surface of the pad 6, and the pad 6 and the steel cage body 2.2 and the auxiliary steel mesh 2.3 form a strong supporting casting bottom surface.

[0084] (7) See Figure 13-14 、 Figure 18-20, outer support rods 8 and inner support rods 9 are respectively inserted into the inner and outer sides of the steel cage 2, and four inner formworks 11 are inserted into the inner side of the inner support rods 9. The inner formwork 11 is provided with a winged inner formwork 11.1 and a wingless inner formwork 11.2. The size of the internal space formed by the winged inner formwork 11.1 and the wingless inner formwork 11.2 is the same as the size of the sand and gravel core 5. The inner formwork 11 adopts a high-rigidity steel plate with a thickness of more than 5 mm; the steel plate is supported on the pad 6; but in order to prevent the side wall concrete 1 from overflowing, the height of the inner formwork 11 plate must be greater than the height of the sand and gravel core 5, and the higher height is 100 mm.

[0085] (8) See Figure 9 、 Figure 10 , Figure 13-14 , place a bracket 7 on the top of the sand and gravel core 5 in the ton bag 4, so that the bracket 7 is against the four sides of the ton bag 4 to prevent the sand and gravel core 5 from deforming when lifting; use lifting equipment to lift the ton bag 4, and place the ton bag 4 in the inner formwork 11. After placement, remove the bracket 7, pour concrete between the inner formwork 11 and the outer formwork 10 of the outer shell, and vibrate while pouring. After the pouring reaches the height of the steel cage 2, use a cantilever crane to pull out the outer support rod 8, pull out the inner support rod 9, pull out the inner formwork 11, continue to pour concrete 1 and vibrate, so that the concrete completely fills the gaps left by the outer support rods 8, inner support rods 9 and inner formwork 11 and is in close contact with the ton bag 4.

[0086] (9) See Figure 3 、 Figure 13-14 , cover the steel cage cover 2.1 to form a closed steel cage 2 with the steel cage body 2.2, and continue pouring concrete so that the upper reinforced concrete shell also reaches 80mm, forming a complete concrete shell.

[0087] (10) After being placed for 24 hours, the outer shell template 10 is demoulded and then cured for 28 days to complete the preparation.

[0088] The construction process of this embodiment is simple, it can be formed in one go, the structure is seamless and has good integrity, and it is convenient for process production; the raw materials of the sand and gravel core are recycled waste, and the concrete shell meets the stress and economic requirements. Therefore, the flood control large stones not only meet the requirements of environmental protection, but also have high economic value.

[0089] The above description is only a preferred embodiment of the present invention. The relevant physical and mechanical parameters used are actual test data in the process of this invention, which may vary with different material sources, batches, and preparation processes. Therefore, the scope of rights of the present invention is not limited thereby. Any equivalent structural changes made using the contents of the present invention specification and drawings are included in the scope of rights of the present invention.

Claims

1. A composite material large block stone for flood prevention and rescue formed in one step, comprising concrete (1) and a steel cage (2), characterized in that: The concrete (1) and the steel cage (2) constitute a concrete shell; The steel cage (2) is located in the middle of the concrete shell. The steel cage (2) is divided into a steel cage cover (2.1), a steel cage body (2.2), an auxiliary steel mesh (2.3) and a steel cage bottom mesh (2.4). The auxiliary steel mesh (2.3) is arranged above the steel cage bottom mesh (2.4). The auxiliary steel mesh (2.3) is tied and connected to the steel cage body (2.2). A spacer (6) is provided between the auxiliary steel mesh (2.3) and the steel cage bottom mesh (2.4). The upper and lower parts of the pad (6) are respectively tied and fixed to the auxiliary steel mesh (2.3) and the steel cage bottom mesh (2.4); The ton bag (4) is set in the concrete shell, the top of the ton bag (4) is open, and the bottom of the ton bag (4) is paved with a support plate (3). The ton bag (4) is filled with a sand and gravel core (5) and then wrapped with the sand and gravel core (5). There are compaction intervals between the tailings (5.2) and the tailings (5.2) in the sand and gravel core (5) and between the tailings (5.2) and the side of the ton bag (4). The compaction interval is 160 mm, and the compaction interval is filled with Yellow River sediment (5.1); The concrete shell has a rectangular pyramidal shape, and the specific dimensions of the outer surface of the shell are that the side length of the lower bottom surface is 700mm, the side length of the upper bottom surface is 1200mm, the height is 1147mm, and the thickness of the concrete shell is 80mm; the dimensions of the inner surface are the same as the dimensions of the outer surface of the sand and gravel core (5).

2. The composite flood prevention and rescue large stone formed in one step according to claim 1 is characterized by: Each steel bar on the steel bar cage cover (2.1) is provided with hooks at both ends, and the hooks are directly clamped on the steel bar cage body (2.2) at the bottom.

3. The one-step formed composite flood prevention and rescue large stone according to claim 1, characterized in that: The thickness of the tailings (5.2) is 90 mm, and the compaction interval between the tailings (5.2) and the side of the tonnage bag (4) is not less than 90 mm.

4. The one-step formed composite flood prevention and rescue large block stone according to claim 1 is characterized by: The cushion block (6) is a rectangular parallelepiped with a size of 40 mm × 40 mm × 160 mm.

5. The one-step formed composite flood prevention and rescue large block stone according to claim 1 is characterized by: The pads (6) are evenly spaced and arranged on the steel cage bottom mesh (2.4).

6. The method for preparing a composite material large block stone for flood prevention and emergency rescue formed in one step according to claim 1, characterized in that: The following steps are involved: (1) Prepare the sand and gravel core outer template (13); (2) placing the sand and gravel core outer template (13) on a flat bottom plate (12), placing the support plate (3) on the inner bottom surface of the ton bag (4), and then placing the ton bag (4) into the sand and gravel core outer template (13); turning the portion of the ton bag (4) that is higher than the sand and gravel core outer template (13) over onto the outer surface of the sand and gravel core outer template (13); (3) After the gravel core (5) is filled in the ton bag (4), the gravel core (5) is wrapped. Compaction intervals are provided between the tailings (5.2) and the tailings (5.2) in the gravel core (5) and between the tailings (5.2) and the side of the ton bag (4). The compaction intervals are filled with Yellow River silt (5.1); the silt is laid from the bottom surface upwards; each layer of Yellow River silt (5.1) is compacted after laying, until the gravel core (5) reaches the required height, and then the Yellow River silt (5.1) is continued to be filled to the ton bag (4). The silt is further compacted by the compaction system until the gravel core (5) reaches the required density; (4) The compaction system is provided with a loading plate (14), a jack (15), and a reaction frame (16). The Yellow River silt (5.1) is filled to the top of the ton bag (4). The reaction frame (16) provides a reaction force, and the jack (15) is extended to allow the loading plate (14) to compact the Yellow River silt (5.1). The compaction is stopped after the silt is compacted to the designed top surface (5.3) of the sand and gravel core and the sand and gravel core (5) reaches the designed density. (5) Prepare the outer shell template (10); (6) Place the outer shell formwork (10) on the flat bottom plate (12); lower the steel cage (2) with the pad (6) to the center of the designed concrete (1), pour concrete to the top surface of the pad (6), and the pad (6) and the auxiliary steel mesh (2.3) form a well-integrated casting bottom surface that relies on the pad to support the inner formwork (11); (7) Insert outer support rods (8) and inner support rods (9) inside and outside the steel cage (2), insert four inner formworks (11) inside the inner support rods (9), and the inner formworks (11) are provided with inner formworks with wings (11.1) and inner formworks without wings (11.2). The size of the inner space formed by the inner formworks with wings (11.1) and the inner formworks without wings (11.2) is the same as the size of the ton bag (4). The inner formworks (11) are made of high-rigidity steel plates; The steel plate is supported on the pad (6); however, in order to prevent the side wall concrete (1) from overflowing, the height of the inner formwork (11) must be greater than the height of the sand and gravel core (5); (8) Place a bracket (7) on the top of the sand and gravel core (5) in the ton bag (4) so ​​that the bracket (7) is against the four sides of the ton bag (4) to prevent the sand and gravel core (5) from being deformed when it is lifted; use a lifting device to lift the ton bag (4) and place the ton bag (4) in the inner formwork (11). After it is placed, remove the bracket (7) and pour concrete between the inner formwork (11) and the outer formwork (10) of the outer shell. Vibrate while pouring. After the pouring reaches the height of the steel cage (2), use a cantilever crane to pull out the outer support rod (8), pull out the inner support rod (9), pull out the inner formwork (11), continue pouring concrete (1) and vibrate until the concrete completely fills the gaps left by the outer support rod (8), the inner support rod (9) and the inner formwork (11) and is in close contact with the ton bag (4); (9) Cover the steel cage cover (2.1) to form a closed steel cage (2) with the steel cage body (2.2), and continue pouring concrete until the upper concrete shell reaches 80mm, forming a complete concrete shell; (10) The outer shell template (10) is demoulded and then cured, and the final preparation is completed.

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