3DFRP system with functions of "template" and "tendon" and construction technology thereof

Abstract

The application provides a 3DFRP system with functions of a template and a rib and a construction process thereof, and relates to the technical field of building construction. A pre-mold is made, a tensile system, an anchoring system and a shear system are pasted on the pre-mold to form a 3DFRP system, and fine sand is used to assist in pouring concrete to form a concrete member, so that the whole process does not need to use a building template, the 3DFRP system replaces the template, and a reinforcing rib is formed in the concrete member, thereby providing the strength of the concrete member.

Description

Technical Field

[0001] This invention relates to the field of building construction technology, and more specifically, to a 3DFRP system that combines the functions of "formwork" and "reinforcement" and its construction process. Background Technology

[0002] Traditional FRP (Fiberglass Reinforced Plastic) methods simulate the shape of familiar two-dimensional (2D) steel reinforcement, making them easily applicable to existing construction practices. Two-dimensional steel reinforcement and plates made of FRP are similar in shape and application, and are easier to predict and analyze. While replicating the shape of steel reinforcement helps improve compatibility, 2D FRP has unique material properties that require specific design considerations to achieve the desired structural performance. Furthermore, the effectiveness of FRP reinforcement largely depends on the bond quality between the FRP material and the concrete substrate. Simulating the shape of steel reinforcement cannot fully meet the bond requirements of FRP, leading to premature debonding failure, susceptibility to damage, and deformation. When simulating the shape of 2D steel plates, FRP may also inherit anisotropic properties, potentially requiring meticulous engineering to ensure optimal and predictable performance. Additionally, traditional construction formwork techniques typically include both wooden and steel formwork. Both types require complex mold construction and demolding processes, and the fabrication of variable cross-section beams is difficult, resulting in high labor and material costs. Summary of the Invention

[0003] This invention discloses a construction process for a 3DFRP system that combines the functions of "formwork" and "reinforcement", aiming to improve the problems of formwork waste and insufficient strength of the concrete components caused by existing concrete component construction.

[0004] The present invention adopts the following solution:

[0005] This application provides a construction process for a 3DFRP system that combines the functions of "formwork" and "reinforcement," including the following steps:

[0006] S1. Pre-mold preparation: Pre-molds are made according to the required concrete pattern. The mold material is an easily shaped material, and the surface of the pre-mold is covered with a plastic film.

[0007] S2. Prepare epoxy resin adhesive;

[0008] S3. Preparation of 3DFRP system components: Cut FRP fabric according to the shape of concrete components to form flexural and flexural anchoring FRP components, closed-wound O-ring components and shear FRP components for assembling the 3DFRP system, and fully impregnate the cut components with prepared epoxy resin.

[0009] S4. Install the 3DFRP system: Sequentially attach the impregnated bending and bending anchoring FRP components, closed-wound O-ring components, and shear-resistant FRP components to the surface of the pre-mold and allow them to cure.

[0010] S5. Constructing a fine sand support: Make a single-sided open iron box, place the 3DFRP system inside, and slowly pour fine sand into the empty part of the iron box until it is level with the height of the 3DFRP system to form a model of the concrete component.

[0011] S6. Impregnate the 3DFRP system: Apply the prepared epoxy resin evenly to the inside of the 3DFRP system and impregnate it thoroughly.

[0012] S7. Concrete pouring: Prepare the required concrete and pour it directly into the 3DFRP system. Place and solidify the components formed after pouring.

[0013] Further, in step S2, E2500S epoxy resin adhesive is used to mix adhesive A and adhesive B in a volume ratio of 2:1, and a stirrer is used to stir at a speed of 400-600 RPM for five minutes to make the AB adhesives evenly mixed.

[0014] Furthermore, the bending and bending-up anchoring FRP assembly is disposed at the bottom of the pre-mold, the shear-resistant FRP assembly is disposed on the side of the pre-mold and together with the bending and bending-up anchoring FRP assembly forms the shape of the pre-mold, and the closed-wrap O-ring assembly is disposed around the periphery of the shear-resistant FRP assembly to fix the shear-resistant FRP assembly and the bending and bending-up anchoring FRP assembly.

[0015] Further, in step S4, the bending and bending anchoring FRP assembly is first pasted onto the bottom of the pre-mold, then the closed-wrap O-ring assembly is installed around the periphery of the shear-resistant FRP assembly, and finally the shear-resistant FRP assembly is installed on the side of the pre-mold.

[0016] Furthermore, the malleable material is paraffin wax or foam.

[0017] The present invention also provides a 3DFRP system that combines the functions of "formwork" and "reinforcement", which is manufactured by the construction process of the 3DFRP system that combines the functions of "formwork" and "reinforcement" described in any one of the above.

[0018] Beneficial effects:

[0019] This invention utilizes a 3DFRP system assisted by fine sand support to precisely mold concrete components with complex geometries, reducing concrete usage by up to 40%, thus achieving carbon reduction at the "quantity" level. This 3D fiber system not only serves as a casting template but also as the "reinforcement" of the component, eliminating the need for traditional formwork and increasing component strength. Therefore, this technology allows for one-time molding of concrete components, eliminating the need for additional materials and energy for "modeling" and "demolding." Furthermore, the 3D fiber system is lightweight and easy to transport. In addition, the 3D fiber system is manufactured using CFRP material with strong corrosion resistance, effectively reducing maintenance requirements throughout the component's life cycle. Attached Figure Description

[0020] Figure 1 This is a structural schematic diagram of a 3DFRP system that combines the functions of a "template" and a "rib" according to an embodiment of the present invention;

[0021] Figure 2 This is a schematic diagram of the construction process of a 3DFRP system that combines the functions of "formwork" and "reinforcement" according to an embodiment of the present invention;

[0022] Figure 3 This is a force diagram of a 3DFRP system that combines the functions of a "template" and a "rib" according to an embodiment of the present invention;

[0023] Figure 4 This is a schematic diagram of the internal cross-section of a 3DFRP system that combines the functions of a "template" and a "rib" according to an embodiment of the present invention;

[0024] Icons: Pre-mold 1, Bending and Bending Anchor FRP Component 2, Bending Section 21, Bending Section 22, Closed Wrapped O-ring Component 3, Shear-resistant FRP Component 4. Detailed Implementation

[0025] Example 1

[0026] Combination Figures 1 to 2 As shown, this embodiment provides a construction process for a 3DFRP system that combines the functions of "formwork" and "reinforcement," including the following steps:

[0027] S1. Preparing pre-mold 1: Pre-mold 1 is made according to the required concrete pattern. The mold material is an easily shaped material, and the surface of the pre-mold 1 is covered with a plastic film.

[0028] S2. Prepare epoxy resin adhesive;

[0029] S3. Prepare the components of the 3DFRP system. Cut the FRP fabric according to the shape of the concrete component to form the bending and bending anchoring FRP component 2, the closed-wrap O-ring component 3 and the shear FRP component 4 for the 3DFRP system. Then, fully impregnate the cut components with the prepared epoxy resin.

[0030] S4. Install the 3DFRP system: sequentially attach the impregnated bending and bending anchoring FRP components 2, closed-wound O-ring components 3, and shear-resistant FRP components 4 to the surface of the pre-mold 1 and allow them to cure.

[0031] S5. Constructing a fine sand support: Make a single-sided open iron box, place the 3DFRP system inside, and slowly pour fine sand into the empty part of the iron box until it is level with the height of the 3DFRP system to form a model of the concrete component.

[0032] S6. Impregnate the 3DFRP system: Apply the prepared epoxy resin evenly to the inside of the 3DFRP system and impregnate it thoroughly.

[0033] S7. Concrete pouring: Prepare the required concrete and pour it directly into the 3DFRP system. Place and solidify the components formed after pouring.

[0034] In this embodiment, the easily malleable material is paraffin wax or foam, etc. Covering the surface of the pre-mold 1 with a plastic film can prevent the pre-mold 1 from being damaged. In step 2, E2500S epoxy resin is used to mix the A and B adhesives in a volume ratio of 2:1, and a stirrer is used to stir at a speed of 400-600 RPM for five minutes to make the A and B adhesives evenly mixed.

[0035] In step S4, the bending and bend-up anchoring FRP assembly 2 includes a bending-resistant portion 21 at the bottom and bend-up portions 22 at both ends of the bending-resistant portion 21. The shape and angle of the bend-up portions 22 and the bending-resistant portion 21 are set according to the actual shape of the pre-mold 1. The bending-up portions 22 are used to be pasted on the bottom of the pre-mold 1, while the bend-up portions 22 are pasted on the side of the pre-mold 1, thereby playing the role of bending resistance and anchoring. The shear-resistant FRP assembly 4 is disposed on the side of the pre-mold 1, and together with the bending and bend-up anchoring FRP assembly 2, it forms the shape of the pre-mold 1. The closed-loop O-ring assembly 3 is configured to be closed and surrounds the periphery of the shear-resistant FRP assembly 4 to fix the shear-resistant FRP assembly 4 and the bending and bend-up anchoring FRP assembly 2. It encircles the side of the shear-resistant FRP assembly 4 and the bend-up portion 22 of the bending and bend-up anchoring FRP assembly 2, thereby enhancing the connection between the shear-resistant FRP assembly 4 and the bending and bend-up anchoring FRP assembly 2, making the pre-mold 1 more stable and providing greater crack resistance after supporting the concrete component. In step S4, when forming the 3D fiber system, the bending and bend-up anchoring FRP assembly 2 is first glued to the bottom of the pre-mold 1, then the shear-resistant FRP assembly 4 is installed on the side of the pre-mold 1, and finally the closed-loop O-ring assembly 3 is fitted around the periphery of the shear-resistant FRP assembly 4. In this embodiment, the bending and bend-up anchoring FRP assembly 2, the closed-loop O-ring assembly 3, and the shear-resistant FRP assembly 4 are made of carbon fiber reinforced polymer or carbon fiber cloth.

[0036] Compared to traditional construction molds, the 3DFRP mold provided in this embodiment solves many problems such as difficult construction, cumbersome processes, and high labor costs. The 3DFRP mold material offers high flexibility and plasticity, allowing for customization according to different component designs and better adapting to complex construction structures. This makes it possible to manufacture complex bends, hyperbolic shapes, and other shapes. Meanwhile, traditional 2DFRP systems often have specific material properties, requiring specific design considerations to achieve structural performance. Furthermore, the effectiveness of FRP reinforcement largely depends on the bond quality between the FRP reinforcement and concrete. Therefore, 2DFRP often fails to fully meet the required bonding shape, leading to premature debonding failure. The 3DFRP system provided in this embodiment can provide reinforcement in multiple directions, offering stronger performance and efficiency, and increasing the shear and bending capabilities of the structure. In addition, carbon fiber reinforced polymer (CFRP) has significant potential advantages in constructing low-carbon structures. Specifically, its lightweight characteristics can significantly reduce energy consumption during transportation and construction, minimizing the overall carbon footprint of structural components. Moreover, the non-corrosive nature of FRP materials greatly improves structural durability and reduces carbon-intensive processes such as material replacement.

[0037] Example 2

[0038] Combination Figure 1 , Figure 3 As shown, this embodiment provides a 3DFRP system that combines the functions of "formwork" and "reinforcement," manufactured using the aforementioned construction process for a 3DFRP system that combines the functions of "formwork" and "reinforcement." Concrete components manufactured using this process can reduce labor and material costs, while also being convenient and quick to construct without the need for formwork removal, with a short construction cycle. Furthermore, it can be used as an FRP reinforcement structure to significantly enhance the structural load-bearing capacity.

[0039] Example 3

[0040] Combination Figures 3 to 4 As shown, this embodiment applies the principles of equilibrium and compatibility to determine the load-deflection response of a three-dimensional FRP reinforced concrete member. Since the internal compressive force of the concrete within any given cross-section is equivalent to the tensile force generated on the sides and bottom, the tensile contribution of the 0.5mm thick FRP to the uncracked section can be neglected, thus allowing the calculation of the moment (M) of the uncracked concrete member. cr ) and curvature (Φ cr ).

[0041] That is, in the pre-cracking stage:

[0042] M cr =f t w b h 2 / 6;

[0043] Φ cr =2f t / (E c h);

[0044]

[0045]

[0046] Where: f t f is the tensile strength of concrete; c E represents the compressive strength of concrete. c The elastic modulus of concrete; w b is the width of the sample cross-section; h is the height of the sample cross-section;

[0047] After a concrete member cracks, the tensile contribution of the concrete is ignored (i.e., the post-cracking strength f). cr =0). The corresponding equilibrium can be calculated as follows:

[0048] C c -F f侧 -F f底 =0;

[0049]

[0050]

[0051]

[0052] F f底 =ε f-app ·E f-app ·A f ;

[0053] ε f-app =ε c-x ·(hx) / x;

[0054] F f侧 =2t f ·E f-app ·ε c-xy / xdy;

[0055]

[0056] Among them, C c F is the internal compressive force. f侧 The tensile force generated by the side FRP; F f底 The tensile stress generated by the bottom FRP; M c M is the internal bending moment of the specimen. f侧 The bending moment generated by the side FRP; ε c-x f(ε) represents the compressive strain at a given concrete layer. c-x ) represents the corresponding compressive stress obtained from the Hognested model; X represents the height of the compression zone; x is the distance from the neutral axis to the concrete layer calculated based on the compressive contribution; y is the distance from the neutral axis to the side fiber layer calculated based on the tensile contribution; A f t is the cross-sectional area of ​​the bottom FRP; f P represents the thickness of the side FRP. app Apply a load at the midpoint of the span; L i E is the distance from the support to the h-th segment; f-app The elastic modulus ε is the value that takes into account the effects of concrete slippage and FRP elongation. f-app The compressive strain of FRP when a load is applied at the mid-span.

[0057] The following modifications are made to the modulus of elasticity, taking into account the effects of concrete slippage and FRP elongation;

[0058] E f-app =0.33E f ;

[0059] Deflection calculation:

[0060] Deflection Δ for any given i segment within half span L / 2i This can be determined using subsequent formulas:

[0061]

[0062] Based on the above equations, load-deflection predictions can be obtained using MATLAB-based scripts. This allows for the determination of the torque (M) for each component. cr Curvature (Φ) cr Based on empirical observation, various types of failures are considered, such as FRP rupture strength of 1200MPa, anchor failure strength of 0.73 times FRP rupture strength, FRP debonding, and shear cracking, to determine the final prediction.

[0063] Strength can be determined using the following formula:

[0064]

[0065] τ max =1.35 + 0.25β w ·f t +0.62f t ;

[0066]

[0067]

[0068] The ultimate shear capacity is:

[0069]

[0070] Where F b For bond strength; w f S is the width of the FRP bonded to the cross-section of the sample; f β represents the shear strength of the FRP. w V is the concrete strength development coefficient. cf E represents the ultimate shear capacity. f τ is the elastic modulus of FRP. max This represents the maximum shear stress.

[0071] Based on the above formula model, the strength and deflection of concrete components constructed using a 3DFRP system that functions as both "formwork" and "reinforcement" can be determined. Furthermore, based on the required strength and deflection of the concrete components, the dimensions and installation location of the required 3DFRP system can be calculated in reverse, thus assisting users in construction design. Verification using the above equations shows that the strength and flexural strength of concrete components constructed using this 3DFRP system are significantly enhanced.

[0072] It should be understood that the above are merely preferred embodiments of the present invention, and the scope of protection of the present invention is not limited to the above embodiments. All technical solutions that fall within the scope of the present invention are within the scope of protection of the present invention.

[0073] The accompanying drawings used in the above description of the embodiments only illustrate certain embodiments of the present invention and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

Claims

1. A construction process for a 3DFRP system that combines the functions of "formwork" and "reinforcement", characterized in that, Includes the following steps: S1. Pre-mold preparation: Pre-molds are made according to the required concrete pattern. The pre-mold material is an easily shaped material, and the surface of the pre-mold is covered with a plastic film. S2. Prepare epoxy resin adhesive; S3. Preparation of 3DFRP system components: Cut FRP fabric according to the shape of concrete components to form flexural and flexural anchoring FRP components, closed-wound O-ring components and shear FRP components for assembling the 3DFRP system, and fully impregnate the cut components with prepared epoxy resin. S4. Install the 3DFRP system: Sequentially attach the impregnated bending and bending anchoring FRP components, closed-wound O-ring components, and shear-resistant FRP components to the surface of the pre-mold and allow them to cure. S5. Constructing a fine sand support: Make a single-sided open iron box, place the 3DFRP system inside, and slowly pour fine sand into the empty part of the iron box until it is level with the height of the 3DFRP system to form a model of the concrete component. S6. Impregnate the 3DFRP system: Apply the prepared epoxy resin evenly to the inside of the 3DFRP system and impregnate it thoroughly. S7. Concrete pouring: Prepare the required concrete and pour it directly into the 3DFRP system. Place and solidify the components formed after pouring.

2. The construction process of the 3DFRP system with both "formwork" and "reinforcing" functions as described in claim 1, characterized in that, In step S2, E2500S epoxy resin adhesive is used. The volume ratio of adhesive A to adhesive B is 2:

1. The mixture is stirred for five minutes at a speed of 400-600 RPM using a stirrer to ensure that the adhesives A and B are mixed evenly.

3. The construction process of the 3DFRP system combining "formwork" and "reinforcement" functions as described in claim 1, characterized in that, The bending and bending-up anchoring FRP assembly is disposed at the bottom of the pre-mold, the shear-resistant FRP assembly is disposed on the side of the pre-mold and together with the bending and bending-up anchoring FRP assembly forms the shape of the pre-mold, and the closed-wrap O-ring assembly is disposed around the periphery of the shear-resistant FRP assembly to fix the shear-resistant FRP assembly and the bending and bending-up anchoring FRP assembly.

4. The construction process of the 3DFRP system combining "formwork" and "reinforcing bar" functions as described in claim 3, characterized in that, In step S4, the bending and bending anchoring FRP assembly is first attached to the bottom of the pre-mold, then the shear-resistant FRP assembly is installed on the side of the pre-mold, and finally the closed-wrap O-ring assembly is fitted around the periphery of the shear-resistant FRP assembly.

5. The construction process of the 3DFRP system combining "formwork" and "reinforcing bar" functions as described in claim 1, characterized in that, The malleable material is paraffin wax or foam.

6. A 3DFRP system that combines the functions of "template" and "rib", characterized in that, It is manufactured using the construction process of the 3DFRP system that combines the functions of "formwork" and "reinforcement" as described in any one of claims 1-5.

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