A method for preparing and constructing fiber-woven mesh reinforced concrete and its composite material

Abstract

This invention belongs to the technical field of fiber-woven mesh reinforced concrete composite material preparation, specifically relating to a method for preparing fiber-woven mesh reinforced concrete composite materials and the composite material structure using this method. This invention effectively solves the problem in existing fiber-woven mesh reinforced concrete preparation methods where concrete cannot effectively penetrate into the fiber bundles, effectively improving the mechanical properties of fiber-woven mesh reinforced concrete composite materials. Furthermore, the ratio of fiber filaments to cement powder within the fiber bundles can be arbitrarily adjusted as needed, making it widely applicable. In addition, the fiber-woven mesh can be pre-prepared in the factory, requiring only simple laying on-site; the construction process is dust-free, highly efficient, convenient, economical, and environmentally friendly.

Description

Technical Field

[0001] This invention belongs to the field of fiber braided mesh reinforced concrete composite material preparation technology, specifically relating to the preparation method of fiber braided mesh reinforced concrete composite material and the composite material structure using this method. Background Technology

[0002] Fiber-woven mesh reinforced concrete composites are widely used in lightweight design of new buildings and reinforcement of existing building structures due to their excellent mechanical properties and lightweight characteristics. However, currently, the poor permeability of the concrete matrix within the fiber bundles, while resulting in good bonding between the fibers on the outer surface of the fiber bundles and the concrete matrix, but with numerous pores inside the fiber bundles, severely affect the mechanical properties of fiber-woven mesh reinforced concrete composites, hindering their further promotion and application. Currently, there are three main technical solutions:

[0003] (1) Fiber filaments or fiber bundles are directly twisted to form fiber bundles, which are then mixed with a cement matrix to form a composite material. This method can improve the synergistic effect between fiber filaments to a certain extent. However, this method still suffers from the problem that the cement matrix cannot effectively wet the fiber filaments inside the fiber bundle. The improvement of the synergistic effect of fiber filaments mainly relies on the frictional effect between fiber filaments, and the frictional force between fiber filaments is directly related to the tension of the fiber bundle. Moreover, the surfaces between fiber filaments are relatively smooth, making it difficult to form sufficient frictional force. In addition, although the synergistic effect of fiber filaments is improved, the fiber bundle contains a large number of fiber filaments with varying tension. During the twisting process, fiber filaments with higher tension have a certain synergistic effect, while fiber filaments with lower tension cannot effectively exert their synergistic effect. Therefore, this method has limited effect on improving the mechanical properties of fabric-reinforced cement-based composite materials, especially the interfacial properties between fiber filaments and the cement matrix, and cannot effectively solve the problem.

[0004] (2) Fiber bundles are impregnated and cured with resin to form a fiber-reinforced resin matrix composite fabric mesh, which is then mixed with a cement matrix to form a fabric-reinforced cement matrix composite. This method utilizes the excellent wettability and superior mechanical properties of the resin matrix, which can significantly enhance the synergistic effect of the fibers within the fiber bundle, further significantly improving the mechanical properties of the fabric-reinforced cement matrix composite. However, this method has two main drawbacks. Firstly, the cost of the resin matrix is ​​significantly higher than that of the cement matrix, and resin curing requires specialized equipment and process conditions. Using this method to prepare materials significantly increases the cost and is not suitable for cost-sensitive engineering applications such as civil building structures. Secondly, the fabric mesh formed after the fiber bundles are impregnated and cured with resin has strong rigidity and is difficult to bond to complex surfaces. Building structures contain a large number of corners, curved surfaces, and other structures, limiting the engineering application scope of this method.

[0005] (3) Fiber filaments or fiber bundles are pre-impregnated with concrete or cement slurry for a certain period of time, and then combined with the concrete matrix to form a composite material. This method can improve the interfacial bonding performance between the fiber filaments and the concrete or cement matrix to a certain extent through pre-impregnation, resulting in a better mechanical property improvement effect. However, this method is only suitable for factory operation. When the structure needs to be prepared on the construction site, the fiber woven mesh and concrete prepreg prepared in the factory are prone to solidification during transportation, affecting construction; if the pre-impregnation operation is carried out on the construction site, on the one hand, it is necessary to set up complex impregnation processing equipment on site, and on the other hand, the construction steps are complicated and time-consuming, which is not convenient for on-site application. Summary of the Invention

[0006] The primary objective of this invention is to address the critical issue of weak interfacial mechanical properties between the fiber filaments within the fiber bundles and the matrix in fiber-reinforced concrete composites, as well as the deficiencies of existing technologies. This invention provides a method for preparing and constructing fiber-reinforced concrete, improving the interfacial bonding performance between the fiber filaments within the fiber bundles and the concrete matrix, effectively enhancing the mechanical properties of the fabric-reinforced cement-based composite material. Simultaneously, it achieves both factory-prepared and on-site-prepared results, improving construction efficiency, reducing construction costs, and avoiding dust pollution during construction.

[0007] The second objective of this invention is to provide a fiber bundle, fiber woven mesh, fiber woven mesh reinforced concrete composite material and structure prepared based on the aforementioned fiber woven mesh reinforced concrete preparation and construction method.

[0008] To achieve the above-mentioned objectives, the present invention adopts the following technical solution:

[0009] A method for preparing and constructing fiber-woven mesh reinforced concrete includes the following steps:

[0010] Step 1: Pour ultrafine concrete powder into a hollow tube made of a water-soluble material;

[0011] Step 2: Mix several hollow tubes containing ultrafine concrete dry powder with several fiber filaments to prepare an embedded fine tube fiber bundle.

[0012] Step 3: Prepare the embedded fine tube fiber bundles into a fiber woven mesh according to engineering requirements;

[0013] Step 4: Transport the woven fiber mesh to the construction site and soak it in water;

[0014] Step 5: Lay a layer of concrete substrate on the surface of the mold or the structure to be constructed;

[0015] Step Six: Lay the soaked fiber mesh on the concrete substrate;

[0016] Step 7: Lay another layer of concrete substrate on the fiber woven mesh;

[0017] Step 8: Use a concrete vibrator to vibrate the concrete substrate layer.

[0018] Step 9: Repeat steps 5 to 8 until the number of fiber woven mesh layers reaches the set value;

[0019] Step 10: After the fiber-reinforced concrete has cured, perform curing treatment.

[0020] As a further preferred technical solution of the present invention, if the final product is a fiber woven mesh reinforced concrete slab or structure of a uniform type, then steps one to ten can be completed in the factory; if structural repair or reinforcement is required at the construction site, then steps one to four can be completed in advance in the factory, and steps five to ten can be operated at the construction site, which can effectively improve on-site construction efficiency and reduce dust pollution at the construction site.

[0021] Furthermore, as a preferred embodiment of the present invention, in step one, the water-soluble material used to prepare the hollow tube needs to have good toughness to ensure that it will not break during subsequent processing, and the water-soluble material needs to have good solubility in aqueous solution to ensure that it can dissolve quickly in subsequent construction steps. The water-soluble material can be a PVA water-soluble film or similar material.

[0022] As a further preferred technical solution of the present invention, in step two, the diameter of the hollow tube containing ultrafine concrete powder is preferably thin, under the premise of cost and pourability; the volume ratio of the hollow tube containing ultrafine concrete powder to the fiber filament can be adjusted arbitrarily according to engineering needs; the hollow tube containing ultrafine concrete powder and the fiber filament are laid parallel to each other along the direction of the fiber filament, and the hollow tube and the fiber filament are evenly distributed in the cross section perpendicular to the direction of the fiber filament; the hollow tube containing ultrafine concrete powder and the fiber filament can be twisted to form a fiber bundle, or bound to form a fiber bundle.

[0023] As a further preferred technical solution of the present invention, in step three, the fiber woven mesh can be a biaxial orthogonal structure, and the specific structure can be designed according to engineering needs.

[0024] As a further preferred technical solution of the present invention, in step four, the water-soluble capillaries inside the fiber woven mesh can be dissolved by soaking in a water tank or spraying with an aqueous solution; the soaking time can be determined by experiment, with the critical point being that the capillaries are completely dissolved and the concrete inside the capillaries does not drip out after being soaked in water.

[0025] As a further preferred technical solution of the present invention, in step five, if the final product is a thin plate or structure of the same model, the operation can be carried out in a mold, and the surface of the mold needs to be cleaned in a routine manner; if it is on-site construction, the surface to be constructed needs to be cleaned in a routine manner first.

[0026] As a further preferred technical solution of the present invention, in step eight, different types of concrete vibrators such as immersion type, attachment type, and plate type can be selected for tamping operations according to specific engineering needs.

[0027] Furthermore, as a preferred technical solution of the present invention, the size of the ultrafine concrete powder particles in steps one and two is as small as possible to ensure the wettability of the ultrafine concrete and the fiber filaments after immersion in water; the concrete in steps five to eight has no specific requirements on the size of the component materials, and can be adjusted according to the specific needs of the project.

[0028] A fiber bundle, fiber woven mesh, fiber woven mesh reinforced concrete composite material and structure prepared according to the method described above.

[0029] The fiber-woven mesh reinforced concrete preparation and construction method and its composite material described in this invention have the following technical advantages compared with the prior art:

[0030] This invention employs a water-soluble thin-film tube to infuse ultrafine concrete powder. Firstly, it ensures that the ultrafine concrete powder, after dissolving in water, can fully contact the fibers within the fiber bundle, effectively improving the interfacial properties between the fibers and the concrete matrix. Secondly, the fiber mesh, before immersion in water, effectively prevents the concrete powder from scattering or leaking during preparation and transportation, thus avoiding dust pollution. This ensures that the ultrafine concrete content remains within a controllable range throughout the material preparation process and significantly improves construction convenience. Furthermore, the volumetric content of fibers and ultrafine concrete within the fiber bundle can be adjusted over a wide range by changing the diameter and number of embedded tubes, allowing for flexible design based on project needs. Finally, the preparation and construction method provided by this invention can be implemented in a factory or on-site, broadening its applicability. In addition, it should be noted that the mechanical properties of concrete are closely related to the water-cement ratio. The proportion of ultrafine concrete in the fiber bundles in the entire fiber-woven mesh reinforced concrete composite material of this invention is relatively low, about 1%. After the fiber-woven mesh is soaked in water and laid on the concrete matrix layer, the water-cement ratio of ultrafine concrete in the fiber bundles gradually tends to be consistent with that of the concrete matrix layer after a period of time. Therefore, the water-cement ratio of ultrafine concrete in the fiber bundles can be indirectly controlled by the water-cement ratio in the concrete matrix layer, which can ensure that the mechanical properties of ultrafine concrete in the fiber bundles are within a controllable range. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of a water-soluble hollow tube containing ultrafine concrete dry powder;

[0032] Figure 2 This is a schematic diagram of a fiber bundle with embedded capillaries;

[0033] Figure 3 This is a schematic diagram of an embedded fine-tube fiber woven mesh. Detailed Implementation

[0034] The present invention will be further explained in detail below with reference to the accompanying drawings, so that those skilled in the art can better understand and implement the present invention. However, the following examples are only used to explain the present invention and are not intended to limit the present invention.

[0035] A method for preparing and constructing fiber-woven mesh reinforced concrete includes the following steps:

[0036] Step 1: Pour ultrafine concrete powder into a hollow tube made of a water-soluble material;

[0037] Step 2: Mix several hollow tubes containing ultrafine concrete dry powder with several fiber filaments to prepare an embedded fine tube fiber bundle.

[0038] Step 3: Prepare the embedded fine tube fiber bundles into a fiber woven mesh according to engineering requirements;

[0039] Step 4: Transport the woven fiber mesh to the construction site and soak it in water;

[0040] Step 5: Lay a layer of concrete substrate on the surface of the mold or the structure to be constructed;

[0041] Step Six: Lay the soaked fiber mesh on the concrete substrate;

[0042] Step 7: Lay another layer of concrete substrate on the fiber woven mesh;

[0043] Step 8: Use a concrete vibrator to vibrate the concrete substrate layer.

[0044] Step 9: Repeat steps 5 to 8 until the number of fiber woven mesh layers reaches the set value;

[0045] Step 10: After the fiber-reinforced concrete has cured, perform curing treatment.

[0046] If the final product is a uniform type of fiber-woven mesh reinforced concrete slab or structure, steps one through ten can be completed in the factory; if structural repair or reinforcement is required on the construction site, steps one through four can be completed in advance in the factory, and steps five through ten can be performed on the construction site, which can effectively improve on-site construction efficiency and reduce dust pollution at the construction site.

[0047] like Figure 1 As shown, in step one, the water-soluble material used to prepare the hollow capillary needs to have good toughness to ensure that it will not break during subsequent processing, and the water-soluble material needs to have good solubility in aqueous solution to ensure that it can dissolve quickly in subsequent construction steps. The water-soluble material can be a PVA water-soluble film or similar material.

[0048] In step two, the diameter of the hollow tube containing ultrafine concrete powder is preferably thin, considering cost and pourability; the volume ratio of the hollow tube containing ultrafine concrete powder to the fiber filaments can be adjusted arbitrarily according to project needs; the hollow tube containing ultrafine concrete powder and the fiber filaments are laid parallel to each other along the fiber filament direction, and the hollow tube and fiber filaments are evenly distributed in the cross-section perpendicular to the fiber filament direction; the hollow tube containing ultrafine concrete powder and the fiber filaments can be twisted to form fiber bundles, or bound to form fiber bundles.

[0049] In step three, the fiber woven mesh can be in the form of biaxial orthogonal structures, and the specific structure can be designed according to engineering needs.

[0050] In step four, the water-soluble capillaries inside the fiber woven mesh can be dissolved by soaking in a water tank or spraying with an aqueous solution. The soaking time can be determined by experiment, with the critical point being that the capillaries are completely dissolved and the concrete inside the capillaries does not drip out after being soaked in water.

[0051] In step five, if the final product is a thin plate or structure of the same model, the operation can be carried out in the mold, and the surface of the mold needs to be cleaned in a routine manner; if it is on-site construction, the surface to be constructed needs to be cleaned in a routine manner first.

[0052] In step eight, different types of concrete vibrators, such as immersion type, attached type, and plate type, can be used for compaction operations according to the specific project requirements.

[0053] The particle size of the ultrafine concrete powder described in steps one and two should be as small as possible to ensure the wettability of the ultrafine concrete and the fiber filaments after immersion in water; there are no specific requirements for the size of the component materials in the concrete described in steps five to eight, and adjustments can be made according to the specific needs of the project.

[0054] like Figure 2-3 As shown, a fiber bundle, fiber woven mesh, fiber woven mesh reinforced concrete composite material and structure prepared according to the method described above are disclosed.

[0055] This invention effectively solves the problem of concrete failing to effectively penetrate the fiber bundles in existing fiber-woven mesh reinforced concrete preparation methods. It effectively improves the mechanical properties of fiber-woven mesh reinforced concrete composites and allows for arbitrary adjustment of the fiber filament to cement powder ratio within the fiber bundles, making it widely applicable. Furthermore, the fiber-woven mesh can be pre-prepared in the factory, requiring only simple on-site laying; the construction process is dust-free, highly efficient, convenient, economical, and environmentally friendly.

[0056] This invention employs a water-soluble thin-film tube to infuse ultrafine concrete powder. Firstly, it ensures that the ultrafine concrete powder, after dissolving in water, can fully contact the fibers within the fiber bundle, effectively improving the interfacial properties between the fibers and the concrete matrix. Secondly, the fiber mesh, before immersion in water, effectively prevents the concrete powder from scattering or leaking during preparation and transportation, thus avoiding dust pollution. This ensures that the ultrafine concrete content remains within a controllable range throughout the material preparation process and significantly improves construction convenience. Furthermore, the volumetric content of fibers and ultrafine concrete within the fiber bundle can be adjusted over a wide range by changing the diameter and number of embedded tubes, allowing for flexible design based on project needs. Finally, the preparation and construction method provided by this invention can be implemented in a factory or on-site, broadening its applicability. In addition, it should be noted that the mechanical properties of concrete are closely related to the water-cement ratio. The proportion of ultrafine concrete in the fiber bundles in the entire fiber-woven mesh reinforced concrete composite material of this invention is relatively low, about 1%. After the fiber-woven mesh is soaked in water and laid on the concrete matrix layer, the water-cement ratio of ultrafine concrete in the fiber bundles gradually tends to be consistent with that of the concrete matrix layer after a period of time. Therefore, the water-cement ratio of ultrafine concrete in the fiber bundles can be indirectly controlled by the water-cement ratio in the concrete matrix layer, which can ensure that the mechanical properties of ultrafine concrete in the fiber bundles are within a controllable range.

[0057] The specific implementation schemes described above further illustrate the purpose, technical solution, and beneficial effects of the present invention. It should be understood that the above descriptions are merely specific implementation schemes of the present invention and are not intended to limit the scope of the present invention. Any equivalent changes and modifications made by those skilled in the art without departing from the concept and principles of the present invention should fall within the scope of protection of the present invention.

Claims

1. A method of manufacturing and constructing a fiber woven mesh reinforced concrete, characterized by, Includes the following steps: Step 1: Pour ultrafine concrete powder into a hollow tube made of a water-soluble material; Step 2: Mix several hollow tubes containing ultrafine concrete dry powder with several fiber filaments to prepare an embedded fine tube fiber bundle. Hollow tubes containing ultrafine concrete dry powder and fiber filaments are laid parallel to each other along the direction of the fiber filaments. In a cross section perpendicular to the direction of the fiber filaments, the hollow tubes and fiber filaments are evenly distributed. The hollow tubes containing ultrafine concrete dry powder and fiber filaments are twisted to form fiber bundles or bound together to form fiber bundles. Step 3: Prepare the embedded fine tube fiber bundles into a fiber woven mesh according to engineering requirements; Step 4: Transport the woven fiber mesh to the construction site and soak it in water; Step 5: Lay a layer of concrete substrate on the surface of the mold or the structure to be constructed; Step Six: Lay the soaked fiber mesh on the concrete substrate; Step 7: Lay another layer of concrete substrate on the fiber woven mesh; Step 8: Use a concrete vibrator to vibrate the concrete substrate layer. Step 9: Repeat steps 5 through 8 until the number of fiber woven mesh layers reaches the set value; Step 10: After the fiber-reinforced concrete has cured, perform curing treatment.

2. The fiber woven mesh reinforced concrete manufacturing construction method according to claim 1, characterized in that, If the final product is a uniform type of fiber woven mesh reinforced concrete slab, steps one through ten are completed in the factory; if structural repair or reinforcement is required at the construction site, steps one through four are completed in advance in the factory, and steps five through ten are performed at the construction site, effectively improving on-site construction efficiency and reducing dust pollution at the construction site.

3. The fiber woven mesh reinforced concrete construction method according to claim 1, characterized in that, In step one, the water-soluble material used to prepare the hollow tube needs to have good toughness to ensure that it will not break during subsequent processing, and the water-soluble material needs to have good solubility in aqueous solution to ensure that it can dissolve quickly in subsequent construction steps; the water-soluble material is a PVA water-soluble film material.

4. The fiber woven mesh reinforced concrete manufacturing construction method according to claim 1, characterized by, In step two, the diameter of the hollow tube containing ultrafine concrete powder is preferably thin, taking into account cost and pourability; the volume ratio of the hollow tube containing ultrafine concrete powder to the fiber filament can be adjusted arbitrarily according to project needs.

5. The method for preparing and constructing fiber-woven mesh reinforced concrete according to claim 1, characterized in that, In step three, the fiber woven mesh has a biaxial orthogonal structure, and the specific structure is designed according to engineering needs.

6. The method for preparing and constructing fiber-woven mesh reinforced concrete according to claim 1, characterized in that, In step four, the fiber woven mesh is dissolved by soaking in a water tank or spraying with an aqueous solution; the soaking time is determined by experiment, with the critical point being that the thin tubes are completely dissolved and the concrete inside the thin tubes does not drip out after being soaked in water.

7. The method for preparing and constructing fiber-woven mesh reinforced concrete according to claim 1, characterized in that, In step five, if the final product is a thin plate of the same model, the operation is carried out in a mold, and the surface of the mold needs to be cleaned routinely; if it is on-site construction, the surface to be constructed needs to be cleaned routinely first.

8. The method for preparing and constructing fiber-woven mesh reinforced concrete according to claim 1, characterized in that, In step eight, immersion type, attached type, or plate type concrete vibrators are selected for tamping operations according to the specific project requirements.

9. The method for preparing and constructing fiber-woven mesh reinforced concrete according to claim 1, characterized in that, The particle size of the ultrafine concrete powder described in steps one and two should be as small as possible to ensure the wettability of the ultrafine concrete and the fiber filaments after immersion in water; there are no specific requirements for the size of the component materials in the concrete described in steps five to eight, and adjustments can be made according to the specific needs of the project.

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