Method for manufacturing a c100 high performance concrete component

Abstract

The application discloses a kind of based on C100 high-performance concrete component preparation method, select steel pipe as the forming appliance of concrete, the raw material of first concrete includes cement, mineral powder, coal ash, river sand, primary crushed stone and secondary crushed stone, the raw material of second concrete also includes photoluminescent material, preassembly is equipped with multiple bending parts and through hole, steel pipe side wall is equipped with opening, opening corresponds preassembly, under the premise of improving the overall performance and the uniformity of microstructure of concrete, utilize the constraint effect of steel pipe, so that the compressive property of concrete material is enhanced in pouring process, to expect to improve the stability of concrete component formed through hole using pipeline structure, pipeline structure is subjected to transverse pressure, the stability of pipeline structure can be influenced, there can be hidden trouble problem of concrete component.

Description

Technical Field

[0001] This invention relates to the use of concrete in mixing, and more specifically to a method for preparing C100 high-performance concrete components. Background Technology

[0002] Currently, C100 high-performance concrete is primarily used to produce high-strength, high-stability components, generally suitable for various high-load and long-term use scenarios. With accelerating urbanization and continuous development of construction technology, the demand for large-span structures is increasing. Current concrete components can no longer fully meet increasingly stringent engineering requirements, particularly in terms of strength, construction efficiency, and material utilization. For example, when considering modular designs for concrete components, appropriate connection points need to be incorporated into the components.

[0003] In practical applications, when casting C100 concrete components, it is common practice to install embedded parts in the casting area. Due to the connection requirements of these embedded parts, they typically need to extend from the outside of the component and match the load-bearing components. However, embedded parts are not conducive to the modular construction requirements of concrete under various working conditions. Therefore, when casting C100 high-performance concrete, it is more common to leave through holes in the components. Due to the casting method, through holes require the assistance of pipes to form, utilizing the pipe structure to form the through holes after casting. However, after the pipe structure is cast, it cannot be removed from the concrete component. The pipe structure needs to be used as a connection point, and the stability of the pipe structure will be affected when the connection point is subjected to lateral pressure. This may lead to the potential instability of the concrete components when used in modular applications. Therefore, optimizing the configuration of high-performance concrete and the preparation of components is worthy of research. Summary of the Invention

[0004] The purpose of this invention is to provide a method for preparing high-performance concrete components based on C100, in order to improve the problem that the concrete components are formed by forming through holes using pipe structures. However, the pipe structures are subjected to lateral pressure, which may affect the stability of the pipe structures and may pose hidden dangers to the concrete components.

[0005] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: A method for preparing C100 high-performance concrete components includes the following steps: S1: Selecting a circular or square steel pipe as a concrete forming tool, grinding and cleaning the inner wall of the steel pipe to remove rust, dirt and grease; vertically placing reinforcing bars inside the steel pipe, setting reinforcing cages between the reinforcing bars, setting pre-installed parts on the reinforcing bars, and providing openings on the side wall of the steel pipe corresponding to the pre-installed parts, wherein the pre-installed parts are provided with multiple bends, and the pre-installed parts are provided with through holes, the through holes penetrating the bends; inserting a limiting rod into the through holes, the size of the limiting rod being adapted to the through holes. S2: Prepare the first concrete. By weight, the raw materials include 380-500 parts cement, 30-200 parts mineral powder, 20-130 parts fly ash, 600-700 parts river sand, 300-400 parts grade I crushed stone, 600-800 parts grade II crushed stone, 4-6 parts water-reducing agent, and 130-150 parts water. Add the cement, mineral powder, fly ash, river sand, grade I crushed stone, and grade II crushed stone to a mixer and mix. Add water and water-reducing agent and mix again to obtain the first concrete. The grade I crushed stone is 5-10mm in size, and the grade II crushed stone is 10-20mm in size. S3: Extend both ends of the limiting rod out of the outer wall of steel pipe A. Cover the outside of the opening with a mold. The inner wall of the mold has placement holes for inserting the limiting rod. The mold closes the opening and houses the limiting rod. Drain the first concrete into the steel pipe and pour it layer by layer, while simultaneously vibrating the surface of the steel pipe using a vibrator. S4: When the height of the first concrete pour exceeds the opening, the mold is knocked out from the opening. Then, the limiting rod is heated using heating equipment, causing it to melt and expose a through hole on the pre-assembled component. This through hole is used to connect the load-bearing components. The concept is as follows: By optimizing the selection and scientific proportioning of concrete raw materials, such as the appropriate addition of mineral powder and fly ash, and adjusting the ratio of river sand and crushed stone, the quality and workability of the concrete are guaranteed. While improving the overall performance and uniformity of the microstructure of the concrete, steel pipes are used as the forming tool for the concrete. The constraint effect of the steel pipes enhances the compressive strength of the concrete material during pouring. Simultaneously, the reinforcement cage and pre-assembled components work together to provide not only the shape of the component but also better support during the concrete hardening process. This improves the overall stability and load-bearing capacity of the structure. More importantly, after the pre-installed components are completed, through holes are reserved in the pre-installed components through the limiting rods, ensuring that no external connectors or additional processing are needed when the load-bearing components are installed laterally. At the same time, the reserved pre-installed components can achieve lateral and longitudinal stability after casting, which makes the components more stable when they are subsequently integrated and modularized.

[0006] Preferably, during the first concrete pouring process, the aforementioned bent portion is in contact with the first concrete; the aforementioned first concrete covers the reinforcing cage in the steel pipe; wherein, the aforementioned limiting rod is made of hot melt wax, the aforementioned heating device is a hot air blower, the aforementioned pre-assembled component is an integrally formed metal material, and after the aforementioned first concrete hardens, the hot air blower is used to input hot air into the opening to heat the pre-assembled component and the limiting rod synchronously until the limiting rod is hot melted.

[0007] Preferably, the above-mentioned layer-by-layer pouring is carried out in segments and multiple pours, with a constant pouring height each time. After each pouring is completed, curing treatment is carried out. When the concrete of the previous pouring begins to show signs of hardening but has not yet fully hardened, the next pouring is carried out until the surface of the first concrete is flush with or overflows the top of the steel pipe.

[0008] Preferably, the step further includes preparing a second concrete by taking the following raw materials by weight: 300-400 parts cement, 30-200 parts mineral powder, 60-130 parts fly ash, 700-850 parts river sand, 100-250 parts grade I crushed stone, 300-500 parts grade II crushed stone, 100-300 parts grade III crushed stone, 2-4 parts water-reducing agent, 130-160 parts water, and 8-20 parts photoluminescent material; the cement, mineral powder, fly ash, river sand, grade I, grade II, and grade III crushed stone are put into a mixer and stirred, and water and water-reducing agent are added and mixed, and then the photoluminescent material is added to obtain the second concrete; the second concrete is applied to the opening and completely covers the opening.

[0009] A further technical solution is that the photoluminescent material is particulate matter formed by mixing zinc sulfide and strontium aluminate in a ratio of 1:1.3.

[0010] A further technical solution is that the first type of concrete, when tested in a standard 150mm×150mm×150mm cube specimen, has a compressive strength greater than or equal to 100 MPa; the second type of concrete, when tested in a standard 150mm×150mm×150mm cube specimen, has a compressive strength less than or equal to 40 MPa. Preferably, the pre-assembled component is larger than the opening height, the side wall of the pre-assembled component is connected with reinforcing bars, and there is a gap between the reinforcing bars and the inner wall of the steel pipe, and both ends of the pre-assembled component abut against the inner wall of the steel pipe.

[0011] A further technical solution is that there are two or more pre-installed components at the same height inside the steel pipe, and there is a gap between two adjacent pre-installed components. This gap is used to limit the position of the pre-installed components in conjunction with the first concrete.

[0012] Preferably, the steel pipe is provided with a dividing opening on both sides. The dividing opening is used to divide the steel pipe into two connecting parts, and both ends of the connecting parts are provided with lugs. The two adjacent connecting parts are fitted together and the lugs are fixedly connected.

[0013] A further technical solution is that the length of the aforementioned support lug matches the length of the steel pipe, and the aforementioned support lug is provided with several bolt holes with the same gap between two adjacent bolt holes. Bolts are inserted into the bolt holes to make the support lug and the connecting part fit together and lock. After the concrete component is completed, the part removal operation is carried out, the bolts on the support lug are removed, and the connecting part of the steel pipe is separated to complete the part removal.

[0014] Compared with the prior art, the beneficial effects of the present invention are at least one of the following: The preparation of the first concrete of this invention incorporates a significant amount of industrial byproducts, fly ash and mineral powder, achieving efficient utilization of these inexpensive materials without compromising concrete performance. Simultaneously, by adding appropriate proportions of river sand and crushed stone, the uniformity of the concrete's internal microstructure is enhanced. This reduces costs while improving the crack resistance and impermeability of the first concrete, also meeting environmental protection requirements. Building upon the concrete's performance, the method further utilizes prefabricated steel pipes as mold forming tools. Openings on the sidewalls of the steel pipes optimize the convenience of subsequent connection of prefabricated components. The special form of the prefabricated components allows them to be installed inside the steel pipes, forming through holes during the pouring process.

[0015] This invention, based on the cooperation of pre-assembled components and limiting rods, ensures the precise positioning of the reinforcing cage within the steel pipe, guaranteeing the structural quality of the concrete component. Simultaneously, a vibratory machine is used to vibrate the steel pipe, ensuring the poured concrete is uniform and compact, resulting in a stable fit between the pre-assembled component and the concrete. This reduces voids and material delamination around the pre-assembled component. Considering the shape of the pre-assembled component, and building upon the above, after the pre-assembled component is poured with concrete, it is constrained by the hardened concrete in both the longitudinal and transverse directions, further ensuring the load-bearing capacity of the pre-assembled component and reducing the risk of accidents.

[0016] This invention also utilizes a steel pipe structure, resulting in a service life far exceeding that of traditional wooden and plastic molds. The steel pipe can be reused, reducing the consumption of existing mold materials and the generation of waste. Furthermore, the steel pipe features a split design, allowing for simple and convenient disassembly when the lugs and connecting parts are tightly fitted together, facilitating recycling, reducing construction waste, and improving the environmental friendliness of the building manufacturing process.

[0017] The second concrete of the present invention uses a luminescent material to cover the opening, so that for some use cases where pre-assembled parts are not required for temporary assembly, the pre-assembled parts can be temporarily sealed by the second concrete. If necessary, the second concrete can be knocked open. The second concrete uses a photoluminescent material, so that the location of the opening of the concrete component is easy for workers to know after it is closed, and the sealing of the opening is guaranteed. Attached Figure Description

[0018] Figure 1This is a schematic diagram showing the opening position of the present invention.

[0019] Figure 2 This is a schematic diagram of the pre-assembled component configuration method of the present invention.

[0020] Figure 3 This is a schematic diagram of the external shape of the molding tool of the present invention.

[0021] Figure 4 This is a schematic diagram of the mold for the present invention.

[0022] Figure 5 This is a schematic diagram of the pre-assembled component structure of the present invention.

[0023] Figure 6 This is a schematic diagram of the connection portion of the present invention.

[0024] Figure 7 This is a schematic diagram of the mounting of the support lugs of the present invention. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0026] Currently, reinforced concrete components are often used as structural supports, with steel cages reinforcing their physical properties. For load-bearing structures, C100 high-performance concrete is primarily used. Traditional C100 concrete component construction typically requires on-site fabrication and dismantling of molds, resulting in relatively high labor and time costs. However, modern construction engineering increasingly favors standardized and modular structures. Currently, C100 concrete components are commonly manufactured through on-site casting and curing. This is because the curing period of C100 concrete is relatively short, thus limiting the application of precast and modular construction. On one hand, concrete is a composite material composed of coarse aggregate, fine aggregate, cementitious material, and water. Uneven distribution of these components can lead to stress concentration within the concrete structure, resulting in microcracks and affecting its overall compressive and tensile strength. On the other hand, during the setting and hardening process, water and cement react chemically to form hydration products, releasing additional water and creating pores. These pores can lead to microscopic defects inside the concrete, thereby reducing its density and affecting its strength and durability. Therefore, although concrete achieves C100 grade performance through the high strength of cement, concrete components are still subject to certain working conditions.

[0027] Example 1: refer to Figures 1 to 5As shown, one embodiment of the present invention is a method for preparing C100 high-performance concrete components, comprising the following steps: selecting a circular or square steel pipe A as a concrete forming tool; grinding and cleaning the inner wall of the steel pipe A to remove rust, dirt, and grease; vertically placing reinforcing bars B inside the steel pipe A; setting reinforcing cages between the reinforcing bars B; setting pre-installed components 1 on the reinforcing bars B; and providing openings 2 on the side wall of the steel pipe A, with the openings 2 corresponding to the pre-installed components 1. The steel pipe A contains reinforcing cages and pre-installed components, ensuring accurate positioning of the reinforcing cages and pre-installed components 1. During the pouring process, the position of the reinforcing bars will not shift due to the liquid flow of the concrete, and the reinforcing cages and pre-installed components 1 remain fixed within the steel pipe. This method helps maintain the structural stability of the concrete component and improves the overall quality and load-bearing capacity of the component.

[0028] Secondly, the material of the steel pipe allows it to be reused multiple times. Unlike traditional concrete molds that may be used only once, the reuse of steel pipe A reduces mold costs and saves environmental resources. Moreover, using steel pipe A as a forming tool optimizes the operation process of mold making, erection, and dismantling, making the placement and fixation of steel pipe A more efficient and reducing the complexity of on-site operations.

[0029] For reference, the use of steel pipe A allows for better control of concrete filling and vibration, thereby enhancing concrete density and uniformity. Simultaneously, the smooth inner wall of steel pipe A can improve the surface quality of the concrete. Furthermore, placing pre-assembled components on steel pipe A makes pre-setting connection points for cast components more efficient, simplifies on-site post-processing, and facilitates subsequent splicing and construction.

[0030] For reference, provided that the side wall of steel pipe A has an opening 2, if necessary, steel pipe A can also be used as part of the component, and the steel pipe can be used together with concrete. The combined effect of steel pipe A and concrete can provide additional compressive and bending resistance, and enhance the stability and service life of concrete components.

[0031] For reference, the opening 2 inside steel pipe A can also serve as an inspection channel for the pre-installed component 1 before pouring. This allows for observation of the pre-installed component 1's installation status before pouring, ensuring installation quality. Therefore, the design of opening 2 and pre-installed component 1 can improve construction efficiency and save costs, contributing to high-quality, high-standard engineering construction.

[0032] To improve the stability of the pre-installed component 1 within the cavity of the steel pipe A, the pre-installed component 1 is provided with multiple bends 3. The bends 3 on the pre-installed component 1 can form a specific shape inside the steel pipe A, maintaining the position and direction of the pre-installed component 1 in contact with the concrete during concrete pouring. This ensures that the pre-installed component 1 does not shift during load bearing after being bonded to the concrete. The principle is that the presence of the bends 3 increases the anchorage length and contact area between the pre-installed component 1 and the concrete, enhancing the bond strength between the pre-installed component 1 and the concrete, thereby improving stability and shear strength.

[0033] The pre-assembled part 1 is provided with a through hole 4, which penetrates the bent part 3; a limiting rod 5 is inserted through the through hole 4, the size of the limiting rod 5 being adapted to the through hole 4. The limiting rod 5 not only serves to reserve a position during the pouring process, but also, after the concrete hardens, by removing the limiting rod 5, the path of the through hole 4 left on the pre-assembled part 1 can be used for the later installation of connectors or other components.

[0034] One of the steps is to prepare the first concrete, which, by weight, consists of 380-500 parts cement, 30-200 parts mineral powder, 20-130 parts fly ash, 600-700 parts river sand, 300-400 parts grade I crushed stone, 600-800 parts grade II crushed stone, 4-6 parts water-reducing agent, and 130-150 parts water.

[0035] Grade 1 crushed stone consists of 5-10mm crushed stone, while Grade 2 crushed stone consists of 10-20mm crushed stone.

[0036] The addition of water-reducing agents can reduce the amount of water used in cement without reducing the workability of concrete, improve the fluidity of materials, and thus improve the pouring flowability and compactness, which helps to reduce air bubbles.

[0037] Its cement content and the use of active admixtures such as mineral powder and fly ash enable a higher degree of hydration and a denser microstructure, improving the strength and durability of concrete. The fine powders, such as mineral powder and fly ash, fill the voids between cement particles, increasing the density of the concrete and thus enhancing its impermeability. This, combined with the initial concrete encapsulation of reinforcing steel, reduces the risk of steel corrosion. Furthermore, using fly ash and mineral powder as substitutes for cement not only optimizes concrete performance but also mitigates its environmental impact.

[0038] In the first demonstration example, 50 catties of cement, 20 catties of mineral powder, 13 catties of fly ash, 70 catties of river sand, 40 catties of Grade I crushed stone, 80 catties of Grade II crushed stone, 0.6 catties of water-reducing agent, and 15 catties of water were taken. The cement, mineral powder, fly ash, river sand, Grade I crushed stone, and Grade II crushed stone were added to a mixer and mixed. Water and water-reducing agent were then added and mixed to obtain the first concrete. This demonstration example uses a relatively large amount of cement, which may promote higher early strength development. The relatively large amount of mineral powder and fly ash can increase the fine structure density of the concrete, reduce porosity, and improve impermeability. The water-reducing agent provides better workability and a lower shrinkage rate. The compressive strength of this first concrete is approximately 101-106 MPa, the drying shrinkage rate is approximately 0.08-0.10%, and the penetration depth is less than 20 mm.

[0039] In the second demonstration example, 38 catties of cement, 3 catties of mineral powder, 2 catties of fly ash, 60 catties of river sand, 30 kg of Grade I crushed stone, 60 catties of Grade II crushed stone, 0.4 catties of water-reducing agent, and 13 catties of water were used. The cement, mineral powder, fly ash, river sand, Grade I crushed stone, and Grade II crushed stone were added to a mixer and mixed. Water and water-reducing agent were then added and mixed to obtain the first concrete. This demonstration example uses less cement than the previous examples. The first concrete has a slower early strength gain, but its long-term strength meets design requirements. The reduced use of mineral powder and fly ash increases its shrinkage rate. The water-reducing agent dosage primarily ensures the concrete's fluidity and low shrinkage rate. The compressive strength of this first concrete is approximately 95-103 MPa, the drying shrinkage rate is approximately 0.06-0.08%, and the penetration depth is less than 30 mm.

[0040] In the third demonstration example, 400 catties of cement, 100 catties of mineral powder, 80 catties of fly ash, 618 catties of river sand, 317 catties of Grade I crushed stone, 712 catties of Grade II crushed stone, 4.2 kg of water-reducing agent, and 145 catties of water were used. The cement, mineral powder, fly ash, river sand, Grade I crushed stone, and Grade II crushed stone were added to a mixer and mixed. Water and water-reducing agent were then added and mixed to obtain the first concrete. This demonstration example is similar to the second demonstration example, continuing to use a relatively low amount of cement. The amounts of mineral powder and fly ash are between those of the first and second demonstration examples. The amount of water-reducing agent is similar to that of the second demonstration example. The compressive strength of the first concrete is approximately 100-104 MPa, the drying shrinkage rate is approximately 0.07-0.09%, and the penetration depth is less than 25 mm.

[0041] Therefore, all three examples contain the basic raw material components of cement, mineral powder, fly ash, river sand, grade I crushed stone, grade II crushed stone, water-reducing agent, and water, which together constitute the main components of the concrete in essentially the same way. The three examples aim to obtain high-performance C100 grade concrete through mixing and to control the shrinkage rate of the concrete and reduce the risk of drying shrinkage cracking through reasonable material proportions.

[0042] Cement is the main binder in concrete, mineral powder is an active admixture that helps improve the density and durability of concrete, and fly ash is also an admixture used to improve the impermeability of concrete and reduce shrinkage. Water-reducing agents reduce the water content of cement paste, optimize the fluidity of concrete, and reduce shrinkage. Different dosages of water-reducing agents affect the water-cement ratio, thus affecting the overall performance of concrete. Water in concrete plays a role in activating the setting and hardening of cement. Within the above weight range, the mineral powder and fly ash can balance the shrinkage rate of concrete, reduce volume shrinkage caused by water evaporation during hardening, and have a certain effect on resisting drying shrinkage cracking. Their dosage indicates that the first concrete meets the performance requirements of the structural foundation.

[0043] One step is to align the two ends of the limiting rod 5 with the outer wall of the steel pipe, cover the outside of the opening 2 with the mold 6, and provide a placement hole 601 for the insertion of the limiting rod 5 on the inner wall of the mold 6. The mold 6 closes the opening 2 and houses the limiting rod 5. The placement hole 601 in the mold 6 provides stable support for the limiting rod 5, which extends out of the outer wall of the steel pipe A. The placement hole 601 ensures that the limiting rod 5 does not shift during the pouring vibration process. After the first concrete has solidified, the mold 6 and the limiting rod 5 are removed.

[0044] The first layer of concrete is poured into the steel pipe layer by layer. This layer-by-layer pouring method effectively controls the curing quality and construction progress of the first layer of concrete. Each layer of the first layer of concrete is fully vibrated and cured, avoiding insufficient compaction at different heights due to a single pour. Simultaneously, a vibrator resonates the surface of the steel pipe, vibrating the steel pipe A. This ensures a more uniform and compact distribution of the first layer of concrete during pouring, improving its density and strength after pouring and reducing the risk of air pockets within the concrete during the pouring process.

[0045] The reference method of layer-by-layer pouring and vibration helps ensure good bonding between each layer of concrete and reduces the occurrence of internal cracks, which is especially noticeable for high-strength concrete such as first concrete.

[0046] One of the steps is that when the height of the first concrete pour exceeds the opening 2, the mold 6 is knocked out from the opening 2, and then the limiting rod 5 is heated by the heating equipment, so that the limiting rod 5 on the pre-assembled part 1 is melted and the through hole 4 is exposed; the through hole 4 is used to connect the bearing component.

[0047] By designing through holes in the pre-assembled components and using heat-fusible retaining rods, the retaining rods can be easily removed by heating, leaving through holes 4. Compared to traditional excavation or drilling methods, this reduces physical damage to the components and ensures that the microstructure of the concrete and the surrounding reinforcing steel structure are not damaged. This limits the potential impact of physical damage to the components and structural strength.

[0048] For workers, pre-setting the pre-assembled component 1 in the concrete pouring via hot melting simplifies subsequent construction steps, avoiding traditional secondary processing such as drilling or threading, and saving time and costs associated with various tools and operations. Furthermore, removing the mold 6 and then heating the limiting rod 5 using heating equipment makes the removal of the limiting rod 5 relatively safe, reducing safety hazards caused by improper mechanical operation on site. The hot melting method also ensures the precision of the through-hole size and position of the pre-assembled component 1, because the heating and melting process is cleaner than physical methods such as drilling, resulting in a cleaner and more aesthetically pleasing surface and holes in the treated component.

[0049] For reference, through hole 4 is used to install the load-bearing component. If the load-bearing component is replaced or repaired in the future, the reserved standardized through hole 4 will also facilitate the operation.

[0050] Example 2: Based on the above embodiments, another embodiment of the present invention is that during the first concrete pouring process, the bent portion 3 is in contact with the first concrete; from the perspective of structural mechanical performance, the close contact between the bent portion and the first concrete means that the pre-assembled part has a good anchoring effect in the concrete, and the first concrete covers the reinforcing cage in the steel pipe.

[0051] The aforementioned limiting rod is made of hot melt wax, and the heating device is a hot air blower. The hot melt wax, used as the material for the limiting rod, can be quickly melted by the hot air blower after pouring. Therefore, using a hot air blower to heat the pre-assembled component and the limiting rod to melt the limiting rod reduces damage to the hardened concrete structure. The aforementioned pre-assembled component 1 is made of a single piece of metal. By integrally setting up the pre-assembled component 1 and inserting it into the corresponding limiting rod 5, no subsequent complex measurements and positioning are required during pouring.

[0052] After the first concrete has hardened, a hot air blower is used to introduce hot air into opening 2, so that the pre-assembled part 1 and the limiting rod 5 are heated simultaneously until the limiting rod 5 melts. Compared with traditional drilling and cutting operations, the method of heating the melted wax with a hot air blower can reduce dust and noise pollution, and is more environmentally friendly and energy-saving.

[0053] Example 3: Based on the above embodiments, another embodiment of the present invention is that the above-mentioned layer-by-layer pouring is a segmented, multiple-stage pouring process. Each segment of concrete undergoes curing treatment after pouring, ensuring that each section receives adequate curing and thus maximizing the quality of the concrete. This method makes it easier to control the quality of each layer compared to monolithic pouring. Compared to single-stage pouring, layer-by-layer pouring allows for better control of concrete temperature and internal stress, thereby reducing cracks caused by temperature gradients or hardening shrinkage.

[0054] The height of each pour is constant; the constant thickness of each layer helps maintain the uniformity of the structure, ensuring that each section of concrete has the same properties and strength, forming a more integrated structure.

[0055] After each pour, curing is carried out. The next pour is carried out after the first concrete has hardened, until the surface of the first concrete is flush with or overflows the top of the steel pipe.

[0056] It is important to emphasize that "hardening" here refers to the hardening trend. Pouring the next layer of concrete when the previous pour has begun to show signs of hardening but has not yet fully hardened ensures better bonding between the old and new concrete and avoids the formation of cold joints.

[0057] For reference, in actual construction, partial pouring may conflict with other construction activities or machinery use. Layer-by-layer pouring allows the construction team to better coordinate various resources and improve work efficiency. Furthermore, for taller components, the bottom concrete may be difficult to fully vibrate and compact during monolithic pouring due to excessive pressure. Segmented pouring makes it easier to ensure sufficient vibration of each layer. Clearly, for precast or embedded components, layer-by-layer pouring ensures that each section of concrete adheres closely to it and also contributes to the stability of precast component 1 within steel pipe A.

[0058] It is worth noting that, since concrete requires different curing conditions at different stages, segmented pouring allows each segment of concrete to harden under its optimal curing conditions.

[0059] Example 4: Based on the above embodiments, another embodiment of the present invention further includes a second concrete, comprising, by weight, the following raw materials: 300-400 parts cement, 30-200 parts mineral powder, 60-130 parts fly ash, 700-850 parts river sand, 100-250 parts grade I crushed stone, 300-500 parts grade II crushed stone, 100-300 parts grade III crushed stone, 2-4 parts water-reducing agent, 130-160 parts water, and 8-20 parts photoluminescent material. The grade III crushed stone is 15-29 mm in size.

[0060] The mixture consists of 30 catties of cement, 3 catties of mineral powder, 6 catties of fly ash, 70 catties of river sand, 10 catties of grade I crushed stone, 30 catties of grade II crushed stone, 10 kg of grade III crushed stone, 0.2 catties of water-reducing agent, 13 catties of water, and 0.8 catties of photoluminescent material. The cement, mineral powder, fly ash, river sand, grade I, grade II, and grade III crushed stone are added to a mixer and mixed. Water and water-reducing agent are then added and mixed. The photoluminescent material is then added to obtain the second concrete. The second concrete is then applied to opening 2, completely covering it.

[0061] The second type of concrete has relatively low performance and is mainly used to provide a certain degree of sealing to prevent the opening from being affected by the external environment. Photoluminescent materials are added to the second type of concrete and applied to cover the opening. The photoluminescent materials can absorb a certain amount of light energy and release light in the dark, so that the opening can be identified.

[0062] Photoluminescent materials are added to concrete as a special additive. Their mixing, stirring, and construction processes are similar to those of ordinary concrete, requiring no special equipment or complex processes, facilitating on-site construction. This allows the second concrete to emit light without an external power source, and it also exhibits strong adaptability to environmental conditions such as temperature and humidity. As a luminescent concrete, the second concrete reduces reliance on electricity.

[0063] For reference, the second concrete covering at the opening can serve as a sign or decoration. Due to the fluorescent effect of the second concrete under the influence of photoluminescent materials, the component helps to increase the aesthetics and guidance at night. In particular, the component can play a certain decorative and guiding role when used in public places such as roads, parking lots, and park trails.

[0064] Furthermore, the photoluminescent material is a particulate mixture of zinc sulfide and strontium aluminate in a 1:1.3 ratio. Zinc sulfide and strontium aluminate are inorganic materials; their addition to concrete provides additional protection through bonding with the concrete, extending the effective lifespan of the photoluminescent material while reducing maintenance costs.

[0065] Furthermore, the first type of concrete exhibits a compressive strength greater than or equal to 100 MPa in a standard 150mm × 150mm × 150mm cube specimen; the second type of concrete exhibits a compressive strength less than or equal to 40 MPa in the same 150mm × 150mm × 150mm cube specimen. The compressive strength of the first type of concrete typically needs to meet the requirements of C100 concrete, while the second type of concrete is primarily used for auxiliary purposes and may involve crushing; therefore, the compressive strength requirement for the second type of concrete is lower than 40 MPa.

[0066] The testing procedure is as follows: Prepare a standard cube measuring 150mm × 150mm × 150mm. First, ensure the specimen surface is flat and free of obvious defects, and that it has been cured to the specified age, typically 28 days. Before testing, lightly sand the upper and lower bearing surfaces of the specimen to make them flat and clean. Then, place the specimen on a dedicated concrete compression testing machine, ensuring the bearing surfaces are parallel and aligned with the upper and lower pressure plates of the machine. Start the compression testing machine and apply a uniform load at a controlled rate until the specimen fails. The machine will record the maximum load-bearing capacity at failure. Finally, calculate the compressive strength of the concrete specimen based on the maximum load it actually withstands and its cross-sectional area. This value is the compressive strength of the specimen, usually expressed in megapascals (MPa).

[0067] Example 5: Based on the above embodiments, refer to Figures 3 to 7 As shown, in another embodiment of the present invention, the height of the pre-assembled component 1 is greater than that of the opening 2, the side wall of the pre-assembled component 1 is connected with reinforcing bars, and there is a gap between the reinforcing bars and the inner cavity of the steel pipe. The two ends of the pre-assembled component 1 abut against the inner wall of the steel pipe. The abutting arrangement of the pre-assembled component 1 is mainly used to prevent the pre-assembled component 1 from shaking, and the abutting of the two ends of the component 1 against the inner wall of the steel pipe A can ensure the consistency of the height of the pre-assembled component 1.

[0068] Furthermore, the number of pre-installed components 1 at the same height inside the aforementioned steel pipe is two or more, and there is a gap between two adjacent pre-installed components 1. This gap is used to limit the position of the pre-installed component 1 in conjunction with the first concrete. The advantages of setting two or more pre-installed components at a certain interval inside the steel pipe, ensuring that their sidewalls are connected to reinforcing bars and abut against but not tightly against the inner wall of the steel pipe, include: First, this design enhances the stability and robustness of the overall structure, because the pre-installed components and reinforcing bars form a robust frame structure, which helps maintain the shape and integrity of the steel pipe and its internal structure.

[0069] For reference, the gap between the precast components 1 provides ample space for the first concrete to enclose them. During the hardening process, the concrete can tightly wrap around and confine the precast components, improving the shear and tensile strength of the structure. At the same time, the gap can also play a role in damping and adjusting internal stress. This method can effectively reduce the complexity and cost of construction. After the structure hardens, the precast components and concrete form an unbreakable whole, ensuring the long-term durability of the components.

[0070] Example 6: Based on the above embodiments, refer to Figures 1 to 7As shown, in another embodiment of the present invention, the steel pipe A is provided with a dividing opening 7 on both sides. The dividing opening 7 is used to divide the steel pipe into two connecting parts 8, and each end of the connecting part 8 is provided with a support lug 9. The two adjacent connecting parts 8 are fitted together, and the support lug 9 is fixedly connected. The design of the steel pipe with dividing openings and the bolt-fixed support lug connection increases the reusability and adjustability of the steel pipe A. Specifically, the dividing opening 7 allows the steel pipe to be directly divided into two connecting parts 8, which facilitates transportation and on-site assembly; the pre-set bolt holes on the support lug 9 can form fixing points to ensure that the two connecting parts fit tightly, maintaining the stability and sealing of the steel mold throughout the casting and curing process.

[0071] Furthermore, the length of the aforementioned support lug 9 matches the length of the steel pipe. The support lug 9 has several bolt holes with equal spacing between adjacent bolt holes. Bolts are inserted into these holes to secure the support lug 9 and the connecting part 8 together. After the concrete component is completed, the bolts on the support lug 9 are removed, and the connecting part 8 of the steel pipe is separated, completing the removal process. This bolt-fitting support lug 9 method allows for quick installation and disassembly of the support lug 9, facilitating demolding and removal of the concrete component, significantly shortening operation time and improving construction efficiency. It also avoids the risk of damage to the steel pipe A structure, extending the service life of the steel pipe A and reducing its wear and cost.

[0072] In this specification, terms such as "one embodiment," "another embodiment," "embodiment," and "preferred embodiment" refer to specific features, structures, or characteristics described in connection with that embodiment, which are included in at least one embodiment described in the general description of this application. The appearance of the same term in multiple places in the specification does not necessarily refer to the same embodiment. Furthermore, when a specific feature, structure, or characteristic is described in connection with any embodiment, the intention is to suggest that implementing such a feature, structure, or characteristic in conjunction with other embodiments also falls within the scope of this invention.

[0073] Although the invention has been described herein with reference to several illustrative embodiments, it should be understood that many other modifications and implementations can be devised by those skilled in the art, which will fall within the scope and spirit of the principles disclosed herein. More specifically, various variations and modifications can be made to the components and / or layout of the subject matter arrangement within the scope of the disclosure, drawings, and claims. Besides variations and modifications to the components and / or layout, other uses will be apparent to those skilled in the art.

Claims

1. A method for preparing C100 high-performance concrete components, characterized in that: Includes the following steps: S1: Select a round or square steel pipe as a concrete forming tool, grind and clean the inner wall of the steel pipe to remove rust, dirt and grease; place steel bars vertically inside the steel pipe, set steel cages between the steel bars, set pre-installed parts (1) on the steel bars, and provide openings (2) on the side wall of the steel pipe, with the openings (2) corresponding to the pre-installed parts (1). The pre-assembled part (1) is provided with multiple bending parts (3), and the pre-assembled part (1) is provided with through holes (4), which penetrate the bending parts (3); a limiting rod (5) is inserted into the through hole (4), and the size of the limiting rod (5) is adapted to the through hole (4); the material of the limiting rod is hot melt wax; S2: Preparation of the first concrete, by weight, the raw materials include 380-500 parts cement, 30-200 parts mineral powder, 20-130 parts fly ash, 600-700 parts river sand, 300-400 parts grade I crushed stone, 600-800 parts grade II crushed stone, 4-6 parts water-reducing agent, and 130-150 parts water; put the cement, mineral powder, fly ash, river sand, grade I crushed stone, and grade II crushed stone into a mixer for mixing, and add water and water-reducing agent for further mixing to obtain the first concrete; grade I crushed stone is 5-10mm crushed stone, and grade II crushed stone is 10-20mm crushed stone; S3: Extend the limiting rod (5) out of the outer wall of the steel pipe A. The mold (6) covers the outside of the opening (2). The inner wall of the mold (6) is provided with a placement hole (601) for inserting the limiting rod (5). The mold (6) closes the opening (2) and stores the limiting rod (5). The first concrete is diverted into the inside of the steel pipe for layer-by-layer pouring. At the same time, the surface of the steel pipe is vibrated by a vibrator. S4: When the height of the first concrete pour exceeds the opening (2), the mold (6) is knocked out from the opening (2), and then the limiting rod (5) is heated by the heating device so that the limiting rod (5) on the pre-assembled part (1) is melted and the through hole (4) is exposed; the through hole (4) is used to connect the bearing component.

2. The method for preparing C100 high-performance concrete components according to claim 1, characterized in that: During the first concrete pouring process, the bent part (3) is in contact with the first concrete; the first concrete covers the steel cage in the steel pipe; after the first concrete hardens, a hot air blower is used to input hot air into the opening (2) to heat the pre-assembled part (1) and the limiting rod (5) simultaneously until the limiting rod (5) is hot melted. The heating device is a hot air blower, and the pre-assembled part (1) is made of metal.

3. The method for preparing C100 high-performance concrete components according to claim 1, characterized in that: The layer-by-layer pouring is carried out in segments and multiple pours, with a constant pouring height each time. After each pour is completed, curing is carried out. When the concrete of the previous pour begins to show signs of hardening but has not yet fully hardened, the next pour is carried out until the surface of the first concrete is flush with or overflows the top of the steel pipe.

4. The method for preparing C100 high-performance concrete components according to claim 1, characterized in that: The steps also include preparing a second concrete by taking the following raw materials by weight: 300-400 parts cement, 30-200 parts mineral powder, 60-130 parts fly ash, 700-850 parts river sand, 100-250 parts grade I crushed stone, 300-500 parts grade II crushed stone, 100-300 parts grade III crushed stone, 2-4 parts water-reducing agent, 130-160 parts water, and 8-20 parts photoluminescent material. The cement, mineral powder, fly ash, river sand, grade I crushed stone, grade II crushed stone, and grade III crushed stone are put into a mixer for mixing, and water and water-reducing agent are added for mixing. Then the photoluminescent material is added to obtain the second concrete. The second concrete is applied to the opening (2) and completely covers the opening (2).

5. The method for preparing C100 high-performance concrete components according to claim 4, characterized in that: The photoluminescent material is a particulate material formed by mixing zinc sulfide and strontium aluminate in a ratio of 1:1.

3.

6. The method for preparing C100 high-performance concrete components according to claim 4, characterized in that: The second concrete has a compressive strength of less than or equal to 40 MPa in a standard 150mm×150mm×150mm cube specimen.

7. The method for preparing C100 high-performance concrete components according to claim 1, characterized in that: The pre-installed component (1) is larger than the height of the opening (2). The side wall of the pre-installed component (1) is connected with reinforcing bars, and there is a gap between the reinforcing bars and the inner wall of the steel pipe. The two ends of the pre-installed component (1) abut against the inner wall of the steel pipe.

8. The method for preparing C100 high-performance concrete components according to claim 7, characterized in that: The number of pre-installed components (1) set at the same height inside the steel pipe is more than two, and there is a gap between two adjacent pre-installed components (1). This gap is used to limit the pre-installed components (1) in conjunction with the first concrete.

9. The method for preparing C100 high-performance concrete components according to claim 1, characterized in that: The steel pipe is provided with a dividing port (7) on both sides. The dividing port (7) is used to divide the steel pipe into two connecting parts (8). Both ends of the connecting parts (8) are provided with lugs (9). The two adjacent connecting parts (8) are fitted together and the lugs (9) are fixedly connected.

10. The method for preparing C100 high-performance concrete components according to claim 9, characterized in that: The length of the support ear (9) matches the length of the steel pipe. The support ear (9) is provided with several bolt holes. The gap between two adjacent bolt holes is the same. Bolts are inserted into the bolt holes to make the support ear (9) and the connecting part (8) fit together and lock. When the concrete component is completed, the part removal operation is carried out. The bolts on the support ear (9) are removed and the connecting part (8) of the steel pipe is separated to complete the part removal.

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