UHPC component manufacturing process

Abstract

The invention relates to the technical field of high-performance concrete, and particularly discloses a UHPC component manufacturing process which comprises the following steps: spraying a retarder on the surface of a mold; stirring the UHPC dry powder premix, the natural coarse aggregate, the additive and the water according to a formulated formula to prepare a surface layer; uniformly beating the surface layer material to the surface of the mold, and compacting by using a roller; adding the UHPC dry powder premix, fibers, water and an additive into a stirrer in batches, uniformly stirring to prepare a structural layer mixture, uniformly spraying the mixture onto the surface layer by using a high-pressure spray gun, compacting by using a roller to form a structural layer, putting a prefabricated embedded part into the structural layer, and manufacturing a reinforcing bag; surface treatment is conducted after demolding, a surface layer is directly washed away through a high-pressure water gun, and uniform coarse aggregate leaks out; curing for 45-55 hours, and spraying a waterproof and antifouling protective agent on the surface. The invention aims to solve the problems that the existing manufacturing process of the natural colored coarse aggregate member is easy to cause environmental pollution and the selected particle size of the coarse aggregate is limited.

Description

Technical Field

[0001] The invention relates to the technical field of high performance concrete, and in particular to a UHPC component manufacturing process. Background Art

[0002] In modern architecture and landscape design, natural colored coarse aggregate components are widely favored due to their unique aesthetics and natural texture. These components are usually produced by molding processes such as firing or pressing. However, these two traditional processes each have some limitations and environmental impact issues.

[0003] A major drawback of the firing process in the production of natural colored coarse aggregate components is its high energy consumption. The firing process requires a lot of energy to reach the necessary high temperature to ensure the hardening and fixation of the material; at the same time, this process is also accompanied by significant carbon dioxide emissions, which has a negative impact on the environment. Taking Yuhua stone bricks as an example, the high energy consumption and carbon emissions in its production process have become the focus of attention in the field of environmental protection. On the other hand, although the pressing process reduces energy consumption to a certain extent, it must be constructed on site, which will cause dust pollution during the construction process; secondly, due to the different depths of exposed aggregates, it is not only easy to fall off, but also difficult to repair. For example, the Yuhua stone decorative pavement in the garden faces such a problem during construction and maintenance.

[0004] In addition, the above two processes can mostly only produce flat products, but cannot produce curved products or other special-shaped components, and there are certain restrictions on the selection of particle size of coarse aggregate, limiting the added particle size range to 4-7mm, which cannot meet the diverse needs of the market and cannot complete the production of three-dimensional special-shaped components. Summary of the invention

[0005] In view of the deficiencies in the prior art, the technical problem solved by the present invention is to provide a UHPC component manufacturing process to solve the problems that the existing natural color coarse aggregate component manufacturing process is prone to cause environmental pollution and the selection of coarse aggregate particle size is limited.

[0006] In order to solve the above problems, the technical solution adopted by the present invention is: a UHPC component manufacturing process, comprising the following steps, step 1: making a mold according to the drawing, and spraying a retarder on the mold surface; step 2: according to the formula, UHPC dry powder premix, natural coarse aggregates of different specifications and additives, water, through a stirring device to make a surface layer slurry; step 3: evenly pat the surface layer material onto the mold surface; and compact it with a roller; step 4: according to the formula, UHPC dry powder premix, fiber, water and admixture are added to the mixer in batches, and stirred evenly to make a structural layer mixture ; Step 5: Use a high-pressure spray gun to spray the mixture evenly onto the surface layer, and use a roller to compact it to form a structural layer; Step 6: Place the prefabricated embedded parts into the sprayed structural layer according to the requirements of the drawings, and make reinforcement bags at the embedded points of the embedded parts, cover them with film for heat preservation and moisture retention, and let them stand for 20-28 hours; Step 7: After demoulding, perform surface treatment, lift the components out of the mold and make them stand upright, use a water gun flushing device to flush away the surface layer, and leak out uniform coarse aggregate; Step 8: Lay the treated components flat, spray mist water, cover with film, and continue to cure for 45-55 hours. Step 9: Spray waterproof and antifouling protective agent on the surface.

[0007] The beneficial effects of this solution are: through this production process, colored coarse aggregates with a wider range of particle sizes can be selected, and the particle size of the added coarse aggregate is 3-15mm. At the same time, different molds can be made according to the modeling requirements of the components, so that various three-dimensional special-shaped components can be made to meet the diverse needs of the market; and the preparation process of this solution is processed at the production site throughout the process, and does not need to be constructed on site like the traditional pressing process to cause environmental pollution; secondly, the preparation process of this method does not require firing, so it does not consume a lot of coal and electricity like the traditional firing process. The production process mainly consumes some electricity from the stirring equipment, spray guns and other equipment. The energy consumption of preparing components is low, and the production process will not cause secondary environmental pollution, which is energy-saving and environmentally friendly. The components of this solution are prefabricated products that can be rebuilt in a different location and disassembled for secondary use.

[0008] Furthermore, the UHPC dry powder premix in step 2 accounts for 50-60% by mass, the coarse aggregate accounts for 30-45%, the additive is a water reducer, the water reducer accounts for 0.5-1.5%, and water accounts for 3-10%.

[0009] Furthermore, the stirring time in step 4 is 8-15 minutes. The mixture is stirred thoroughly to ensure that all components are mixed evenly.

[0010] Furthermore, in step 4, the mass percentage is 82-87% of UHPC dry powder premix, 3-6% of fiber, 5-12% of water, and the additive is a water reducer, which accounts for 0.5-1.5%. The humidity of the mixed slurry is controlled by controlling the amount of water added, so that the slurry presents a wet mixed material that cannot flow.

[0011] Furthermore, the size of the reinforcement package is not less than 10*10*3 cm, which strengthens the firmness of the embedded parts and avoids the embedded parts from falling off due to insufficient depth.

[0012] Furthermore, the mold is made of steel. Since the density of UHPC reaches 2400-2700kg / m 3 , exceeding the 2000-2300kg / m 3 The density of the material is high. Ordinary wooden molds and fiberglass molds cannot withstand such a large density pressure, and mold expansion will occur, destroying the entire mold. Steel molds are not easily deformed, ensuring the product molding effect.

[0013] Furthermore, the thickness of the sprayed retarder is 2-8 mm. By spraying the retarder, the setting time of the surface layer is later than that of the aggregate layer and the structural layer, so that after the structural layer and the coarse aggregate are completely set and hardened, the surface retarder is washed away with water to expose the coarse aggregate. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 A flow chart was prepared for the present invention.

[0015] Figure 2 It is a front view of the water gun flushing device of the present invention.

[0016] Figure 3 This is a top view of the water gun flushing device.

[0017] Figure 4 for Figure 3 Top view of the swing assembly in part A.

[0018] The figure marks in the specification include: bottom plate 1, limit strip 11, adjustment rod 12, limit rubber strip 13, positioning rubber plate 14, slide bar 15, bracket 2, roller 21, slide rod 22, first spring 23, support rod 3, base 31, mounting seat 32, roller mounting seat 4, roller 41, motor 42, baffle 43, connecting plate 44, connecting rod 5, transmission rod 51, transmission bevel gear 52, driving bevel gear 53, second spring 54, driven bevel gear 55, turntable 56, pull rod 57, high-pressure water gun 6, plate 7. DETAILED DESCRIPTION

[0019] The following is further described in detail through specific implementation methods:

[0020] Example 1 This is as attached Figure 1 As shown: The UHPC component manufacturing process includes the following steps:

[0021] Step 1: Make the mold according to the drawing and spray the retarder on the mold surface; the thickness of the sprayed retarder is 0.5mm. To control the thickness of the retarder, it is necessary to calculate the area and volume of the product, weigh the weight of the retarder, and convert the thickness of the retarder to be controlled according to the relationship between volume, density and weight. For example, the thickness of the retarder to be sprayed is 0.5mm, and the bulk density is 1000kg / m 3 Calculation shows that the retarder is 500g / m 2 , that is, 500g of retarder is needed for spraying per square meter.

[0022] By spraying the retarder, the setting time of the surface layer is made later than that of the aggregate layer and the structural layer, so that after the structural layer and the coarse aggregate are completely set and hardened, the surface retarder can be washed away with water to expose the coarse aggregate.

[0023] Step 2: According to the formula, UHPC dry powder premix, natural coarse aggregate of different specifications and additives, and water are mixed through a mixing device to make a surface slurry; UHPC dry powder premix accounts for 50% of the total, coarse aggregate accounts for 42%; water reducer accounts for 1% and water accounts for 7%.

[0024] Step 3: Pat the surface material evenly onto the mold surface and compact it with a roller;

[0025] Step 4: Add 86% UHPC dry powder premix, 4% fiber, 9% water and 1% water reducer into the mixer in batches according to the formula, and stir evenly to form the structural layer mixture; the stirring time is 8-15 minutes, and the added fiber material accounts for 6% of the total mass percentage of the entire structural layer slurry. The fiber material is glass fiber.

[0026] Step 5: Use a high-pressure spray gun to evenly spray the mixture onto the surface layer, and compact it with a roller to form a structural layer;

[0027] Step 6: Place the prefabricated embedded parts into the sprayed structural layer according to the requirements of the drawings, and make reinforcement bags at the embedded points of the embedded parts, cover them with film for heat preservation and moisture retention, and leave them for curing for 24 hours; the size of the reinforcement bag should not be less than 10*10*3cm. Strengthen the firmness of the embedded parts and avoid falling off due to insufficient depth of the embedded parts.

[0028] Step 7: After demoulding, perform surface treatment, lift the component out of the mold and make it stand upright, use a water gun flushing device to flush away the surface layer, and leak out uniform coarse aggregate;

[0029] Step 8: Lay the treated components flat, spray with mist water, cover with film, and continue curing for 46 hours.

[0030] Step 9: Spray waterproof and anti-fouling protective agent on the surface.

[0031] Through this production process, colored coarse aggregates with a wider range of particle sizes can be selected, and different molds can be made according to the modeling requirements of the components, so as to complete the production of various three-dimensional special-shaped components and meet the diverse needs of the market; and the preparation process of this scheme is processed entirely at the production site, and does not require on-site construction like the traditional pressing process to cause environmental pollution; secondly, the preparation process of this method does not require firing, so it does not consume a lot of coal and electricity like the traditional firing process. The production process is mainly consumed by stirring equipment, spray guns and other equipment. The energy consumption of preparing components is low, and the production process will not cause secondary environmental pollution, which is energy-saving and environmentally friendly.

[0032] The mold is made of steel. Since the density of UHPC reaches 2400-2700kg / m 3 , exceeding the 2000-2300kg / m 3 The density of the material is high. Ordinary wooden molds and fiberglass molds cannot withstand such a large density pressure, and mold expansion will occur, destroying the entire mold. Steel molds are not easily deformed, ensuring the product molding effect.

[0033] Step 4 and step 5 both use a drum mixer to prevent the aggregate from being crushed and failing to achieve the desired effect.

[0034] like Figure 2 , Figure 3 As shown, the water gun flushing device includes a limiting mechanism, a transmission mechanism, a fixed length mechanism and a water gun flushing mechanism. The limiting mechanism is used to limit the bottom of the manufactured special-shaped or flat plate 7. The limiting mechanism is placed on the transmission mechanism for directional transmission, so that the limited plate 7 can pass through the water gun flushing mechanism to flush away the retarder part of the surface layer. The water gun flushing mechanism is arranged on one side of the transmission direction of the transmission mechanism, and the water outlet of the water gun faces the surface layer. The fixed length mechanism and the limiting mechanism cooperate to control the distance between the water gun and the plate 7, so that the distance between the water gun and the plate 7 is equal at all locations.

[0035] The limiting mechanism includes a bottom plate, a limiting strip 11, a positioning rod 12, a limiting rubber strip 13 and a positioning rubber plate 14. The limiting strip 11 is arranged along the longitudinal direction, that is, along the transmission direction of the transmission mechanism. The positioning rod 12 is arranged along the transverse direction and passes through the limiting strip 11. The positioning rod 12 is also threadedly connected to a limiting nut, and the limiting nut abuts against the limiting strip 11 to strengthen the fixed position of the positioning rod 12. The end of the positioning rod 12 close to the longitudinal center line of the bottom plate is hinged to the limiting rubber strip 13, and the bottom of the limiting rubber strip 13 is slidably connected to the bottom plate or in contact with the bottom plate. If two limiting strips 11 are arranged in parallel along the longitudinal direction, then two groups of positioning rods 12 are correspondingly arranged. The two groups of positioning rods 12 are named first positioning rods 12 and second positioning rods 12 from left to right. Each group of positioning rods 12 has multiple positioning rods 12 distributed along the longitudinal direction, and the multiple positioning rods 12 are equal in length; correspondingly, two limiting rubber strips 13 are arranged. A group of adjusting rods 12 near the water gun flushing mechanism, that is, the second adjusting rod 12, is hinged with a positioning rubber plate 14 at one end away from the limiting rubber strip 13. Take the curved plate 7 as an example to explain the use of this mechanism. The curved plate 7 is placed vertically on the bottom plate, and the adjusting rods 12 are adjusted left and right so that the limiting rubber strip 13 abuts against the side of the curved plate 7, thereby fixing the curved plate 7 to the bottom plate. The limiting rubber plate and the positioning rubber plate 14 are both made of rubber material, which has a certain hardness and flexibility, so that they can bend and maintain their shape. When the second adjusting rod 12 moves, it drives the positioning rubber plate 14 to move, so that the positioning rubber plate 14 is also bent into the shape of the plate 7. With this positioning structure, the limiting groove composed of the two limiting rubber strips 13 can be adaptively changed into any curved or flat shape to adapt to the production of various special-shaped plates 7, without the need to make additional targeted molds.

[0036] The fixed length mechanism includes a positioning rubber plate 14, a roller 21, a slide bar 22 and a bracket 2. The roller 21 is rotatably connected to one end of the slide bar 22 arranged in the transverse direction. The roller 21 abuts against the positioning rubber plate 14, so that the roller 21 can rotate along the surface of the fixed length mechanism when the positioning rubber plate 14 moves; the other end of the slide bar 22 is slidably connected to a sleeve, one end of the sleeve is welded to the bracket 2, and a first spring 23 is arranged in the sleeve, and the two ends of the first spring 23 abut against the inner wall of the slide bar 22 and the end of the sleeve respectively. The water gun flushing mechanism includes a high-pressure water gun 6 and a water gun seat. The high-pressure water gun 6 is clamped on the water gun seat. The water gun seat includes a mounting seat 32, a support rod 3 and a base 31 arranged in sequence from top to bottom. The support rod 3 passes through the slide bar 22 and is slidably connected to the base 31, and the support rod 3 is sleeved with the slide bar 22. A slide bar 15 is also provided on the side of the positioning rubber plate 14 close to the roller 21, and the roller 21 rolls along the slide bar 15.

[0037] The roller 21 is always in contact with the side wall of the positioning rubber plate 14 by the elastic force of the second spring 54; when the plate 7 is a curved surface, the slide bar 22 will reciprocate in the longitudinal direction under the action of the elastic force and the reaction force of the positioning rubber plate 14; because the support rod 3 is sleeved with the slide bar 22, the support rod 3 also reciprocates in the lateral direction with the slide bar 22, and because the relative positions of the support rod 3 and the slide bar 22 are fixed, the distance between the high-pressure water gun 6 on the mounting seat 32 and the plate 7 is constant, thereby ensuring that the impact force of the water gun on the surface layer of the plate 7 is similar, so that the high-pressure water gun 6 can flush the surface layer evenly, thereby exposing uniform coarse aggregate. The traditional method uses manual hand-held, the high-pressure water gun 6 is heavy, and it is laborious to hold for a long time, and if the water gun distance is manually adjusted according to the distance of the curved surface, the manual judgment error is large; the flushing force is unstable, affecting the consistency and uniformity of the flushed product; and the manual adjustment of the distance will further consume the operator's physical strength and cannot adapt to mass production.

[0038] The transmission mechanism includes a roller 41 and a roller 41 seat for mounting the roller 41. The roller 41 is rotatably connected to the roller 41 seat. A plurality of rollers 41 are provided along the length direction. The rollers 41 are connected by synchronous belts. The rollers 41 include an active roller 41 connected to a motor 42 and a plurality of driven rollers 41. The active roller 41 is located at one end of the roller 41 seat near the water gun flushing mechanism. A baffle 43 is provided on one side of the roller 41 seat along the transmission direction. A connecting plate 44 is abutted between the baffle 43 and the bottom plate of the limiting mechanism. The connecting plate 44 provides a rightward reaction force for the limiting mechanism to prevent the limiting mechanism from sliding in the lateral direction during the transmission. Although the friction between the plate 7 and the roller 41 under the action of the gravity makes it difficult for the plate 7 to slide in the lateral direction with the roller 41, the baffle 43 and the connecting plate 44 can further ensure that the limiting mechanism will not produce relative displacement in the lateral direction.

[0039] The water gun mechanism also includes a swing assembly, which includes a connecting rod 5 welded to the support rod 3, and the connecting rod 5 is rotatably connected to a transmission rod 51 arranged in the vertical direction, and the upper and lower ends of the transmission rod 51 are both arranged on a transmission bevel gear 52; one end of the rotating shaft of the active roller 41 extends to the roller 41 seat and is fixed with an active bevel gear 53 meshing with the transmission bevel gear 52, and the active bevel gear 53 is spline-connected with the rotating shaft of the active roller 41, so that the active gear can slide along the rotating shaft of the active roller 41 and can rotate with it; the rotating shaft of the active roller 41 is also provided with a limit ring A second spring 54 is provided between the active bevel gear 53 and the limiting ring, so that the active bevel gear 53 always maintains engagement with the transmission bevel gear 52 when it moves back and forth left and right; a vertical pole arranged in the vertical direction is also welded on the connecting rod 5, and a turntable 56 is rotatably connected to the upper end of the vertical pole, and a driven bevel gear 55 meshing with the transmission bevel gear 52 is provided at one end of the rotating shaft of the turntable 56; a pull rod 57 is rotatably connected to the outer edge of the turntable 56, and one end of the pull rod 57 is hinged to one end of the water gun seat, and the water gun seat is hinged to the support rod 3; thereby forming a crank rocker mechanism.

[0040] When the slide bar 22 drives the support rod 3 to move to the left, it also drives the connecting rod 5 to move, and then drives the transmission rod 51 to move, so that the rotating gear pushes the active gear to move to the left; similarly, when the slide bar 22 drives the support rod 3 to move to the right, the transmission gear moves to the right, and the second spring 54 pushes the active bevel gear 53 to move to the right, so that the active bevel gear 53 keeps meshing with the driven bevel gear 55 to ensure the operation of the swing assembly. The active bevel gear 53 rotates to drive the transmission bevel gear 52 to rotate, and the transmission bevel gear 52 drives the driven bevel gear 55 to rotate, so that the turntable 56 rotates, and the rotation of the turntable 56 pulls the pull rod 57 to move, so that the water gun mounting seat 32 swings back and forth in the vertical direction; so that the plate 7 can be reciprocated from top to bottom or from bottom to top, so that the surface layer of the plate 7 is cleaned. No additional driving mechanism is required to drive the water gun mounting support to swing.

[0041] The similarities between Example 2 and Example 1 are not repeated here. The difference is that in step 2, the total proportion of UHPC dry powder premix is ​​51%, the additive is a water reducer, and the water reducer accounts for 0.8%; the coarse aggregate accounts for 42%, and the water accounts for 6.2%;

[0042] The curing time of step 6 is 26 hours, and the curing time of step 8 is 48 hours.

[0043] The similarities between Example 3 and Example 1 and Example 2 are not repeated here. The difference is that in step 2, the total proportion of UHPC dry powder premix is ​​46%, the additive is a water reducer, the water reducer accounts for 1%, the coarse aggregate accounts for 45%, and the water accounts for 8%;

[0044] Step 4: According to the formula, 83% by mass of UHPC dry powder premix, 6% by mass of fiber, 10% by mass of water and 1% by mass of water reducer are added into the mixer in batches.

[0045] The cement used in Examples 1-3 all has a strength grade of 52.5 MPa.

[0046] The above is only an embodiment of the present invention, and the common knowledge such as the known specific structure and characteristics in the scheme is not described in detail here. It should be pointed out that for those skilled in the art, several deformations and improvements can be made without departing from the structure of the present invention, which should also be regarded as the protection scope of the present invention, and these will not affect the effect of the implementation of the present invention and the practicality of the patent. The scope of protection required by this application shall be based on the content of its claims, and the specific implementation methods and other records in the specification can be used to interpret the content of the claims.

Claims

1. UHPC component manufacturing process, Features: The following steps are included: Step 1: Make the mold according to the drawing and spray the retarder on the mold surface; Step 2: According to the formula, UHPC dry powder premix, natural coarse aggregates of different specifications and additives, and water are mixed into a surface slurry through a mixing device; Step 3: Pat the surface material evenly onto the mold surface and compact it with a roller; Step 4: Add UHPC dry powder premix, fiber, water and additives into the mixer in order according to the formula, and mix them evenly to form a structural layer mixture; Step 5: Use a high-pressure spray gun to evenly spray the mixture onto the surface layer, and compact it with a roller to form a structural layer; Step 6: Place the prefabricated embedded parts into the sprayed structural layer according to the requirements of the drawings, and make reinforcement packs at the embedded points of the embedded parts, cover them with film for heat preservation and moisture retention, and leave them to stand for 20-28 hours; Step 7: After demoulding, perform surface treatment, lift the component out of the mold and make it stand upright, use a water gun flushing device to flush away the surface layer, and leak out uniform coarse aggregate; Step 8: Lay the treated components flat, spray with mist water, cover with film, and continue to cure for 45-55 hours. Step 9: Spray waterproof and anti-fouling protective agent on the surface.

2. A UHPC component manufacturing process according to claim 1, Features: The UHPC dry powder premix in step 2 accounts for 45-55% by mass, the coarse aggregate accounts for 40-45%, the additive is a water reducer, the water reducer accounts for 0.5-1.5%, and water accounts for 6-10%.

3. The UHPC component manufacturing process according to claim 1, Features: The stirring time in step 4 is 8-15 min.

4. The UHPC component manufacturing process according to claim 1, Features: In step 4, the UHPC dry powder premix comprises 82-87% by mass, fiber 3-6% by mass, water 5-12% by mass, and a water reducer is used as an additive, with the water reducer accounting for 0.5-1.5%.

5. The UHPC component manufacturing process according to claim 1, Features: The size of the reinforcement pack is not less than 10*10*3cm.

6. The UHPC component manufacturing process according to claim 1, Features: The mould is made of steel.

7. The UHPC component manufacturing process according to claim 1, Features: The thickness of the sprayed retarder is 0.2-0.5 mm.

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