Lightweight high-toughness fiber concrete prefabricated component and construction method

Abstract

The application discloses a kind of lightweight high toughness fiber concrete prefabricated component, comprising: prefabricated component main body, including outer stable layer, lightweight reinforcement and lightweight toughness layer, prefabricated component main body is provided with containing groove, lightweight reinforcement and lightweight toughness layer are located in containing groove, and lightweight reinforcement is penetrated in lightweight toughness layer.The structure of the tunnel concrete prefabricated component for reinforcing repair is improved by the application, the outer layer is stable layer, the containing groove is arranged inside, the lightweight reinforcement of a plurality of transverse steel pipes and longitudinal steel pipes is arranged in the containing groove, the lightweight toughness layer is filled in the lightweight reinforcement and the containing groove, the lightweight toughness layer is mainly composed of cement base, lightweight aggregate, fiber and steel pipe etc., the outer stable layer is mainly composed of cement base, heavy aggregate, fiber and steel pipe etc., compared with the traditional concrete prefabricated component, the structure quality is greatly reduced, and the overall stability is not affected, and the labor degree of artificial handling is reduced.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of lightweight concrete prefabricated components, and particularly relates to a lightweight high-toughness fiber concrete prefabricated component and a construction method. BACKGROUND

[0002] In tunnel reinforcement and repair, the application of concrete prefabricated components brings significant advantages to the project. These components are pre-manufactured in factories to ensure their high precision and stability. After being transported to the tunnel site, prefabricated components can be quickly and efficiently installed, greatly shortening the construction period.

[0003] Concrete prefabricated components play a crucial role in tunnel reinforcement and repair. They can be used to repair damaged tunnel walls, vaults and floors, and enhance the overall structural strength of the tunnel.

[0004] Currently, the prefabricated components used in tunnel reinforcement and repair are generally too heavy, requiring manual handling to repair and reinforce the tunnel. This not only increases the labor intensity and construction time of construction personnel, but also may cause damage to the components or injury to the construction personnel due to improper operation. SUMMARY

[0005] The purpose of the present application is to solve the problem of the current prefabricated components used in tunnel reinforcement and repair, which are generally too heavy, requiring manual handling to repair and reinforce the tunnel, not only increasing the labor intensity and construction time of construction personnel, but also may cause damage to the components or injury to the construction personnel due to improper operation.

[0006] To achieve the above purpose, the present application adopts the following technical scheme: a lightweight high-toughness fiber concrete prefabricated component, comprising: a prefabricated component main body comprising an outer stable layer, a lightweight reinforcing member and a lightweight toughness layer, the prefabricated component main body is provided with a containing groove, the lightweight reinforcing member and the lightweight toughness layer are located in the containing groove, and the lightweight reinforcing member penetrates the lightweight toughness layer.

[0007] As a further description of the above technical scheme:

[0008] The lightweight reinforcing member comprises a plurality of horizontal pieces and a plurality of vertical pieces, and the plurality of horizontal pieces and the plurality of vertical pieces intersect with each other.

[0009] As a further description of the above technical scheme:

[0010] The horizontal pieces and the vertical pieces are both steel pipes.

[0011] As a further description of the above technical scheme:

[0012] The shape of the steel pipe matches the shape of the containing groove.

[0013] As a further description of the above technical solution:

[0014] The precast component body is provided with a plurality of limiting grooves.

[0015] As a further description of the above technical solution:

[0016] The limiting groove can be T-shaped or trapezoidal.

[0017] The application also provides a construction method of lightweight high-toughness fiber concrete precast component, comprising the following steps:

[0018] S1: raw material preparation, 40-60% cement-based material, 15-35% lightweight aggregate and heavy aggregate, 2-10% fiber material, 2-10% microsilica or silica fume, 0.5-2% water reducing agent and 10-15% water:

[0019] S2: mixing, the cement-based material, the lightweight aggregate, the microsilica or silica fume, the water reducing agent and the water raw material are added into the mixer, and are mixed sufficiently;

[0020] S3: adding the fiber material: adding the fiber material in the mixed concrete, and continuing to mix until the fiber is uniformly dispersed in the concrete to form lightweight tough concrete;

[0021] S4: the lightweight reinforcing piece is built, a plurality of the transverse pieces and a plurality of the vertical pieces are built in the mold;

[0022] S5: pouring, the mixed concrete is poured into the precast mold, and is vibrated and compacted to realize the filling connection between the lightweight tough concrete and the lightweight reinforcing piece;

[0023] S6: curing, the inner layer structure of the poured concrete precast component is cured until the design strength is reached to form the lightweight tough layer;

[0024] S7: continue mixing, the heavy aggregate and the fiber material are continuously added to the lightweight tough concrete to continue uniform stirring to form the concrete for the outer stable layer;

[0025] S8: pouring again, the lightweight tough layer peripheral side baffle in the mold is removed, the mixed concrete for the outer stable layer is poured into the mold, and is located outside the lightweight tough layer;

[0026] S9: curing again, the outer layer structure of the poured precast component is cured until the design strength is reached to form the outer stable layer.

[0027] As a further description of the above technical solution:

[0028] In the pouring step, the mold is cleaned and treated with a mold release agent in advance.

[0029] Further description of the above technical solution:

[0030] The light aggregate is perlite, vermiculite or ceramsite, and the heavy aggregate is iron ore, gravel or pebble.

[0031] In summary, due to the adoption of the above technical solution, the beneficial effects of the present application are:

[0032] In the present application, the structure of the tunnel concrete prefabricated member for reinforcement and repair is improved, the outer layer is a stable layer, the inside is provided with a containing groove, a light weight reinforcing member composed of a plurality of transverse steel pipes and longitudinal steel pipes is arranged in the containing groove, a light weight toughness layer is filled in the light weight reinforcing member and the containing groove, the light weight toughness layer is mainly composed of a cement base, light weight aggregate, fiber and steel pipe, and the outer stable layer is mainly composed of a cement base, heavy weight aggregate, fiber and steel pipe, compared with the traditional concrete prefabricated member, the structure greatly reduces the weight while maintaining the stability of the whole, facilitating manual carrying and reducing the labor degree of manual carrying. BRIEF DESCRIPTION OF DRAWINGS

[0033] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following will briefly introduce the drawings needed to be used in the embodiments, and it should be understood that the following drawings only show some embodiments of the present application, and therefore should not be regarded as a limitation to the scope, and for those skilled in the art, other related drawings can also be obtained without creative labor on the basis of these drawings.

[0034] Figure 1 It is a kind of light high toughness fiber concrete prefabricated member's solid Figure 1 .

[0035] Figure 2 It is a kind of light high toughness fiber concrete prefabricated member's solid Figure 2 .

[0036] Figure 3 It is a kind of light high toughness fiber concrete prefabricated member's sectional view.

[0037] Figure 4 It is a kind of light high toughness fiber concrete prefabricated member's solid Figure 3 .

[0038] Figure 5 It is a kind of light high toughness fiber concrete prefabricated member construction method's step diagram.

[0039] Legend:

[0040] 1 - prefabricated component body; 11 - outer stabilizing layer; 12 - lightweight reinforcement; 121 - transverse element; 122 - vertical element; 13 - lightweight flexible layer; 2 - containment slot; 3 - limiting slot. DETAILED DESCRIPTION

[0041] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by a person of ordinary skill in the art without creative work fall within the protection scope of the present application.

[0042] To make the objectives, technical solutions, and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, rather than all the embodiments. The components of the embodiments of the present application described and shown in the drawings herein can be arranged and designed in various different configurations.

[0043] Therefore, the following detailed description of the embodiments of the present application provided in the drawings is not intended to limit the scope of the claimed present application, but only represents selected embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by a person of ordinary skill in the art without creative work fall within the protection scope of the present application.

[0044] It should be noted that: similar reference numbers and letters represent similar items in the following drawings, therefore, once an item is defined in one drawing, it does not need to be further defined and explained in subsequent drawings.

[0045] In the description of the embodiments of the present application, it should be noted that the orientation or position relationship indicated by the terms "upper", "inner", and the like is based on the orientation or position relationship shown in the drawings, or the orientation or position relationship in which the product of the present application is usually placed, which is only for the convenience of describing the present application and simplifying the description, and does not indicate or imply that the indicated device or element must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application.

[0046] In the description of the present application, it is also necessary to explain that, unless otherwise explicitly specified and limited, the terms "arrangement", "installation", "connection", "connection" should be understood broadly, for example, it can be fixedly connected, or it can be detachably connected, or integrally connected, it can be directly connected, or indirectly connected through an intermediate medium, or the communication inside two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0047] Please refer to Figures 1-5 The present application provides a technical solution: a lightweight high-toughness fiber concrete prefabricated component, comprising:

[0048] The prefabricated component body 1 comprises an outer stable layer 11, a lightweight reinforcing member 12 and a lightweight tough layer 13, a containing groove 2 is arranged in the prefabricated component body 1, the lightweight reinforcing member 12 and the lightweight tough layer 13 are located in the containing groove 2, and the lightweight reinforcing member 12 penetrates in the lightweight tough layer 13.

[0049] The lightweight reinforcing member 12 comprises a plurality of transverse pieces 121 and a plurality of vertical pieces 122, and the plurality of transverse pieces 121 and the plurality of vertical pieces 122 intersect with each other.

[0050] The transverse piece 121 and the vertical piece 122 are both steel pipes.

[0051] The shape of the steel pipe matches the shape of the containing groove 2.

[0052] A plurality of limiting grooves 3 are arranged on the prefabricated component body 1.

[0053] The limiting groove 3 can be T-shaped or trapezoidal.

[0054] The present application also provides a construction method of a lightweight high-toughness fiber concrete prefabricated component, comprising the following steps:

[0055] S1: raw material preparation, 40-60% cement-based material, 15-35% lightweight aggregate and heavy aggregate, 2-10% fiber material, 2-10% microsilica or silica fume, 0.5-2% water reducing agent and 10-15% water:

[0056] S2: mixing, the cement-based material, the lightweight aggregate, the microsilica or silica fume, the water reducing agent and the water raw material are added into the mixer, and are mixed sufficiently;

[0057] S3: adding the fiber material: adding the fiber material in the uniformly mixed concrete, and continuing to mix until the fiber is uniformly dispersed in the concrete to form lightweight tough concrete;

[0058] S4: the lightweight reinforcement 12 is built, several of the transverse pieces 121 and several of the vertical pieces 122 are built in the mold;

[0059] S4: the lightweight reinforcement 12 is built, several of the transverse pieces 121 and several of the vertical pieces 122 are built in the mold;

[0060] S5: pouring, the mixed concrete is poured into the prefabricated mold, and vibration and compaction are carried out to realize the filling connection between the lightweight ductile concrete and the lightweight reinforcement 12;

[0061] S6: curing, the inner layer structure of the poured concrete prefabricated component is cured until the design strength forms the lightweight ductile layer 13;

[0062] S7: continue mixing, continue to add the heavy aggregate and the fiber material in the lightweight ductile concrete to continue uniform stirring to form the concrete for the outer stable layer 11;

[0063] S8: pouring again, the side baffle of the lightweight ductile layer 13 in the mold is removed, and the stirred concrete for the outer stable layer 11 is poured into the mold to be located outside the lightweight ductile layer 13;

[0064] S9: curing again, the outer layer structure of the poured prefabricated component is cured until the design strength forms the outer stable layer 11.

[0065] In the pouring step, the mold is cleaned and treated with a release agent in advance.

[0066] The lightweight aggregate is perlite, vermiculite or ceramsite, and the heavy aggregate is iron ore, gravel or pebble.

[0067] Working principle: the structure of the tunnel concrete prefabricated component for reinforcement and repair is improved, the outer layer is a stable layer, the inside is provided with a containing groove, the lightweight reinforcement composed of a plurality of transverse steel pipes and longitudinal steel pipes is arranged in the containing groove, the lightweight ductile layer is filled in the lightweight reinforcement and the containing groove, the lightweight ductile layer is mainly composed of a cement base, lightweight aggregate, fibers and steel pipes, and the outer stable layer is mainly composed of a cement base, heavy aggregate, fibers and steel pipes, compared with the traditional concrete prefabricated component, the structure greatly reduces the quality while not affecting the overall stability, is convenient for manual carrying, and reduces the labor degree of manual carrying.

[0068] The above is only the preferred specific embodiment of the present application, but the protection scope of the present application is not limited to this, any person skilled in the art can make equivalent replacement or change according to the technical scheme and the inventive concept of the present application within the technical range disclosed by the present application, which should be covered in the protection scope of the present application.

Claims

1. A construction method for a lightweight, high-toughness fiber-reinforced concrete precast component, characterized in that, Lightweight, high-toughness fiber-reinforced concrete precast components include: The precast component body includes an outer stabilizing layer, a lightweight reinforcing member, and a lightweight toughness layer. A receiving groove is provided inside the precast component body. The lightweight reinforcing member and the lightweight toughness layer are located in the receiving groove. The lightweight reinforcing member passes through the lightweight toughness layer. The lightweight reinforcing member includes a plurality of horizontal members and a plurality of vertical members, which intersect each other. The construction method includes the following steps: S1: Raw material preparation: 40-60% cement-based materials, 15-35% lightweight and heavy aggregates, 2-10% fiber materials, 2-10% silica fume or silica fume, 0.5-2% water-reducing agent, and 10-15% water; the lightweight aggregates are perlite, vermiculite, or ceramsite; the heavy aggregates are iron ore, crushed stone, or pebbles. S2: Mixing, adding the cement-based material, the lightweight aggregate, the silica fume or silica fume, the water-reducing agent and the water into a mixer and mixing them thoroughly; S3: Add the fiber material: Add the fiber material to the well-mixed concrete and continue mixing until the fiber is evenly dispersed in the concrete to form lightweight and tough concrete; S4: The lightweight reinforcement assembly involves assembling several horizontal components and several vertical components within the mold; S5: Pouring, pouring the mixed concrete into the precast mold, vibrating and compacting it to achieve the filling connection between the lightweight tough concrete and the lightweight reinforcement. S6: Curing, curing the inner structure of the poured precast concrete component until it reaches the design strength to form the lightweight tough layer; S7: Continue mixing, continue adding the heavy aggregate and the fiber material to the lightweight tough concrete and continue mixing evenly to form concrete for the outer stabilizing layer; S8: Cast again, remove the perimeter baffle of the lightweight tough layer inside the mold, and pour the mixed concrete for the outer stabilizing layer into the mold so that it is located outside the lightweight tough layer. S9: Secondary curing: Curing the outer structure of the cast precast component until it reaches the design strength to form the outer stable layer.

2. The construction method for a lightweight, high-toughness fiber-reinforced concrete precast component according to claim 1, characterized in that, Both the horizontal and vertical components are steel pipes.

3. The construction method for a lightweight, high-toughness fiber-reinforced concrete precast component according to claim 2, characterized in that, The shape of the steel pipe matches the shape of the receiving groove.

4. The construction method for a lightweight, high-toughness fiber-reinforced concrete precast component according to claim 1, characterized in that, The prefabricated component body can also be provided with several limiting grooves.

5. The construction method for a lightweight, high-toughness fiber-reinforced concrete precast component according to claim 4, characterized in that, The limiting groove is T-shaped or trapezoidal.

6. The construction method for a lightweight, high-toughness fiber-reinforced concrete precast component according to claim 1, characterized in that, In the casting process, the mold is cleaned and coated with a release agent beforehand.

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