Modularized permeable floor tile on-site manufacturing device and process

Abstract

The invention discloses a modular permeable floor tile on-site manufacturing device and process, the device is composed of a shaping metal mold manufactured and processed in a factory, mold patterns are preset according to design requirements, floor tile manufacturing is divided into two processes of in-mold pouring and light pressure printing, and the manufactured floor tile has the self-permeable characteristic. The in-mold pouring method comprises the following steps: placing a shaping mold on the leveled compacted road base, uniformly pouring the water-permeable mortar into the mold, compacting and plastering, and uniformly and upwards pulling out the mold, so that the water-permeable floor tile with the drainage grooves and the floral patterns can be formed and is used for a large-area construction area. According to the shallow-pressing printing method, shallow-pressing printing is conducted on the surface of the evenly-flattened permeable cement mortar through a mold, and then the permeable floor tile with the drainage grooves and the floral patterns can be formed and used for local corner areas. The water-permeable floor tiles manufactured on site through the device and the process are durable, not prone to damage and capable of being widely applied to the fields of various buildings and municipal engineering.

Description

Technical Field

[0001] The invention relates to the field of building construction and municipal administration, and is a device and process for on-site modular rapid production of road or site floor tiles. Background Art

[0002] With the acceleration of urban construction, the urban ground is gradually covered by various buildings and various natural stones and concrete. Convenient transportation and flat roads have brought great convenience to people's travel, but these impermeable roads have also brought many negative impacts on the ecological environment of the city. Due to the lack of water permeability and air permeability of the paved road surface, rainwater cannot penetrate into the ground, resulting in surface plants being difficult to grow normally due to severe water shortage. It is difficult for the impermeable road surface to exchange heat and moisture with the air, and it lacks the ability to regulate the temperature and humidity of the urban surface, resulting in the urban "heat island effect". In addition, the impermeable road surface is prone to water accumulation, which reduces the comfort and safety of the road. When rainfall is concentrated in a short period of time, rainwater can only be discharged into the river through drainage facilities, which greatly increases the burden on drainage facilities.

[0003] Permeable mortar floor tiles are a kind of building materials that are both permeable, environmentally friendly and decorative. They are made by forming permeable cement mortar into floor tiles, and then paving them at the construction site. They are widely used in urban sidewalks, parking lots, squares, garden paths and other areas that require drainage and beauty. It is permeable, environmentally friendly, decorative and durable. It is a key component of the concept of "sponge city" in modern cities and occupies an important position in the urban rainwater utilization system.

[0004] The functional requirements for permeable floor tiles are generally as follows: permeable brick pavement should meet the functional requirements of load, permeability, anti-skid and other functions and durability requirements such as anti-frost heave. At the same time, the design of permeable brick pavement should meet the permeability (drainage) requirements of the local two-year rainstorm intensity, continuous rainfall for 60 minutes, and no runoff should be generated on the surface. According to the requirements of the "Urban Road Pavement Design Code" (CJJ 169-2012), the reasonable service life of permeable pavement should be 8 to 10 years.

[0005] Traditional outdoor permeable floor tiles are usually installed on site by splicing prefabricated floor tiles. The structural section from top to bottom is generally: permeable brick surface layer, leveling layer, base layer and cushion layer. Its construction process generally includes: site preparation, compacting the base layer and laying the cushion layer, leveling layer construction, floor tile paving and caulking treatment, etc. Although traditional outdoor permeable floor tiles have certain ecological functions in actual applications, when they are laid on site or in use, if the base layer strength is insufficient, the laying process is not standardized, the joint treatment is improper, the foundation settlement or overload effect and other factors often lead to poor permeability, a large amount of settlement, deformation or damage of floor tiles, thus affecting the use function and overall appearance.

[0006] Therefore, in actual engineering applications, it is necessary to find an on-site construction method that can effectively improve the quality of floor tile paving construction and effectively increase the functionality and durability of floor tiles, to replace the traditional prefabricated floor tile joint paving process. Summary of the invention

[0007] The purpose of the present invention is to provide a modular floor tile construction device and related processes for directly manufacturing and laying on the construction site, so as to solve the problem of deformation and damage caused by insufficient overall strength of prefabricated floor tiles commonly used in current projects, which affects the use function and overall appearance.

[0008] The outstanding advantages of the present invention are: first, the floor tiles themselves have water-permeable properties, and suitable specifications and patterns can be used according to the use function and drainage requirements, and the site adaptability is strong; second, because the floor tiles are made on-site, the bonding strength between the permeable brick surface layer and the leveling layer is high, and the floor tiles made on-site have good quality, high strength, stability and durability, which are significantly better than the prefabricated floor tile paving process. The modular permeable floor tiles made on-site have the comprehensive advantages of self-permeability and durability, which not only meet the requirements of urban immediate drainage under the concept of "sponge city" construction, but also have a long service life, which can effectively reduce the maintenance cost of the floor tiles during their use period, and have obvious comprehensive cost advantages.

[0009] To achieve the above-mentioned purpose, the technical solution adopted by the present invention is: a modular on-site production device and process for permeable floor tiles. The device is composed of a standardized metal mold produced and processed in the factory. The mold pattern is preset according to the design requirements. The floor tile production is divided into two processes: in-mold casting and shallow embossing. The produced floor tiles have self-permeable characteristics.

[0010] The in-mold pouring method places a shaping mold after leveling the compacted base layer, and then evenly pours the permeable mortar into the shaping mold. After compacting and plastering the surface, the shaping mold is evenly pulled upward to form a permeable floor tile with hydrophobic grooves and patterns.

[0011] The shallow embossing method uses a mold to shallowly emboss the surface of the permeable cement mortar that has been evenly smoothed to form permeable floor tiles with hydrophobic grooves and patterns.

[0012] The metal mold is manufactured and processed in the factory. The inner and outer shapes of the mold plane are square or regular polygons, and its outer edges can be assembled into a whole. The large mold is the same height as the floor tiles to be cast. There is no special requirement for the height of the small mold. The mold pattern is preset according to the design requirements.

[0013] Permeable cement mortar is mixed on site and poured. The mortar material is made by mixing aggregate, cement, additives and water according to a mix ratio. The additive is a polymer material that improves the strength and durability of the mortar floor tiles.

[0014] The structural cross section of the modular permeable floor brick of the present invention comprises, from top to bottom, a permeable brick surface layer, a leveling layer, a base layer, a cushion layer and a soil base.

[0015] First of all, the surface layer of permeable bricks is not only directly exposed to the impact of pedestrians and wheels, but also directly exposed to the impact of temperature and humidity and their changes such as sunlight, rain, snow, and freezing. Therefore, it should have sufficient structural strength. In addition, in order to ensure the safety and comfort of pedestrians or vehicles, the surface layer should also have sufficient anti-slip ability and good flatness. The permeability of the permeable floor tile surface layer should not be less than 1.0×10 -2 cm / s, anti-slip performance (BPN) is not less than 60, and wear resistance coefficient is not less than 25.

[0016] Secondly, since the present invention adopts a modular on-site production process for permeable floor tiles, a reasonable leveling layer must be set under the permeable floor tile surface layer. One is for construction leveling, and the other is to provide stable bonding for the permeable floor tile surface layer to form a force-bearing whole. Therefore, the leveling layer preferably uses soft hard cement mortar.

[0017] Thirdly, the base layer below the leveling layer mainly plays a load-bearing role and should have sufficient strength and load diffusion capacity and sufficient water stability. In addition, as a permeable base layer, it must of course have the functions of water permeability and water storage.

[0018] Preferably, a graded crushed stone compacted cushion layer is preferably set under the base layer, and the compaction degree of the top surface of the cushion layer should reach more than 95% according to the heavy compaction standard. The main purpose of setting a graded crushed stone compacted cushion layer is to improve the bearing capacity of the soil base at saturated water content, and to effectively prevent the floating of clay particles or the occurrence of capillary phenomena, which affects the use function of the base layer. If the water stability of the soil base is good (such as sandy soil, sandy soil, etc.), it can be omitted, so the basic structural composition should be selected according to the actual situation.

[0019] Finally, the soil base under the permeable floor brick pavement should be stable, dense, homogeneous, and have sufficient strength, stability, deformation resistance and durability. The soil base compaction degree should not be less than 93%. At the same time, the soil base should have a certain water permeability, and the soil water permeability coefficient should not be less than 1.0×10 -3 mm / s, and the top surface of the soil base should be greater than 1.0m from the groundwater level. When the soil base, soil permeability coefficient and groundwater level elevation do not meet this requirement, it is advisable to increase the pavement drainage design content, and the drainage design inside the pavement can be combined with the rainwater collection and utilization system. Soft soil (silt and silty soil), untreated artificial fill, collapsible soil, expansive soil and other special soils are not suitable for paving permeable pavement. Soil types that do not meet the requirements for roadbed soil shall be replaced, and the replacement soil shall be general clay soil or sandy soil.

[0020] The implementation steps adopted by the present invention are: First, measure the site topography and elevation, document it, and make site markings.

[0021] Secondly, the soil base performance is tested, and parameters such as compaction and permeability meet the design requirements.

[0022] Secondly, the natural graded gravel base layer is compacted and the compaction degree meets the design requirements.

[0023] Furthermore, the base layer is paved, and its strength, water stability and permeability meet the design requirements.

[0024] Furthermore, the leveling layer is laid, and its strength and flatness meet the design requirements.

[0025] Furthermore, modular permeable floor tiles are manufactured on-site, with the in-mold casting method used in large-area construction areas and the shallow embossing method used in flat irregular edge and corner areas.

[0026] Furthermore, the finished floor tiles are watered and cured, and fine sand is used to fill the joints after final setting.

[0027] Finally, an overall quality inspection is carried out and if qualified, the requirements for floor tiles can be met.

[0028] Compared with the existing traditional methods, the beneficial effects of the present invention are: first, the floor tiles and their lower structures have self-permeable properties, strong site adaptability, and meet the high standards for "sponge city" construction; second, the floor tile manufacturing process is different from the on-site laying of prefabricated floor tiles. After adopting the on-site manufacturing process, the floor tile surface layer and the lower structural layer have high bonding strength, strong structural durability, longer service life, and more obvious comprehensive cost advantages. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The present invention will be further described below in conjunction with the accompanying drawings and specific embodiments.

[0030] Figure 1 A top view of a modularized permeable floor tile on-site production device and a process for producing floor tiles by in-mold casting provided by the present invention.

[0031] Figure 2 A top view of a modularized permeable floor tile on-site production device and process for producing floor tiles using a shallow embossing printing method provided by the present invention.

[0032] Figure 3 A modular permeable floor tile on-site production device and process structure cross-sectional view provided by the present invention.

[0033] Figure 4 A modular permeable floor tile on-site production device and a process implementation operation flow chart provided by the present invention.

[0034] In the figure: the device is mainly composed of a metal mold 1, cast-in-place floor tiles 2, a single floor tile 201, a joint gap 202, a leveling layer 3, a base layer 4, a cushion layer 5 and a bare soil compaction layer 6, and the operation process steps are implemented from S101 to S108. DETAILED DESCRIPTION

[0035] In order to make the technical means, creative features, objectives and effects achieved by the present invention easy to understand, the present invention is further explained below with reference to specific diagrams.

[0036] It should be noted that the structures, proportions, sizes, etc. illustrated in the drawings of this specification are only used to match the contents disclosed in the specification for people familiar with this technology to understand and read, and are not used to limit the limiting conditions for the implementation of the present invention, so they have no substantial technical significance. Any modification of the structure, change of the proportion relationship or adjustment of the size should still fall within the scope of the technical content disclosed by the present invention without affecting the effects and purposes that can be achieved by the present invention. At the same time, the terms such as "upper", "lower", "left", "right", "middle" and "one" quoted in this specification are only for the convenience of description, and are not used to limit the scope of the implementation of the present invention. The change or adjustment of their relative relationship should also be regarded as the scope of the implementation of the present invention without substantially changing the technical content.

[0037] The present invention is described in detail below in conjunction with the accompanying drawings: A modular on-site permeable floor tile production device and process. The floor tile surface layer 2 production device is composed of a standardized metal mold 1 produced and processed in a factory. The plane pattern of the mold 1 is preset according to design requirements. The production of floor tiles 2 is divided into two processes: in-mold casting S1 and shallow embossing S2. The produced floor tiles 2 have self-permeable characteristics.

[0038] In the mold casting method S1, a shaping mold 1 is placed on the compacted leveling layer 3, and then the permeable mortar is evenly poured into the shaping mold 1. After compacting and plastering, the shaping mold 1 is evenly pulled upward to form a permeable floor tile 2 with a hydrophobic groove and a pattern. Preferably, the leveling layer 3 is a dry hard cement mortar leveling layer.

[0039] The shallow embossing method S2 uses a mold 1 to shallowly emboss the surface of the permeable cement mortar that has been evenly smoothed, so that a permeable floor tile 2 with a hydrophobic groove and a pattern can be formed.

[0040] The metal mold 1 is manufactured and processed in the factory. The inner and outer shapes of the mold 1 are square or regular polygons, and its outer edges can be assembled into a whole. The large mold is the same height as the floor tiles 2 to be cast, and there is no special requirement for the height of the small mold. The pattern of the mold 1 is preset according to the design requirements.

[0041] Permeable cement mortar is mixed and poured on site. The mortar material is made of aggregate, cement, additives and water according to the mix ratio. The additive is a polymer material to improve the strength and durability of the mortar floor tiles. Aggregates mainly use coarse aggregates (quartz sand, gravel) with a particle size between 2 and 6 mm. Fine aggregates are appropriately reduced to improve permeability. Cement uses silicate cement (PO 42.5 or above) to enhance strength. Polyacrylate is used as a polymer additive to improve strength and durability. Use clean water with a water-cement ratio between 0.3 and 0.4.

[0042] The modular permeable floor 2 brick structure cross-section of the present invention is as follows from top to bottom: a permeable brick surface layer 2, a leveling layer 3, a base layer 4, a cushion layer 5 and a soil base 6.

[0043] Preferably, the water permeability of the permeable floor tile 2 is not less than 1.0×10 -2 cm / s, anti-slip performance (BPN) is not less than 60, and wear resistance coefficient is not less than 25.

[0044] Preferably, the permeable floor tiles 2 are mixed on-site with cement mortar and spread and poured for curing. The mortar material is made by mixing aggregate, cement, additives and water according to a mix ratio. The additive is a polymer material to improve the strength and durability of the mortar floor tiles.

[0045] Preferably, the leveling layer 3 is made of dry hard cement mortar.

[0046] Preferably, the base layer 4 is a sand-free macroporous plain concrete base layer.

[0047] Preferably, the cushion layer 5 is compacted with natural graded crushed stone, and the compaction degree of the top surface of the cushion layer 4 is more than 95% according to the heavy compaction standard. Preferably, the compaction degree of the soil base 6 is not less than 93%, and the soil permeability coefficient is not less than 1.0×10 -3 mm / s, and the top surface of the soil foundation 6 should be greater than 1.0m away from the groundwater level. Example

[0048] Due to the high-standard construction requirements of a "sponge city" in a project park in a coastal soft soil area, after sufficient investigation and analysis and comparison with the project feasibility study, it was found that due to the poor foundation characteristics of the lower part of the site where the park is located, the traditional outdoor floor tile paving method is difficult to meet the durability requirements of the road surface and site during the use stage. In order to ensure the overall use requirements and durability of the paved roads and sites, after sufficient comparison of the schemes, a modular permeable floor tile on-site production device and process provided by the present invention is adopted to implement the pavement and site structure paving.

[0049] See also Figures 1 to 4The embodiment adopts a modular permeable floor tile on-site production device and process, and the device is mainly composed of a shaped metal mold 1, a cast-in-place permeable floor tile 2, a single floor tile 201, a floor tile joint gap 202, a leveling layer 3, a base layer 4, a cushion layer 5 and a bare soil compaction layer 6.

[0050] The device is composed of a factory-made and processed finalized metal mold 1. The pattern of the mold 1 is preset according to the design requirements. The production of the permeable floor tile 2 is divided into two processes: in-mold pouring S1 and shallow embossing S2. The large mold is used for in-mold pouring S1 production, which is suitable for large-area construction. The small mold is used for shallow embossing S2 production, which is suitable for local corner area construction.

[0051] Furthermore, the metal mold 1 is made of aluminum in the factory. The plane of the large mold 1 is square, and the internal shape of the large mold is four small squares + four cross polygons. The thickness of the large mold frame is 3mm, and the specifications of the small square floor tiles are 300mm×300mm×80mm. The large mold is the same height as the poured floor tiles, which is also 80mm. There is no special requirement for the height of the small mold. The height of the small mold in the embodiment is 30mm, and the mold pattern is arranged in a 160mm×80mm rectangular shape. The thickness of the small mold frame is 3mm, and the embossing depth is 3mm.

[0052] Furthermore, the permeable floor tiles are mixed on site with cement mortar and paved for pouring and curing. The mortar material is made by mixing aggregate, cement, additives and water according to the mix ratio. The additive is a polymer material to improve the strength and durability of the mortar floor tiles. According to the required permeability and strength, the mix ratio is: aggregate: cement: water = 4:1:0.35. First, dry mix the coarse aggregate and cement evenly (about 2 to 3 minutes). Then slowly add water and stir until the slurry is evenly covered on the surface of the aggregate. Ensure that there is no obvious bleeding and the slurry should not be too much. Then add a reinforcing agent or a water reducer and continue stirring for 1 to 2 minutes.

[0053] Furthermore, a layer of mold release agent is brushed on the inside of the mold for demoulding. Fill the mixed permeable mortar into the mold and distribute it evenly. Use a vibrating table or pat it manually to make the material fill the mold tightly and eliminate bubbles. After molding, let it stand for 12 to 24 hours for preliminary curing. During this period, avoid strong light exposure or rapid water loss. After preliminary curing, gently remove the floor tile from the mold. After demoulding, cover the floor tile with a wet cloth for curing, and the curing time is not less than 7 days. Keep it moist during the curing process to ensure the strength of the floor tile material. After molding, the permeability of the permeable floor tile 2 is not less than 1.0×10 -2 cm / s, anti-slip performance (BPN) is not less than 60, and wear resistance coefficient is not less than 25.

[0054] Furthermore, it is preferred to apply a layer of water-permeable protective coating on the surface of the floor tiles to prevent fine particles from clogging the pores, and color powder and grinding treatment are also added to improve the aesthetics.

[0055] Furthermore, the leveling layer 3 of the embodiment adopts a 30 mm thick 1:6 dry hard cement mortar leveling layer.

[0056] Furthermore, the base layer 4 of the embodiment adopts a 100 mm thick C20 sandless macroporous plain concrete base layer.

[0057] Furthermore, the cushion layer 5 of the embodiment adopts a 150 mm thick natural graded crushed stone cushion layer, and the compaction degree of the top surface of the cushion layer 5 reaches more than 95% according to the heavy compaction standard.

[0058] Furthermore, the soil base 6 of the embodiment is compacted with plain soil, the compaction degree is more than 93%, and the soil permeability coefficient is not less than 1.0×10 -3 mm / s, and the top surface of the soil base is greater than 1.0m from the groundwater level.

[0059] See also Figure 4 , the implementation steps of the present invention are further described.

[0060] S101 Measure the site topography and elevation and document them, making on-site markings.

[0061] S102 tests the soil base performance, and parameters such as compaction and permeability meet the design requirements.

[0062] The S103 natural graded crushed stone cushion layer is compacted and the compaction degree meets the design requirements.

[0063] The S104 base layer is paved, and its strength, water stability and permeability meet the design requirements.

[0064] S105 leveling layer is laid, and its strength and flatness meet the design requirements.

[0065] S106 modular permeable floor tiles are manufactured on-site, with in-mold casting used in large construction areas and shallow embossing used in flat irregular edge and corner areas.

[0066] S107 Water and maintain the finished floor tiles, and use fine sand to fill the joints after final setting.

[0067] S108 conducts overall quality inspection, and once qualified, it can meet the requirements for floor tile use.

[0068] In the embodiment, a modular permeable floor tile on-site production device and process method provided by the present invention were used to successfully implement the pavement and site structure paving of roads and sites within the project site. The actual use effect after paving shows that the modular permeable floor tile on-site production process provided by the present invention has strong adaptability to the site and can well meet the high standards of "sponge city" construction. At the same time, the structural strength and stability are also high. The total number of damaged tiles in the surface structure after 3 years of use does not exceed 50. The example has a good use effect and can be further promoted and applied to more construction and municipal engineering fields.

[0069] The above shows and describes the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The above embodiments and descriptions are only for explaining the principles of the present invention. The present invention may be subject to various changes and improvements without departing from the spirit and scope of the present invention. These changes and improvements fall within the scope of the present invention. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A modular permeable floor tile on-site production device and process, characterized by: The device is composed of a standardized metal mold made and processed in the factory. The mold pattern is preset according to the design requirements. The production of permeable floor tiles is divided into two processes: in-mold pouring and shallow embossing. The large mold is used for in-mold pouring, which is suitable for large-area construction. The small mold is used for shallow embossing, which is suitable for corner area construction.

2. The modular permeable floor tile on-site production device and process according to claim 1 is characterized by: The metal mold is manufactured and processed in the factory. The shape of the mold plane is square or regular polygon, and its outer edges can be assembled into a whole. The large mold is the same height as the cast floor tiles, and there is no special requirement for the height of the small mold. The mold pattern is preset according to the design requirements.

3. The modular permeable floor tile on-site production device and process according to claim 1 is characterized by: Permeable floor tiles are made of cement mortar mixed on site and spread and poured for curing. The mortar material is made by mixing aggregate, cement, additives and water according to a mix ratio. The additive is a polymer material that improves the strength and durability of the mortar floor tiles.

4. The modular permeable floor tile on-site production device and process according to claim 1 is characterized by: The in-mold pouring method places a shaping mold on the compacted base layer, then evenly pours the permeable mortar into the mold. After compacting and smoothing, the mold is evenly pulled upward to form a permeable floor tile with drainage grooves and patterns, which can be used in large construction areas.

5. The modular permeable floor tile on-site production device and process according to claim 1 is characterized by: The shallow embossing method uses a mold to shallowly emboss the surface of the cement mortar that has been evenly smoothed to form permeable floor tiles with hydrophobic grooves and patterns, which are used for finishing edges and corners of irregular planes.

6. A modular permeable floor tile on-site production device and process according to claims 1 to 5, characterized in that: The implementation steps include the following: ① Measure the site topography and elevation and form a record file, and make on-site markings. ② Test the soil base performance, and the parameters such as compaction and permeability meet the design requirements. ③ Roll the natural graded crushed stone cushion layer, and the compaction meets the design requirements. ④ Pave the base layer, and the strength, water stability, and permeability meet the design requirements. ⑤ Lay the leveling layer, and the strength and flatness meet the design requirements. ⑥ Modular permeable floor tiles are made on site, and the in-mold casting method is used in large-area construction areas; the shallow embossing method is used for irregular edge and corner areas on the plane. ⑦ Water and maintain the made floor tiles, and use fine sand to fill the joints after final setting. ⑧ Carry out overall quality acceptance, and if qualified, it can meet the requirements for floor tile use.

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