Process method for producing tunnel cement-based RPC grouting pipe

Abstract

The invention relates to a process method for producing a tunnel cement-based RPC (reactive powder concrete) grouting pipe, which comprises the following steps: carrying out factory-like rapid production on the tunnel grouting pipe in manners of assembly line, partitioned operation, automatic feeding, secondary stirring and partitioned storage of grouting pipe slurry, pressure injection of the slurry into a grouting pipe mold from bottom to top under pressure by a constant-pressure screw pump under pressure, steam centralized maintenance and the like. According to the construction method, the formwork can be rapidly and accurately mounted and dismounted, the meshes can be rapidly and accurately mounted, the formed slurry is stirred in a high-quality mode, the slurry is pressed into the formwork, operation is convenient, and the expected forming effect is achieved. The method is high in practicability, simple in construction process, high in forming quality, economical, practical, convenient to operate and easy to master, assembly line high-efficiency production can be achieved, and batch and large-scale production can be achieved.

Description

Technical Field

[0001] The invention belongs to the technical field of secondary lining concrete grouting with formwork for railway tunnels, and in particular relates to a process for producing cement-based RPC grouting pipes for tunnels. Background Art

[0002] At present, tunnels are widely used in railway projects. The main method of tunnel construction is drilling and blasting. After excavation, primary support, waterproof board and secondary lining concrete are constructed. After the secondary lining is completed, due to concrete performance, construction technology, common quality problems and other reasons, the back of the secondary lining concrete is hollowed out and there are gaps around the tunnel, which cannot form effective support. In order to solve the above problems, the main process of secondary lining grouting with mold is adopted. The embedded pipe of grouting with mold adopts steel pipe, plastic pipe, cement pipe, etc. Through the comparison of the use of various pipes, cement-based grouting pipe is widely used because of its homogeneity with concrete and easy connection with secondary lining concrete. However, there is no mature method for how to mass-produce RPC grouting pipes quickly.

[0003] In view of the above problems, how to solve the problem of efficient, high-quality and mass production of RPC grouting pipes for tunnel secondary lining concrete grouting with mold requires a new method to solve this problem. Summary of the invention

[0004] The invention aims to solve the production process problem of pre-buried grouting pipes for tunnel secondary lining concrete grouting with mold, and aims to provide a process method for producing cement-based RPC grouting pipes for tunnels.

[0005] The technical solution of the present invention is: A process for producing a tunnel cement-based RPC grouting pipe, characterized in that it comprises the following steps: Step 1: The construction personnel, machines, materials, methods, environment, and measurements must be prepared in advance. Qualified fine steel wire meshes are placed in the mesh cutting and welding area, and ordinary silicate 52.5 (low alkali) cement and composite materials are placed in the casting area. Step 2: In the mesh blanking and welding area, use a cutter to cut the 10mm×10mm fine steel wire mesh into meshes according to the designed length and width, wrap multiple pieces of formed fine steel wire meshes on a plastic rod with a diameter of 15mm and fix them with wire ties, and weld the joints of the meshes with an electric welder. After all welding is completed, put the ringed mesh into the rack for self-inspection and standby; Step 3. In the mold cleaning and installation area, after disassembling the mold, clean the surface of the inner mold with a steel wool to remove the floating slurry on the surface, and clean the inside of the open circular outer mold back and forth with a small round fine steel wool. After all the molds are cleaned, hang all the inner molds in the storage rack and put all the outer molds in a fixed storage box; Step 4: Use a sprayer to spray a water-soluble release agent on the inner mold suspended in the storage rack, with the release agent not flowing in a line on the surface as the standard; the inner surface of the outer mold in the fixed storage box is coated with a plurality of cotton balls with a diameter of about 15 mm, and the surface of the cotton balls is sprayed with a water-soluble release agent by a sprayer; the mold is installed and fastened on the connecting pipe, the processed and welded steel mesh is placed in the mold, and the inner mold of the mold is placed and fixed until the connecting pipe is filled; Step 5. In the pouring area, input the mix ratio determined by the test, and start mixing after measuring the ordinary silicate 52.5 (low alkali) cement, machine-made sand, silicon powder, and the qualified composite materials in the storage area and 85% of the total water consumption. After stirring for 2 minutes, add the remaining water and continue stirring for 2 minutes. After the slurry passes the test, put it into the storage bin; cement, machine-made sand, and silicon powder are directly fed into the main machine in the mixing area by a screw machine, and the manual operation of the primary mixture is fed from the auxiliary feeding area. The order of feeding is cement, machine-made sand, and primary mixture; after forced mixing, the grouting material is transported to the unloading area, packaged by a pressurized quantitative packaging machine, and transported to the storage area by a forklift for use after passing the inspection. The screw pump pressurizes 0.6Mpa to press the qualified slurry from bottom to top into the grouting pipe mold. After the construction of all molds is completed, the cycle construction is completed and put into the steaming area; Step 6. In the steam curing area, the cast grouting pipe is subjected to four stages of static, heating, constant temperature and cooling. The static time is 4 hours. After the static time is completed, the cast grouting pipe is placed in the storage rack in the steam curing shed and the temperature is raised. The heating rate is not more than 10℃ / h. The maximum temperature during the constant temperature period is not more than 45℃, and the cooling rate is not more than 10℃ / h. The constant temperature time needs to be determined by process tests; Step 7: In the demolding area, first remove the inner mold of the grouting pipe mold, then remove the outer mold of the mold. If there are obvious defects in the appearance, remove them, and if there are no obvious defects, transport them to the natural curing area; Step 8: In the natural curing area, store the grouting pipe vertically and cover it with geotextile, spray water with a temperature difference of no more than 15°C and cure it naturally for 14 days; after the curing is completed, transport the grouting pipe to the finished product testing area; Step 9. In the finished product inspection area, observe each one for cracks, use a vernier caliper to check the inner and outer diameters of the grouting pipe, and use a steel ruler to check whether the length of the grouting pipe meets the requirements. Those that do not meet the requirements will be removed, and those that pass the inspection will be stamped with the inspection stamp and transferred to the finished product stacking area.

[0006] 2. A process for producing a tunnel cement-based RPC grouting pipe according to claim 1, characterized in that the composite material mixed with the slurry in the pouring area in step 5 comprises the following steps: Step 51: Load fly ash, quartz sand, and silicon powder into the batching area, and load other materials into the auxiliary feeding area for material preparation; Step 52: The control area inputs the primary mixed material proportion, and the fly ash, quartz sand, and silica powder are directly fed into the main machine of the mixing area by the screw machine. The other parts are manually operated and fed in sequence by the auxiliary feeding area. The feeding order is polycarboxylate water reducer, defoamer, rheological agent and boric acid; Step 53: After forced mixing, open the middle unloading switch of the screw machine of the main machine in the mixing area, convey the primary mixed material to the ton bag in the unloading area, and transport it to the storage area by forklift for inspection and use; Step 54: Empty the fly ash in the batching area, suck the machine-made sand into the batching bin by the hose sand suction machine, place the qualified primary mixed material in the auxiliary feeding area, and close the intermediate unloading switch of the screw machine in the mixing area.

[0007] Furthermore, the main machine of the mixing zone is a forced horizontal mixer with an automatic metering device, the mixing time for one mixed material production is not less than 15 minutes, and the mixing time for the grouting material is not less than 10 minutes.

[0008] Furthermore, according to the composition and proportion of some raw materials of the primary mixture, they are evenly mixed to obtain a mixed powder, and the primary mixture is compounded for a second time according to the proportion to obtain a grouting material mixture except water; water is added first and then the mixed powder on site, the water-to-material ratio is 0.18-0.20, the on-site mixing equipment is a high-speed mortar mixer with a speed of not less than 500 rpm, the grouting machine pressure is not less than 10MPa, and the accuracy should be not less than 0.2Mpa.

[0009] The present invention has the following beneficial effects: The tunnel cement-based RPC grouting pipe production method provided by the present invention is to carry out factory-based rapid production of tunnel grouting pipes through assembly line, zoning operation, automatic feeding of grouting pipe slurry, secondary stirring and zoning storage, constant pressure screw pump stabilization to make the slurry pressurized from bottom to top and inject the grouting pipe mold, centralized steam maintenance, etc. This construction method can quickly and accurately install and disassemble the template and install the mesh, high-quality stirring and molding slurry, and pressurized slurry into the mold, which is easy to operate and achieves the expected molding effect. The present invention is highly practical, simple in construction process, high in molding quality, economical and practical, easy to operate, and easy to master. The present invention can realize high-efficiency production of assembly line and can be mass-produced. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 It is the production process diagram of the present invention; Figure 2 It is a production area division diagram of the present invention. DETAILED DESCRIPTION

[0011] The present invention is further described below in conjunction with the accompanying drawings.

[0012] like Figure 1 , 2As shown, a process for producing a tunnel cement-based RPC grouting pipe is characterized by comprising the following steps: Step 1: The construction personnel, machines, materials, methods, environment, and measurements must be prepared in advance. Qualified fine steel wire meshes are placed in the mesh cutting and welding area, and ordinary silicate 52.5 (low alkali) cement and composite materials are placed in the casting area. Step 2: In the mesh blanking and welding area, use a cutter to cut the 10mm×10mm fine steel wire mesh into meshes according to the designed length and width, wrap multiple pieces of formed fine steel wire meshes on a plastic rod with a diameter of 15mm and fix them with wire ties, and weld the joints of the meshes with an electric welder. After all welding is completed, put the ringed mesh into the rack for self-inspection and standby; Step 3. In the mold cleaning and installation area, after disassembling the mold, clean the surface of the inner mold with a steel wool to remove the floating slurry on the surface, and clean the inside of the open circular outer mold back and forth with a small round fine steel wool. After all the molds are cleaned, hang all the inner molds in the storage rack and put all the outer molds in a fixed storage box; Step 4: Use a sprayer to spray a water-soluble release agent on the inner mold suspended in the storage rack, with the release agent not flowing in a line on the surface as the standard; the inner surface of the outer mold in the fixed storage box is coated with a plurality of cotton balls with a diameter of about 15 mm, and the surface of the cotton balls is sprayed with a water-soluble release agent by a sprayer; the mold is installed and fastened on the connecting pipe, the processed and welded steel mesh is placed in the mold, and the inner mold of the mold is placed and fixed until the connecting pipe is filled; Step 5. In the pouring area, input the mix ratio determined by the test, and start mixing after measuring the ordinary silicate 52.5 (low alkali) cement, machine-made sand, silicon powder, and the qualified composite materials in the storage area and 85% of the total water consumption. After stirring for 2 minutes, add the remaining water and continue stirring for 2 minutes. After the slurry passes the test, put it into the storage bin; cement, machine-made sand, and silicon powder are directly fed into the main machine in the mixing area by a screw machine, and the manual operation of the primary mixture is fed from the auxiliary feeding area. The order of feeding is cement, machine-made sand, and primary mixture; after forced mixing, the grouting material is transported to the unloading area, packaged by a pressurized quantitative packaging machine, and transported to the storage area by a forklift for use after passing the inspection. The screw pump pressurizes 0.6Mpa to press the qualified slurry from bottom to top into the grouting pipe mold. After the construction of all molds is completed, the cycle construction is completed and put into the steaming area; Step 6. In the steam curing area, the cast grouting pipe is subjected to four stages of static, heating, constant temperature and cooling. The static time is 4 hours. After the static time is completed, the cast grouting pipe is placed in the storage rack in the steam curing shed and the temperature is raised. The heating rate is not more than 10℃ / h. The maximum temperature during the constant temperature period is not more than 45℃, and the cooling rate is not more than 10℃ / h. The constant temperature time needs to be determined by process tests; Step 7: In the demolding area, first remove the inner mold of the grouting pipe mold, then remove the outer mold of the mold. If there are obvious defects in the appearance, remove them, and if there are no obvious defects, transport them to the natural curing area; Step 8: In the natural curing area, store the grouting pipe vertically and cover it with geotextile, spray water with a temperature difference of no more than 15°C and cure it naturally for 14 days; after the curing is completed, transport the grouting pipe to the finished product testing area; Step 9. In the finished product inspection area, observe each one for cracks, use a vernier caliper to check the inner and outer diameters of the grouting pipe, and use a steel ruler to check whether the length of the grouting pipe meets the requirements. Those that do not meet the requirements will be removed, and those that pass the inspection will be stamped with the inspection stamp and transferred to the finished product stacking area.

[0013] 2. A process for producing a tunnel cement-based RPC grouting pipe according to claim 1, characterized in that the composite material mixed with the slurry in the pouring area in step 5 comprises the following steps: Step 51: Load fly ash, quartz sand, and silicon powder into the batching area, and load other materials into the auxiliary feeding area for material preparation; Step 52: The control area inputs the primary mixed material proportion, and the fly ash, quartz sand, and silica powder are directly fed into the main machine of the mixing area by the screw machine. The other parts are manually operated and fed in sequence by the auxiliary feeding area. The feeding order is polycarboxylate water reducer, defoamer, rheological agent and boric acid; Step 53: After forced mixing, open the middle unloading switch of the screw machine of the main machine in the mixing area, convey the primary mixed material to the ton bag in the unloading area, and transport it to the storage area by forklift for inspection and use; Step 54: Empty the fly ash in the batching area, suck the machine-made sand into the batching bin by the hose sand suction machine, place the qualified primary mixed material in the auxiliary feeding area, and close the intermediate unloading switch of the screw machine in the mixing area.

[0014] Furthermore, the main machine of the mixing zone is a forced horizontal mixer with an automatic metering device, the mixing time for one mixed material production is not less than 15 minutes, and the mixing time for the grouting material is not less than 10 minutes.

[0015] Furthermore, according to the composition and proportion of some raw materials of the primary mixture, they are evenly mixed to obtain a mixed powder, and the primary mixture is compounded for a second time according to the proportion to obtain a grouting material mixture except water; water is added first and then the mixed powder on site, the water-to-material ratio is 0.18-0.20, the on-site mixing equipment is a high-speed mortar mixer with a speed of not less than 500 rpm, the grouting machine pressure is not less than 10MPa, and the accuracy should be not less than 0.2Mpa.

[0016] The present invention uses the following methods to carry out factory-based rapid production of tunnel grouting pipes, such as through assembly lines, zoning operations, automatic feeding of grouting pipe slurry, secondary stirring and zoning storage, constant pressure screw pump stabilization to pressurize the slurry into the grouting pipe mold from bottom to top, and centralized steam maintenance. This construction method can quickly and accurately install and disassemble the template and install the mesh, stir and mold the slurry with high quality, and put the pressurized slurry into the mold, which is easy to operate and achieves the expected molding effect. The present invention has strong practicality, simple construction process, high molding quality, economical and practical, convenient operation, and easy to master. The present invention can realize high-efficiency assembly line production and can be mass-produced.

Claims

1. A process for producing a tunnel cement-based RPC grouting pipe, characterized in that: The following steps are involved: Step 1: The construction personnel, machines, materials, methods, environment, and measurements must be prepared in advance. Qualified fine steel wire meshes are placed in the mesh cutting and welding area, and ordinary silicate 52.5 (low alkali) cement and composite materials are placed in the casting area. Step 2: In the mesh blanking and welding area, use a cutter to cut the 10mm×10mm fine steel wire mesh into meshes according to the designed length and width, wrap multiple pieces of formed fine steel wire meshes on a plastic rod with a diameter of 15mm and fix them with wire ties, and weld the joints of the meshes with an electric welder. After all welding is completed, put the ringed mesh into the rack for self-inspection and standby; Step 3. In the mold cleaning and installation area, after disassembling the mold, clean the surface of the inner mold with a steel wool to remove the floating slurry on the surface, and clean the inside of the open circular outer mold back and forth with a small round fine steel wool. After all the molds are cleaned, hang all the inner molds in the storage rack and put all the outer molds in a fixed storage box; Step 4: Use a sprayer to spray a water-soluble release agent on the inner mold suspended in the storage rack, with the release agent not flowing in a line on the surface as the standard; the inner surface of the outer mold in the fixed storage box is coated with a plurality of cotton balls with a diameter of about 15 mm, and the surface of the cotton balls is sprayed with a water-soluble release agent by the sprayer; Install and fasten the mold on the connecting pipe, put the processed and welded steel wire mesh into the mold, put the inner mold of the mold in and fix it until the connecting pipe is filled; Step 5. In the pouring area, input the mix ratio determined by the test, and start mixing after measuring the ordinary silicate 52.5 (low alkali) cement, machine-made sand, silicon powder, and the qualified composite materials in the storage area and 85% of the total water consumption. After stirring for 2 minutes, add the remaining water and continue stirring for 2 minutes. After the slurry passes the test, put it into the storage bin; cement, machine-made sand, and silicon powder are directly fed into the main machine in the mixing area by a screw machine, and the manual operation of the primary mixture is fed from the auxiliary feeding area. The order of feeding is cement, machine-made sand, and primary mixture; after forced mixing, the grouting material is transported to the unloading area, packaged by a pressurized quantitative packaging machine, and transported to the storage area by a forklift for use after passing the inspection. The screw pump pressurizes 0.6Mpa to press the qualified slurry from bottom to top into the grouting pipe mold. After all molds are completed, the cycle construction is completed and put into the steaming area; Step 6. In the steam curing area, the cast grouting pipe is subjected to four stages of static, heating, constant temperature and cooling. The static time is 4 hours. After the static time is completed, the cast grouting pipe is placed in the storage rack in the steam curing shed and the temperature is raised. The heating rate is not more than 10℃ / h. The maximum temperature during the constant temperature period is not more than 45℃, and the cooling rate is not more than 10℃ / h. The constant temperature time needs to be determined by process tests; Step 7: In the demolding area, first remove the inner mold of the grouting pipe mold, then remove the outer mold of the mold. If there are obvious defects in the appearance, remove them, and if there are no obvious defects, transport them to the natural curing area; Step 8: In the natural curing area, store the grouting pipe vertically and cover it with geotextile, spray water with a temperature difference of no more than 15°C and cure it naturally for 14 days; after the curing is completed, transport the grouting pipe to the finished product testing area; Step 9. In the finished product inspection area, observe each one for cracks, use a vernier caliper to check the inner and outer diameters of the grouting pipe, and use a steel ruler to check whether the length of the grouting pipe meets the requirements. Those that do not meet the requirements will be removed, and those that pass the inspection will be stamped with the inspection stamp and transferred to the finished product stacking area.

2. A process for producing a tunnel cement-based RPC grouting pipe according to claim 1, characterized in that: The composite material mixed with the slurry in the pouring area described in step 5 comprises the following steps: Step 51: Load fly ash, quartz sand, and silicon powder into the batching area, and load other materials into the auxiliary feeding area for material preparation; Step 52: The control area inputs the primary mixed material proportion, and the fly ash, quartz sand, and silica powder are directly fed into the main machine of the mixing area by the screw machine. The other parts are manually operated and fed in sequence by the auxiliary feeding area. The feeding order is polycarboxylate water reducer, defoamer, rheological agent and boric acid; Step 53: After forced mixing, open the middle unloading switch of the screw machine of the main machine in the mixing area, convey the primary mixed material to the ton bag in the unloading area, and transport it to the storage area by forklift for inspection and use; Step 54: Empty the fly ash in the batching area, suck the machine-made sand into the batching bin by the hose sand suction machine, place the qualified primary mixed material in the auxiliary feeding area, and close the intermediate unloading switch of the screw machine in the mixing area.

3. A process for producing a tunnel cement-based RPC grouting pipe according to claim 1, characterized in that: The main machine of the mixing zone is a forced horizontal mixer with an automatic metering device. The mixing time for one mixed material production is not less than 15 minutes, and the mixing time for the grouting material is not less than 10 minutes.

4. A process for producing a tunnel cement-based RPC grouting pipe according to claim 1, characterized in that: According to the composition and proportion of some raw materials of the primary mixture, mix them evenly to obtain a mixed powder, and then compound the primary mixture for a second time according to the proportion to obtain the grouting material mixture except water; on-site water is added first and then the mixed powder, the water-to-material ratio is 0.18-0.20, the on-site mixing equipment is a high-speed mortar mixer with a speed of not less than 500 rpm, the grouting machine pressure is not less than 10MPa, and the accuracy should be not less than 0.2Mpa.

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