Design and processing method of ribbon type special-shaped UHPC (Ultra High Performance Concrete) structure

Abstract

The invention relates to a design and processing method of a ribbon type special-shaped UHPC (Ultra High Performance Concrete) structure, and aims to realize efficient prefabrication and precise assembly of a ribbon type structure with an irregular shape and a long size through precise modeling and numerical control machining. The method comprises the following steps: firstly, carrying out 1: 1 modeling on a structure by utilizing Sketchup software, and partitioning the structure according to the weight and size requirements of each block; and then, a numerical control carving machine is guided in for precise carving of the template, template splicing and supporting are carried out, and the precision of the size and the spatial position is ensured. And then, the UHPC component is prepared through a spraying technology, layered spraying is conducted, the layer thickness is monitored in real time, and the quality of the component is ensured. Early maintenance is conducted after pouring is completed, demolding is conducted after the strength requirement is met, and surface repairing and protective layer treatment are conducted. And finally, the durability and appearance quality of the component are ensured through long-age maintenance. According to the method, the precision and the construction efficiency of the structure are improved, the labor cost, the material cost and the construction period cost are greatly reduced, and the method is suitable for prefabrication of the UHPC structure with the complex shape and the large size.

Description

Technical Field

[0001] The present invention relates to the technical field of ribbon-shaped special-shaped UHPC structures, and particularly relates to a design and processing method for a ribbon-shaped special-shaped UHPC structure. Background Art

[0002] Ultra-high performance concrete (UHPC), as a cement-based material with excellent properties such as high strength and high durability, has been widely used in thin-walled structures such as benches and landscape components. However, with the diversification of architectural design requirements, especially the requirements for irregular shapes and long-sized structures, existing prefabrication methods are difficult to meet the dual requirements of precision and cost-effectiveness. How to achieve efficient deep processing and on-site precise assembly of ribbon-shaped structures with irregular and complex spatial postures has become a technical problem to be solved urgently. Summary of the Invention

[0003] Aiming at the deficiencies in the prior art, the purpose of the present invention is to provide a design and processing method for a ribbon-shaped special-shaped UHPC structure to solve the problem in the prior art that for "ribbon-shaped" long-sized structures with irregular shapes and arbitrarily changing spatial and planar dimensions, existing prefabrication methods are difficult to meet the dual requirements of precision and cost-effectiveness.

[0004] To achieve the above purpose, the present invention adopts the following technical scheme: A design and processing method for a ribbon-shaped special-shaped UHPC structure, comprising the following steps:

[0005] Step 1. Modeling and block division: Use Sketchup software to perform 1:1 modeling on the ribbon-shaped UHPC structure to obtain a structural model; and divide the structure into several modules according to the weight and size requirements of each block of UHPC to meet the transportation and on-site installation requirements; during assembly, accurately splice the templates according to the numerical control machine numbers to ensure that the spatial position and size of the templates meet the model requirements.

[0006] Step 2. Template production and assembly: Import the relevant data of the built structural model into a numerical control engraving machine. The numerical control engraving machine automatically generates template production data according to the data, performs intelligent block numbering on the templates, engraves and manufactures them, and after manual verification is correct, numbers and cuts the templates for standby; after the templates are prepared, assemble each template in sequence according to the numerical control machine numbers, and after the templates are assembled, use templates to interrupt at intervals at the joint positions according to the model block division requirements.

[0007] Step 3. UHPC component production: Adopt the spraying process. After uniformly stirring the UHPC slurry, use the spraying process to pour the components.

[0008] Step 4. Curing and demolding: Perform early curing after the components are poured, and perform demolding treatment after the components reach the predetermined strength.

[0009] Step 5, Surface treatment and long-term curing: Inspect the surface of the component and repair defects. After completing the surface treatment, place it in the curing area for long-term curing.

[0010] Compared with the prior art, the present invention has the following beneficial effects:

[0011] 1. By using Sketchup software for 1:1 modeling, the consistency between the structural design and actual production is ensured. At the same time, the application of the CNC engraving machine guarantees the precise block division and engraving of the template, reduces manual errors, realizes precise modeling and control, and makes the prefabrication process intelligent.

[0012] 2. The modular block design of the structure makes the transportation and assembly of each component more convenient, and can be adjusted according to the actual situation on site, realizing efficient prefabrication and assembly.

[0013] 3. Through the high-precision processing of CNC machinery and the efficient construction of the spraying process, the waste of labor, materials and construction period costs is greatly reduced.

[0014] 4. Precise control of the proportion and spraying process of UHPC materials ensures the strength and durability of the components and improves the quality of the finished products.

[0015] Further, in the second step, when assembling each template in sequence, the corresponding template is cut simultaneously to support and reinforce the template, so as to ensure that the spatial position and size of the template meet the design requirements.

[0016] Further, in the third step, the spraying process is divided into spraying UHPC slurry without fibers as the decorative layer and the structural layer. Among them, when the slurry of the decorative layer is close to initial setting, the structural layer is sprayed again.

[0017] Further, in the third step, the single spraying thickness and the number of layers will be confirmed according to the thickness of the overall component.

[0018] Further, in the third step, during the spraying process, brushes and pressure rollers are used for each layer, and a patterned pressure roller is used to roll the fibers between layers.

[0019] Further, in the third step, during the spraying construction, real-time acupuncture detection is carried out on the thickness of the spraying layer until the specified thickness is reached.

[0020] Further, in the fourth step, after the component is poured, use a film to cover the component and maintain the temperature and humidity.

[0021] Further, in the fourth step, for the demolding treatment, a rubber mallet is used to demold the mold.

[0022] Further, in step five, the components after surface treatment are wrapped with plastic film, and foam is used to wrap the parts that are prone to being knocked and damaged. Description of the Drawings

[0023] Appendix Figure 1 : Segmented plan view of the ribbon-shaped UHPC structure;

[0024] Appendix Figure 2 : Cross-sectional view of the ribbon-shaped UHPC structure. Detailed Implementation Modes

[0025] In order to make the objectives, technical solutions and beneficial effects of the present invention clearer and more understandable, the technical solutions in the present invention will be further described below in conjunction with the drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention:

[0026] As Figure 1 shown, an embodiment of the present invention provides a design and processing method for a ribbon-shaped special-shaped UHPC structure, including the following steps:

[0027] Step 1. Modeling and block division: Use Sketchup software to perform 1:1 modeling on the ribbon-shaped UHPC structure to obtain a structure model; and divide the structure into several modules according to the weight and size requirements of each block of UHPC to meet the transportation and on-site installation requirements; during assembly, accurately splice the templates according to the numerical control machine numbers to ensure that the spatial position and size of the templates meet the model requirements.

[0028] Step 2. Template production and assembly: Import the relevant data of the built structure model into a numerical control engraving machine. The numerical control engraving machine automatically generates template production data according to the data, and performs intelligent block numbering on the templates, engraves and manufactures them, and after manual review is correct, numbers and cuts the templates for standby; after the templates are prepared, assemble each template in sequence according to the numerical control machine numbers, and after the templates are assembled, use templates to interrupt at intervals at the joint positions according to the model block requirements.

[0029] Step 3. UHPC component production: Adopt the spraying process. After uniformly stirring the UHPC slurry, use the spraying process to pour the components.

[0030] Step 4. Curing and demolding: Perform early curing after the components are poured, and perform demolding treatment after the components reach the predetermined strength.

[0031] Step 5. Surface treatment and long-term curing: Inspect the surface of the component and repair defects. After completing the surface treatment, place it in the curing area for long-term curing. Specifically, after the component is fabricated, the surface quality shall be strictly inspected. For defects such as air bubbles, sand lines, air bubbles, impurities, corner chipping, and mold seams, surface repair shall be carried out in a timely manner. And complete the treatment of the protective layer according to the design requirements to ensure the apparent design effect of the UHPC finished component.

[0032] The present invention uses Sketchup software to model the special-shaped UHPC structure, and divides the structure into several segments for factory prefabrication through the model. The modeling data is imported into the numerical control engraving machine. The numerical control engraving machine intelligently numbers the template blocks for the structure according to the imported data, and then precisely engraves and manufactures each template block in contact with the UHPC structure one by one. Workers assemble and formwork the modules, and finally pour the components through the spraying process, and finally fabricate precast components in the form of "ribbons" that meet the design requirements. The whole process is intelligent and equipment-based, with high precision in one-time forming, good linearity in on-site assembly, and high aesthetics.

[0033] In one embodiment, in the second step, when assembling each template in sequence, the corresponding template is cut simultaneously to support and reinforce the template, so as to ensure that the spatial position and dimensions of the template meet the design requirements.

[0034] In one embodiment, in the third step, the spraying process is divided into spraying UHPC slurry without fibers as the decorative layer and the structural layer. Among them, when the decorative layer slurry is approaching initial setting, the structural layer is sprayed again;

[0035] Among them, the preparation of the UHPC slurry is determined according to the finally determined UHPC mix ratio. Its core material, additives, etc. are strictly prepared, and effective mixing is carried out using appropriate equipment. During the process, the feeding sequence, stirring time, stirring method, etc. are strictly controlled. During the process, pay attention to observing the state of the material to prevent the material from being dry and thick or segregating and bleeding. After stirring evenly, it is discharged from the machine, and the UHPC mixture is transported to the mold using tools.

[0036] In one embodiment, in the third step, the single spraying thickness and the number of layering are confirmed according to the thickness of the overall component. When reaching the embedded thickness of the connecting piece, after laying out the steel bars, support pieces, connecting pieces, etc., continue to complete the spraying of the subsequent materials until the design thickness.

[0037] In one embodiment, in the third step, during the spraying process, auxiliary tools such as brushes and pressure rollers are used between layers to ensure the dense filling between the UHPC material and each texture shape of the template. The fiber is rolled with a pattern pressure roller between layers while ensuring the effective contact area between layers to enhance the bonding effect.

[0038] In one embodiment, in step three, during the spraying construction, real-time needle detection is carried out on the thickness of the sprayed layer until the specified thickness is reached.

[0039] In one embodiment, in step four, after the component is completed with pouring, the component is covered with a film and the temperature and humidity are maintained to prevent plastic cracking due to water loss. At the same time, when the ambient temperature in the production workshop is lower than 0°C, steam or radiators need to be provided to ensure that the product is in an environment above 5°C.

[0040] In one embodiment, in step four, for the demolding treatment, a rubber mallet is used to demold the mold; specifically, after the component meets the strength requirements (without special requirements, the specification requires the one-day strength ≥ 15 MPa), demolding is carried out. When demolding, use a rubber mallet to gently tap, strike, and place according to the mold parting direction. It is strictly prohibited to use a hammer, angle iron, etc. to strike the mold.

[0041] In one embodiment, in step five, the component with the surface treatment completed is wrapped with a plastic film, and foam is used to wrap the parts prone to being bumped and damaged (tips, corners, etc.) to prevent contamination and bump damage during the later placement. After wrapping, place it in the product stacking area and cure for more than 7 days.

[0042] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that the technical solutions of the present invention can be modified or equivalently replaced without departing from the purpose and scope of the technical solutions of the present invention, and they should all be covered within the scope of the claims of the present invention.

Claims

1. A design and processing method for a ribbon-shaped special-shaped UHPC structure, characterized in that, It includes the following steps: Step 1, Modeling and Block Division: Use Sketchup software to perform 1:1 modeling on the ribbon-shaped UHPC structure to obtain a structural model; and divide the structure into several modules according to the weight and size requirements of each block of UHPC to meet the transportation and on-site installation requirements; during assembly, accurately splice the templates according to the numerical control machine numbers to ensure that the spatial position and size of the templates meet the model requirements. Step 2, Template Making and Assembly: Import the relevant data of the built structural model into the numerical control engraving machine. The numerical control engraving machine automatically generates template making data according to the data, intelligently divides and numbers the templates, engraves and manufactures them, and after manual review and verification, numbers and cuts the templates for standby; after the templates are prepared, assemble each template in sequence according to the numerical control machine numbers, and after the templates are assembled, use templates to interrupt at intervals at the joint positions according to the model block division requirements. Step 3, UHPC Component Manufacturing: Adopt the spraying process. After uniformly stirring the UHPC slurry, use the spraying process to pour the components. Step 4, Curing and Demoulding: Conduct early curing after the components are poured, and perform demoulding treatment after the components reach the predetermined strength. Step 5, Surface Treatment and Long-Term Curing: Inspect the surface of the components and repair the defects. After the surface treatment is completed, place them in the curing area for long-term curing.

2. The design and processing method of a ribbon-shaped special-shaped UHPC structure according to claim 1, wherein In the second step, when assembling each template in sequence, cut the corresponding templates at the same time to support and reinforce the templates to ensure that the spatial position and size of the templates meet the design requirements.

3. The design and processing method of a ribbon-shaped special-shaped UHPC structure according to claim 1, characterized in that In the third step, the spraying process is divided into spraying UHPC slurry without fibers as the decorative layer and the structural layer. Among them, when the decorative layer slurry is close to initial setting, then spray the structural layer.

4. A design and processing method for a ribbon-shaped special-shaped UHPC structure according to claim 3, characterized in that, In the third step, the single spraying thickness and the number of layers will be determined according to the thickness of the overall component.

5. The design and processing method of a ribbon-shaped special-shaped UHPC structure according to claim 3, characterized in that In the third step, during the spraying process, brushes and pressing rollers are used for each layer, and a patterned pressing roller is used to roll the fibers between layers.

6. The design and processing method of a ribbon-shaped special-shaped UHPC structure according to claim 3, characterized in that, In the third step, during the spraying construction, real-time needle detection is carried out on the thickness of the spraying layer until the specified thickness is reached.

7. A design and processing method for a ribbon-shaped special-shaped UHPC structure according to claim 1, characterized in that, In the fourth step, after the components are poured, cover the components with a film and maintain the temperature and humidity.

8. A design and processing method for a ribbon-shaped special-shaped UHPC structure according to claim 1, characterized in that In the fourth step, for the demoulding treatment, use a rubber mallet to demould the mold.

9. The design and processing method of a ribbon-shaped special-shaped UHPC structure according to claim 1, characterized in that, In the fifth step, the components with the surface treatment completed are wrapped with plastic film, and foam is used to wrap the parts that are easily damaged by bumping.

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