A low environmental impact ultra-high performance concrete compaction reinforcement and repair method

Abstract

The present invention relates to a low-environmental-impact ultra-high-performance concrete compaction reinforcement and repair method, comprising the following steps: 1. roughening the surface of an existing building structure to be reinforced and repaired and dividing it into three areas from left to right according to the total horizontal length; 2. cleaning the roughened surface; 3. fixing a steel formwork on the roughened surface; 4. preparing ultra-high-performance concrete; 5. placing the ultra-high-performance concrete into three grouting machines respectively, and starting the grouting machines to begin continuous pouring construction; 6. providing a PLC controller to collect basic parameters such as horizontal pouring endpoint coordinates, average roughening thickness, and pouring time in real time, and to calculate the optimal pouring flow of the grouting machines in different areas in combination with built-in pouring construction quality control equations based on height-flow coordinated control at different stages, and to obtain the optimal pouring flow of the grouting machines in different areas in real time, and to feed back the optimal pouring flow information to the grouting machines in real time, and to adjust the pouring speed of the grouting machines in real time to ensure that the pouring height deviation of each area is within a scientifically controllable range until the reinforcement and repair construction is completed.

Description

Technical Field

[0001] The present invention belongs to the technical field of urban renewal, and in particular relates to an ultra-high performance concrete compaction reinforcement and repair method with low environmental impact. Background Art

[0002] With the continuous acceleration of urbanization, the infrastructure and buildings of many cities (such as urban elevated crash barriers, etc.) are facing increasingly serious aging problems, mainly manifested in cracks, spalling, wear and corrosion in concrete structures, which greatly affect the safety and service life of buildings. Therefore, the importance of urban renewal is becoming increasingly prominent.

[0003] At present, the two main approaches to address the quality problems caused by the increasing aging of existing urban building structures (such as urban elevated crash barriers) are overall replacement and material repair. However, these two approaches have certain defects: (1) The overall replacement method has a long construction period, high cost, high material waste, large construction equipment footprint, and a large impact on the surrounding environment and traffic; (2) Traditional material repair methods, such as the use of ordinary concrete, mortar and other materials, not only have insufficient structural repair strength, unsatisfactory interface bonding effect, and reliance on interface enhancers, but the traditional top-down "pour-type" pouring construction process often results in material "hanging on the wall", which easily leads to poor structural density and uniformity of the repair layer, and a decline in the long-term durability of the structural layer, which in turn causes structural defects such as cracking and peeling, ultimately affecting structural safety.

[0004] Therefore, how to provide a low environmental impact ultra-high performance concrete compaction reinforcement and repair method is a technical problem that technical personnel in this field urgently need to solve. Summary of the Invention

[0005] The present invention provides an ultra-high performance concrete extrusion reinforcement and repair method with low environmental impact. Ultra-high performance concrete is used as the reinforcement and repair material, and a bottom-up "extrusion" pouring construction process is adopted. Combined with a pouring construction quality control method based on height-flow coordinated control, it effectively solves the quality problems of the traditional "pouring" pouring construction process caused by the "hanging on the wall" phenomenon of repair materials, such as poor density and uniformity of the repair structure layer, easy shrinkage and cracking, insufficient mechanical and durability properties, etc. It overcomes the defects of traditional repair materials in terms of structural strength and bonding strength between them and existing building structures, and high dependence on interface enhancers, effectively reduces the impact of the construction process on the surrounding environment and transportation, and strongly promotes high-quality and sustainable development in the field of urban renewal.

[0006] In order to solve the above technical problems, the present invention includes the following technical solutions:

[0007] A low environmental impact ultra-high performance concrete compaction reinforcement and repair method comprises the following steps:

[0008] Step S1: roughening the surface of the existing building structure to be reinforced and repaired, dividing the roughened surface into several areas from left to right according to the total horizontal length, and recording the average thickness, horizontal length and total height of the roughened surface of each area;

[0009] Step S2: Clean the roughened surface until it is moist and free of water.

[0010] Step S3, fixing a steel template on the roughened surface, wherein the size of the steel template matches the roughened surface;

[0011] Step S4, preparing C120 grade steel fiber / hybrid fiber ultra-high performance concrete or C100 grade non-metallic fiber ultra-high performance concrete;

[0012] Step S5: providing three grouting machines, placing the ultra-high performance concrete prepared in step S4 into each grouting machine, starting the grouting machine to begin continuous pouring construction, recording the pouring time, grouting flow rate, and cross-sectional area. The pouring cross-sectional shape is initially triangular, and then evolves into a pentagon. After the pouring construction is completed, the cross-sectional shape becomes rectangular;

[0013] Step S6: During the pouring process, for the central area, the real-time pouring height of the area is calculated based on the pouring volume identity and parameters such as the initial pouring flow rate. For each area on the other two sides, the pouring height control value of the area is obtained by taking a random number. Furthermore, according to the height-flow coordinated control pouring construction quality control equation derived based on the pouring volume identity, the pouring flow control value of each area on the other two sides is calculated;

[0014] Step S7: Provide a PLC controller to collect basic parameters such as horizontal pouring endpoint coordinates, average roughening thickness, and pouring time in real time. Combined with the built-in pouring construction quality control equation based on height-flow collaborative control in different stages, the optimal pouring flow of the grouting machine in different areas is calculated in real time, and the optimal pouring flow information is fed back to the grouting machine in real time. Through the automatic control system, the pouring speed of the grouting machine is adjusted in real time to ensure that the pouring height deviation of each area is within a scientific and controllable range, avoid the wall hanging phenomenon of ultra-high performance concrete, and effectively ensure the quality of ultra-high performance concrete reinforcement and repair construction until the reinforcement and repair construction is completed.

[0015] Furthermore, the roughened surface is divided into three areas from left to right according to the total horizontal length, which are respectively 1 # , 2 # , 3 #The average thickness of each area is recorded as d1, d2, d3, the horizontal length of each area is recorded as L1, L2, L3, and the total height of the roughened surface is recorded as H; the pouring time in step S5 is recorded as T, the grouting flow rate is recorded as Q1, Q2, Q3, and the cross-sectional area of ​​ultra-high performance concrete pouring is recorded as S1, S2, S3. The initial shape is a triangle. i = L1, L2 or L3, the triangle reaches its maximum, and then the cross-sectional shape evolves into a pentagon until the pouring construction is completed, and the cross-sectional shape becomes a rectangle. The pouring volume formula is V=S×d=Q×T; in the triangular stage, the total pouring height is recorded as H1=h 1,i 、H2=h 2,i 、H3=h 3,i ,at this time:

[0016] For 2 # Area, according to the pouring volume formula: V2=0.5×(L 2,b -L 2,a )×h 2,i ×d2=Q2×T, then h 2,i =Q2×T / [0.5×(L 2,b -L 2,a )×d2];

[0017] For 1 # , 3 # Area, take h 1,i or h 3,i =rand(0.95×h 2,i , 1.05×h 2,i ), ensuring that the pouring heights of the three areas remain consistent, and the pouring construction quality control equation based on height-flow coordinated control is derived according to the pouring volume formula:

[0018] Q1=0.5×(L 1,b -L 1,a )×h 1,i ×d1 / T,Q3=0.5×(L 3,b -L 3,a )×h 3,i ×d3 / T;

[0019] When the triangle reaches its maximum, the pouring height is recorded as h 1,imax 、h 2,imax 、h 3,imax ;

[0020] At the pentagon stage, the casting section is divided into two parts: the largest triangle at the top and the lower rectangle. The height of the lower rectangle is recorded as h. 1,k 、h 2,k 、h 3,k , the total pouring height is recorded as H1=h1,imax +h 1,k 、H2=h 2,imax +h 2,k 、H3=h 3,imax +h 3,k ,at this time:

[0021] For 2 # Area, obtained according to the pouring volume formula:

[0022] V2=(0.5×L2×h 2,imax +L2×h 2,k )×d2=Q2×T, then h 2,k =Q2×T / (L2×d2)-0.5×h 2,imax , H2=h 2,imax +h 2,k =Q2×T / (L2×d2)+0.5×h 2,imax ;

[0023] For 1 # , 3 # For each area, take H1 or H3 = rand(0.95×H2, 1.05×H2) to ensure that the pouring heights of the three areas are consistent. According to the pouring volume formula, the pouring construction quality control equation based on height-flow coordinated control is derived:

[0024] Q1=(H1-0.5×h 1,imax )×L1×d1 / T、Q3=(H3-0.5×h 3,imax )×L3×d3 / T, where d is the average roughening thickness.

[0025] Furthermore, step S3 includes:

[0026] The steel formwork is provided with a grouting hole in the middle of the bottom of each area. The bottom of the steel formwork is provided with a number of humidity sensors for real-time identification of the left and right pouring endpoint coordinates of the ultra-high performance concrete grouting material in the horizontal direction, which are recorded as L a 、L b , then the horizontal pouring distance of each area is L 1,i =L 1,b -L 1,a 、L 2,i =L 2,b -L 2,a 、L 3,i =L 3,b -L 3,a .

[0027] Furthermore, the inner surface of the steel template is flat, smooth and free of impurities.

[0028] Furthermore, an ultra-high performance concrete reinforcement and repair layer is formed through step S7, and the ultra-high performance concrete reinforcement and repair layer is located outside the base structure.

[0029] Compared with the prior art, the present invention has the following beneficial effects:

[0030] (1) The present invention provides a low-environmental-impact ultra-high-performance concrete compaction reinforcement and repair method. Based on the pouring construction quality control method of height-flow coordinated control, it can scientifically and accurately control and coordinate the reinforcement and repair construction process of different areas, effectively avoid the "hanging on the wall" phenomenon of reinforcement and repair materials between adjacent pouring areas caused by the uncontrolled pouring height difference, thereby ensuring the uniformity and density of the reinforcement and repair layer, and greatly improving the interface bonding, compressive strength and other mechanical and crack resistance and other durability properties of the reinforcement and repair layer, effectively meeting the structural safety requirements.

[0031] (2) The bottom-up "compacting" pouring construction process is adopted, and grouting holes are designed at the bottom of the formwork, which can effectively avoid the "hanging wall" phenomenon caused by the traditional top-down "pouring" pouring construction process. It can not only greatly improve the key performance of the reinforced repair layer, such as pouring density, mechanics and durability, but also, compared with the traditional "overall replacement" method, this process has low construction cost, less resource waste, small construction equipment, little impact on the surrounding environment, small footprint, short construction period, and can minimize the impact on urban traffic, with significant economic and social benefits.

[0032] (3) Ultra-high performance concrete is used as a reinforcement and repair material. Compared with traditional ordinary concrete, mortar and other materials, it not only has high mechanical strength, good crack resistance and impact resistance of the repaired structural layer, but also has good bonding effect with the substrate interface, which can get rid of the dependence on interface enhancers. After reinforcement and repair, the overall structure is safe and reliable; at the same time, the ultra-high performance concrete repaired structural layer has a fast setting speed and high early strength, which can greatly shorten the construction period, thereby meeting the urgent need to open traffic as soon as possible. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 This is a front view of the regional distribution in the ultra-high performance concrete compaction reinforcement and repair method with low environmental impact in one embodiment of the present invention;

[0034] Figure 2 A top view of a reinforcement and repair layer in a low-environmental-impact ultra-high-performance concrete compaction reinforcement and repair method according to an embodiment of the present invention;

[0035] Figure 3 A front view of a triangle pouring stage in a low-environmental-impact ultra-high-performance concrete compaction reinforcement and repair method according to an embodiment of the present invention;

[0036] Figure 4This is a front view of the pentagon casting stage in the ultra-high performance concrete compaction reinforcement and repair method with low environmental impact in one embodiment of the present invention.

[0037] In the figure, 1-grouting machine; 2-steel formwork; 3-grouting hole; 4-humidity sensor; 5-PLC controller. DETAILED DESCRIPTION

[0038] The following is a further detailed description of a low environmental impact ultra-high performance concrete compaction reinforcement and repair method provided by the present invention in conjunction with the accompanying drawings and specific embodiments. The advantages and features of the present invention will become more apparent from the following description.

[0039] Example 1

[0040] The following combination Figure 1 , a detailed description of the low environmental impact ultra-high performance concrete extrusion reinforcement and repair method of the present invention is given.

[0041] A low environmental impact ultra-high performance concrete compaction reinforcement and repair method comprises the following steps:

[0042] Step S1: Use manual / mechanical methods to roughen the surface of the existing building structure to be reinforced and repaired, and divide the roughened surface into 3 areas from left to right according to the horizontal total length L (1 # , 2 # , 3 # ), the average thickness of each area is recorded as d1, d2, d3, the horizontal length of each area is recorded as L1, L2, L3, and the total height of the roughened surface is recorded as H;

[0043] Step S2: After using a vacuum pump to blow and remove dust and debris from the roughened surface, clean the roughened surface with water until the surface is moist and there is no obvious water accumulation;

[0044] Step S3: Install and fix the steel template 2 on the roughened surface. The horizontal length and area division of the steel template 2 are completely consistent with the roughened surface. The steel template 2 is provided with a grouting hole 3 in the middle of the bottom of each area, for a total of 3 holes. A number of humidity sensors 4 are provided at the bottom of the steel template 2 for real-time identification of the left and right pouring end point coordinates of the ultra-high performance concrete grouting material in the horizontal direction, which are recorded as L. a 、L b , then the horizontal pouring distance of each area is L1,i =L 1,b -L 1,a 、L 2,i =L 2,b -L 2,a 、L 3,i =L 3,b -L 3,a , the inner surface of the steel template 2 is flat, smooth and free of impurities;

[0045] Step S4, preparing C120 grade steel fiber / hybrid fiber ultra-high performance concrete or C100 grade non-metallic fiber ultra-high performance concrete;

[0046] Step S5: Provide three grouting machines 1, each grouting machine 1 is responsible for the grouting work of one area, put the ultra-high performance concrete into the grouting machine, start the grouting machine to start continuous pouring construction, the pouring time is recorded as T, the grouting flow rate is recorded as Q1, Q2, Q3 respectively, the ultra-high performance concrete pouring cross-sectional area is recorded as S1, S2, S3, the shape is initially a triangle, wait for L i = L1, L2 or L3, the triangle reaches its maximum, and then the cross-sectional shape evolves into a pentagon until the pouring construction is completed, and the cross-sectional shape becomes a rectangle. The pouring volume formula is

[0047] V = S × d = Q × T;

[0048] In particular, in the triangle stage, the total height of the pouring is recorded as H1=h 1,i 、H2=h 2,i 、H3=h 3,i ,at this time:

[0049] 1) For 2 # According to the pouring volume formula, we can get: V2=0.5×(L2, b -L2, a )×h 2,i ×d2=Q2×T, then h 2,i =Q2×T / [0.5×(L2, b -L2, a )×d2];

[0050] 2) For 1 # , 3 # Area, take h 1,i or h 3,i =rand(0.95×h 2,i , 1.05×h 2,i ), ensure that the pouring height of the three areas remains consistent, thereby effectively avoiding the "hanging wall" phenomenon. According to the pouring volume formula, the pouring construction quality control equation based on height-flow coordinated control can be derived: Q1=0.5×(L1, b -L1, a )×h 1,i ×d1 / T, Q3=0.5×(L3, b -L3, a )×h 3,i ×d3 / T;

[0051] 3) When the triangle reaches its maximum, the pouring height is recorded as h 1,imax、h 2,imax 、h 3,imax ;

[0052] Similarly, in the pentagon stage, the casting section is divided into two parts: the largest triangle at the top and the lower rectangle, where the height of the lower rectangle is recorded as h 1,k 、h 2,k 、h 3,k , the total pouring height is recorded as H1=h 1,imax +h 1,k 、H2=h 2,imax +h 2,k 、H3=h 3,imax +h 3,k ,at this time:

[0053] For 2 # Area, according to the pouring volume formula:

[0054] V2=(0.5×L2×h 2,imax +L2×h 2,k )×d2=Q2×T, then h 2,k =Q2×T / (L2×d2)-0.5×h 2,imax , H2=h 2,imax +h 2,k =Q2×T / (L2×d2)+0.5×h 2,imax ;

[0055] 2) For 1 # , 3 # For the three areas, take H1 or H3 = rand (0.95 × H2, 1.05 × H2) to ensure that the pouring height of the three areas remains consistent, thereby effectively avoiding the "hanging wall" phenomenon. According to the pouring volume formula, the pouring construction quality control equation based on height-flow coordinated control can be derived: Q1 = (H1-0.5 × H2) 1,imax )×L1×d1 / T、Q3=(H3-0.5×h 3,imax )×L3×d3 / T;

[0056] Step S6, provide a PLC controller 5, collect various basic parameters such as horizontal pouring endpoint coordinates, average roughening thickness, pouring time, etc. in real time, combine the built-in pouring construction quality control equation based on height-flow collaborative control in different stages, calculate the optimal pouring flow of the grouting machine in different areas in real time, and feed back the optimal pouring flow information to the grouting machine in real time through the automatic control system, and adjust the pouring speed of the grouting machine in real time to ensure that the pouring height deviation of each area is within a scientific and controllable range, avoid the "hanging wall" phenomenon of ultra-high performance concrete, and effectively ensure the quality of ultra-high performance concrete reinforcement and repair construction until the reinforcement and repair construction is completed.

[0057] Among them, the PLC (Programmable Logic Controller) is the core real-time computing and execution unit. Its control process can be roughly divided into four steps: "data acquisition - algorithm operation - execution control - feedback correction". In this solution, the specific performance is as follows:

[0058] (1) The PLC collects key parameters such as the horizontal pouring endpoint coordinates and pouring time, which are located and wirelessly transmitted by the humidity sensor, in real time through the data acquisition module. The average thickness of the roughening and the initial pouring flow of the 2# grouting machine are manually input into the data acquisition module.

[0059] (2) The built-in calculation formula is used to calculate the pouring height of each area, and further, the optimal pouring flow rate of the grouting machine in different areas is calculated;

[0060] (3) The calculated optimal pouring flow rate of the grouting machine in each area is converted into a voltage or current signal, and the proportional valve or variable frequency drive (VFD) of the grouting machine is controlled through the analog output module (AO) to adjust the pump speed or valve opening (i.e., adjust the pouring speed of the grouting machine) so that the grouting machine can perform grouting operations at the specified flow rate, ensuring that the pouring height deviation of each area is within a scientific and controllable range, thereby ensuring the quality of reinforcement and repair.

[0061] The above examples are preferred embodiments of the present invention, but the embodiments of the present invention are not limited to the above embodiments. The above embodiments only express several embodiments of the present invention, and their descriptions are relatively specific and detailed, but they cannot be understood as limiting the scope of the invention patent. It should be pointed out that for ordinary technicians in this field, without departing from the concept of the present invention, several variations and improvements can be made, which all fall within the scope of protection of the present invention. Therefore, the scope of protection of the patent of the present invention shall be based on the attached claims.

Claims

1. A low environmental impact ultra-high performance concrete compaction reinforcement and repair method, characterized in that: The steps include: Step S1: roughening the surface of the existing building structure to be reinforced and repaired, dividing the roughened surface into several areas from left to right according to the total horizontal length, and recording the average thickness, horizontal length and total height of the roughened surface of each area; Step S2: Clean the roughened surface until it is moist and free of water. Step S3, fixing a steel template on the roughened surface, wherein the size of the steel template matches the roughened surface; Step S4, preparing C120 grade steel fiber ultra-high performance concrete or C120 grade mixed fiber ultra-high performance concrete or C100 grade non-metallic fiber ultra-high performance concrete; Step S5: providing three grouting machines, placing the ultra-high performance concrete prepared in step S4 into each grouting machine, starting the grouting machine to begin continuous pouring construction, recording the pouring time, grouting flow rate, and cross-sectional area. The pouring cross-sectional shape is initially triangular, and then evolves into a pentagon. After the pouring construction is completed, the cross-sectional shape becomes rectangular; Step S6: During the pouring process, for the central area, the real-time pouring height of the area is calculated based on the pouring volume identity and the initial pouring flow parameter. For each area on the other two sides, the pouring height control value of the area is obtained by taking a random number. Furthermore, according to the height-flow coordinated control pouring construction quality control equation derived based on the pouring volume identity, the pouring flow control value of each area on the other two sides is calculated; Step S7: Provide a PLC controller to collect basic parameters such as horizontal pouring endpoint coordinates, average roughening thickness, and pouring time in real time. Combined with the built-in pouring construction quality control equation based on height-flow collaborative control in different stages, the optimal pouring flow of the grouting machine in different areas is calculated in real time, and the optimal pouring flow information is fed back to the grouting machine in real time. Through the automatic control system, the pouring speed of the grouting machine is adjusted in real time to ensure that the pouring height deviation of each area is within a scientific and controllable range, avoid the wall hanging phenomenon of ultra-high performance concrete, and effectively ensure the quality of ultra-high performance concrete reinforcement and repair construction until the reinforcement and repair construction is completed.

2. The method according to claim 1, characterized in that The roughened surface is divided into three areas from left to right according to the total horizontal length, which are marked as 1 # , 2 # , 3 # The average thickness of each area is recorded as d1, d2, d3, the horizontal length of each area is recorded as L1, L2, L3, and the total height of the roughened surface is recorded as H; the pouring time in step S5 is recorded as T, the grouting flow rate is recorded as Q1, Q2, Q3, and the cross-sectional area of ​​ultra-high performance concrete pouring is recorded as S1, S2, S3. The shape is initially triangular. i = L1, L2 or L3, the triangle reaches its maximum, and then the cross-sectional shape evolves into a pentagon until the pouring construction is completed, and the cross-sectional shape becomes a rectangle. The pouring volume formula is V=S×d=Q×T; in the triangular stage, the total pouring height is recorded as H1=h 1,i 、H2=h 2,i 、H3=h 3,i ,at this time: For 2 # Area, according to the pouring volume formula: V2=0.5×(L 2,b -L 2,a )×h 2,i ×d2=Q2×T, then h 2,i =Q2×T / [0.5×(L 2,b -L 2,a )×d2]; For 1 # , 3 # Area, take h 1,i or h 3,i =rand(0.95×h 2,i , 1.05×h 2,i ), ensuring that the pouring heights of the three areas remain consistent, and the pouring construction quality control equation based on height-flow coordinated control is derived according to the pouring volume formula: Q1=0.5×(L 1,b -L 1,a )×h 1,i ×d1 / T,Q3=0.5×(L 3,b -L 3,a )×h 3,i ×d3 / T; When the triangle reaches its maximum, the pouring height is recorded as h 1,imax 、h 2,imax 、h 3,imax ; At the pentagon stage, the casting section is divided into two parts: the largest triangle at the top and the lower rectangle. The height of the lower rectangle is recorded as h. 1,k 、h 2,k 、h 3,k , the total pouring height is recorded as H1=h 1,imax +h 1,k 、H2=h 2,imax +h 2,k 、H3=h 3,imax +h 3,k , L 1,a 、L 1,b Indicates 1 # Coordinates of the left and right pouring endpoints of the regional ultra-high performance concrete grouting material in the horizontal direction; L 2,a 、L 2,b Representation 2 # Coordinates of the left and right pouring endpoints of the regional ultra-high performance concrete grouting material in the horizontal direction; L 3,a 、L 3,b Represents 3 # The coordinates of the left and right pouring endpoints of the regional ultra-high performance concrete grouting material in the horizontal direction are: For 2 # Area, obtained according to the pouring volume formula: V2=(0.5×L2×h 2,imax +L2×h 2,k )×d2=Q2×T, then h 2,k =Q2×T / (L2×d2)-0.5×h 2,imax , H2=h 2,imax +h 2,k =Q2×T / (L2×d2)+0.5×h 2,imax ; For 1 # , 3 # For each area, take H1 or H3 = rand(0.95×H2, 1.05×H2) to ensure that the pouring heights of the three areas are consistent. According to the pouring volume formula, the pouring construction quality control equation based on height-flow coordinated control is derived: Q1=(H1-0.5×h 1,imax )×L1×d1 / T、Q3=(H3-0.5×h 3,imax )×L3×d3 / T, where d is the average roughening thickness; The steel formwork is provided with a grouting hole in the middle of the bottom of each area. The bottom of the steel formwork is provided with a number of humidity sensors for real-time identification of the left and right pouring endpoint coordinates of the ultra-high performance concrete grouting material in the horizontal direction, which are recorded as L a 、L b , then the horizontal pouring distance of each area is L 1,i =L 1,b -L 1,a 、L 2,i =L 2,b -L 2,a 、L 3,i =L 3,b -L 3,a .

3. The method according to claim 2, characterized in that The inner surface of the steel template is flat, smooth and free of impurities.

4. The method according to claim 2, characterized in that An ultra-high performance concrete reinforcement and repair layer is formed through step S7, and the ultra-high performance concrete reinforcement and repair layer is located outside the base structure.

Images