Construction method of waterproof ceramic layer based on open-cut assembled tunnel and tunnel construction equipment

Abstract

The present application provides a construction method for a waterproof ceramic layer based on an open-cut assembled tunnel and tunnel construction equipment, which specifically relate to the technical field of open-cut tunnel construction. In the construction method for a waterproof ceramic layer based on an open-cut assembled tunnel, during foundation pit excavation, the earthwork is directly split and crushed to obtain a soil-rock mixture. The soil-rock mixture is then screened to separate aggregates and coarse clay particles. The aggregates are then made into tunnel structural components on site and assembled to form a tunnel structure. At the same time, the coarse clay particles are made into a waterproof ceramic coating to form a waterproof ceramic coating on the surface of the tunnel structure. In this way, the earthwork is directly processed on site into tunnel structural components and waterproof ceramic coatings, and a waterproof ceramic coating is directly formed on the surface of the tunnel structure. On the one hand, this avoids the problems of low construction efficiency and long construction period caused by the transportation and processing of earthwork, and on the other hand, it can also make full use of the earthwork to achieve the purpose of reducing costs and increasing efficiency.

Description

Technical Field

[0001] The present application relates to the technical field of open-cut tunnel construction, and in particular to a construction method for a waterproof ceramic layer based on an open-cut assembled tunnel and tunnel construction equipment. Background Art

[0002] At present, significant progress has been made in open-cut prefabricated tunnel technology, and many open-cut prefabricated tunnel projects have been successfully implemented. The successful implementation of these projects not only verifies the feasibility and superiority of open-cut prefabricated tunnel technology, but also provides valuable experience and reference for subsequent similar projects.

[0003] In current open-cut tunnel construction, the foundation pit is excavated first, followed by the formation of the tunnel roof structure. Backfill is then followed by secondary tunnel construction. During construction, the excavated earthwork must be transported and stored to reduce land occupation at the construction site. Prefabricated tunnel construction, on the other hand, requires waterproofing, which takes a long time. Consequently, the transportation and storage of earthwork significantly increases the space and time required, severely impacting construction efficiency and extending the project duration.

[0004] It should be noted that the information disclosed in the above background technology section is only used to enhance the understanding of the background of this application, and therefore may include information that does not constitute prior art known to ordinary technicians in this field. Summary of the Invention

[0005] The purpose of this application is to overcome the shortcomings of the above-mentioned prior art and provide a construction method and tunnel construction equipment for a waterproof ceramic layer based on an open-cut prefabricated tunnel, so as to solve the problems of low construction efficiency and long construction period caused by earthwork transportation and processing in the open-cut tunnel in the prior art.

[0006] According to one aspect of the present application, a method for constructing a waterproof ceramic layer in an open-cut prefabricated tunnel comprises the following steps:

[0007] Excavation of foundation pit, splitting and crushing of earth to obtain soil-rock mixture;

[0008] Screening of soil-rock mixture to separate aggregate and coarse clay particles;

[0009] The tunnel structure is formed by fabricating and assembling tunnel structural components on site using aggregates;

[0010] Coarse clay particles are used to make a waterproof ceramic coating, which is then formed on the surface of the tunnel structure.

[0011] According to some embodiments of the present application, screening the soil-rock mixture to separate aggregate and coarse clay particles includes the following steps:

[0012] Crush the soil-rock mixture and control its moisture content between 8% and 12%.

[0013] According to some embodiments of the present application, screening the soil-rock mixture includes the following steps:

[0014] Screening the soil-rock mixture with a sieve having an aperture of 5 mm to 10 mm to obtain a primary screened mixture;

[0015] Sieve the primary sieve mixture with a sieve having an aperture of 200 μm to 400 μm to separate the aggregate and the secondary sieve mixture;

[0016] The mixture was sieved through a sieve with a pore size of 100 μm to 180 μm to separate the coarse clay particles.

[0017] According to some embodiments of the present application, a waterproof ceramic coating is prepared using coarse clay particles, comprising the following steps:

[0018] Grinding coarse clay particles to obtain coarse clay particles, wherein the coarse clay particles have a particle size of 20 μm to 40 μm;

[0019] Adjust the viscosity of the coarse clay particles to 3000mPa·s to 8000mPa·s.

[0020] According to some embodiments of the present application, adjusting the viscosity of coarse clay particles to 3000 mPa·s to 8000 mPa·s includes the following steps:

[0021] Adding a defoamer, a dispersant, a thickener and a functional filler to the coarse clay particles, wherein the functional filler includes at least a pH regulator and a preservative, and grinding for at least 90 minutes to form a preliminary slurry;

[0022] Add film-forming agent and leveling agent to the preliminary slurry and continue grinding for at least 20 minutes to form a mixed slurry.

[0023] According to some embodiments of the present application, after forming the mixed slurry, the following steps are further included:

[0024] The mixed slurry was filtered through a filter with a pore size of 25 μm to 50 μm.

[0025] According to some embodiments of the present application, after forming the mixed slurry, the following steps are further included:

[0026] The mixed slurry is pressed into shape to obtain a sheet-shaped ceramic blank;

[0027] The ultra-fast high-temperature sintering process is used to directly heat the flaky ceramic blank with radiation to produce a solidified ceramic blank.

[0028] The ceramic blank is ground for at least 90 minutes to solidify until the particle size of the solidified ceramic blank is between 20 μm and 40 μm, and a coating additive is added to form a waterproof ceramic coating.

[0029] According to some embodiments of the present application, the coating additives include at least a wetting agent, an antibacterial agent, a flame retardant, and a coupling agent.

[0030] According to some embodiments of the present application, before excavating the foundation pit, the following steps are also included:

[0031] Extracting foundation pit soil at the construction site;

[0032] Monitor the soil type, moisture content, plasticity index and impurity content of foundation pit soil;

[0033] According to the soil type, moisture content, plasticity index, impurity content, ratio of materials for preparing waterproof ceramic coatings, and the area and thickness of the coating layer of the foundation pit, the amount of soil-rock mixture, auxiliary solvent and functional filler are calculated. The amount of soil-rock mixture accounts for between 40% and 60%, the amount of auxiliary solvent accounts for between 25% and 45%, and the amount of functional filler accounts for between 10% and 15%.

[0034] According to one aspect of the present application, a tunnel construction device is provided, which is used for implementing the above-mentioned method for constructing a waterproof ceramic layer in an open-cut assembled tunnel. The tunnel construction device includes:

[0035] A mixing assembly, the mixing assembly comprising a mixing tank, wherein the waterproof ceramic coating is stored in the mixing tank;

[0036] A spraying assembly is connected to the mixing tank and includes a driving structure and a spraying output end;

[0037] The control component is electrically connected to the mixing component and the spraying component to drive the driving structure to drive the spraying output end to form a waterproof ceramic coating on the surface of the tunnel structure.

[0038] This application provides a method and equipment for constructing a waterproof ceramic layer for an open-cut prefabricated tunnel. In this method, during foundation pit excavation, the earth is directly split and crushed to produce a soil-rock mixture. The soil-rock mixture is then screened to separate aggregate and coarse clay particles. The aggregate is then fabricated on-site into tunnel structural components and assembled to form the tunnel structure. Simultaneously, the coarse clay particles are used to make a waterproof ceramic coating, forming a waterproof ceramic coating on the surface of the tunnel structure.

[0039] In this way, the earthwork can be processed directly on site into tunnel structural components and waterproof ceramic coatings, and a waterproof ceramic coating can be directly formed on the surface of the tunnel structure. On the one hand, it avoids the problems of low construction efficiency and long construction period caused by earthwork transportation and processing. On the other hand, it can make full use of the earthwork to achieve the goal of reducing costs and increasing efficiency.

[0040] It should be understood that the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] The accompanying drawings are incorporated into and constitute a part of the specification, illustrate embodiments consistent with the present application, and together with the specification, are used to explain the principles of the present application. Obviously, the drawings described below are only some embodiments of the present application, and those skilled in the art can derive other drawings based on these drawings without inventive effort.

[0042] Figure 1 A schematic flow chart of a construction method for a waterproof ceramic layer in an open-cut assembled tunnel provided in an embodiment of the present application is shown.

[0043] Figure 2 A schematic diagram of a process for screening a soil-rock mixture in a waterproof ceramic layer of an open-cut assembled tunnel provided in an embodiment of the present application is shown.

[0044] Figure 3 A schematic diagram of a process for producing a waterproof ceramic coating using coarse clay particles in a waterproof ceramic layer of an open-cut assembled tunnel provided in an embodiment of the present application is shown.

[0045] Figure 4 A schematic diagram of a process for adjusting the viscosity of coarse clay particles in a waterproof ceramic coating made of coarse clay particles for a waterproof ceramic layer of an open-cut prefabricated tunnel provided by an embodiment of the present application is shown.

[0046] Figure 5 A structural schematic diagram of an open-cut assembled tunnel construction provided by an embodiment of the present application is shown.

[0047] Figure 6 A schematic diagram of the three-dimensional structure of a screening assembly of a tunnel construction equipment provided in an embodiment of the present application is shown.

[0048] Figure 7 A schematic diagram of the three-dimensional structure of a crushing assembly of a tunnel construction equipment provided in an embodiment of the present application is shown.

[0049] Figure 8 A schematic top view of a crushing assembly of a tunnel construction equipment provided in an embodiment of the present application is shown.

[0050] Figure 9 A schematic diagram of the three-dimensional structure of a spraying assembly of a tunnel construction equipment provided in an embodiment of the present application is shown.

[0051] Figure 10 A schematic diagram of the three-dimensional structure of a hybrid component of a tunnel construction equipment provided in an embodiment of the present application is shown.

[0052] The above drawings contain the following reference numerals:

[0053] 10. Foundation pit; 20. Mixing assembly; 21. Mixing tank; 22. End cap; 23. Flange outlet; 24. Saddle; 25. Support seat; 26. Production ladder; 30. Spraying assembly; 31. Drive structure; 311. Base; 312. Rotating support; 313. Feeding port; 314. Shoulder joint; 315. Upper arm; 316. Elbow joint; 317. Lower arm; 318. Wrist joint; 32. Spraying Output end; 40. Screening assembly; 41. Screening machine body; 42. Screen device silo; 43. Screening motor; 44. Control console; 45. Sand and gravel discharge port; 46. Soil particle discharge port; 47. Rotating shaft; 48. Rotating drum; 50. Crushing assembly; 51. Feed hopper; 52. Crushing motor; 53. Crusher frame; 54. Roller teeth; 55. Crushing chamber; 56. Crusher discharge port; 60. Tunnel structure. DETAILED DESCRIPTION

[0054] To make the purpose, technical solutions, and advantages of the embodiments of this application more clear, the technical solutions in the embodiments of this application will be clearly and completely described below in conjunction with the drawings in the embodiments of this application. Obviously, the described embodiments are part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0055] The disclosure below provides many different embodiments or examples for implementing different structures of the present application. In order to simplify the disclosure of the present application, the components and settings of specific examples are described below. Of course, these are merely examples and are not intended to limit the present application. In addition, the present application may repeat reference numbers and / or letters in different examples. Such repetition is for the purpose of simplicity and clarity and does not in itself indicate the relationship between the various embodiments and / or settings discussed.

[0056] For ease of description, spatially relative terms may be used herein to describe the relative position or movement of one element or feature relative to another element or feature as shown in the figures, such as "inside," "outside," "inside," "outside," "below," "beneath," "above," "above," "front," "rear," and the like. Such spatially relative terms are intended to encompass different orientations of the device during use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures undergoes a positional flip, a change in posture, or a change in motion, the directional indications will also change accordingly. For example, an element described as "below" or "below" another element or feature would subsequently be oriented "above" or "above" the other element or feature. Thus, the example term "below" can encompass both above and below orientations. The device may be alternatively oriented rotated 90 degrees or in other orientations and the spatially relative descriptors used herein should be interpreted accordingly.

[0057] like Figure 1 As shown, in some exemplary embodiments of the present application, a construction method for a waterproof ceramic layer based on an open-cut assembled tunnel is provided, which includes the following steps:

[0058] S10, excavation of foundation pit, splitting and crushing of earth to obtain soil-rock mixture.

[0059] S20, screening the soil-rock mixture to separate aggregate and coarse clay particles.

[0060] S30, fabricating and assembling tunnel structural components on-site using aggregate to form a tunnel structure.

[0061] S40, a waterproof ceramic coating is made of coarse clay particles and forms a waterproof ceramic coating on the surface of the tunnel structure.

[0062] Through this process, earthwork can be processed directly on-site into tunnel structural components and waterproof ceramic coatings, forming a waterproof ceramic coating on the tunnel structure surface. This not only effectively avoids the inefficiencies and extended construction periods associated with traditional earthwork transportation and handling, but also fully utilizes the earthwork on-site, significantly reducing costs and improving construction efficiency.

[0063] In the above embodiment, the foundation pit 1 can be excavated in sections, and screening procedures can be carried out simultaneously, thereby further improving construction efficiency.

[0064] In step S30, the tunnel structural member 0 is manufactured and assembled on-site using aggregates. Construction workers can directly form it using 3D printing, realizing on-site printing and curing of the tunnel structural member, so that the excavation of the tunnel or foundation pit and the installation of the tunnel structural member can be carried out simultaneously, thereby saving the transportation time of the tunnel structural member and significantly improving the construction efficiency of the open-cut tunnel.

[0065] It can be understood that the method of the above embodiment can be simultaneously implemented and used in various processes of open-cut tunneling, and is not limited to the excavation work of foundation pits.

[0066] like Figure 2 As shown, in some exemplary embodiments of the present application, step S20, screening the soil-rock mixture to separate aggregate and coarse clay particles, includes the following steps:

[0067] S21, crush the soil-rock mixture and control its moisture content between 8% and 12%.

[0068] When crushing the soil-rock mixture, some water can be added to avoid dust, and controlling the moisture content after crushing can avoid excessive wetting and agglomeration, or excessive drying and dusting.

[0069] The specific control method can be natural drying.

[0070] During the specific operation, the crushing process is to crush the oversized soil and rock mixture, which is convenient for transportation and screening and will not cause high damage to the machine.

[0071] like Figure 2 As shown, in some exemplary embodiments of the present application, further, screening the soil-rock mixture includes the following steps:

[0072] S22, sieve the soil-rock mixture with a 5mm to 10mm pore size sieve to obtain the primary sieved mixture. It is mainly used to remove large particles such as residual stones.

[0073] S23, sieves the primary sieve mixture with a sieve with an aperture of 200μm to 400μm to separate the aggregate and secondary sieve mixture. It is mainly used to remove residual coarse particles.

[0074] In one embodiment, the sieve for separating the aggregate and the secondary sieve mixture is preferably a sieve with a pore size of 300 μm.

[0075] S24, sieving the two-sieve mixture with a sieve having an aperture of 100 μm to 180 μm to separate coarse clay particles.

[0076] In one embodiment, the sieve for separating the coarse clay particles is preferably a sieve with a pore size of 150 μm.

[0077] The stepwise screening method can effectively separate the soil-rock mixture to obtain aggregate and coarse clay particles.

[0078] The soil and gravel in the soil-stone mixture are initially separated, and the soil part is collected. The sieve with a pore size of 5mm to 10mm removes the remaining coarse particles

[0079] like Figure 3 As shown, in some exemplary embodiments of the present application, making a waterproof ceramic coating with coarse clay particles includes the following steps:

[0080] S41, grinding the coarse clay particles to obtain coarse clay particles, wherein the coarse clay particles have a particle size of 20 μm to 40 μm. This can make the coarse clay particles uniform and facilitate the subsequent blending process.

[0081] S42: Adjust the viscosity of the coarse clay particles to 3000 mPa·s to 8000 mPa·s. This viscosity range is the most suitable for bonding with concrete mortar.

[0082] like Figure 4 As shown, in some exemplary embodiments of the present application, the viscosity of the coarse clay particles is adjusted to 3000 mPa·s to 8000 mPa·s, including the following steps:

[0083] S421, add a defoamer, dispersant, thickener, and functional filler to the coarse clay particles. The functional filler includes at least a pH regulator and a preservative. Grind for at least 90 minutes to form a preliminary slurry. This is used to adjust the viscosity of the coating.

[0084] S422, adding a film-forming agent and a leveling agent to the preliminary slurry, and continuing to grind for at least 20 minutes to form a mixed slurry.

[0085] The purpose of grinding is to reduce the particle size of the mixture and improve the homogenization of the coating, so that the particles can be evenly and stably dispersed in the resin system under the action of shear force, making the coating more uniform and reliable.

[0086] In some exemplary embodiments of the present application, the reagents mainly used in the process of preparing waterproof ceramic coating with coarse clay particles are as follows:

[0087] Defoamer: This agent eliminates bubbles generated during production and construction to prevent pinholes in the coating. A silicone defoamer (BYK-024) can be used, which is a compound of polymethylsiloxane and a low-foaming surfactant.

[0088] Dispersant: Its function is to ensure uniform dispersion of fillers, prevent agglomeration, and improve coating stability. An organic polymer dispersant (BYK-154), based on ammonium polyacrylate, can be used.

[0089] Waterproofing agent: Its function is to make the waterproof ceramic coating hydrophobic and improve its waterproof performance. You can choose silicone modified resin waterproofing agent, which is made of polydimethylsiloxane.

[0090] Thickener: Its function is to adjust the viscosity of the slurry coating, prevent sagging, and enhance construction performance. Synthetic polymer thickeners (such as ASE-60) can be used, which belong to the polyurethane thickener class.

[0091] Film-forming agents: These agents provide the coating with core properties such as high adhesion, long-lasting waterproofing, and weather resistance. Water-based epoxy resins can be used as the primary film-forming agent in the coating. Through the curing reaction, water-based epoxy resins form a continuous, dense network structure, tightly bonding the ceramic substrate with the filler and additives.

[0092] Leveling agent: This helps the paint form a uniform, smooth coating, improves film fluidity, and reduces surface defects (such as orange peel and brush marks). An organic algae-based water-based leveling agent, BYK-333, made from polyether-modified polydimethylsiloxane, can be used.

[0093] Functional fillers include nano-silica and mica powder, which increase the hardness of the coating, reduce the porosity, and overall enhance the mechanical and waterproof properties of the waterproof ceramic.

[0094] Before step S421, the coarse clay particles may be mixed with purchased bauxite, aluminum tailings waste, waste porcelain powder and other powders according to appropriate formula ratios and recycled to increase the physical and chemical properties of the coating to meet usage requirements.

[0095] like Figure 4 As shown, in some exemplary embodiments of the present application, after forming the mixed slurry, the following steps are further included:

[0096] S423: Filter the mixed slurry through a filter with a pore size of 25 μm to 50 μm to avoid sedimentation or agglomeration, thereby reducing the possibility of blockage in subsequent operations.

[0097] In one embodiment, a mesh with a pore size of 30 μm is preferred.

[0098] like Figure 4 As shown, in some exemplary embodiments of the present application, after forming the mixed slurry, the following steps are further included:

[0099] S424, pressing the mixed slurry into a sheet-like ceramic blank.

[0100] S425, using ultra-fast high-temperature sintering technology to directly heat the sheet-shaped ceramic blank with radiation to produce a solidified ceramic blank.

[0101] Specifically, the ultrafast high-temperature sintering process involves placing a pressed ceramic blank between two Joule-heated carbon ribbons in a sealed inert atmosphere. Direct radiation and heat conduction rapidly heat the blank, creating a uniform high-temperature environment that enables rapid solid-state reaction and reactive sintering. This method can reach sintering temperatures as high as 3000°C in approximately 10 seconds.

[0102] S426 , grinding the solidified ceramic blank for at least 90 minutes until the particle size of the solidified ceramic blank is between 20 μm and 40 μm, and adding a coating additive to form a waterproof ceramic coating. Materials that may be added include, but are not limited to, water, thickeners, and other solvents.

[0103] In some exemplary embodiments of the present application, after forming the mixed slurry, the coating additives added to the ground and solidified ceramic blank include: wetting agents, antibacterial agents, flame retardants and other functional additives. Their functions are as follows:

[0104] Wetting agent: Its function is to improve the wettability of the coating to the substrate and enhance the coating adhesion. Non-ionic surfactant (TritonX-100) can be used.

[0105] Antimicrobial agent: Its function is to inhibit the growth of microorganisms on the coating surface in the dark and humid environment of the tunnel. Quaternary ammonium salt organic antimicrobial agents can be used.

[0106] Flame retardant: Its function is to improve the fire resistance of waterproof ceramic coating. Aluminum hydroxide and silicon-based inorganic compound flame retardants can be used.

[0107] Coupling agent: Its function is to strengthen the interface bonding between inorganic filler and organic resin and solvent. Silane coupling agent (KH-550) can be used.

[0108] After adding the coating additives to the solidified porcelain blank, grind it for at least 90 minutes until the coating particle size is roughly between 20μm and less than 40μm, which can meet the requirements of waterproof coating spraying at the construction site.

[0109] Before step S426, the solidified ceramic blank may be processed, such as by cutting, grinding, or other processes to form it into a block shape.

[0110] In some exemplary embodiments of the present application, the coating additives include at least a wetting agent, an antibacterial agent, a flame retardant, and a coupling agent.

[0111] In some exemplary embodiments of the present application, before excavation of the foundation pit, the following steps are also included:

[0112] Extracting foundation pit soil at the construction site;

[0113] Monitor the soil type, moisture content, plasticity index and impurity content of foundation pit soil;

[0114] The amount of soil-rock mixture, auxiliary solvent, and functional filler required is calculated based on the soil type, moisture content, plasticity index, impurity content, the ratio of materials used to prepare the waterproof ceramic coating, and the area and thickness of the coating layer in the foundation pit. The soil-rock mixture accounts for between 40% and 60%, the auxiliary solvent accounts for between 25% and 45%, and the functional filler accounts for between 10% and 15%. This setup facilitates the purchase of auxiliary solvents and functional fillers.

[0115] In some embodiments, before using foundation pit soil in the preparation of waterproof ceramic coatings, a small amount of soil is extracted at the construction site for soil testing. Key parameters such as soil type, moisture content, plasticity index, and impurity content are measured to aid in the pre-purchase and proportioning of solvents and fillers, reducing procurement costs and time. Because the foundation pit soil is subjected to particle size screening and filtration and purification of impurities and organic matter, the resulting coarse clay particles are small in size and meet the required purity standards for the preparation of waterproof ceramic coatings.

[0116] In some embodiments, the relative contents of clay, required auxiliary solvents, and fillers in the total formulation are as follows:

[0117] Clay 40%~60%; nano-silica 5%~10%; mica powder 5%; film-forming agent 20%~30%; defoaming agent 0.2%~1.5%; dispersant 0.5%~2%; curing agent 5%; leveling agent 0.2%~1.5%; wetting agent 0.1%~0.5%; thickener 0.2%~1.5%; waterproofing agent 1%~5%; coupling agent 0.5%~2%.

[0118] Auxiliary solvents and functional fillers can be purchased in advance based on the above approximate relative content reference, and the proportion of ingredients can be changed according to the following specific conditions and construction requirements.

[0119] In some embodiments, for high-purity, fine-particle clay, the dispersant content is 0.5%. If the clay still contains a lot of impurities after purification, the dispersant content needs to be increased to 1%-2%. For clay with a high moisture content (≥12%), the film-forming agent content needs to be increased to 30%-35%. For clay with poor plasticity, the wetting agent content needs to be increased to (0.3%-0.5%). The curing agent ratio is generally 15%-20% of the film-forming agent mass (two-component system). For projects requiring high water resistance of waterproof ceramic coatings, the waterproofing agent can be added to 5%; nano-silica can be added to 10%. Since it is used to make spray-type waterproof ceramic materials, the thickener dosage should be lower (0.2%-0.8%).

[0120] In an optional embodiment, the construction method of the waterproof ceramic layer based on the open-cut prefabricated tunnel is as follows:

[0121] Screening of the soil-rock mixture: The excavated foundation pit soil is a soil-rock mixture, which undergoes preliminary processing. On-site crushing and screening components effectively separate the soil-rock mixture and crush the rocks to the desired particle size. This system offers a compact process, simple operation, and high processing efficiency.

[0122] Use crushing components to crush large pieces of soil and rock mixture, and let the crushed soil and rock mixture dry naturally until the moisture content is 8% to 12% to avoid excessive wetting and agglomeration, or excessive drying and dust generation.

[0123] After that, it is sent into the screening assembly. The first layer of screen is replaced with a screen with a pore size of 5mm to 10mm. When the motor drives the screen to rotate at high speed, under the action of the centrifugal field, the soil and stone particles are subjected to different centrifugal forces due to the significant differences in particle size and weight. At the same time, the motor also drives the drum 48 under the screen to rotate, and the sand and gravel above the screen are discharged from the discharge port, and the soil particles under the screen are discharged by the action of the drum 48.

[0124] After the initial separation of the soil and gravel in the mixture, the soil part is collected. At this time, the first layer of screen is replaced with a 50-mesh (300-micron) screen to remove residual coarse particles (mainly from particles that do not meet the crushing process).

[0125] At the same time, the second screen is replaced with a 100-mesh (150-micron) screen to obtain the main ceramic material, namely coarse clay particles. Waterproof ceramic coatings are used in construction, requiring both strength and molding efficiency. The collected soil, initially separated from the gravel, is fed into screening assembly 40 to ensure uniform feed and control the speed to avoid screen overload. The multiple screens separate the particles step by step, with the desired fine particles centrifugally screened and discharged from the lower outlet. Coarse particles remain on the two screens, awaiting return to crushing or discharge from the coarse material outlet for disposal. If different particle sizes are required to produce waterproof ceramic coatings of varying quality grades and applications, these particles can be obtained by replacing the screens to achieve the desired results. Clay particles of varying sizes are packaged separately, labeled with mesh size and intended use.

[0126] The separated sand and gravel, also known as aggregate, has a particle size of approximately 3mm to 5mm, meeting the requirements for daily fine aggregate production. If finer aggregate or construction mortar is required, it is poured into a crusher for further crushing. Depending on the particle size required, different levels of multi-stage crushing devices can be selected to adjust the crushed stone particle size. After crushing, the different particle sizes of stones are collected separately and used to produce aggregates of different particle sizes.

[0127] Aggregates are cleaned to remove surface dirt and impurities, then dried. According to the concrete formula, the aggregates are mixed with other raw materials (such as cement, water, etc.), stirred thoroughly using a mixing device, and then poured into a storage tank for use.

[0128] Then the soil is purified: the separated soil needs to be further processed and purified. First, the soil is cleaned to remove the mud and sand in the soil. Then, the further purification method is determined based on the soil conditions of the excavation area (organic matter content, impurity content, metal mineral content or soil cohesion, etc.).

[0129] The production of waterproof ceramic coatings requires highly purified soil. However, the soil in the on-site foundation pit contained excessively high levels of organic impurities and was not as good as the kaolin and bentonite used in traditional ceramic firing. Therefore, an innovative comprehensive purification method was employed, combining physical and chemical methods for efficient purification.

[0130] First, add an appropriate amount of acid or base solvent to react chemically with the impurities to generate soluble salts or compounds, and then remove these impurities through washing and filtration to improve the purity of the soil; then use membrane separation technology, that is, use the selective permeability of the semi-permeable membrane to separate the different components in the soil. By adjusting the pore size of the membrane and the operating conditions, the different components can be effectively separated and purified, or the second step can use other physical methods (such as ultrasound, centrifugal separation, etc.) for further purification.

[0131] The purified soil needs to be dried in preparation for subsequent use in sintering ceramics. A small amount of soil should be purified using the above method for ceramic firing, and its working performance should be tested. Then, the purification method should be adjusted and optimized according to actual conditions.

[0132] In addition, the purification effect should be tested regularly during the purification process, and the purification method and parameters should be adjusted in time to obtain the best purification effect.

[0133] In fact, the specific purification method should be selected based on the soil conditions and the purpose of purification.

[0134] The combined treatment of the above two methods can produce low-impurity, highly purified soil. Using this purification technology can significantly reduce production costs and avoid environmental pollution.

[0135] In some embodiments of this application, a waterproof ceramic coating is applied to a concrete mortar surface. The concrete mortar is pre-sprayed to cover the exposed surfaces on both sides of the foundation pit, providing support. As underground facilities, prefabricated tunnels require waterproofing, anti-seepage, and corrosion resistance as key features in the preparation of waterproof coatings. Furthermore, the key objectives of this prefabricated tunnel construction method are to shorten construction time, reduce costs, and ensure safety and reliability.

[0136] Furthermore, some embodiments of this application utilize a novel ceramic sintering method, namely an ultrafast high-temperature sintering process achieved in an inert atmosphere via radiant heating. This method can reach sintering temperatures as high as 3000°C in an extremely short time (approximately 10 seconds), meeting the requirements for rapid on-site preparation and application.

[0137] The specific construction methods are as follows:

[0138] The purified and dried foundation pit soil is ground into fine powder, and bauxite, aluminum tailings waste, waste porcelain powder and other powders are purchased for mixed recycling. Functional fillers such as defoamers, dispersants, thickeners and other additives (such as pH regulators, preservatives, etc.) are added according to the appropriate formula ratio and on-site needs to adjust the viscosity of the coating to the most suitable range for bonding with concrete mortar and improve the performance and stability of the coating.

[0139] After 1.5 hours of mixing and grinding, the resulting slurry is then added with a film-forming agent and a leveling agent and stirred. The film-forming agent, as a film-forming substance, forms a continuous coating film after the coating dries, playing a bonding and protective role. Grinding is continued for more than 20 minutes. Grinding is performed using a sand mill. Grinding is to reduce the particle size of the mixture and improve the homogenization of the coating, so that the particles are evenly and stably dispersed in the resin system under the action of shear force. Then, filter and package with a 30-micron filter for later use.

[0140] A portion of the mixture is taken out and pressed to obtain a sheet-like ceramic blank. The pressed ceramic sheet is placed between two Joule-heated carbon belts and placed in a closed inert atmosphere to achieve the ultrafast high-temperature sintering (UHS) process.

[0141] The ceramic sheet is rapidly heated through direct radiation and thermal conduction, creating a uniform high-temperature environment for rapid solid-state reaction and reactive sintering. This method can reach sintering temperatures as high as 3000°C in approximately 10 seconds. The microstructure and properties of the UHS-sintered ceramic material are then evaluated using techniques such as SEM (scanning electron microscopy), XRD (X-ray diffraction), and electrochemical measurements. Based on these measured data, the mixture ratio and purification techniques are optimized.

[0142] The fired ceramic material needs to be processed, such as cutting, grinding and other processes to make it into blocks, and then the processed ceramic material is ground into fine powder and added with water, thickener and other solvents to make coatings and store them in storage tanks for spraying construction.

[0143] The prepared waterproof ceramic spray material is tested for performance, including water absorption, water resistance, and weather resistance, to ensure it meets application requirements and exhibits good waterproof properties. The waterproof ceramic coating is poured into a storage tank and connected to the spray equipment via a discharge pipe. Ensure the equipment and spray gun are in good condition. Before spraying, carefully control the coating thickness and uniformity, and adjust parameters such as spray pressure and distance.

[0144] Relationship between each step: Each step is basically carried out in chronological order, but there may be overlap in time. Figure 6 As shown, the on-site foundation pit is excavated in sections, the foundation pit soil is cleaned, and large hard rocks are split and crushed to prepare for the subsequent step 1 soil and rock screening, step 2 soil purification, and sand and gravel fine aggregate production. The fine aggregate will be used to make concrete mortar as the raw material for supporting the foundation pit 1 and printing the prefabricated tunnel components. After the soil and rock are separated in step 1, the soil that has been preliminarily screened in step 2 will be purified with high precision using a comprehensive purification method, followed by step 3 preparation and spraying of the waterproof ceramic coating. The waterproof ceramic coating will be sprayed onto the surface of the foundation pit and the inner surface of the prefabricated tunnel components, creating a double-layer waterproof lining, which greatly improves the waterproof and anti-seepage performance of the tunnel. In the actual construction process, each step can be carried out in parallel in time, improving construction efficiency and shortening the construction period.

[0145] like Figures 5 to 10 The exemplary embodiment of the present application further provides a tunnel construction device, which is applied to the implementation of the construction method of the waterproof ceramic layer based on the open-cut prefabricated tunnel as described in any of the above embodiments, and the tunnel construction device includes:

[0146] The mixing assembly 20 includes a mixing tank 21, and the mixing tank 21 stores the waterproof ceramic coating;

[0147] The spray assembly 30 is in communication with the mixing tank 21 and includes a driving structure 31 and a spray output end 32;

[0148] The control component is electrically connected to the mixing component 20 and the spraying component 30 to drive the driving structure 31 to drive the spraying output end 32 to form a waterproof ceramic coating on the surface of the tunnel structure 60.

[0149] like Figure 9 As shown, in some exemplary embodiments of the present application, the driving structure 31 is a robotic arm, which includes a base 311 , a rotating support 312 , a feed port 313 , a shoulder joint 314 , an upper arm 315 , an elbow joint 316 , a lower arm 317 , and a wrist joint 318 .

[0150] In some exemplary embodiments of the present application, the tunnel construction equipment further includes a screening assembly 40, which includes at least a screen with a pore size of 5 mm to 10 mm, a screen with a pore size of 200 μm to 400 μm, and a screen with a pore size of 100 μm to 180 μm. The screening assembly 40 includes a screening machine body 41, a screening device silo 42, a screening motor 43, a control console 44, a sand and gravel discharge port 45, a soil particle discharge port 46, a rotating shaft 47, and a rotating drum 48.

[0151] In some exemplary embodiments of the present application, the tunnel construction equipment further includes a crushing assembly 50 for crushing earthwork, specifically a roller crusher or a splitting crusher. The crushing assembly 50 includes a feed hopper 51, a crushing motor 52, a crusher frame 53, roller teeth 54, a crushing chamber 55, and a crusher discharge port 56.

[0152] In some exemplary embodiments of this application, please refer to Figure 5 As shown in the on-site work diagram, during the segmented excavation of foundation pit 10, the cleared foundation pit soil is split and crushed to obtain a soil-rock mixture. This soil-rock mixture is poured into screening assembly 40 for soil and rock screening to separate aggregate and coarse clay particles. The coarse clay particles after preliminary screening are further processed through a comprehensive purification method to obtain a mixed slurry. The mixed slurry undergoes ceramic sintering and coating to obtain a waterproof ceramic coating. This is then loaded into mixing tank 21 of mixing assembly 20 and finally connected to spray assembly 30 via a discharge pipe, ensuring smooth transportation of the waterproof ceramic coating and smooth spraying.

[0153] In some optional embodiments, the sand and gravel screened by the screening component 40 are poured into the adjacent crushing component 50 for further crushing. According to the particle size requirements of the sand and gravel fine aggregate, different degrees of grading devices can be selected to adjust the crushing particle size of the stone. The fine aggregate is used for subsequent foundation pit 10 support and in-situ printing of assembly components.

[0154] Figure 5 The following figure shows a screening assembly 40, a screening machine equipment, used in an embodiment of the present application. The specific operation process is as follows:

[0155] The initially crushed soil-rock mixture is poured into the screening device hopper 42 of the screening machine in batches. The screening motor 43 is activated via the control console 44. The motor drives the rotating shaft 47 at high speed, which in turn rotates the impeller of the upper drum 48. Under the influence of the centrifugal field, the soil and rock particles, due to their significant differences in particle size and density, are subjected to different centrifugal forces. The gravel and stone remaining on the screen are discharged through the gravel outlet 45. The soil particles below the screen are discharged from the lower soil outlet 46 by the drum 48, thus separating the soil and stone from the mixture. The soil is collected and then screened through multiple screens. The above process is repeated to obtain coarse clay particles of the desired particle size for subsequent use in waterproof ceramic coatings and other applications.

[0156] Figure 7 and Figure 8 The crushing assembly 50, a roller crusher, used in one embodiment of the present application is shown, and its specific operation process is as follows:

[0157] The excavated soil-rock mixture, or sand and gravel that needs to be further processed to a finer particle size, is poured into the roller crusher's discharge port 56. The crusher's motor 52 is activated, and the multi-stage toothed rollers 54 on both sides of the crushing chamber 55 rotate periodically, crushing the sand and gravel into the small-sized particles required for fine aggregate production. Once the required particle size is reached, the material is discharged from the crusher discharge port 56 for subsequent use in concrete fine aggregate production and in-situ printing of assembly components.

[0158] Figure 9 The following figure shows a spraying assembly 30, a spraying robot arm equipment, used in an embodiment of the present application. The specific operation process is as follows:

[0159] The main body of the device is a multi-degree-of-freedom robotic arm. Its base 311 can be placed on a work surface or trailer. A feed port 313 is connected to a storage tank via a discharge pipe, ensuring the delivery and spraying of the waterproof ceramic coating. The arm 312, shoulder joint 314, elbow joint 316, and wrist joint 318 are used to control the arm's swing. The upper and lower arms (upper arm 315, lower arm 317) and the front spray gun coordinate to achieve arbitrary angles and positions, spraying the waterproof ceramic coating onto ten surfaces of the foundation pit and the inner surfaces of tunnel assembly components. This significantly reduces the time and labor required for spraying.

[0160] Figure 9 The figure shows a mixing assembly 20 used in an embodiment of the present application. The mixing tank 21 of the mixing assembly 20 can store and supply raw materials required for on-site construction, such as waterproof coatings, concrete, sand and gravel fine aggregates and other raw materials. A stirring and mixing device, such as a stirring blade, can be set inside the mixing tank to avoid sedimentation.

[0161] Specifically, on-site workers ascend production ladders 26, open end caps 22, pour raw materials into the storage tank, connect the discharge pipe to the flange outlet 23, and then connect it to the feed port 313 on the spray robot arm, ensuring smooth transportation of waterproof ceramic coating and subsequent spraying work. Support bases 25 and upper saddles 24 ensure the stable placement of the storage tank.

[0162] The above embodiments have the following advantages:

[0163] 1. Excavation soil is processed and fired into ceramics, which are then used to create a waterproof ceramic coating. Utilizing scientifically advanced soil and rock screening and purification techniques, as well as high-temperature ceramic firing technology, the ceramic particles maintain high strength and durability while also possessing excellent waterproof properties. This reduces the production cost of the waterproof ceramic coating. A high-strength, durable, water-stopping, flame-retardant, and environmentally friendly waterproof ceramic coating is applied to the interface between the excavation soil and the assembly, as well as to the inner surfaces of each assembly component. This creates a strong double-layer waterproof barrier, reducing the cost of subsequent repairs due to leaks and providing a solid foundation for the long-term, stable operation of the open-cut prefabricated tunnel.

[0164] 2. It achieves a high utilization rate of earthwork, providing new ideas and paths for the purification and utilization of foundation pit soil and rock resources, avoiding the turnover and waste of foundation pit soil and rock resources and reducing soil transportation costs. Compared to traditional waterproofing materials, this waterproof ceramic coating, made from foundation pit soil, not only offers significant economic advantages but also better aligns with current green, environmental, and sustainable development concepts. It offers excellent economic, environmental, and social benefits. Therefore, its widespread application will inject new vitality into technological innovation and development in open-cut prefabricated tunneling and related fields.

[0165] It should be understood that the present application is not limited to the detailed structure and arrangement of the components proposed in this application. The present application can have other embodiments and can be implemented and executed in a variety of ways. The aforementioned variations and modifications fall within the scope of this application. It should be understood that the present application disclosed and defined in this application extends to all alternative combinations of two or more individual features mentioned or apparent in the text and / or the drawings. All of these different combinations constitute multiple alternative aspects of the present application. The embodiments of the present application illustrate the best mode known for implementing the present application and will enable those skilled in the art to utilize the present application.

Claims

1. A construction method for a waterproof ceramic layer based on an open-cut assembled tunnel, characterized in that: The steps include: Excavation of foundation pit, splitting and crushing of earth to obtain soil-rock mixture; screening the soil-rock mixture to separate aggregate and coarse clay particles; Using the aggregate, on-site fabrication and assembly of tunnel structural components to form a tunnel structure; preparing a waterproof ceramic coating with the coarse clay particles and forming a waterproof ceramic coating on the surface of the tunnel structure; The method of preparing a waterproof ceramic coating using the coarse clay particles comprises: Grinding the coarse clay particles to a particle size of 20 μm to 40 μm; Adjusting the viscosity of the coarse clay particles to 3000 mPa·s to 8000 mPa·s; Adding defoamer, dispersant, thickener and functional filler to the coarse clay particles, and grinding for at least 90 minutes to form a preliminary slurry; Adding a film-forming agent and a leveling agent to the preliminary slurry and continuing grinding for at least 20 minutes to form a mixed slurry; Filtering the mixed slurry through a filter with a pore size of 25 μm to 50 μm; Pressing the mixed slurry into a shape to obtain a sheet-shaped ceramic blank; Directly radiating heat is applied to the sheet-shaped ceramic blank by an ultrafast high-temperature sintering process to obtain a solidified ceramic blank; The solidified ceramic green body is ground for at least 90 minutes until the particle size of the solidified ceramic green body is between 20 μm and 40 μm, and a coating additive is added to form the waterproof ceramic coating.

2. The construction method of waterproof ceramic layer based on open-cut assembled tunnel according to claim 1 is characterized in that: Screening the soil-rock mixture to separate aggregate and coarse clay particles comprises the following steps: The soil-rock mixture is crushed and its moisture content is controlled between 8% and 12%.

3. The construction method of waterproof ceramic layer based on open-cut assembled tunnel according to claim 2 is characterized in that: Screening the soil-rock mixture comprises the following steps: Screening the soil-rock mixture with a sieve having an aperture of 5 mm to 10 mm to obtain a primary screened mixture; Sieving the primary sieve mixture with a sieve having an aperture of 200 μm to 400 μm to separate the aggregate and the secondary sieve mixture; The two-sieve mixture is sieved with a sieve with a pore size of 100 μm to 180 μm to separate the coarse clay particles.

4. The construction method of waterproof ceramic layer based on open-cut assembled tunnel according to claim 1, characterized in that: The functional filler at least includes a pH regulator and a preservative.

5. The construction method of waterproof ceramic layer based on open-cut assembled tunnel according to claim 4 is characterized in that: Coating additives include at least wetting agents, antimicrobial agents, flame retardants and coupling agents.

6. The method for constructing a waterproof ceramic layer based on an open-cut assembled tunnel according to any one of claims 1 to 5, characterized in that: Before excavation of the foundation pit, the following steps are also included: Extracting foundation pit soil at the construction site; Monitoring the soil type, moisture content, plasticity index and impurity content of the foundation pit soil; According to the soil type, the moisture content, the plasticity index, the impurity content, the ratio of the materials for preparing the waterproof ceramic coating, and the area and thickness of the coating layer of the foundation pit, the amount of soil-rock mixture, the amount of auxiliary solvent and the amount of functional filler are calculated. The amount of soil-rock mixture accounts for between 40% and 60%, the amount of auxiliary solvent accounts for between 25% and 45%, and the amount of functional filler accounts for between 10% and 15%.

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