Lightweight aggregate concrete structure with floating resistance and preparation device and process thereof

Abstract

The invention discloses a light aggregate concrete structure with anti-floating property and a preparation process thereof, the light aggregate concrete structure comprises light aggregate concrete layers and net-shaped reinforced material layers which are alternately distributed, the height of the light aggregate concrete layers is 50-300mm, and the height of the net-shaped reinforced material layers is 50-300mm. The light aggregate concrete layers and the net-shaped reinforced material layers which are alternately distributed are adopted to form a physical separation barrier, the floating path of light aggregate is directly blocked through layered constraint, meanwhile, the light characteristic of the light aggregate concrete is maintained, and cooperation of anti-floating and light weight is achieved. A polyester fiber net, a glass fiber grid and other net-shaped reinforced material layers are implanted into a light aggregate concrete system in a layered mode, and the mesh size matched according to the aggregate particle size and the 50-300 mm interlayer interval and staggered laying technology are combined, so that floating of light aggregate is effectively restrained through a physical barrier mechanism, the tensile strength and the crack resistance of concrete are synchronously improved, and the service life of the concrete is prolonged. And collaborative optimization of anti-floating stability and mechanical properties is realized.

Description

Technical Field

[0001] The present invention relates to the technical field of deep processing of concrete, and particularly to a lightweight aggregate concrete structure with anti-floating property, and its preparation device and process. Background Art

[0002] Lightweight aggregate concrete is a special concrete prepared by replacing traditional aggregates with lightweight coarse / fine aggregates (pumice, expanded perlite, ceramsite, expanded glass beads, vitrified microspheres, rubber), and is mixed with cement, water and additives. Its dry apparent density is ≤1950 kg / m 3 . Compared with ordinary concrete, lightweight aggregate concrete has comprehensive performance advantages such as light weight and high strength (the apparent density of strength grade above LC30 is 1600 - 1900 kg / m 3 , with a weight reduction of 25% - 30% compared with the same grade ordinary concrete), heat preservation and insulation (thermal conductivity of 0.18 - 1.01 W / (m·K)), earthquake resistance and ductility (low elastic modulus and deformation adaptability), fire resistance and durability, and is widely used in engineering fields such as long-span bridges, super high-rise buildings, and energy-saving walls.

[0003] Restricted by the inherent characteristics of lightweight aggregates (low strength, high porosity, easy water absorption), lightweight aggregate concrete is prone to process defects such as large strength discreteness, poor workability, and aggregate floating. Existing technical improvement solutions include: optimizing the surface of lightweight aggregates by coating with silica sol and coating with mineral admixtures (silica fume, fly ash) to reduce water absorption and enhance the bond between aggregate and paste; introducing ultra-fine powders (silica fume, metakaolin) to improve the matrix density, and compounding with high-performance polycarboxylate water reducer to improve fluidity and wrapping property; using graded lightweight aggregates and optimizing the water-binder ratio, and combining with additives such as thickeners and anti-settling agents to inhibit aggregate floating.

[0004] Patent ZL201910626537.1 proposes the "magnetic lightweight aggregate + magnetic control vibration" positioning technology to regulate the spatial distribution of aggregates through magnetic fields; Patent ZL201910564716.7 dynamically adjusts the admixture dosage based on the mortar stratification degree; Patent ZL201711324773.5 uses pre-wetted spherical lightweight aggregates to form an arch-shaped interface area to achieve the synergistic effect of internal curing and anti-floating.

[0005] The above improvement schemes have improved the properties of lightweight aggregate concrete through material chemical modification (such as surface coating, ultrafine powder compounding) and ratio optimization (such as grading ratio design, thickener incorporation), etc., but no physical constraints have been constructed, which are mainly reflected in the following aspects: Anti-floating depends on chemical intervention: Surface treatment and admixture regulation only indirectly inhibit the floating of lightweight aggregates by enhancing the interfacial bond or the viscosity of the slurry, and cannot directly block their migration path, resulting in the risk of uneven aggregate distribution during vibration or pouring. Limitations of special processes: Taking the magnetic improvement technology represented by patent ZL201910626537.1 as an example, customized magnetic lightweight aggregates and supporting magnetic control vibration equipment are required. Such methods not only significantly increase the material cost and equipment investment, but also are limited by the magnetic field uniformity and construction environment adaptability, and are difficult to be popularized and applied in in-situ or large-scale precast scenarios.

[0006] Therefore, we provide a lightweight aggregate concrete structure with anti-floating properties, as well as its preparation device and process to solve the above problems. Summary of the Invention

[0007] In view of the problems existing in the above-mentioned prior art, the present invention provides a lightweight aggregate concrete structure with anti-floating properties. By using mesh reinforcement materials such as polyester fiber mesh and glass fiber grille to be implanted into the lightweight aggregate concrete system in layers, combined with the mesh size matching the aggregate particle size and the multi-layer staggered laying technology, the floating of lightweight aggregates is effectively inhibited through the physical separation mechanism, and the tensile strength and crack resistance of the concrete are simultaneously improved, realizing the coordinated optimization of anti-floating stability and mechanical properties.

[0008] In order to achieve the above object, the lightweight aggregate concrete structure with anti-floating properties adopted by the present invention includes: alternately distributed lightweight aggregate concrete layers (3) and mesh reinforcement material layers (2), and the height of the lightweight aggregate concrete layer (3) is 50 - 300 mm. By adopting the alternately distributed lightweight aggregate concrete layers (3) and mesh reinforcement material layers (2) to form a physical separation barrier, the floating path of lightweight aggregates is directly blocked through layered constraints, and at the same time, the lightweight characteristics of lightweight aggregate concrete are maintained, realizing the coordination of anti-floating and lightweight.

[0009] As a further preferred scheme of the above scheme, the lightweight aggregate concrete layer (3) includes fine aggregate, admixture, cementitious material and lightweight aggregate. By optimizing the cementitious system and the admixture dosage, the wrapping property and fluidity of the slurry are improved, and the risk of segregation between the lightweight aggregate and the slurry is reduced.

[0010] As a further preferred solution of the above solution, the lightweight aggregate of the lightweight aggregate concrete layer (3) is one or two or more mixtures of pumice, expanded perlite, expanded glass beads, vitrified microspheres, ceramsite, rubber particles, etc., and the particle size range is: 2-20 mm for pumice, 0.5-5 mm for expanded perlite, 0.1-5 mm for expanded glass beads, 0.1-3 mm for vitrified microspheres, 5-25 mm for ceramsite, and 0.5-10 mm for rubber particles.

[0011] As a further preferred solution of the above solution, the reinforcing material of the mesh reinforcing material layer (2) is selected from one of polyester fiber mesh, fiberglass grille, carbon fiber reinforced composite material, basalt fiber reinforced composite material, and aramid fiber mesh cloth; it meets the requirements of different engineering scenarios and combines lightweight and mechanical properties.

[0012] The mesh size of the mesh reinforcing material layer (2) is selected in accordance with the particle size of the lightweight aggregate; the mesh size of the mesh reinforcing material layer (2) is smaller than the particle size of the lightweight aggregate and larger than or close to the maximum particle size of the mortar. The mesh size of the mesh reinforcing material layer (2) is optimized according to the particle size of the lightweight aggregate to ensure that the mesh is smaller than the particle size of the lightweight aggregate to intercept floating, and at the same time larger than the mortar particles to ensure dense filling of the slurry and avoid forming internal cavities.

[0013] As a further preferred solution of the above solution, the lightweight aggregate of the lightweight aggregate concrete layer (3) is selected as pumice lightweight aggregate concrete, and the mesh size of the mesh reinforcing material layer (2) is 3-8 mm.

[0014] As a further preferred solution of the above solution, the lightweight aggregate of the lightweight aggregate concrete layer (3) is selected as expanded perlite lightweight aggregate concrete, and the mesh size of the mesh reinforcing material layer (2) is 1-3 mm.

[0015] As a further preferred solution of the above solution, the lightweight aggregate of the lightweight aggregate concrete layer (3) is selected as expanded glass bead lightweight aggregate concrete, and the mesh size of the mesh reinforcing material layer (2) is 0.5-5 mm.

[0016] As a further preferred solution of the above solution, the lightweight aggregate of the lightweight aggregate concrete layer (3) is selected as vitrified microsphere lightweight aggregate concrete, and the mesh size of the mesh reinforcing material layer (2) is 0.5-2 mm.

[0017] As a further preferred solution of the above solution, the lightweight aggregate of the lightweight aggregate concrete layer (3) is selected as ceramsite lightweight aggregate concrete, and the mesh size of the mesh reinforcing material layer (2) is 4-10 mm.

[0018] As a further preferred solution of the above solution, the lightweight aggregate of the lightweight aggregate concrete layer (3) is rubber lightweight aggregate concrete, and the mesh size of the mesh reinforcing material layer (2) is 2-6 mm.

[0019] As a further preferred embodiment of the above solution, the mesh positions of adjacent two layers of mesh reinforced material layers (2) are staggered by 1 / 2 grid width in the horizontal direction to form a staggered arrangement, thus forming a multi-layer constraint structure to effectively prevent the lightweight aggregate from floating vertically due to its light weight.

[0020] As a further preferred embodiment of the above solution, the mesh reinforced material layer (2) is a double-layer honeycomb mesh structure, and the upper honeycomb mesh and the lower honeycomb mesh are connected and the mesh openings are staggered.

[0021] The double-layer honeycomb mesh structure of the mesh reinforced material layer (2) mainly plays the role of enhancing the stability and bearing capacity of the lightweight aggregate concrete structure with anti-floating property; improving the compressive strength: the honeycomb structure can effectively disperse and bear the external forces from all directions, significantly enhancing the overall compressive strength of the concrete; enhancing the shear resistance: the honeycomb-shaped reinforced material can limit the shear deformation inside the concrete, improve the shear resistance, and prevent cracks and dislocations in the structure; improving the durability and preventing crack propagation: the reinforced material can effectively inhibit the generation and development of micro-cracks inside the concrete, improve the crack resistance, and extend the service life of the structure; enhancing the fatigue resistance: under the action of repeated loads, the honeycomb-shaped reinforced material can improve the fatigue resistance of the concrete and prevent premature damage of the structure.

[0022] As a further preferred embodiment of the above solution, it further includes reinforcing bars vertically arranged and passing through the multi-layer alternately distributed lightweight aggregate concrete layers (3) and mesh reinforced material layers (2), which can improve the overall stiffness, flexural bearing capacity and anti-peeling ability.

[0023] As a further preferred embodiment of the above solution, the reinforcing bars are provided with horizontal ribs in different directions according to the lightweight aggregate concrete layer (3). The horizontal ribs in different directions on the reinforcing bars disperse the loads acting on the concrete structure, reduce the stress concentration in the concrete, and enable the structure to bear greater loads.

[0024] As a further preferred embodiment of the above solution, the mesh reinforced material layer (2) adopts a polyester fiber mesh with a mesh size of 1mm×1mm; the height of the lightweight aggregate concrete layer (3) is 50mm, and its mix ratio is: cement 500kg / m 3 , sand 500kg / m 3 , vitrified microbeads 200kg / m 3 , water 175kg / m 3 , admixture 6.0kg / m 3 , and the water-binder ratio is 0.35.

[0025] As a further preferred embodiment of the above solution, the mesh reinforced material layer (2) adopts a glass fiber grille with a mesh size of 6mm×6mm; the height of the lightweight aggregate concrete layer (3) is 50mm, and its mix ratio is: cement 450kg / m 3, sand 550 kg / m 3 , shale ceramsite 450 kg / m 3 , water 170 kg / m 3 , admixture 5.4 kg / m 3 , water-binder ratio is 0.38.

[0026] As a further preferred solution of the above solution, the mesh reinforcement material layer (2) adopts a polyester fiber mesh with a mesh size of 5 mm × 5 mm; the height of the lightweight aggregate concrete layer (3) is 250 mm, and its mix ratio is: cement 480 kg / m 3 , sand 600 kg / m 3 , expanded perlite 180 kg / m 3 , water 190 kg / m 3 , admixture 7.2 kg / m 3 .

[0027] As a further preferred solution of the above solution, the mesh reinforcement material layer (2) adopts a carbon fiber reinforced composite grid cloth with a mesh size of 3 mm × 3 mm; the height of the lightweight aggregate concrete layer (3) is 50 mm, and its mix ratio is: cement 450 kg / m 3 , sand 550 kg / m 3 , rubber particles 200 kg / m 3 , water 180 kg / m 3 , admixture 6.0 kg / m 3 .

[0028] The present invention also provides a preparation device for a lightweight aggregate concrete structure with anti-floating property, including a mold (4) and a vibrating device. The mold (4) includes a bottom plate (41) and side plates (42) surrounding the four sides of the bottom plate (41). The bottom plate (41) and the side plates (42) are adjusted to enclose a casting cavity with an open top. The side plates (42) are longitudinally arranged at equal intervals with a positioning hole array (5) for passing through the raised parts (21) on the mesh reinforcement material layer (2). Each group of positioning hole arrays (5) includes positioning holes arranged horizontally at equal intervals.

[0029] As a further preferred solution of the above solution, a vibrating table is provided at the lower end of the bottom plate (41).

[0030] As a further preferred solution, it includes a vibrator. The vibrator is inserted through the positioning holes around the side plates to vibrate the lightweight aggregate concrete layer, and the vibration intensity of the vibrator is controlled to avoid the displacement of the mesh reinforcement material.

[0031] The present invention also provides a preparation process for a lightweight aggregate concrete structure with anti-floating property, including:

[0032] S1: Adjust the installation positions of the surrounding side plates and the bottom plate of the preparation device adaptively according to the dimensions of the lightweight aggregate concrete structural members to be poured, and define the construction scope.

[0033] S2: Pour the lightweight aggregate concrete mixture into the preparation device described in step S1 to a height of 50 - 300 mm.

[0034] S3: Lay a mesh reinforcing material in the lightweight aggregate concrete mixture to cover the entire lightweight aggregate concrete mixture, and at the same time leave holes around for the insertion of a plug - in vibrator.

[0035] S4: Insert a vibrator through the positioning holes around the side plates for low - frequency vibration, control the vibration intensity of the vibrator, and avoid the displacement of the mesh reinforcing material.

[0036] S5: Check whether the mesh reinforcing material has shifted or sunk. If so, adjust the vibration intensity in time.

[0037] S6: Repeat S2 to S5 until the pouring reaches the designed height.

[0038] S7: After removing the formwork and curing, a lightweight aggregate concrete member is formed.

[0039] In the preparation process of the lightweight aggregate concrete structure with anti - floating property of the present invention, layered pouring is combined with plug - in vibration. By reserving holes, the vibration compactness is ensured, the uniformity of the lightweight aggregate layer distribution is improved, and the strength discreteness caused by the floating of aggregates in the process is avoided.

[0040] The lightweight aggregate concrete structure with anti - floating property of the present invention, its preparation device and process have the following beneficial effects:

[0041] (1) In the lightweight aggregate concrete structure with anti - floating property of the present invention, by alternately laying lightweight aggregate concrete layers and mesh reinforcing material layers in layers, a multi - layer physical constraint structure is formed, which effectively blocks the vertical floating of lightweight aggregates due to their light weight. The floating of lightweight aggregates is effectively inhibited, ensuring uniform distribution; the mesh reinforcing material layer is a double - layer honeycomb mesh structure, and the upper honeycomb mesh and the lower honeycomb mesh are connected and the mesh openings are staggered, enhancing the stability and load - bearing capacity of the lightweight aggregate concrete structure with anti - floating property; the honeycomb structure effectively disperses and bears external forces from all directions, significantly improving the overall compressive strength of the concrete.

[0042] (2) The lightweight aggregate concrete structure with anti-floating property of the present invention effectively enhances the tensile and crack resistance of lightweight aggregate concrete components. The mesh hole positions of adjacent two layers of mesh reinforced material layers are staggered horizontally by 1 / 2 grid width, forming a staggered arrangement. A multi-layer restraint structure is formed to effectively prevent the lightweight aggregate from floating vertically due to its light weight; the mesh reinforced material forms a reinforcement grid inside the concrete, improving the tensile strength and reducing the risk of crack propagation, and is particularly suitable for components such as lightweight wall panels, floor slabs, and shear walls that are prone to cracking due to tension.

[0043] (3) The preparation process of the lightweight aggregate concrete structure with anti-floating property of the present invention does not need to change the traditional casting construction process. Only the mesh reinforced material is arranged layer by layer during the construction of lightweight aggregate concrete, without additional complex operations, facilitating the application of both precast and cast-in-place construction methods, and is suitable for large-scale project promotion and application. Brief Description of the Drawings

[0044] Figure 1 It is a schematic structural diagram of a lightweight aggregate concrete structure with anti-floating property;

[0045] Figure 2 It is a schematic structural diagram of the mesh reinforced material layer of rectangular grid in the present invention;

[0046] Figure 3 It is a schematic structural diagram of the mesh reinforced material layer of diamond grid in the present invention;

[0047] Figure 4 It is a schematic diagram of the staggered lap joint method of the mesh reinforced material layer in the present invention;

[0048] Figure 5 、 Figure 6 It is a schematic diagram of the staggered arrangement method of the mesh reinforced material layer in the present invention;

[0049] Figure 7 It is a schematic diagram of the fixing method of the mesh reinforced material layer in the present invention;

[0050] Figure 8 It is a schematic structural diagram of the mold in the present invention;

[0051] Figure 9 In the present invention Figure 8 The enlarged structural schematic diagram of the combined fixing mechanism at position A;

[0052] Figure 10 It is a schematic structural diagram of the anti-floating cover plate in the present invention.

[0053] In the figure: 1. Formwork; 2. Mesh reinforced material layer; 21. Protruding part; 3. Lightweight aggregate concrete layer; 4. Mold; 41. Bottom plate; 42. Side plate; 5. Array of positioning holes; 6. Anti-floating cover plate; 61. Fitting groove; 7. Guide slide rail; 71. Limit groove; 72. Notch; 73. Steel wire rope; 8. Combined fixing mechanism; 81. First limit seat; 82. Second limit seat; 83. Connecting part; 831. Accommodating channel; 84. First movable buckle; 85. Second movable buckle; 86. First positioning guide rod; 87. Second positioning guide rod. Detailed implementation mode

[0054] To make the purpose, technical solutions and advantages of the present invention clearer, the present invention will be further described in detail below through the accompanying drawings and embodiments. However, it should be understood that the specific embodiments described herein are only used to explain the present invention and do not limit the scope of the present invention.

[0055] See Figures 1-6 , a lightweight aggregate concrete structure with anti-floating property, a layer of mesh reinforced material layer 2 is arranged on a layer of lightweight aggregate concrete layer 3, and the height of the lightweight aggregate concrete layer 3 is 50 - 300 mm. In a preferred embodiment, the mesh hole positions of two adjacent mesh reinforced material layers 2 are staggered by 1 / 2 grid width in the horizontal direction to form an alternating arrangement. The multi-layer constraint structure effectively blocks the floating of lightweight aggregates in the vertical direction due to their light weight, has a good anti-floating effect, ensures the uniformity of lightweight aggregate concrete, and improves the overall density of lightweight aggregate concrete components.

[0056] In a preferred embodiment, the mesh reinforced material layer 2 is a double-layer honeycomb mesh structure, and the upper honeycomb mesh and the lower honeycomb mesh are connected and the mesh openings are staggered. The above structure utilizes the high specific stiffness and multi-directional equal-strength characteristics of honeycomb units to form a continuous force transmission path. The staggered layout of the upper and lower mesh openings forces the concrete slurry to form an S-shaped flow path in the honeycomb units, and a continuous reinforced skeleton is formed after curing to inhibit crack propagation.

[0057] In a preferred embodiment, the lightweight aggregate concrete structure with anti-floating property includes reinforcing bars that are vertically arranged and penetrate through multiple layers of alternately distributed lightweight aggregate concrete layers 3 and mesh reinforced material layers 2. It improves the overall stiffness, flexural bearing capacity and anti-peeling ability. The reinforcing bars are provided with horizontal ribs in different directions according to the lightweight aggregate concrete layer 3. The horizontal ribs in different directions on the reinforcing bars disperse the loads acting on the concrete structure, reduce the stress concentration in the concrete, and enable the structure to withstand greater loads.

[0058] The vertical stiffeners serve as vertical load transfer paths, forming a three-dimensional composite reinforcement system with the horizontal mesh reinforcement materials, effectively resisting shear forces, and improving the overall stiffness, flexural bearing capacity, and anti-peeling ability. Under lateral loads (such as earthquakes and wind loads), the stiffeners transfer shear forces through axial tension or compression, reducing the risk of interlayer slip. At the same time, the vertical stiffeners penetrate through each layer, enhancing the interlayer bond strength through mechanical anchoring and inhibiting the delamination and peeling phenomenon. Under dynamic loads (such as fatigue vibration), it can reduce the propagation of interfacial microcracks. The vertical stiffeners directly bear longitudinal loads (including gravity, etc.), forming an orthogonal grid with the horizontal mesh reinforcement materials, converting shear stresses into axial stresses, and avoiding local stress concentration.

[0059] The lightweight aggregate in the lightweight aggregate concrete layer is one or a mixture of two or more of pumice, expanded perlite, expanded glass beads, vitrified microspheres, ceramsite, rubber particles, etc. The particle size range is as follows: pumice 2 - 20 mm, expanded perlite 0.5 - 5 mm, expanded glass beads 0.1 - 5 mm, vitrified microspheres 0.1 - 3 mm, ceramsite 5 - 25 mm, rubber particles 0.5 - 10 mm.

[0060] The reinforcement material of the mesh reinforcement material layer 2 is selected from one of polyester fiber mesh, glass fiber grid, carbon fiber reinforced composite material, basalt fiber reinforced composite material, aramid fiber mesh cloth; it meets the requirements of different engineering scenarios and combines lightweight and mechanical properties. The mesh size of the mesh reinforcement material layer 2 is selected in accordance with the lightweight aggregate particle size; the mesh size of the mesh reinforcement material layer 2 is smaller than the lightweight aggregate particle size and larger than or close to the maximum particle size of the mortar. The mesh size of the mesh reinforcement material layer 2 is optimized according to the lightweight aggregate particle size to ensure that the mesh is smaller than the lightweight aggregate particle size to intercept the floating, and at the same time larger than the mortar particles to ensure the dense filling of the slurry and avoid the formation of internal cavities.

[0061] The specific application scopes of the mesh reinforcement materials for different lightweight aggregate concretes and projects are as follows:

[0062] (1) Polyester fiber mesh is suitable for low-density lightweight aggregate concrete (such as expanded perlite, vitrified microspheres, expanded glass beads), and can be used to prepare non-load-bearing components with relatively low crack resistance requirements, such as filling layers, internal partition walls, roof insulation layers, etc.;

[0063] (2) Glass fiber grid is suitable for lightweight aggregate concrete with large particle sizes (such as ceramsite, pumice), and can be used to prepare load-bearing components such as precast or cast-in-place beams, slabs, shear walls, etc.;

[0064] (3) Carbon fiber reinforced composite material is suitable for ultra-high performance lightweight aggregate concrete and can be used to prepare components with relatively high crack resistance requirements, such as ultra-thin lightweight boards, exterior wall panels of super high-rise buildings, etc.;

[0065] (4) Basalt fiber reinforced composite materials are suitable for ultra-high performance lightweight aggregate concrete and can be used to prepare components with high requirements for crack resistance and impact resistance, such as lightweight structural panels;

[0066] (5) Aramid fiber mesh cloth: suitable for ceramsite and rubber lightweight aggregate concrete, and can be used to prepare lightweight aggregate concrete components with large span and high impact resistance requirements.

[0067] The comparison of the applicable scope of different mesh reinforcement materials is shown in Table 1.

[0068] Table 1 Comparison of application scope of different mesh reinforcement materials

[0069]

[0070]

[0071] See also Figure 1 、 Figure 2 , Figures 7-10 , intuitively presenting the preparation device of the lightweight aggregate concrete structure with anti-floating properties of the present invention, including an anti-floating mold 4 and a vibrating device. The anti-floating mold 4 includes a bottom plate 41 and side plates 42 surrounding the bottom plate 41. The bottom plate 41 and the side plates 42 enclose a casting cavity with an open top, and the lightweight aggregate concrete mixture is injected into the cavity through the opening to complete the molding operation. The side plates 42 are provided with multiple groups of positioning hole arrays 5 along the longitudinal axis. The positioning holes on each group of positioning hole arrays 5 are evenly distributed along the horizontal axis. The specifications of the positioning holes match the raised portions 21 around the mesh reinforcement material, so that the raised portions 21 can penetrate the positioning holes and complete the positioning installation. After construction, the openings of the positioning holes are sealed with a sealing medium to achieve boundary fixation. By controlling the dimensional relationship between the positioning holes and the raised portions 21 to construct an interference fit mechanism, the relative displacement between the mesh reinforcement material and the mold 4 during the casting stage can be suppressed, thereby ensuring the positioning accuracy of the mesh reinforcement material inside the concrete.

[0072] The opening of the anti-floating mold is equipped with an anti-floating cover plate 6. The light aggregate is suppressed from floating by top pressure.

[0073] In the preferred embodiment, further improvements are made to the anti-floating effect. Vertically arranged guide rails 7 are provided on the side panels 42, each of which has a vertical limiting groove 71. The anti-floating cover plate 6 is provided with an interlocking groove 61 that interfaces with the notch of the limiting groove 71. One end of a steel wire rope 73 passes through the limiting groove 71 and the interlocking groove 61 and is fixed to the top of the anti-floating cover plate 6. The end is then bolted to the fixing ring at the top of the anti-floating cover plate 6. The lower portion of the steel wire rope 73 is fixed to the base plate 41. (In typical pouring operations, steel bars or other supporting members are placed below the base plate 41. In the present invention, the lower portion of the steel wire rope 73 can be hooked and fixed to the lower portion of the base plate 41 using a hook or other structure.)

[0074] In the above structure, an anti-floating cover plate 6 is provided at the opening at the top of the casting cavity. When in the closed state, a rigid compression interface is formed. A vertical pressure is applied to the cover plate through the steel wire rope 73 fixed structure, which can actively inhibit the floating of lightweight aggregate.

[0075] In the preferred embodiment, the preparation device further includes a combined fixing mechanism 8. The combined fixing mechanism 8 has a first limit seat 81 and a second limit seat 82. The circumferential contact surfaces of adjacent two protruding parts 21 are respectively located on the first limit seat 81 and the second limit seat 82. A connecting part 83 connects the first limit seat 81 and the second limit seat 82.

[0076] A first movable buckle 84 is formed on one side of the first limit seat 81, and the second movable buckle 85 can selectively close the second limit seat 82. The second movable buckle 85 is formed on one side of the second limit seat 82, and the second movable buckle 85 can selectively close the second limit seat 82. A first positioning guide rod 86 is formed on one side of the first movable buckle 84 and when the first movable buckle 84 is in the closed state, the first positioning guide rod 86 contacts and positions with the connecting part 83. A second positioning guide rod 87 is formed on one side of the second movable buckle 85 and when the first movable buckle 84 and the second movable buckle 85 are in the closed state, the second positioning guide rod 87 contacts and positions with the first movable buckle 84.

[0077] The above combined fixing mechanism 8 is composed of a first limit seat 81, a second limit seat 82 and a connecting part 83. The two respectively clamp the circumferential contact surfaces of the protruding parts 21 of adjacent reticulated reinforced materials. When the two movable buckles are closed, the two limit seats and the protruding part 21 form a contact clamping structure to prevent the displacement disturbance of the reinforced material under the flowing state of the concrete.

[0078] In the preferred embodiment, a notch 72 with a matching structure with the connecting part 83 is opened on the above-mentioned guide rail 7. The connecting part 83 passes through the guide rail 7 and a receiving channel 831 for accommodating the steel cable is formed above the connecting part 83. The top surface of the receiving channel 831 faces the second movable buckle 85.

[0079] In the preferred embodiment, the receiving channel 831 is in a substantially semi-circular ring structure. The above structure realizes the coordinated positioning of the guide rail 7 and the combined fixing mechanism 8. Specifically, the guide rail 7 is provided with a notch 72 adapted to the outer contour of the connecting part 83. When the connecting part 83 penetrates the guide rail 7, its side wall constraint generates a mechanical limiting effect, effectively inhibiting the degree of freedom of vertical displacement and eliminating the longitudinal disturbance risk of the connecting part 83 caused by the fluid pressure during the concrete pouring process. Synchronously, a receiving channel 831 is preset inside the connecting part 83 to carry the steel wire rope 73. The geometric shape of the receiving channel 831 is coupled with the movement track of the steel wire rope 73 to constrain the spatial position of the steel wire rope 73.

[0080] The present invention provides a preferred embodiment of a process for preparing a lightweight aggregate concrete structure with anti-floating properties, comprising the following steps:

[0081] S1: Preparation of anti-floating mold 4: Customize the anti-floating mold 4 according to the size of the component, and form a casting cavity with an open top by enclosing a bottom plate 41 and side plates 42.

[0082] S2: Layered pouring and reinforcement layer layout: First layer pouring: Pour lightweight aggregate concrete mixture (height 50-300mm) to ensure that the slurry evenly covers the base plate 41;

[0083] Laying of reinforcement layer: Cover with mesh reinforcement material (polyester fiber mesh, glass fiber grid, etc.), the mesh size is adapted to the type of light aggregate, and vibration holes are reserved around. Preferably, in some examples, the hole diameter is ≥ 1.2 times the diameter of the vibrating rod; Repeated layering: Alternate concrete pouring (50-300mm / layer) and reinforcement layer laying until the design height is reached.

[0084] S3: Vibration compaction: For cast-in-place components: Use a Φ50mm inserted vibrator to vibrate vertically along the reserved holes, with a single vibration time of ≤30s to prevent light aggregate from floating up; for precast components: Use a low-amplitude vibration table to vibrate (amplitude 0.3-0.8mm), controlling the vibration frequency to ≤40Hz to suppress buoyancy disturbances.

[0085] S4: Reinforcement material fixation:

[0086] Unreinforced / less-reinforced components (lightweight wall panels, floor slabs): The template 1 slot anchoring method can be used to fix the reinforcement layer through the pre-installed fixed slots, anchor nails or magnetic clamps in the side wall template 1;

[0087] Reinforced components (filling layer, partition wall): adopt the "binding-clip composite method", cross-fix galvanized wire ties and nylon clips every 300mm along the main reinforcement.

[0088] In some improvements of the embodiments, the following method can also be used for fixation: the side panel 42 is provided with an array of positioning holes 5 at equal intervals in the longitudinal direction, and each array contains positioning holes distributed at equal intervals in the horizontal direction, and the aperture of the positioning hole is adapted to the size of the raised portion 21 on the mesh reinforcement material.

[0089] S5: Check whether the mesh reinforcement material is offset or sinking, and make timely adjustments if so;

[0090] S6: Repeat steps S2 to S5 until the casting reaches the designed height;

[0091] S7: De-moulding and curing: After de-moulding and curing, lightweight aggregate concrete components are formed. For example, after initial setting, the side wall formwork 1 is removed and covered with plastic film for moisture maintenance. When the ambient temperature is ≥20℃, the curing period is ≥7 days.

[0092] Example 1:

[0093] A preparation process of a lightweight aggregate concrete structure with anti - floating property, preparing a precast lightweight aggregate concrete floor slab, and the floor slab size is 2000mm×1000mm×120mm (length×width×thickness).

[0094] (1) Raw materials and laying method:

[0095] Lightweight aggregate: Shale ceramsite is used, with a particle size of 5 - 15mm and an apparent density of 750kg / m 3 , and the water absorption rate is 10.5%;

[0096] Cementitious material: Ordinary Portland cement of grade P·O42.5 is used, with a density of 3.1g / cm 3 , and the fineness is 350m 2 / kg;

[0097] Fine aggregate: Medium sand is used, with a fineness modulus of 2.7 and a mud content of < 3%;

[0098] Admixture: Polycarboxylate superplasticizer is used, and the dosage accounts for 1.2% of the mass of the cementitious material;

[0099] Mesh reinforcement material: Glass fiber grille is used (square mesh holes, with a size of 6mm×6mm, two - way stress, simple construction and easy to fix), the unidirectional tensile strength is ≥50kN / m, and the alkali resistance is excellent. The floor slab is 120mm thick and a total of 1 layer is laid; The fixing method adopts formwork fixing and lap joint fixing. Fixed slots are set around the formwork, the slot spacing is 50cm, and the adjacent glass fiber grilles overlap by 50mm.

[0100] The mix proportion of shale ceramsite lightweight aggregate concrete is: cement 450kg / m 3 , sand 550kg / m 3 , shale ceramsite 450kg / m 3 , water 170kg / m 3 , admixture 5.4kg / m 3 , and the water - binder ratio is 0.38. The 28 - day cube compressive strength of the obtained lightweight aggregate concrete is 36.2MPa, and the apparent density is 1850kg / m 3 , meeting the use requirements of the floor slab.

[0101] (2) Construction steps:

[0102] S1: Preparation and fixation of formwork 1 system:

[0103] Select a precast floor steel formwork 1 with dimensions of 2000mm×1000mm×120mm. The joints of the formwork 1 are processed using a high-precision milling process. The inner wall of the formwork 1 is coated with a solvent-based release agent, which is applied in two coats with an interval of 15 minutes to ensure uniform film formation. T-shaped fixed card slots are arranged around the formwork 1 and on the bottom plate 41 at intervals of 50 cm. The card slots are rigidly connected to the formwork 1 through bolts and are used to fix the fiberglass grille.

[0104] S2: Pouring and spreading of the bottom-layer concrete:

[0105] Use a pumping device to inject the shale ceramsite lightweight aggregate concrete mixture (mix ratio: cement 450 kg / m 3 , sand 550 kg / m 3 , shale ceramsite 450 kg / m 3 , water 170 kg / m 3 , polycarboxylate water reducer 5.4 kg / m 3 ) into the bottom of the formwork 1, and control the pouring thickness at 60 mm. Use an aluminum alloy vibrating screed to scrape evenly along the long side direction of the formwork 1 to eliminate surface undulations.

[0106] S3: Laying and fixing of the first-layer reinforcement mesh:

[0107] Lay the fiberglass grille on the concrete surface, with a lap width of 50 mm between adjacent grilles. The lap joints are temporarily fixed with stainless steel U-shaped buckles to ensure the continuity of the reinforcement layer. Use the fixed card slots to fix the fiberglass grille to ensure stability and prevent it from floating or shifting due to vibration.

[0108] S4: Vibration compaction of the first layer at low amplitude:

[0109] Use a low-amplitude vibrating table to continuously vibrate (40 Hz, amplitude 0.8 mm) until no obvious bubbles escape from the concrete surface and the slurry evenly appears. After vibration, use a steel rolling roller to roll twice along the short side direction of the formwork 1 to eliminate surface microvoids.

[0110] S5: Pouring and covering of the second layer of concrete:

[0111] Pour the second layer of shale ceramsite lightweight aggregate concrete above the first-layer fiberglass grille, with a pouring thickness of 60 mm. Ensure that the total pouring thickness reaches 120 mm.

[0112] S6: Secondary vibration:

[0113] Repeat the low-amplitude vibration process in S4, with key vibration in the grille lap area.

[0114] S7: Form removal and standardized curing:

[0115] Remove the side form after the concrete initial sets, and cure it under standard curing conditions until the specified age to obtain a shale ceramsite lightweight aggregate concrete floor slab.

[0116] Example 2:

[0117] A preparation process for a lightweight aggregate concrete structure with anti-floating property, preparing a cast-in-place lightweight aggregate concrete floor slab with a floor slab size of 4000mm×2000mm×160mm (length×width×thickness).

[0118] (1) Raw materials and laying method

[0119] Lightweight aggregate: Expanded perlite is used, with a particle size of 1 - 2mm and an apparent density of 250 kg / m 3 , and the water absorption rate is 5.8%;

[0120] Cementitious material: Ordinary Portland cement of grade P·O42.5 is used, with a density of 3.1 g / cm 3 , and the fineness is 350 m 2 / kg;

[0121] Fine aggregate: Medium sand is used, with a fineness modulus of 2.5 and a mud content of <2%;

[0122] Admixture: Polycarboxylate superplasticizer is used, with a dosage of 1.2% of the mass of the cementitious material;

[0123] Mesh reinforcement material: Polyester fiber mesh (square grid, size 1mm×1mm, two-way stress, easy to construct and fix) is used, with a unidirectional tensile strength of ≥30 kN / m, good flexibility, and suitable for fine-grained lightweight aggregate concrete. The floor slab is 160 mm thick, and a total of 3 layers are laid with a layer spacing of 50 mm. The polyester fiber mesh is staggered horizontally by 1 / 2 grid width to form a staggered arrangement; the fixing method adopts formwork fixing and lap joint fixing. Fixed card slots are set around the formwork, with a card slot spacing of 50 cm, and adjacent polyester fiber meshes are lapped by 50 mm.

[0124] The mix ratio of expanded perlite lightweight aggregate concrete is: cement 500 kg / m 3 , sand 500 kg / m 3 , expanded perlite 200 kg / m 3 , water 175 kg / m 3 , admixture 6.0 kg / m 3 , and the water-cement ratio is 0.35. The 28-day cube compressive strength of the obtained lightweight aggregate concrete is 15.8 MPa, and the apparent density is 1100 kg / m 3 , meeting the usage requirements of the floor slab.

[0125] (2) Construction steps:

[0126] S1: Preparation and fixation of formwork 1:

[0127] A cast-in-place steel formwork 1 with a size of 4000mm×2000mm×160mm is used. The joints of the formwork 1 are treated with sealing strips to ensure that there is no slurry leakage. Fixed slots are set around the formwork and on the bottom plate 41. The slots are connected to the formwork 1 by bolts. The slots are spaced 50cm apart and are used to fix the polyester fiber mesh. A release agent is applied to the inner wall of the formwork.

[0128] S2: bottom concrete pouring and paving:

[0129] Pour the first layer of glass microsphere lightweight aggregate concrete mixture (ratio: cement 500kg / m 3 , sand 500kg / m 3 , Vitrified microspheres 200kg / m 3 , water 175kg / m 3 , polycarboxylate water reducer 6.0kg / m 3 ), use a pumping hose to evenly distribute the material, control the pouring thickness to 50mm, spread it evenly, use an aluminum alloy scraper to initially level it and remove surface bubbles.

[0130] S3: Laying and fixing of the first layer reinforcement mesh:

[0131] Lay polyester fiber mesh on the surface of glass bead lightweight aggregate concrete to ensure uniform coverage of the entire area, with an overlap width of 50mm, and temporarily fix the overlap with nylon ties; ensure the continuity of the reinforcement layer; use fixing slots to fix the first layer of polyester fiber mesh to ensure that it will not float or shift due to vibration during construction; reserve holes around the first layer of polyester fiber mesh to facilitate the insertion of insert vibrators for vibration.

[0132] S4: First layer vibration compaction:

[0133] Use an insert vibrator to vibrate, insert it vertically into the reserved holes to make the glass bead lightweight aggregate concrete dense. Specifically, the density standard is that the concrete surface is slurry and there is no bubble escape. After the vibrating rod is slowly pulled out, use a wooden trowel to smooth the surface and eliminate the marks of the insertion hole.

[0134] S5: Second layer concrete pouring:

[0135] A second layer of lightweight aggregate concrete with vitrified microspheres was poured over the first layer of polyester mesh, with a thickness of 50 mm. The concrete was laid perpendicularly to the first layer to reduce aggregate orientation. A laser thickness gauge was used to monitor the thickness in real time to ensure uniform layer thickness.

[0136] S6: The second layer of reinforcement mesh is laid in a staggered manner:

[0137] Lay the second layer of polyester fiber mesh, staggering it by 1 / 2 grid width horizontally to form a staggered arrangement, and fix the second layer of polyester fiber mesh using fixed card slots; reserve holes around the second layer of polyester fiber mesh to facilitate the insertion of a vibrator for vibration.

[0138] S7: Vibration compaction of the second layer:

[0139] Use an insertion vibrator for vibration to make the vitrified microbead lightweight aggregate concrete dense.

[0140] S8: Pouring of the third layer of concrete:

[0141] Continue to pour the third layer of vitrified microbead lightweight aggregate concrete above the second layer of polyester fiber mesh, with a pouring thickness of 50 mm.

[0142] S9: Laying and positioning of the third layer of reinforcement mesh:

[0143] Lay the third layer of polyester fiber mesh, staggering it by 1 / 2 grid width horizontally to form a staggered arrangement, and fix the third layer of polyester fiber mesh using fixed card slots; reserve holes around the third layer of polyester fiber mesh to facilitate the insertion of a vibrator for vibration.

[0144] S10: Vibration and surface treatment of the third layer:

[0145] Use an insertion vibrator for vibration to make the vitrified microbead lightweight aggregate concrete dense.

[0146] S11: Covering and leveling of the surface layer:

[0147] Pour the vitrified microbead lightweight aggregate concrete with a final thickness of 10 mm to completely cover the third layer of polyester fiber mesh and ensure its embedding inside the vitrified microbead lightweight aggregate concrete.

[0148] S12: Form removal and curing:

[0149] After the concrete begins to set, remove the side formwork and retain the bottom formwork support for 7 days. Immediately cover with non-woven fabric after form removal and spray for curing, with a curing period of 14 days to obtain a vitrified microbead lightweight aggregate concrete floor slab.

[0150] Example 3:

[0151] A preparation process for a lightweight aggregate concrete structure with anti-floating property, preparing a cast-in-place lightweight aggregate concrete wall with wall dimensions of 3000 mm × 2800 mm × 250 mm (length × height × thickness).

[0152] (1) Raw materials and laying method

[0153] Lightweight aggregate: Expandable perlite is used, with a particle size of 0.5 - 5 mm and an apparent density of 150 kg / m 3 , and a water absorption rate of 8.5%;

[0154] Binder: Use P·O 42.5 ordinary Portland cement, with a density of 3.1 g / cm 3 , fineness 350 m 2 / kg;

[0155] Fine aggregate: Use manufactured sand, with a fineness modulus of 2.8 and a mud content of < 2%;

[0156] Admixture: Use polycarboxylate superplasticizer, with a dosage of 1.2% of the binder mass;

[0157] Mesh reinforcement material: Use polyester fiber mesh (rhombic mesh holes, size 5 mm × 5 mm, with good vertical load-bearing capacity), unidirectional tensile strength ≥ 45 kN / m, excellent alkali resistance, suitable for high-durability lightweight aggregate concrete. The wall is 2800 mm high, and a layer of polyester fiber mesh is laid every 250 mm, for a total of 10 layers; the polyester fiber mesh is staggered horizontally by 1 / 2 grid width to form a staggered arrangement to reduce the upward floating path of lightweight aggregate in the vertical direction; fixed with a steel bar skeleton, the polyester fiber mesh is tied to the vertical steel bars with nylon straps, and the tying point spacing is 300 mm to ensure that the polyester fiber mesh will not shift during pouring and vibration.

[0158] The mix proportion of expanded perlite lightweight aggregate concrete is: cement 480 kg / m 3 , sand 600 kg / m 3 , expanded perlite 180 kg / m 3 , water 190 kg / m 3 , admixture 7.2 kg / m 3 . The 28-day cube compressive strength of the obtained lightweight aggregate concrete is 12.5 MPa, and the apparent density is 1050 kg / m 3 , meeting the requirements of lightweight wall structures.

[0159] (2) Construction steps:

[0160] S1: Adjust the positions of the bottom plate 41 and side plate 42 of the preparation device to enclose a casting cavity with an open top. Use cast-in-place steel formwork, with dimensions of 3000 mm × 2800 mm × 250 mm, ensure the stability of the wall formwork, and apply a release agent to the inner wall of the formwork.

[0161] Install vertical Φ12 mm steel bars, with a spacing of 200 mm; horizontally set Φ8 mm stirrups, with a spacing of 250 mm, to form a steel bar skeleton.

[0162] S2: Pour the first layer of expanded perlite lightweight aggregate concrete mixture at the bottom of the wall (mix proportion: cement 480 kg / m 3 , sand 600 kg / m 3 , expanded perlite 180 kg / m3 , water: 190 kg / m 3 , polycarboxylate superplasticizer: 7.2 kg / m 3 ), control the pouring thickness at 250 mm and spread evenly.

[0163] S3: Lay the first layer of polyester fiber mesh along the height direction of the wall, with a layout spacing of 250 mm, and tie it to the vertical steel bars using nylon ties, with a tie point spacing of 300 mm. Reserve holes around the first layer of polyester fiber mesh to facilitate the insertion of the internal vibrator for vibration.

[0164] S4: Use an internal vibrator for vibration to make the expanded perlite lightweight aggregate concrete dense.

[0165] S5: Continue to pour the second layer of expanded perlite lightweight aggregate concrete on top of the first layer of polyester fiber mesh, with a pouring thickness of 250 mm.

[0166] S6: Continue to lay the second layer of polyester fiber mesh along the height direction of the wall, with a layout spacing of 250 mm, staggering by 1 / 2 grid width, and tie it to the vertical steel bars using nylon ties, with a tie point spacing of 300 mm. Reserve holes around the second layer of polyester fiber mesh to facilitate the insertion of the internal vibrator for vibration.

[0167] S7: Use an internal vibrator for vibration to make the expanded perlite lightweight aggregate concrete dense.

[0168] S8: Repeat pouring, laying the polyester fiber mesh, and vibration in sequence until the wall height reaches 2800 mm, with a total of 10 layers of polyester fiber mesh laid. After laying the last layer of polyester fiber mesh, pour 10 mm thick expanded perlite lightweight aggregate concrete to completely cover the polyester fiber mesh and ensure its embedding inside the expanded perlite lightweight aggregate concrete.

[0169] S9: Demold and cure, sprinkle water or cure naturally until the specified age to obtain the expanded perlite lightweight aggregate concrete wall.

[0170] Example 4:

[0171] A preparation process for a lightweight aggregate concrete structure with anti-floating property, preparing a precast lightweight aggregate concrete partition wall with wall dimensions of 3000 mm × 1500 mm × 120 mm (length × height × thickness).

[0172] (1) Raw materials and laying method

[0173] Lightweight aggregate: Use rubber particles with a particle size of 0.5 - 10 mm and an apparent density of 450 kg / m 3 , water absorption rate of 3.5%.

[0174] Cementitious material: Use P·O 42.5 grade ordinary Portland cement with a density of 3.1 g / cm3 , fineness 350m 2 / kg;

[0175] Fine aggregate: Mechanically produced sand is used, with a fineness modulus of 2.6 and a mud content of <2%;

[0176] Admixture: Polycarboxylate superplasticizer is used, with a dosage of 1.3% of the mass of the cementitious materials;

[0177] Mesh reinforcement material: Carbon fiber reinforced composite grid cloth is used (rhombic mesh holes, size 3mm×3mm, with good vertical load-bearing capacity), unidirectional tensile strength ≥60kN / m; The partition board is 120mm thick, and a total of 2 layers of carbon fiber reinforced composite grid cloth are laid, with a spacing of 50mm, arranged along the thickness direction and staggered; A combined method of template fixing and steel bar skeleton fixing is adopted, with lateral fixing card slots and vertical steel bar binding for fixing.

[0178] The mix proportion of rubber lightweight aggregate concrete is: cement 450kg / m 3 , sand 550kg / m 3 , rubber particles 200kg / m 3 , water 180kg / m 3 , admixture 6.0kg / m 3 . The 28-day cube compressive strength of the obtained lightweight aggregate concrete is 10.5MPa, and the apparent density is 1300kg / m 3 , meeting the requirements of the lightweight partition wall.

[0179] (2) Construction steps:

[0180] S1: Adjust the positions of the bottom plate 41 and the side plate 42 of the preparation device to enclose a casting cavity with an open top. Prefabricated steel templates are used, with dimensions of 3000mm×1500mm×100mm. Fixed card slots are set on the inner walls around the template, with a card slot spacing of 300mm. Release agent is applied to the inner part of the template. Install vertical Φ10mm steel bars, with a spacing of 400mm, as the steel bar skeleton.

[0181] S2: Pour the first layer of rubber lightweight aggregate concrete mixture (mix proportion: cement 450kg / m 3 , sand 550kg / m 3 , rubber particles 200kg / m 3 , water 180kg / m 3 , polycarboxylate water reducer 6.0kg / m 3 ), control the pouring thickness at 50mm, and spread it evenly.

[0182] S3: Lay the first layer of carbon fiber reinforced composite grid cloth along the wall thickness direction to ensure uniform coverage of the entire area with a lap width of 50 mm and ensure the continuity of the reinforced layer; use fixed card slots to fix the carbon fiber reinforced composite grid cloth to ensure stability and prevent it from floating or shifting due to vibration.

[0183] S4: Use a low-amplitude vibrating table (40 Hz, amplitude 0.8 mm) for vibration.

[0184] S5: Pour the second layer of rubberized lightweight aggregate concrete, control the pouring thickness at 50 mm, and spread it evenly.

[0185] S6: Lay the second layer of carbon fiber reinforced composite grid cloth along the wall thickness direction, stagger the grids horizontally by 1 / 2 grid width to ensure uniform coverage of the entire area with a lap width of 50 mm and ensure the continuity of the reinforced layer; use fixed card slots to fix the carbon fiber reinforced composite grid cloth to ensure stability and prevent it from floating or shifting due to vibration.

[0186] S7: Pour the third layer of rubberized lightweight aggregate concrete with a pouring thickness of 20 mm until the design height is reached.

[0187] S8: Demold and cure. After initial setting, cover with a plastic film and cure under standard curing conditions until the specified age to obtain a rubberized lightweight aggregate concrete partition wall.

[0188] According to the above embodiments and the content of the invention, recommendations for different lightweight aggregates and different mesh reinforcing materials are given, as shown in Table 2 specifically.

[0189] Table 2 Recommendations for Different Lightweight Aggregates and Different Mesh Reinforcing Materials

[0190]

[0191]

[0192] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. In summary, the present invention constructs a dynamic constraint mechanism at the contact interface between lightweight aggregate and mortar by hierarchically configuring a grid structure system matching the aggregate particle size. The reinforcing material forms a grid barrier with its rigid grid form to control the displacement trajectory of the lightweight aggregate, and combines with the staggered laying process to effectively neutralize the influence of the buoyancy gradient generated during the concrete vibration operation.

[0193] The lightweight aggregate concrete structure with anti-floating property and its preparation process of the present invention construct a dynamic constraint network at the lightweight aggregate-mortar interface by laying a mesh reinforcement material layer on the lightweight aggregate concrete layer, forming a three-dimensional reinforcement network as a whole. It can not only effectively inhibit the floating of lightweight aggregates, ensure the uniformity of lightweight aggregate concrete, and improve the overall density of lightweight aggregate concrete components, but also effectively disperse the stress generated by external loads, reduce stress concentration, and enhance the overall bearing capacity. Moreover, the mesh reinforcement material layers at different positions act synergistically to improve the stiffness of the component in multiple directions, resist complex load combinations, and effectively enhance the tensile and crack resistance performance of lightweight aggregate concrete components. It is especially suitable for components such as lightweight wall panels, floor slabs, and shear walls that are prone to cracking due to tension, and can meet the preparation of lightweight aggregate concrete structures under different working conditions such as precast and cast-in-place.

[0194] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, or improvements made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A lightweight aggregate concrete structure with anti-floating property, characterized in that, Comprising: Alternately distributed lightweight aggregate concrete layers (3) and reticulated reinforcement material layers (2), the height of the lightweight aggregate concrete layer (3) being 50 - 300 mm.

2. The lightweight aggregate concrete structure with anti-floating property according to claim 1, wherein: The lightweight aggregate concrete layer comprises fine aggregate, admixture, cementitious material and lightweight aggregate; the lightweight aggregate of the lightweight aggregate concrete layer is one or two or more of pumice, expanded perlite, expanded glass beads, vitrified microspheres, ceramsite, rubber particles, and the particle size range is: pumice 2 - 20 mm, expanded perlite 0.5 - 5 mm, expanded glass beads 0.1 - 5 mm, vitrified microspheres 0.1 - 3 mm, ceramsite 5 - 25 mm, rubber particles 0.5 - 10 mm.

3. The lightweight aggregate concrete structure with anti-floating property according to claim 1 or 2, characterized in that: The reinforcement material of the reticulated reinforcement material layer (2) is selected from one of polyester fiber mesh, glass fiber grille, carbon fiber reinforced composite material, basalt fiber reinforced composite material, aramid fiber mesh cloth; the mesh size of the reticulated reinforcement material layer (2) is selected in coordination with the lightweight aggregate particle size; the mesh size of the reticulated reinforcement material layer (2) is smaller than the lightweight aggregate particle size and greater than or close to the maximum particle size of the mortar.

4. The lightweight aggregate concrete structure with anti-floating property according to claim 3, characterized in that: The lightweight aggregate of the lightweight aggregate concrete layer (3) is expanded glass bead lightweight aggregate concrete, and the mesh size of the reticulated reinforcement material layer (2) is 0.5 - 5 mm.

5. The lightweight aggregate concrete structure with anti-floating property according to claim 4, characterized in that: The mesh positions of adjacent two reticulated reinforcement material layers (2) are staggered by 1 / 2 grid width in the horizontal direction to form a staggered arrangement.

6. The lightweight aggregate concrete structure with anti-floating property according to claim 5, characterized in that: The reticulated reinforcement material layer (2) is a double-layer honeycomb reticulated structure, and the upper honeycomb mesh and the lower honeycomb mesh are connected and the mesh openings are staggered.

7. The lightweight aggregate concrete structure with anti-floating property according to claim 5, characterized in that: It further comprises reinforcing bars vertically arranged and penetrating through multiple alternately distributed lightweight aggregate concrete layers (3) and reticulated reinforcement material layers (2); the reinforcing bars are matched with horizontal ribs in different directions according to the lightweight aggregate concrete layer (3).

8. The lightweight aggregate concrete structure with anti-floating property according to claim 6, characterized in that: The mesh reinforced material layer (2) uses a glass fiber grille with a mesh size of 6 mm × 6 mm; the height of the lightweight aggregate concrete layer (3) is 50 mm, and its mix ratio is: cement 450 kg / m 3 , sand 550 kg / m 3 , shale ceramsite 450 kg / m 3 , water 170 kg / m 3 , admixture 5.4 kg / m 3 , and the water-binder ratio is 0.

38.

9. The preparation device for a lightweight aggregate concrete structure with anti-floating property according to any one of claims 1-8, characterized in that: Comprising a mold (4) and a vibrating device, the mold (4) comprises a bottom plate (41) and side plates (42) enclosing the four sides of the bottom plate (41), adjusting the bottom plate (41) and the side plates (42) to enclose a casting cavity with an open top, and the side plates (42) are longitudinally arranged at equal intervals with a positioning hole array (5) for passing through the raised parts (21) on the reticulated reinforcement material layer (2), and each group of positioning hole arrays (5) comprises positioning holes arranged horizontally at equal intervals.

10. The preparation process of the lightweight aggregate concrete structure with anti-floating property according to claim 9, characterized in that: S1: Adaptively adjust the installation positions of the surrounding side plates and the bottom plate of the preparation device according to the size of the lightweight aggregate concrete structure member to be cast; S2: Pour the lightweight aggregate concrete mixture into the preparation device described in step S1, with a height of 50 - 300 mm; S3: Lay the reticulated reinforcement material in the lightweight aggregate concrete mixture, covering the lightweight aggregate concrete mixture, and at the same time leaving holes around for the insertion of the internal vibrator; S4: Insert the vibrator through the positioning holes around the side plates for low-frequency vibration; S5: Check whether the reticulated reinforcement material has shifted or sunk, and if so, adjust the vibration frequency in time; S6: Repeat S2 to S5 until it is poured to the designed height; S7: Demold and cure to form a lightweight aggregate concrete member.

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