Lightweight aggregate concrete structure with anti-floating property and preparation device and process thereof

Abstract

The application discloses a lightweight aggregate concrete structure with anti-floating performance and a preparation process thereof, and the lightweight aggregate concrete structure comprises alternately distributed lightweight aggregate concrete layers and net-shaped reinforcing material layers, and the height of the lightweight aggregate concrete layer is 50-300 mm. The physical separation barrier is formed by adopting the alternately distributed lightweight aggregate concrete layers and the net-shaped reinforcing material layers, the floating path of the lightweight aggregate is directly blocked by the layered constraint, the lightweight characteristic of the lightweight aggregate concrete is maintained, the anti-floating and lightweight are cooperated, the polyester fiber net, the glass fiber grid and other net-shaped reinforcing material layers are layered implanted into the lightweight aggregate concrete system, the mesh size is matched according to the particle size of the aggregate, and the 50-300 mm interlayer interval staggered laying technology is combined. Therefore, the lightweight aggregate floating is effectively inhibited through the physical blocking mechanism, the tensile strength and the crack resistance of the concrete are simultaneously improved, and the anti-floating stability and the mechanical property are cooperatively optimized.

Description

Technical Field

[0001] This invention relates to the technical field of deep processing of concrete, specifically to lightweight aggregate concrete structures with anti-buoyancy properties and their preparation apparatus and process. Background Technology

[0002] Lightweight aggregate concrete is a special type of concrete prepared by replacing traditional aggregates with lightweight coarse / fine aggregates (pumice, expanded perlite, ceramsite, expanded glass beads, vitrified microspheres, and rubber), and mixing it with cement, water, and admixtures. Its dry apparent density is ≤1950 kg / m³. 3 Compared to ordinary concrete, lightweight aggregate concrete is lightweight and high-strength (apparent density of 1600-1900 kg / m³ for strength grades above LC30). 3 With comprehensive performance advantages such as 25%-30% weight reduction compared to ordinary concrete of the same grade, thermal insulation (thermal conductivity 0.18-1.01W / (m·K)), seismic resistance (low elastic modulus and deformation adaptability), fire resistance and durability, it is widely used in engineering fields such as long-span bridges, super high-rise buildings, and energy-saving walls.

[0003] Due to the inherent characteristics of lightweight aggregates (low strength, high porosity, and easy water absorption), lightweight aggregate concrete is prone to defects such as large strength dispersion, poor workability, and aggregate floating. Existing technical improvement solutions include: optimizing the surface of lightweight aggregates by coating with silica sol and covering with mineral admixtures (silica fume, fly ash) to reduce water absorption and enhance the bond between aggregate and paste; introducing ultrafine powders (silica fume, metakaolin) to improve matrix density; and using composite high-performance polycarboxylate superplasticizers to improve fluidity and encapsulation; and using graded lightweight aggregates and optimizing the water-cement ratio, combined with thickeners, anti-settling agents, and other admixtures to suppress aggregate floating.

[0004] Patent ZL201910626537.1 proposes a "magnetic lightweight aggregate + magnetically controlled vibration" positioning technology, which regulates the spatial distribution of aggregates through a magnetic field; Patent ZL201910564716.7 dynamically adjusts the amount of admixtures based on the mortar segregation degree; Patent ZL201711324773.5 utilizes pre-wetted spherical lightweight aggregates to form an arched interface zone, achieving synergistic effects of internal curing and anti-floating.

[0005] The aforementioned improvement schemes enhance the performance of lightweight aggregate concrete through material chemical modification (such as surface coating and ultrafine powder composite) and proportion optimization (such as graded proportion design and thickener incorporation), but none of them establish physical constraints. This is mainly reflected in the following aspects: Anti-buoyancy relies on chemical intervention: surface treatment and admixture control only indirectly inhibit the floating of lightweight aggregates by enhancing interfacial bonding or slurry viscosity, failing to directly block their migration path. This results in the risk of uneven aggregate distribution during vibration or pouring. Special process limitations: Taking the magnetic modification technology represented by patent ZL201910626537.1 as an example, it requires customized magnetic lightweight aggregates and matching magnetically controlled vibration equipment. This method not only significantly increases material costs and equipment investment but is also limited by the uniformity of the magnetic field and adaptability to the construction environment, making it difficult to promote and apply in cast-in-place or large-scale precast scenarios.

[0006] To address these issues, we provide lightweight aggregate concrete structures with anti-buoyancy properties, along with their preparation equipment and processes. Summary of the Invention

[0007] To address the problems existing in the prior art, this invention provides a lightweight aggregate concrete structure with anti-buoyancy properties. By embedding mesh reinforcement materials such as polyester fiber mesh and glass fiber grid into the lightweight aggregate concrete system layer by layer, combined with mesh size matched to aggregate particle size and multi-layer staggered laying technology, the floating of lightweight aggregate is effectively suppressed through physical separation mechanism, while simultaneously improving the tensile strength and crack resistance of concrete, thus achieving synergistic optimization of anti-buoyancy stability and mechanical properties.

[0008] To achieve the above objectives, the present invention employs a lightweight aggregate concrete structure with anti-buoyancy properties. This structure comprises alternating layers of lightweight aggregate concrete (3) and a mesh-reinforced material layer (2), the height of which is 50-300 mm. By using alternating layers of lightweight aggregate concrete (3) and mesh-reinforced material layer (2) to form a physical separation barrier, the upward path of the lightweight aggregate is directly blocked through layered constraints, while maintaining the lightweight characteristics of the lightweight aggregate concrete, thus achieving a synergistic effect of anti-buoyancy and lightweighting.

[0009] As a further preferred option 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 amount of admixture, the slurry encapsulation and fluidity are improved, and the risk of segregation between lightweight aggregate and slurry is reduced.

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

[0011] As a further preferred option of the above scheme, the reinforcing material of the mesh reinforcement layer (2) is selected from one of polyester fiber mesh, glass fiber grid, carbon fiber reinforced composite material, basalt fiber reinforced composite material, and aramid fiber mesh; it is suitable for different engineering scenarios and has both lightweight and mechanical properties.

[0012] The mesh size of the mesh reinforcement material layer (2) is selected in combination with the particle size of the lightweight aggregate; the mesh size of the mesh reinforcement 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 reinforcement material layer (2) is optimized according to the particle size of the lightweight aggregate to ensure that the mesh size is smaller than the particle size of the lightweight aggregate to intercept floating particles, and larger than the mortar particles to ensure dense filling of the slurry and avoid the formation of internal voids.

[0013] As a further preferred option of the above scheme, the lightweight aggregate of the lightweight aggregate concrete layer (3) is selected as pumice lightweight aggregate concrete, and the mesh size of the mesh reinforcement layer (2) is 3 to 8 mm.

[0014] As a further preferred option of the above scheme, 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 reinforcement material layer (2) is 1-3mm.

[0015] As a further preferred option of the above scheme, 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 reinforcement layer (2) is 0.5 to 5 mm.

[0016] As a further preferred option of the above scheme, 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 reinforcement material layer (2) is 0.5 to 2 mm.

[0017] As a further preferred option of the above scheme, the lightweight aggregate of the lightweight aggregate concrete layer (3) is selected as ceramsite lightweight aggregate concrete, and the mesh size of the mesh reinforcement layer (2) is 4 to 10 mm.

[0018] As a further preferred option of the above scheme, the lightweight aggregate of the lightweight aggregate concrete layer (3) is rubber lightweight aggregate concrete, and the mesh size of the mesh reinforcement layer (2) is 2 to 6 mm.

[0019] As a further preferred embodiment of the above scheme, the mesh positions of two adjacent layers of mesh reinforcement material (2) are staggered by 1 / 2 mesh width in the horizontal direction, forming an alternating arrangement. This creates a multi-layer constraint structure, effectively preventing the lightweight aggregate from floating vertically due to its light weight.

[0020] As a further preferred option of the above scheme, the mesh reinforcement 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 mesh reinforcement layer (2) is a double-layer honeycomb mesh structure, which mainly plays a role in enhancing the stability and load-bearing capacity of lightweight aggregate concrete structures with anti-buoyancy properties; improving compressive strength: the honeycomb structure effectively disperses and bears external forces from all directions, significantly improving the overall compressive strength of concrete; enhancing shear resistance: the honeycomb reinforcement material can limit the internal shear deformation of concrete, improve shear resistance, and prevent cracks and displacement in the structure; improving durability and preventing crack propagation: the reinforcement material can effectively inhibit the generation and development of micro-cracks inside concrete, improve crack resistance, and extend the service life of the structure; enhancing fatigue resistance: under repeated loading, the honeycomb reinforcement material can improve the fatigue resistance of concrete and prevent premature damage to the structure.

[0022] As a further preferred option of the above scheme, it also includes reinforcing bars that are vertically arranged and run through multiple alternating layers of lightweight aggregate concrete (3) and mesh-reinforced material (2). This improves the overall stiffness, flexural bearing capacity, and anti-peeling ability.

[0023] As a further preferred option of the above scheme, the reinforcing bars are matched with horizontal supports in different directions according to the lightweight aggregate concrete layer (3). The horizontal supports in different directions on the reinforcing bars disperse the load acting on the concrete structure, reduce stress concentration in the concrete, and enable the structure to withstand greater loads.

[0024] As a further preferred option of the above scheme, the mesh reinforcement material layer (2) is made of 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 / m³. 3 500 kg / m³ of sand 3 Vitrified microspheres 200kg / m 3 Water 175kg / m 3 Admixture 6.0 kg / m³ 3 The water-to-binder ratio is 0.35.

[0025] As a further preferred option of the above scheme, the mesh reinforcement layer (2) adopts glass fiber grid 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 / m³. 3550kg / m³ of sand 3 Shale ceramsite 450kg / m³ 3 170 kg / m³ of water 3 Additive 5.4 kg / m 3 The water-to-binder ratio is 0.38.

[0026] As a further preferred embodiment of the above scheme, the mesh reinforcement layer (2) is made of polyester fiber mesh with a mesh size of 5mm×5mm; the lightweight aggregate concrete layer (3) has a height of 250mm and a mix ratio of 480kg / m³ of cement. 3 , sand 600kg / m 3 Expanded perlite 180kg / m 3 Water 190kg / m 3 Admixture 7.2 kg / m 3 .

[0027] As a further preferred option of the above scheme, the mesh reinforcement layer (2) adopts carbon fiber reinforced composite mesh fabric with a mesh size of 3mm×3mm; the height of the lightweight aggregate concrete layer (3) is 50mm, and its mix ratio is: cement 450kg / m³ 3 550kg / m³ of sand 3 200kg / m of rubber granules 3 Water 180kg / m 3 Admixture 6.0 kg / m³ 3 .

[0028] The present invention also provides a device for preparing a lightweight aggregate concrete structure with anti-buoyancy properties, including a mold (4) and a vibrating device. The 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) are adjusted to form a casting cavity with an open top. The side plates (42) are longitudinally and equally spaced with an array (5) of positioning holes for passing through the protrusions (21) on the mesh reinforcement material layer (2). Each array (5) of positioning holes includes positioning holes arranged horizontally at equal intervals.

[0029] As a further preferred option of the above scheme, a vibration table is provided at the lower end of the base plate (41).

[0030] As a further preferred embodiment of the above scheme, a vibrator is included, which is inserted into the vibrating lightweight aggregate concrete layer through positioning holes around the side plate to control the vibration intensity of the vibrator and prevent the mesh reinforcement material from shifting.

[0031] This invention also provides a process for preparing a lightweight aggregate concrete structure with anti-buoyancy properties, comprising:

[0032] S1: Adjust the installation positions of the four side plates and the bottom plate of the preparation device according to the size of the lightweight aggregate concrete structural components to be poured, and limit the construction range.

[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 reinforcement material in the lightweight aggregate concrete mixture to cover the entire lightweight aggregate concrete mixture, and leave holes around the perimeter for inserting a vibrator.

[0035] S4: Insert the vibrator through the positioning holes around the side plate and vibrate at low frequency to control the vibration intensity and prevent the mesh reinforcement material from shifting.

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

[0037] S6: Repeat S2 to S5 until the design height is reached;

[0038] S7: Lightweight aggregate concrete components are formed after demolding and curing.

[0039] In the preparation process of the lightweight aggregate concrete structure with anti-buoyancy of the present invention, layered pouring combined with immersion vibration is used. The pre-reserved holes ensure the compaction of the vibration, improve the uniformity of the distribution of the lightweight aggregate layer, and avoid the strength dispersion caused by the floating of aggregates during the process.

[0040] The lightweight aggregate concrete structure with anti-buoyancy properties of the present invention, as well as its preparation apparatus and process, have the following beneficial effects:

[0041] (1) The lightweight aggregate concrete structure with anti-buoyancy properties of the present invention forms a multi-layer physical constraint structure by alternately laying lightweight aggregate concrete layers and mesh reinforcement material layers, which effectively prevents the lightweight aggregate from floating vertically due to its light weight. It effectively inhibits the floating of lightweight aggregate and ensures uniform distribution; the mesh reinforcement material layer is a double-layer honeycomb mesh structure, and the upper and lower honeycomb meshes are connected and the mesh openings are staggered, which enhances the stability and load-bearing capacity of the lightweight aggregate concrete structure with anti-buoyancy properties; the honeycomb structure effectively disperses and bears external forces from all directions, which significantly improves the overall compressive strength of the concrete.

[0042] (2) The lightweight aggregate concrete structure of the present invention, which possesses anti-buoyancy properties, effectively enhances the tensile and crack resistance of lightweight aggregate concrete components. The mesh positions of two adjacent layers of mesh reinforcement are staggered by 1 / 2 mesh width in the horizontal direction, forming an alternating arrangement. This forms a multi-layered constraint structure, effectively preventing the lightweight aggregate from floating vertically due to its light weight; the mesh reinforcement forms a reinforcing mesh inside the concrete, improving tensile strength and reducing the risk of crack propagation, making it particularly suitable for lightweight wall panels, floor slabs, shear walls, and other components prone to tensile cracking.

[0043] (3) The preparation process of the lightweight aggregate concrete structure with anti-buoyancy of the present invention does not require changing the traditional casting construction process. It only requires the layering of mesh reinforcement material during the construction of lightweight aggregate concrete. No additional complicated operations are required. It is easy to apply to both precast and cast-in-place construction methods and is suitable for large-scale engineering promotion and application. Attached Figure Description

[0044] Figure 1 A structural schematic diagram of a lightweight aggregate concrete structure with anti-buoyancy properties;

[0045] Figure 2 This is a schematic diagram of the rectangular mesh reinforcement material layer in this invention;

[0046] Figure 3 This is a schematic diagram of the structure of the rhomboid mesh reinforcement material layer in this invention;

[0047] Figure 4 This is a schematic diagram of the staggered overlapping method of the mesh-reinforced material layer in this invention;

[0048] Figure 5 , Figure 6 This is a schematic diagram of the staggered arrangement of the mesh-reinforced material layers in this invention;

[0049] Figure 7 This is a schematic diagram of the fixing method of the mesh reinforcement material layer in this invention;

[0050] Figure 8 This is a schematic diagram of the mold structure in this invention;

[0051] Figure 9 In this invention Figure 8 Enlarged structural diagram of the combined fixing mechanism at point A;

[0052] Figure 10 This is a schematic diagram of the anti-buoyancy cover plate in this invention.

[0053] In the diagram: 1. Template; 2. Mesh reinforcement material layer; 21. Protruding part; 3. Lightweight aggregate concrete layer; 4. Mold; 41. Base plate; 42. Side plate; 5. Positioning hole array; 6. Anti-buoyancy cover plate; 61. Fitting groove; 7. Guide slide rail; 71. Limiting groove; 72. Notch; 73. Steel wire rope; 8. Combined fixing mechanism; 81. First limiting seat; 82. Second limiting seat; 83. Connecting part; 831. Accommodation channel; 84. First movable buckle; 85. Second movable buckle; 86. First positioning guide rod; 87. Second positioning guide rod. Detailed Implementation

[0054] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. However, it should be understood that the specific embodiments described herein are merely illustrative and are not intended to limit the scope of the invention.

[0055] See Figure 1-6 A lightweight aggregate concrete structure with anti-buoyancy properties is provided, comprising a layer of mesh reinforcement material 2 on a layer of lightweight aggregate concrete 3, the height of which is 50-300mm. In a preferred embodiment, the mesh positions of adjacent mesh reinforcement material layers 2 are staggered horizontally by 1 / 2 mesh width, forming an alternating arrangement. This multi-layered constraint structure effectively prevents the lightweight aggregate from floating vertically due to its light weight, resulting in good anti-buoyancy performance, ensuring the uniformity of the lightweight aggregate concrete, and improving the overall density of the lightweight aggregate concrete component.

[0056] In a preferred embodiment, the mesh reinforcement layer 2 is a double-layer honeycomb mesh structure, with the upper and lower honeycomb meshes connected and their openings staggered. This structure utilizes the high specific stiffness and multi-directional equal strength characteristics of the honeycomb units to form a continuous force transmission path. The staggered layout of the upper and lower meshes forces the concrete slurry to form an S-shaped flow path within the honeycomb units, resulting in a continuously reinforced skeleton after curing, thus inhibiting crack propagation.

[0057] In a preferred embodiment, the lightweight aggregate concrete structure with anti-buoyancy properties includes vertically arranged reinforcing bars that penetrate multiple alternating layers of lightweight aggregate concrete 3 and mesh reinforcement material 2. This improves overall stiffness, flexural bearing capacity, and anti-stripping ability. The reinforcing bars are matched with horizontal supports in different directions according to the lightweight aggregate concrete layers 3. The horizontal supports in different directions on the reinforcing bars disperse the load acting on the concrete structure, reducing stress concentration in the concrete and enabling the structure to withstand greater loads.

[0058] Vertical stiffeners, acting as vertical force transmission paths, form a three-dimensional composite reinforcement system with the horizontal mesh reinforcement material, effectively resisting shear forces and improving overall stiffness, flexural bearing capacity, and delamination resistance. Under lateral loads (such as earthquakes and wind loads), the stiffeners transmit shear forces through axial tension or compression, reducing the risk of interlayer slippage. Simultaneously, the vertical stiffeners penetrate each layer, enhancing interlayer adhesion through mechanical anchoring and suppressing delamination. Under dynamic loads (such as fatigue vibration), they can reduce the propagation of interfacial microcracks. The vertical stiffeners directly bear longitudinal loads (including gravity), forming an orthogonal grid with the horizontal mesh reinforcement material, converting shear stress into axial stress and avoiding localized stress concentration.

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

[0060] The reinforcing material of the mesh reinforcement layer 2 is selected from one of the following: polyester fiber mesh, glass fiber grid, carbon fiber reinforced composite material, basalt fiber reinforced composite material, and aramid fiber mesh; it adapts to the needs of different engineering scenarios and combines lightweight and mechanical properties. The mesh size of the mesh reinforcement layer 2 is selected in conjunction with the particle size of the lightweight aggregate; the mesh size of the mesh reinforcement 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 reinforcement layer 2 is optimized according to the particle size of the lightweight aggregate to ensure that the mesh size is smaller than the particle size of the lightweight aggregate to intercept floating particles, and larger than the mortar particles to ensure dense filling of the slurry and avoid the formation of internal voids.

[0061] Mesh reinforcement materials are applicable to various lightweight aggregate concrete and engineering projects, and their specific scope of application is 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 low crack resistance requirements, such as filling layers, internal partitions, roof insulation layers, etc.

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

[0064] (3) Carbon 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, such as ultra-thin lightweight panels and exterior wall panels of ultra-high-rise buildings.

[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: 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] Table 1 shows a comparison of the applicable ranges of different mesh reinforcement materials.

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

[0069]

[0070]

[0071] See Figure 1 , Figure 2 , Figures 7-10 The present invention provides a visually intuitive apparatus for preparing a lightweight aggregate concrete structure with anti-buoyancy properties. The apparatus includes an anti-buoyancy mold 4 and a vibrating device. The anti-buoyancy mold 4 comprises a base plate 41 and side plates 42 surrounding the base plate 41. The base plate 41 and side plates 42 together form an open-top casting cavity. The lightweight aggregate concrete mixture is injected into the cavity through the opening to complete the molding process. Multiple sets of positioning hole arrays 5 are arranged along the longitudinal axis of the side plates 42. The positioning holes on each set of positioning hole arrays 5 are evenly distributed along the horizontal axis. The specifications of the positioning holes match the protrusions 21 around the mesh reinforcement material, allowing the protrusions 21 to penetrate the positioning holes and complete the positioning installation. After construction, a sealing medium is used to seal the openings of the positioning holes to achieve boundary fixation. By controlling the dimensional relationship between the positioning holes and the protrusions 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] An anti-buoyancy cover plate 6 is installed at the opening of the anti-buoyancy mold. The floating of light aggregate is suppressed by top pressure.

[0073] In the preferred embodiment, further improvements are made to the anti-buoyancy effect. A vertically arranged guide rail 7 is provided on the side plate 42, and a vertical limiting groove 71 is provided on the guide rail 7. The anti-buoyancy cover plate 6 is provided with a fitting groove 61 that mates with the opening of the limiting groove 71. One end of the wire rope 73 passes through the limiting groove 71 and the fitting groove 61 and is fixed to the top of the anti-buoyancy cover plate 6, and is locked with bolts at the fixing ring at the top of the anti-buoyancy cover plate 6. The lower part of the wire rope 73 is fixed to the bottom plate 41. (In common pouring operations, reinforcing bars or other supporting components are usually placed under the bottom plate 41. In this invention, the lower part of the wire rope 73 can be hooked and fixed to the lower part of the bottom plate 41 using hooks or other structures.)

[0074] The above structure, by setting an anti-buoyancy cover plate 6 at the top opening of the casting cavity, forms a rigid pressure interface when closed. The cover plate is fixed by a steel wire rope 73 to apply vertical pressure, which can actively suppress the floating of lightweight aggregates.

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

[0076] A first movable latch 84 is formed on one side of the first limiting seat 81, and a second movable latch 85 is selectively closed to the second limiting seat 82. A second movable latch 85 is formed on one side of the second limiting seat 82, and a first positioning guide rod 86 is formed on one side of the first movable latch 84, and the first movable latch 84 is in a closed state. The first positioning guide rod 86 contacts and positions the connecting part 83. A second positioning guide rod 87 is formed on one side of the second movable latch 85, and the first movable latch 84 and the second movable latch 85 are in a closed state. The second positioning guide rod 87 contacts and positions the first movable latch 84.

[0077] The aforementioned combined fixing mechanism 8 consists of a first limiting seat 81, a second limiting seat 82, and a connecting part 83, both of which respectively engage with the circumferential contact surfaces of the protruding portions 21 of adjacent mesh reinforcing materials. When the two movable latches are closed, the two limiting seats and the protruding portions 21 form a contact clamping structure, preventing the reinforcing materials from being displaced or disturbed in the flow state of concrete.

[0078] In the preferred embodiment, the guide slide rail 7 is provided with a notch 72 that is in mate with the connecting part 83. The connecting part 83 passes through the guide slide rail 7 and forms a receiving channel 831 above the connecting part 83 to accommodate the steel cable. The top surface of the receiving channel 831 faces the second movable buckle 85.

[0079] In the preferred embodiment, the receiving channel 831 has a roughly semi-circular ring structure. This structure enables the coordinated positioning of the guide rail 7 and the combined fixing mechanism 8. Specifically, the guide rail 7 has a notch 72 that matches the outer contour of the connecting part 83. When the connecting part 83 passes through the guide rail 7, its sidewall constraint provides a mechanical limiting effect, effectively suppressing vertical displacement freedom and eliminating the risk of longitudinal disturbance of the connecting part 83 caused by fluid pressure during concrete pouring. Simultaneously, the connecting part 83 has a pre-set receiving channel 831 inside to support the wire rope 73. The geometry of the receiving channel 831 is coupled with the movement trajectory of the wire rope 73, constraining the spatial position of the wire rope 73.

[0080] This invention provides a preferred embodiment of a process for preparing lightweight aggregate concrete structures with anti-buoyancy properties, comprising the following steps:

[0081] S1: Preparation of anti-buoyancy mold 4: Anti-buoyancy mold 4 is customized according to the component size, and is formed by the bottom plate 41 and the side plate 42 to form a casting cavity with an open top.

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

[0083] Reinforcement layer laying: Cover with mesh reinforcement material (polyester fiber mesh, fiberglass grid, etc.), the mesh size is adapted to the type of lightweight aggregate, and vibration holes are reserved around the perimeter. Preferably, in some examples, the hole diameter is ≥ 1.2 times the diameter of the vibrator; Repeated layering: Alternately pour concrete (50-300mm / layer) and lay reinforcement layer until the design height is reached.

[0084] S3: Vibration compaction: Cast-in-place components: Use a Φ50mm immersion vibrator to vibrate vertically along the reserved holes, with a single vibration time of ≤30s to avoid light aggregates from floating; Precast components: Vibrate on a low-amplitude vibrating table (amplitude 0.3-0.8mm), control the vibration frequency to ≤40Hz, and suppress buoyancy disturbance.

[0085] S4: Fixing the reinforcing material:

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

[0087] For reinforced structural members (fill layer, partition wall): the “tying-clip composite method” is adopted, and galvanized wire and nylon clips are fixed at intersections every 300mm along the direction of the main reinforcement.

[0088] In some improved embodiments, the fixing can also be carried out in the following way: the side plate 42 is arranged with a positioning hole array 5 at equal intervals in the longitudinal direction, and each array contains positioning holes distributed at equal intervals in the horizontal direction. The diameter of the positioning hole is adapted to the size of the protrusion 21 on the mesh reinforcing material.

[0089] S5: Check if the mesh reinforcement material has shifted or sunk, and adjust it promptly if necessary;

[0090] S6: Repeat steps S2 to S5 until the design height is reached;

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

[0092] Example 1:

[0093] A process for preparing a lightweight aggregate concrete structure with anti-buoyancy properties, comprising preparing a precast lightweight aggregate concrete floor slab with dimensions of 2000mm×1000mm×120mm (length×width×thickness).

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

[0095] Lightweight aggregate: Shale ceramsite with a particle size of 5-15 mm and an apparent density of 750 kg / m³. 3 Water absorption rate: 10.5%;

[0096] Cementitious material: P·O42.5 grade ordinary Portland cement, density 3.1 g / cm³. 3 Fineness 350m 2 / kg;

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

[0098] Admixture: Polycarboxylate superplasticizer is used, with a dosage of 1.2% of the cementitious material mass;

[0099] Mesh reinforcement material: Fiberglass grid (square mesh, 6mm×6mm, bidirectional stress, easy to install and fix), uniaxial tensile strength ≥50kN / m, excellent alkali resistance. The floor slab is 120mm thick, with one layer laid. Fixing methods include template fixing and overlapping fixing. Fixing slots are set around the template, with a slot spacing of 50cm, and adjacent fiberglass grids overlap by 50mm.

[0100] The mix proportion of shale ceramsite lightweight aggregate concrete is: cement 450kg / m³. 3 550kg / m³ of sand 3 Shale ceramsite 450kg / m³ 3 170 kg / m³ of water 3 Additive 5.4 kg / m 3 The water-cement ratio was 0.38. The resulting lightweight aggregate concrete had a 28-day cubic compressive strength of 36.2 MPa and an apparent density of 1850 kg / m³. 3 It meets the requirements for use of floor slabs.

[0101] (2) Construction steps:

[0102] S1: Template 1 System Preparation and Fixation:

[0103] A precast steel formwork 1 with dimensions of 2000mm×1000mm×120mm was selected. The joints of formwork 1 were machined using a high-precision milling process. A solvent-based release agent was applied to the inner wall of formwork 1 in two coats, with a 15-minute interval between coats, to ensure uniform film formation. T-shaped fixing slots were installed at 50cm intervals around formwork 1 and on the base plate 41. These slots were rigidly connected to formwork 1 via bolts to secure the fiberglass grid.

[0104] S2: Bottom layer concrete pouring and paving:

[0105] Shale ceramsite lightweight aggregate concrete mixture (mixture ratio: cement 450kg / m³) is transported using pumping equipment. 3 550kg / m³ of sand 3 Shale ceramsite 450kg / m³ 3 170kg / m³ of water 3 Polycarboxylate superplasticizer 5.4 kg / m 3 Pour the mixture into the bottom of template 1, controlling the pouring thickness to 60mm. Use an aluminum alloy vibratory leveling ruler to evenly scrape the surface along the long side of template 1 to eliminate surface undulations.

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

[0107] Fiberglass geogrids are laid on the concrete surface, with an overlap of 50mm between adjacent geogrids. The overlaps are temporarily secured with stainless steel U-shaped clips to ensure the continuity of the reinforcement layer. Fixing slots are used to secure the fiberglass geogrids, ensuring stability and preventing them from floating or shifting due to vibration.

[0108] S4: First layer low-amplitude vibration compaction:

[0109] Continuous vibration using a low-amplitude vibrating table (40Hz, amplitude 0.8mm) is applied until no obvious air bubbles escape from the concrete surface and the grout is evenly distributed. After vibration, a steel roller is used to compact the concrete twice along the short side of template 1 to eliminate fine surface pores.

[0110] S5: Second layer of concrete pouring and covering:

[0111] A second layer of shale ceramsite lightweight aggregate concrete, 60mm thick, is poured over the first layer of fiberglass grating. The total pouring thickness is ensured to reach 120mm.

[0112] S6: Secondary vibration:

[0113] Repeat the S4 low-amplitude vibration process, focusing on additional vibration in the grid overlap area.

[0114] S7: Demolding and Standardized Curing:

[0115] After the concrete has initially set, the side formwork is removed, and the concrete is cured under standard curing conditions until the specified age to obtain a shale ceramsite lightweight aggregate concrete floor slab.

[0116] Example 2:

[0117] A process for preparing a lightweight aggregate concrete structure with anti-buoyancy properties, wherein a cast-in-place lightweight aggregate concrete floor slab is prepared with dimensions of 4000mm×2000mm×160mm (length×width×thickness).

[0118] (1) Raw materials and laying method

[0119] Lightweight aggregate: Vitrified microspheres with a particle size of 1-2 mm and an apparent density of 250 kg / m³ 3 Water absorption rate: 5.8%;

[0120] Cementitious material: P·O42.5 grade ordinary Portland cement, density 3.1 g / cm³. 3 Fineness 350m 2 / kg;

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

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

[0123] Mesh reinforcement material: Polyester fiber mesh (square grid, 1mm×1mm, bidirectional stress, easy to construct and fix), with a unidirectional tensile strength ≥30kN / m, good flexibility, suitable for fine-particle lightweight aggregate concrete. The floor slab is 160mm thick, with 3 layers laid, each layer spaced 50mm apart. The polyester fiber mesh is staggered horizontally by 1 / 2 mesh width, forming an alternating arrangement. Fixing methods include template fixing and overlapping fixing. Fixing slots are set around the template, with a slot spacing of 50cm, and adjacent polyester fiber meshes overlap by 50mm.

[0124] The mix proportion of vitrified microsphere lightweight aggregate concrete is: cement 500kg / m³ 3 500 kg / m³ of sand 3 Vitrified microspheres 200kg / m 3 Water 175kg / m 3 Admixture 6.0 kg / m³ 3 The water-cement ratio was 0.35. The resulting lightweight aggregate concrete had a 28-day cubic compressive strength of 15.8 MPa and an apparent density of 1100 kg / m³. 3 It meets the requirements for use of floor slabs.

[0125] (2) Construction steps:

[0126] S1: Template 1 preparation and fixation:

[0127] A cast-in-place steel formwork 1 with dimensions of 4000mm×2000mm×160mm is used. The joints of the formwork 1 are treated with sealing strips to ensure no grout leakage. Fixing slots are set around the formwork and on the base plate 41. The slots are connected to the formwork 1 with 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 layer concrete pouring and paving:

[0129] Pour the first layer of vitrified microsphere lightweight aggregate concrete mixture (mixture ratio: cement 500kg / m³) into the bottom of the formwork. 3 500kg / m³ of sand 3 200kg / m² of vitrified microspheres 3 175 kg / m³ of water 3 Polycarboxylate superplasticizer 6.0 kg / m 3 The material is evenly distributed using a pumping hose, with the pouring thickness controlled at 50mm. It is then spread evenly and initially leveled using an aluminum alloy scraper to remove surface air bubbles.

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

[0131] Lay polyester fiber mesh on the surface of vitrified microsphere lightweight aggregate concrete to ensure uniform coverage of the entire area, with an overlap width of 50mm, and temporarily fix the overlap with nylon cable ties; ensure the reinforcement layer is continuous; use fixing slots to fix the first layer of polyester fiber mesh to ensure that it will not float or shift during construction due to vibration; reserve holes around the first layer of polyester fiber mesh to facilitate the addition and vibration of the immersion vibrator.

[0132] S4: First layer compacted by vibration:

[0133] An immersion vibrator is used for compaction. It is inserted vertically into the pre-drilled hole to make the vitrified microsphere lightweight aggregate concrete dense. Specifically, the standard for density is that the concrete surface is covered with slurry and no air bubbles escape. After the vibrator is slowly pulled out, a wooden trowel is used to finish the surface and remove the insertion hole marks.

[0134] S5: Second layer of concrete pouring:

[0135] A second layer of vitrified microsphere lightweight aggregate concrete, 50mm thick, is poured on top of the first layer of polyester fiber mesh. The pouring direction is perpendicular to the first layer to reduce the directional arrangement of aggregates. A laser thickness gauge is used to monitor the thickness in real time to ensure uniform layer thickness.

[0136] S6: Second layer of reinforcing mesh laid in an alternating pattern:

[0137] Lay a second layer of polyester fiber mesh, staggered by 1 / 2 mesh width in the horizontal direction to form an alternating arrangement, and fix the second layer of polyester fiber mesh with fixing slots; leave holes around the second layer of polyester fiber mesh to facilitate the insertion of a vibrator for compaction.

[0138] S7: Second layer compaction by vibration:

[0139] An immersion vibrator is used for compaction to make the vitrified microsphere lightweight aggregate concrete dense.

[0140] S8: Third layer of concrete pouring:

[0141] A third layer of vitrified microsphere lightweight aggregate concrete, 50 mm thick, is poured on top of the second layer of polyester fiber mesh.

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

[0143] Lay a third layer of polyester fiber mesh, staggered by 1 / 2 mesh width in the horizontal direction to form an alternating arrangement, and fix the third layer of polyester fiber mesh with fixing slots; leave holes around the third layer of polyester fiber mesh to facilitate the insertion of a vibrator for compaction.

[0144] S10: Third layer vibration and surface treatment:

[0145] An immersion vibrator is used for compaction to make the vitrified microsphere lightweight aggregate concrete dense.

[0146] S11: Surface Covering and Leveling:

[0147] The final 10mm thick layer of vitrified microsphere lightweight aggregate concrete is poured to completely cover the third layer of polyester fiber mesh, ensuring that it is embedded inside the vitrified microsphere lightweight aggregate concrete.

[0148] S12: Demolding and Curing:

[0149] After the concrete has initially set, the side formwork is removed, while the bottom formwork is retained for support for 7 days. Immediately after demolding, the concrete is covered with non-woven fabric and sprayed for curing. The curing period is 14 days, resulting in a vitrified microsphere lightweight aggregate concrete floor slab.

[0150] Example 3:

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

[0152] (1) Raw materials and laying method

[0153] Lightweight aggregate: Expanded perlite, particle size 0.5-5mm, apparent density 150kg / m³ 3 Water absorption rate: 8.5%;

[0154] Cementitious material: P·O42.5 grade ordinary Portland cement, density 3.1 g / cm³. 3 Fineness 350m 2 / kg;

[0155] Fine aggregate: Manufactured sand with a fineness modulus of 2.8 and a mud content of <2% is used;

[0156] Admixture: Polycarboxylate superplasticizer is used, with a dosage of 1.2% of the cementitious material mass;

[0157] Mesh reinforcement material: Polyester fiber mesh (diamond mesh size, 5mm×5mm, good vertical stress resistance) is used, with a uniaxial tensile strength ≥45kN / m, excellent alkali resistance, and suitable for high-durability lightweight aggregate concrete. The wall height is 2800mm, with one layer of polyester fiber mesh laid every 250mm, for a total of 10 layers. The polyester fiber mesh is staggered horizontally by 1 / 2 mesh width to reduce the vertical upward floating path of the lightweight aggregate. It is fixed with a steel reinforcement skeleton, and the polyester fiber mesh is tied to the vertical reinforcement with nylon tape at 300mm intervals to ensure that the polyester fiber mesh does not shift during pouring and vibration.

[0158] The mix proportion of expanded perlite lightweight aggregate concrete is: cement 480kg / m³ 3 , sand 600kg / m 3 Expanded perlite 180kg / m 3 Water 190kg / m 3 Admixture 7.2 kg / m 3 The resulting lightweight aggregate concrete has a 28-day cubic compressive strength of 12.5 MPa and an apparent density of 1050 kg / m³. 3 This meets the requirements for lightweight wall structures.

[0159] (2) Construction steps:

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

[0161] Install vertical Φ12mm steel bars at 200mm intervals; install horizontal Φ8mm stirrups at 250mm intervals to form a steel reinforcement cage.

[0162] S2: Pour the first layer of expanded perlite lightweight aggregate concrete mixture at the bottom of the wall (mixture ratio: cement 480kg / m³). 3 , sand 600kg / m 3 Expanded perlite 180kg / m3 Water 190kg / m 3 Polycarboxylate superplasticizer 7.2kg / m 3 Control the pouring thickness to 250mm and spread it evenly.

[0163] S3: Lay the first layer of polyester fiber mesh along the height of the wall at a spacing of 250mm, and tie it to the vertical steel bars with nylon cable ties at a spacing of 300mm. Leave holes around the first layer of polyester fiber mesh to facilitate the addition of an immersion vibrator for compaction.

[0164] S4: Use an immersion vibrator to compact the expanded perlite lightweight aggregate concrete.

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

[0166] S6: Continue to lay the second layer of polyester fiber mesh along the height of the wall, with a spacing of 250mm and a staggered spacing of 1 / 2 mesh width. Use nylon cable ties to tie it to the vertical steel bars with a tying point spacing of 300mm. Leave holes around the second layer of polyester fiber mesh to facilitate the addition of an immersion vibrator for compaction.

[0167] S7: Use an immersion vibrator to compact the expanded perlite lightweight aggregate concrete.

[0168] S8: Repeat the pouring, laying of polyester fiber mesh, and vibration until the wall height reaches 2800mm. A total of 10 layers of polyester fiber mesh are laid. After the final laying of the polyester fiber mesh, pour a 10mm thick expanded perlite lightweight aggregate concrete to completely cover the polyester fiber mesh and ensure that it is embedded inside the expanded perlite lightweight aggregate concrete.

[0169] S9: Demolding and curing, watering or natural curing to the specified age, to obtain expanded perlite lightweight aggregate concrete wall.

[0170] Example 4:

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

[0172] (1) Raw materials and laying method

[0173] Lightweight aggregate: made of rubber granules, with a particle size of 0.5–10 mm and an apparent density of 450 kg / m³. 3 Water absorption rate: 3.5%.

[0174] Cementitious material: P·O42.5 grade ordinary Portland cement, density 3.1 g / cm³.3 Fineness 350m 2 / kg;

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

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

[0177] Mesh reinforcement material: Carbon fiber reinforced composite mesh (diamond mesh, size 3mm×3mm, good vertical stress) is used, with a uniaxial tensile strength ≥60kN / m; the partition wall is 120mm thick, with a total of 2 layers of carbon fiber reinforced composite mesh laid with a spacing of 50mm, laid along the thickness direction and arranged in an alternating manner; a combination of template fixing and steel reinforcement frame fixing is adopted, with lateral fixing slots and vertical steel reinforcement binding fixation.

[0178] The mix proportion of rubber lightweight aggregate concrete is: cement 450kg / m³ 3 550kg / m³ of sand 3 200kg / m of rubber granules 3 Water 180kg / m 3 Admixture 6.0 kg / m³ 3 The resulting lightweight aggregate concrete has a 28-day cubic compressive strength of 10.5 MPa and an apparent density of 1300 kg / m³. 3 This meets the requirements for lightweight partition walls.

[0179] (2) Construction steps:

[0180] S1: Adjust the positions of the base plate 41 and side plate 42 of the preparation device to form an open-top casting cavity. Use precast steel formwork with dimensions of 3000mm × 1500mm × 100mm. Fixing slots are set on the inner walls of the formwork at 300mm intervals. Apply a release agent to the inside of the formwork. Install vertical Φ10mm steel bars at 400mm intervals as a steel reinforcement framework.

[0181] S2: Pour in the first layer of rubber lightweight aggregate concrete mix (mixing ratio: cement 450kg / m³). 3 550kg / m³ of sand 3 200kg / m of rubber granules 3 Water 180kg / m 3 Polycarboxylate superplasticizer 6.0 kg / m 3 Control the pouring thickness to 50mm and spread it evenly.

[0182] S3: Lay the first layer of carbon fiber reinforced composite mesh along the thickness of the wall to ensure uniform coverage of the entire area, with an overlap width of 50mm to ensure the continuity of the reinforcement layer; use fixing slots to fix the carbon fiber reinforced composite mesh to ensure stability and prevent it from floating or shifting due to vibration.

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

[0184] S5: Pour in the second layer of rubber lightweight aggregate concrete, controlling the pouring thickness to 50mm, and spread it evenly.

[0185] S6: Lay the second layer of carbon fiber reinforced composite mesh along the wall thickness direction. The mesh is staggered by 1 / 2 mesh width in the horizontal direction to ensure uniform coverage of the entire area. The overlap width is 50mm to ensure the continuity of the reinforcement layer. Use fixing slots to fix the carbon fiber reinforced composite mesh to ensure stability and prevent it from floating or shifting due to vibration.

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

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

[0188] Based on the above embodiments and the invention, recommendations for different lightweight aggregates and different mesh reinforcement materials are given, as detailed in Table 2.

[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 solution of the present invention, and not to limit it. In summary, the present invention constructs a dynamic constraint mechanism at the interface between lightweight aggregate and mortar by configuring a grid structure system with layered configurations that match the aggregate particle size. The reinforcing material utilizes its rigid grid shape to form a grid barrier, controlling the displacement trajectory of the lightweight aggregate, and combined with the staggered laying process, effectively neutralizes the buoyancy gradient effect generated during concrete vibration.

[0193] The present invention relates to a lightweight aggregate concrete structure with anti-buoyancy properties and its preparation process. By laying a mesh-reinforced material layer on the lightweight aggregate concrete layer, a dynamic constraint network is constructed at the lightweight aggregate-mortar interface, forming a three-dimensional reinforcement network. This not only effectively inhibits the floating of lightweight aggregates, ensuring the uniformity of lightweight aggregate concrete and improving the overall density of lightweight aggregate concrete components, but also effectively disperses the stress generated by external loads, reduces stress concentration, and improves the overall load-bearing capacity. Furthermore, the mesh-reinforced material layers at different locations work synergistically to improve the stiffness of the components in multiple directions, resisting complex load combinations and effectively enhancing the tensile and crack resistance of lightweight aggregate concrete components. It is particularly suitable for lightweight wall panels, floor slabs, shear walls, and other components prone to tensile cracking, and can meet the preparation requirements of lightweight aggregate concrete structures under different working conditions, such as precast and cast-in-place.

[0194] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions or improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A lightweight aggregate concrete structure with anti-buoyancy properties, characterized in that, include: Alternating layers of lightweight aggregate concrete (3) and mesh reinforcement material (2), the height of which is 50-300 mm; The mesh positions of two adjacent mesh reinforcement material layers (2) are staggered by 1 / 2 mesh width in the horizontal direction to form an alternating arrangement; The mesh reinforcement 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; It also includes vertically arranged and penetrating multiple alternating layers of lightweight aggregate concrete (3) and mesh reinforcement material (2) with reinforcing bars; the reinforcing bars are matched with horizontal support edges in different directions according to the lightweight aggregate concrete layer (3), and the concrete pouring and reinforcement layer layout are carried out alternately until the design height is reached; A layer of mesh reinforcement material (2) is set on a layer of lightweight aggregate concrete (3).

2. The lightweight aggregate concrete structure with anti-buoyancy properties according to claim 1, characterized in that: The lightweight aggregate concrete layer includes fine aggregate, admixtures, cementitious materials, and lightweight aggregate; the lightweight aggregate of the lightweight aggregate concrete layer is one or a mixture of two or more of the following: pumice, expanded perlite, expanded glass beads, vitrified microspheres, ceramsite, and rubber particles, with a particle size range of: pumice 2-20mm, expanded perlite 0.5-5mm, expanded glass beads 0.1-5mm, vitrified microspheres 0.1-3mm, ceramsite 5-25mm, and rubber particles 0.5-10mm.

3. The lightweight aggregate concrete structure with anti-buoyancy properties according to claim 1 or 2, characterized in that: The reinforcing material of the mesh reinforcement layer (2) is selected from one of polyester fiber mesh, glass fiber grid, carbon fiber reinforced composite material, basalt fiber reinforced composite material, and aramid fiber mesh cloth; the mesh size of the mesh reinforcement layer (2) is selected according to the particle size of the lightweight aggregate; the mesh size of the mesh reinforcement 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.

4. The lightweight aggregate concrete structure with anti-buoyancy properties 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 mesh reinforcement layer (2) is 0.5-5mm.

5. The lightweight aggregate concrete structure with anti-buoyancy properties according to claim 4, characterized in that: The mesh reinforcement layer (2) is made of glass fiber grid with a mesh size of 6mm×6mm; the lightweight aggregate concrete layer (3) has a height of 50mm and a mix ratio of: cement 450kg / m3, sand 550kg / m3, shale ceramsite 450kg / m3, water 170kg / m3, admixture 5.4kg / m3, and water-cement ratio of 0.

38.

6. The apparatus for preparing a lightweight aggregate concrete structure with anti-buoyancy properties according to any one of claims 1-5, characterized in that: The mold (4) includes a base plate (41) and a vibrating device. The mold (4) includes a base plate (41) and side plates (42) surrounding the base plate (41). The base plate (41) and the side plates (42) are adjusted to form a casting cavity with an open top. The side plates (42) are longitudinally and equally spaced to provide positioning hole arrays (5) for passing through the protrusions (21) on the mesh reinforcement material layer (2). Each positioning hole array (5) includes positioning holes arranged horizontally at equal intervals.

7. The preparation process of the lightweight aggregate concrete structure with anti-buoyancy properties according to claim 6, characterized in that: S1: Adjust the installation positions of the four side plates and the bottom plate of the preparation device according to the size of the lightweight aggregate concrete structural components to be poured. S2: Pour the lightweight aggregate concrete mixture into the preparation device described in step S1, to a height of 50-300 mm; S3: Lay a mesh reinforcement material in the lightweight aggregate concrete mixture to cover the lightweight aggregate concrete mixture, and leave holes around the perimeter for inserting a vibrator. S4: Insert the vibrator through the pre-drilled holes around the perimeter for low-frequency vibration; S5: Check whether the mesh reinforcement material has shifted or settled. If so, adjust the vibration frequency in time. S6: Repeat S2 to S5 until the design height is reached; S7: Lightweight aggregate concrete components are formed after demolding and curing.

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