Water-based reduced asphalt ultrathin wear-resistant layer material and construction method

Abstract

The invention relates to the technical field of highway bridge construction materials, and discloses a water-based reduced asphalt ultrathin wear-resistant layer material and a construction method, and the water-based reduced asphalt ultrathin wear-resistant layer material is applied to an anti-cracking batten seam surface layer part at the rear part of an expansion joint device; the concrete comprises the following components in parts by weight: 60-65 parts of cement, 20-30 parts of high-performance water-based reduced asphalt, 2-5 parts of fibers, 10-20 parts of coarse aggregate, 10-20 parts of fine aggregate and 5-10 parts of filler. The water-based reduced asphalt ultrathin wear-resistant layer material disclosed by the invention is filled in a strip seam around an anti-cracking plate, so that the flexibility of the material is improved, and pit seams formed by separation from a steel plate are avoided.

Description

Technical Field

[0001] The invention relates to the technical field of highway bridge construction materials, in particular to a water-based reduced asphalt ultra-thin wear-resistant layer material and a construction method. Background Art

[0002] Bridge expansion joints are designed to meet the requirements of bridge deck deformation, and are usually set between the two beam ends, between the beam ends and the abutments, or at the hinged positions of the bridge. The invention patent with the announcement number CN115323910A discloses a unit-type impact-resistant multi-directional displacement comb plate bridge expansion device, which includes a left anchor plate, a left tooth plate, a right anchor plate, a right tooth plate, and a dustproof support plate. It also includes a left anti-crack plate and a right anti-crack plate. The left anti-crack plate is arranged parallel to the rear of the left tooth plate and its bottom surface is fixedly connected to the left anchor plate. The right anti-crack plate is arranged parallel to the rear of the right tooth plate and its bottom surface is fixedly connected to the right anchor plate. The top surfaces of the left anti-crack plate and the right anti-crack plate are not higher than the top surfaces of the left tooth plate and the right tooth plate. The unit-type impact-resistant multi-directional displacement comb plate bridge expansion device in this invention can effectively resist vehicle impact, improve the damage to the concrete or asphalt on the outside of the expansion joint device, and increase the service life of the equipment. The patent specification clearly states that a long gap is set between the anti-crack plate and the tooth plate; concrete is poured flush around the anti-crack plate. In other words, although the patented technical solution separates the anti-crack plate separately and uses it as a skeleton plate for the surface concrete, when a vehicle passes by, the tire rolls over the anti-crack plate, reducing the impact on the surrounding concrete and reducing the degree of damage to the surrounding concrete. Practical experience shows that with the protection of the anti-crack plate, the impact on the tooth plate is also significantly reduced. However, the separated anti-crack plate also increases the joint between the concrete and the steel plate. The joint between the concrete and the steel plate is increased because of the material difference between the steel plate and the concrete and the influence of temperature deformation. Long-term rolling and climate influences will cause the concrete to fall off or even peel off at the joint. The long-term accumulation will cause the formation of concave potholes at the joint between the concrete and the steel plate, increasing tire noise and affecting vehicle driving safety.

[0003] Therefore, it is necessary to develop water-based reduced asphalt ultra-thin wear-resistant layer materials and construction methods to solve the problems in the existing technology. Summary of the Invention

[0004] The purpose of the present invention is to provide a water-based reduced asphalt ultra-thin wear-resistant layer material, which is filled in the cracks around the anti-cracking plate to increase the flexibility of the material and avoid separation from the steel plate to form pits.

[0005] In order to solve the above technical problems, the present invention adopts the following technical solutions:

[0006] The present invention discloses an ultra-thin wear-resistant layer material of water-based reduced asphalt, which is applied to the surface layer of the anti-cracking slats at the rear of an expansion joint device. The material comprises the following components by weight: 60-65 parts of cement, 20-30 parts of high-performance water-based reduced asphalt, 2-5 parts of fiber, 10-20 parts of coarse aggregate, 10-20 parts of fine aggregate, and 5-10 parts of filler.

[0007] Furthermore, the high-performance water-based reduced asphalt adopts high-polymer modified emulsified asphalt, which is stirred at room temperature and cold-laid for application.

[0008] Furthermore, the coarse aggregate and the fine aggregate are specifically basalt stones of different particle sizes, the particle size of the coarse aggregate is 5-10 mm, and the particle size of the fine aggregate is in the range of 3-5 mm.

[0009] Furthermore, the filler is specifically mineral powder, slaked lime or a mixture of the two.

[0010] The present invention also discloses a method for constructing a water-based reduced asphalt ultra-thin wear-resistant layer material. The construction and use of any of the above-mentioned water-based reduced asphalt ultra-thin wear-resistant layer materials include the following steps:

[0011] Step 1: Material preparation: weigh cement, high-performance water-based reduced asphalt, fiber, coarse aggregate, fine aggregate and filler according to the total amount of materials used;

[0012] Step 2: Mixing: Put cement, high-performance water-based reduced asphalt, fiber, coarse aggregate, fine aggregate and filler into a mixer and add water and stir for 15 minutes to form a slurry mixture;

[0013] Step 3: Apply and spread it evenly on the surface of the anti-cracking board seams, and open to traffic after two hours.

[0014] Furthermore, after step 2 is completed, a cohesion test needs to be carried out, and the cohesion test needs to take into account the lowest temperature encountered during the construction process.

[0015] Furthermore, before step three, the bottom surface of the anti-cracking board seam needs to be cleaned and coated with modified emulsified asphalt tack coat oil.

[0016] Furthermore, before step three, the side walls of the comb plate and the anti-cracking plate need to be cleaned and coated with an interface agent.

[0017] Furthermore, the side walls of the comb plate and the anti-cracking plate are cleaned by grinding and removing rust with a wire brush, and the interface agent is specifically implemented by brushing epoxy asphalt.

[0018] Compared with the prior art, the present invention has the following beneficial technical effects:

[0019] The present invention discloses an ultra-thin wear-resistant layer of water-based reduced asphalt. This layer utilizes high-performance water-based reduced asphalt, using a chemical crosslinking reaction to form a three-dimensional crosslinked network structure that coats coarse and fine aggregates. The resulting surface layer surrounding the anti-cracking plate (3) exhibits excellent flexibility, resistance to high-temperature deformation, resistance to low-temperature cracking, and exceptional wear resistance and durability. The ultra-thin wear-resistant layer of water-based reduced asphalt fills the cracks surrounding the anti-cracking plate, increasing its flexibility and preventing separation from the steel plate, forming cracks.

[0020] Furthermore, the use of basalt as a filler aggregate, with its high hardness, low water absorption, strong asphalt adhesion, and multi-angle bearing capacity, enhances anti-slip properties, making it suitable for heavy-duty traffic applications. The addition of fiber components creates a three-dimensional network within the asphalt mixture, dispersing stress and reducing thermal shrinkage cracks and reflective cracks.

[0021] The construction method of the water-based reduced asphalt ultra-thin wear-resistant layer material of the present invention adopts a simple cold-laying construction process, which has a short construction time, is quickly open to traffic, and has a long construction season, that is, construction can be carried out when the temperature is greater than 5°C. Moreover, no toxic or harmful gases are generated during the construction process, which is green, environmentally friendly and pollution-free. The material has strong flexibility, effectively improves the driving comfort of the road surface, and extends the service life of the road surface. By coating the side walls of the comb plate 2 and the anti-cracking plate 3 with an interface agent, the bonding strength between the water-based reduced asphalt ultra-thin wear-resistant layer material of the present invention and the side walls of the steel plate can be significantly improved. At the same time, the excellent hydrophobicity also plays a role in preventing the steel plate from rusting. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The present invention will be further described below with reference to the accompanying drawings.

[0023] Figure 1 This is a schematic diagram of the main structure of the application of the water-based reduced asphalt ultra-thin wear-resistant layer material of the present invention.

[0024] Explanation of the accompanying symbols: 1. Anchor plate; 2. Comb plate; 3. Anti-cracking plate; 4. Concrete material; 5. Inner seam; 6. Outer seam. DETAILED DESCRIPTION

[0025] The core of the present invention is to provide a water-based reduced asphalt ultra-thin wear-resistant layer material, which is filled in the cracks around the anti-cracking plate to increase the flexibility of the material and avoid separation from the steel plate to form pits.

[0026] The following will be combined with the accompanying drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0027] In the description of the present invention, it should be understood that the terms "upper", "lower", "front", "back", "left", "right", "top", "bottom", "inside", "outside", etc., indicating directions or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore should not be understood as limiting the present invention.

[0028] Example 1

[0029] like Figure 1 As shown, the water-based reduced asphalt ultra-thin wear-resistant layer material of the present application is applied to the inner and outer slits 5 and 6 on both sides of the anti-cracking plate 3 at the rear of the expansion joint device, serving as the surface layer on the concrete material 4 and the anchor plate 1. The water-based reduced asphalt ultra-thin wear-resistant layer material of the present invention comprises the following components by weight: 60 parts cement, 20 parts high-performance water-based reduced asphalt, 5 parts fiber, 20 parts coarse aggregate, 20 parts fine aggregate, and 10 parts filler.

[0030] Unlike concrete materials that are highly rigid and easily broken, the water-based reduced asphalt ultra-thin wear-resistant layer material of the present invention adopts high-performance water-based reduced asphalt and utilizes chemical cross-linking reactions to form a three-dimensional cross-linked network structure to cover coarse aggregate and fine aggregate. The surface layer material around the anti-cracking plate 3 formed has excellent flexibility, resistance to high-temperature deformation, resistance to low-temperature cracking, and super wear resistance and durability.

[0031] The water-based reduced asphalt ultra-thin wear-resistant layer material of this embodiment is filled in the cracks around the anti-cracking plate to increase the flexibility of the material. After solidification, repeated vehicle rolling tests within the specified time range did not reveal any pits or cracks formed by separation from the steel plate.

[0032] Specifically, the high-performance water-based reduced asphalt utilizes a high-polymer modified emulsified asphalt, such as SBS-modified emulsified asphalt, which can be cold-laid and applied by adding water and stirring at room temperature. SBS (styrene-butadiene-styrene) forms an elastic network within the asphalt, enhancing adhesion and durability, breaking the emulsion and solidifying without the need for an additional curing agent.

[0033] The water-based reduced asphalt ultra-thin wear-resistant layer material in this application was tested using a low-temperature needle penetration tester (GL01080003), an asphalt elongation tester (GL01080006), and a fully automatic asphalt softening point tester (GL01080007). The test results showed a needle penetration (25°C, 5s, 100g) of 73 (0.1mm); an elongation (5°C) of 85 (cm); and a softening point (°C) of 86 (°C). Its tear resistance is significantly higher than that of existing common asphalt overlay materials.

[0034] The coarse aggregate and the fine aggregate are specifically stones formed by crushing basalt with different particle sizes. The particle size of the coarse aggregate is 5-10 mm, and the particle size of the fine aggregate is in the range of 3-5 mm.

[0035] Table 1 Technical indicators of coarse aggregate

[0036]

[0037]

[0038] Note 1: Robustness test can be carried out as needed.

[0039] Note 2: For coarse aggregate with a particle size of 5-10mm, the content of needle-like particles may not be required.

[0040] Table 2 Technical indicators of fine aggregate

[0041]

[0042] Note 1: Robustness test can be carried out as needed.

[0043] Determine the mix ratio of aggregates, calculate the percentage of various aggregates based on the selected mixed aggregate gradation range and the actual particle size gradation of each raw material mineral, so that the initial mineral gradation can meet the gradation range required by the design.

[0044] By selecting basalt as the aggregate to act as the filling aggregate, its high hardness, low water absorption, strong asphalt adhesion, and multi-angular bearing capacity increase the anti-slip performance, making it suitable for heavy-load transportation applications.

[0045] Specifically, the filler is mineral powder, slaked lime, or a mixture of the two. The filler should be dry, loose, and free of agglomerates, and its technical indicators should meet the requirements of Table 3.

[0046] Table 3 Packing technical indicators

[0047]

[0048] Specifically, the fiber is made of mineral fiber, which is made by drawing basalt or slag after melting, and has a length of no more than 8 mm.

[0049] By increasing the fiber component, the fiber forms a three-dimensional network structure in the asphalt mixture, dispersing stress and reducing thermal shrinkage cracks and reflective cracks.

[0050] Example 2

[0051] Different from the above-mentioned Example 1, the water-based reduced asphalt ultra-thin wear-resistant layer material in this embodiment includes the following components by weight: 65 parts of cement, 30 parts of high-performance water-based reduced asphalt, 2 parts of fiber, 10 parts of coarse aggregate, 10 parts of fine aggregate, and 5 parts of filler.

[0052] After mixing, it is cold-laid and applied to fill the cracks around the anti-cracking plate. The material has good flexibility and can be cured in a few hours. After curing, repeated vehicle rolling tests within the specified time range did not find any separation from the steel plate to form visible cracks.

[0053] Example 3

[0054] Different from the above-mentioned Example 1, the water-based reduced asphalt ultra-thin wear-resistant layer material in this embodiment includes the following components by weight: 62 parts of cement, 25 parts of high-performance water-based reduced asphalt, 4 parts of fiber, 15 parts of coarse aggregate, 16 parts of fine aggregate, and 7 parts of filler.

[0055] After mixing, it is cold-laid and applied to fill the gaps around the anti-cracking plate. The material has good flexibility. After solidification, repeated vehicle rolling tests within the specified time range did not reveal any separation from the steel plate to form visible cracks.

[0056] Example 4

[0057] As a comparative example, hot-laid asphalt was applied to the seams around the anti-cracking plate. Repeated vehicle rolling tests within the specified time range found that the asphalt material and the steel plate separated, and the side wall of the steel plate was sunken to form a pit, which needed to be filled again.

[0058] Example 5

[0059] As a comparative example, concrete was applied to the seams around the anti-cracking plate. Repeated vehicle rolling tests within the specified time range revealed that the concrete and steel plate were separated and had seams, and the concrete on the side wall of the steel plate was falling off and chipping, requiring refilling and repairing.

[0060] Example 6

[0061] The present invention also discloses a method for constructing a water-based reduced asphalt ultra-thin wear-resistant layer material, which is used for the construction of the water-based reduced asphalt ultra-thin wear-resistant layer material described in the above embodiment, and comprises the following steps:

[0062] Step 1: Prepare materials. Weigh cement, high-performance water-based reduced asphalt, fiber, coarse aggregate, fine aggregate and filler according to the total amount of materials used and set them aside.

[0063] Step 2: Mixing: Put the weighed cement, high-performance water-based reduced asphalt, fiber, coarse aggregate, fine aggregate and filler into a mixer, add water and stir for 15 minutes to form a slurry mixture.

[0064] Step 3: Apply the anti-cracking board, spreading it flat on the surface of the anti-cracking board strips with a thickness of 12-20mm. Spread it thinly and evenly and keep it consistent with the thickness of the anti-cracking board steel plate. After two hours, the water will dry and the road can be opened to traffic.

[0065] The simple cold-laying construction process shortens construction time, allows for quick traffic opening, and allows for a long construction season. Construction can be carried out at temperatures above 5°C. Furthermore, the construction process produces no toxic or harmful gases, making it environmentally friendly and pollution-free. The material's high flexibility effectively improves driving comfort and extends the service life of the pavement.

[0066] Specifically, after completing step 2, a cohesion test is required. This test should take into account the influence of the lowest temperature encountered during construction. Generally speaking, the required bond strength is greater than 3MPa.

[0067] Specifically, if Figure 1 As shown, before step 3, the bottom surfaces of the inner and outer slits 5 and 6 on both sides of the anti-crack plate 3 need to be cleaned by blowing them clean with compressed air. Then, modified emulsified asphalt tack coat oil is used for coating.

[0068]

[0069] By coating the top surface of the concrete material 4 with modified emulsified asphalt tack coat oil, the bonding strength between the protective layer material and the concrete material 4 can be significantly increased, thereby preventing the two from peeling off after bulging occurs.

[0070] In a specific implementation of this embodiment, in the construction method of the water-based reduced asphalt ultra-thin wear-resistant layer material of the present invention, the side walls of the comb plate 2 and the anti-cracking plate 3 need to be cleaned and coated with an interface agent before step three.

[0071] Specifically, the side walls of the comb plate 2 and the crack prevention plate 3 facing the slits are cleaned. When cleaning, a handheld electric tool with a wire brush is used to polish and remove rust until the metallic luster is exposed. The interface agent is specifically applied by brushing epoxy asphalt.

[0072] By coating the side walls of the comb plate 2 and the anti-cracking plate 3 with an interface agent, the bonding strength between the water-based reduced asphalt ultra-thin wear-resistant layer material and the side walls of the steel plate can be significantly improved. At the same time, the excellent hydrophobicity also plays a role in preventing the steel plate from rusting.

[0073] It should be noted that the water-based reduced asphalt ultra-thin wear-resistant layer material of the present invention can not only be applied to the anti-cracking slat seam surface layer at the rear of the expansion joint device, but can also be used for large-area road construction and local road repair.

[0074] As long as the pavement's base layer is in good condition, it can be directly filled and repaired on the original pavement. Paving can be carried out directly without milling, simplifying the construction process, avoiding the use of large-scale construction equipment, improving construction efficiency, and enabling continuous construction. Construction time is short, traffic is quickly opened, and the construction season is long. Due to the material's characteristics, construction can be carried out as long as the ambient temperature is >5°C. No toxic or harmful gases are produced during construction, making it environmentally friendly and pollution-free. Asphalt is enriched at the bottom to form a slurry, effectively sealing water and ensuring interlayer adhesion. This effectively addresses pavement problems such as pockmarks, looseness, cracks, and rutting. It has excellent road performance and wear resistance, improving driving comfort and extending the pavement's service life by more than five years.

[0075] The embodiments described above are merely descriptions of preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Without departing from the spirit of the present invention, various modifications and improvements made to the technical solutions of the present invention by persons skilled in the art shall fall within the scope of protection defined by the claims of the present invention.

Claims

1. A water-based reduced asphalt ultra-thin wear-resistant layer material, characterized by: It is applied to the anti-cracking slat seam surface layer at the rear of the expansion joint device; it includes the following components by weight: 60-65 parts of cement, 20-30 parts of high-performance water-based reduced asphalt, 2-5 parts of fiber, 10-20 parts of coarse aggregate, 10-20 parts of fine aggregate, and 5-10 parts of filler.

2. The water-based reduced asphalt ultra-thin wear-resistant layer material according to claim 1, characterized in that: The high-performance water-based reduced asphalt adopts high-polymer modified emulsified asphalt, which is stirred at room temperature and cold-laid for application.

3. The water-based reduced asphalt ultra-thin wear-resistant layer material according to claim 1, characterized in that: The coarse aggregate and the fine aggregate are specifically made of basalt stones with different particle sizes. The particle size of the coarse aggregate is 5-10 mm, and the particle size of the fine aggregate is in the range of 3-5 mm.

4. The water-based reduced asphalt ultra-thin wear-resistant layer material according to claim 1, characterized in that: The filler is specifically mineral powder, slaked lime or a mixture of the two.

5. The water-based reduced asphalt ultra-thin wear-resistant layer material according to claim 1, characterized in that: The fibers are specifically mineral fibers with a length no greater than 8 mm.

6. A method for constructing a water-based reduced asphalt ultra-thin wear-resistant layer material, characterized in that: The construction and use of the water-based reduced asphalt ultra-thin wear-resistant layer material according to any one of claims 1 to 5 comprises the following steps: Step 1: Material preparation: weigh cement, high-performance water-based reduced asphalt, fiber, coarse aggregate, fine aggregate and filler according to the total amount of materials used; Step 2: Mixing: Put cement, high-performance water-based reduced asphalt, fiber, coarse aggregate, fine aggregate and filler into a mixer and add water and stir for 15 minutes to form a slurry mixture; Step 3: Apply and spread it evenly on the surface of the anti-cracking board seams, and open to traffic after two hours.

7. The method for constructing the water-based reduced asphalt ultra-thin wear-resistant layer material according to claim 5, characterized in that: After step 2 is completed, a cohesion test needs to be carried out, and the cohesion test needs to take into account the lowest temperature encountered during the construction process.

8. The method for constructing the water-based reduced asphalt ultra-thin wear-resistant layer material according to claim 5, characterized in that: Before step three, the bottom surface of the anti-cracking board seam needs to be cleaned and coated with modified emulsified asphalt tack coat.

9. The method for constructing the water-based reduced asphalt ultra-thin wear-resistant layer material according to claim 7, characterized in that: Before step 3, the side walls of the comb plate and anti-crack plate need to be cleaned and coated with interface agent.

10. The method for constructing the water-based reduced asphalt ultra-thin wear-resistant layer material according to claim 9, characterized in that: The side walls of the comb plate and the anti-cracking plate are cleaned by grinding and removing rust with a wire brush, and the interface agent is specifically implemented by brushing epoxy asphalt.

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