A high-toughness, low-shrinkage, low-cost repair material for manhole spraying and a preparation method thereof

Abstract

The application discloses a kind of high tough low shrinkage low cost inspection well spray repair materials and preparation method thereof, the repair material is prepared from the following weight parts of raw materials: 25~35 parts ternary compound cementitious material, 50~80 parts double silicon-based composite functional aggregate, 0.1~1 parts admixture, 1~3 parts macro-micro composite reinforced repair base material, 6~15 parts water.The preparation method of the repair material is: ternary compound cementitious material, double silicon-based composite functional aggregate and macro-micro composite reinforced repair base material are mixed uniformly, then water is added, continue to be stirred uniformly.The application introduces macro-micro composite reinforced repair base material, through multi-scale enhancement (millimeter+micron), structure and function reinforcement can be realized simultaneously, with the advantages of high adhesion, low shrinkage, resistance to extreme environment and low cost, while effectively utilizing industrial solid waste during material preparation, overcoming the environmental protection bottleneck of existing epoxy resin repair material, which helps to realize the technical breakthrough of solid waste resource utilization.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of road engineering materials, and particularly relates to a high-strength and high-toughness low-shrinkage low-cost repair material for inspection well spraying and a preparation method thereof. BACKGROUND

[0002] In the urban drainage facilities in China, an inspection well is generally arranged every 30-50m along the drainage pipeline, and the number is huge. However, with the increase of service life, the inspection well is prone to leakage, corrosion, surface peeling, cracking, well perimeter settlement, structure damage and other phenomena due to cavitation, vehicle load, soil damage and other reasons, so the repair of the inspection well is particularly important.

[0003] The traditional excavation repair technology or replacement of the pipeline has more disturbance to the surrounding environment, long construction time, great construction risk, high cost of road surface and green recovery, and there is a certain contradiction between efficiency and safety, so the trenchless repair technology becomes a development trend.

[0004] At present, spraying repair has become a widely used technology in trenchless repair due to the characteristics of not being easily limited by structure and being flexible. However, the existing spraying repair materials still have the following problems:

[0005] 1) The commonly used silicate repair material has the problems of low early strength, long construction time and low 28d strength, and although the repair material using part of sulphoaluminate cement has high early strength, it often has the problem of large reduction of structure strength in later period;

[0006] 2) The material is difficult to realize structure and function reinforcement at the same time, and is difficult to adapt to complex and variable actual application environment, which is manifested as low adhesion, poor shrinkage, easy to fall off and crack, and difficult to maintain good performance in low and high temperature environments;

[0007] 3) The current popular epoxy resin repair material has high strength and high adhesion, but its high temperature resistance is limited, and the resin often has irritating odor when it has not been cured, the curing time is long, and the environmental protection is poor;

[0008] 4) The existing high-performance repair material is generally expensive, with a price of about 2000 yuan / ton.

[0009] Therefore, a new technology is needed to overcome the defects of the existing spraying material, realize structure and function reinforcement, have self-repairing function, enhance environmental protection, reduce carbon emission and reduce cost to a certain extent. SUMMARY

[0010] Based on the above prior art, the application provides a high-toughness low-shrinkage low-cost repair material for inspection well spraying and a preparation method thereof, the application introduces a macro-micro composite reinforcing repair base material, cooperates with sulphoaluminate cement and other cementitious materials and double-silicon-based composite functional aggregate, constructs a fast-hardening system with high strength, high toughness, adhesion, low shrinkage, self-repair and environmental protection functions through multi-scale reinforcement (millimeter+micron) by a small amount of addition, solves the problems of low adhesion of traditional materials, easy collapse of late strength, high cost and poor environmental protection, realizes significant improvement of inspection well repair efficiency and significant reduction of comprehensive cost, and achieves a technical breakthrough in solid waste resource utilization.

[0011] The technical scheme adopted by the application to achieve the above-mentioned purposes is:

[0012] A high-toughness low-shrinkage low-cost repair material for inspection well spraying is prepared from the following raw materials by weight: 25-35 parts of ternary compounded cementitious material, 50-80 parts of double-silicon-based composite functional aggregate, 0.1-1 part of additive, 1-3 parts of macro-micro composite reinforcing repair base material, and 6-15 parts of water.

[0013] The ternary compounded cementitious material is composed of the following components by weight: 1-30 parts of sulphoaluminate cement, 2-5 parts of silicon powder, and 1-5 parts of phosphogypsum.

[0014] The double-silicon-based composite functional aggregate is prepared from the following raw materials by weight through autoclave curing method: 15-20 parts of steel slag, 15-20 parts of blast furnace slag, 20-30 parts of quartz sand, 10-20 parts of quicklime, and 0.1-1 part of gas evolution agent.

[0015] The macro-micro composite reinforcing repair base material is composed of the following components by weight: 0.5-2 parts of volcanic rock fiber, 0.25-1 part of wollastonite whisker, and 0.01-0.05 part of fly ash microbead.

[0016] Further, the mass fraction of SiO2 in the silicon powder is not less than 95%.

[0017] Further, the preparation method of the double-silicon-based composite functional aggregate is as follows:

[0018] 1. Mix the steel slag, blast furnace slag, quartz sand, quicklime and gas evolution agent uniformly, then add 12-25 parts by weight of water, stir uniformly, and obtain a slurry;

[0019] 2. The slurry is statically cured at room temperature for 4-6 h, then put into an autoclave for autoclave curing at a steam pressure of 1-1.5 MPa for 6-10 h, and obtain autoclaved material;

[0020] 3. Crush and screen the autoclaved material to obtain the double-silicon-based composite functional aggregate.

[0021] Further, the gas generating agent is H2O2.

[0022] Further, the particle size of the double-silicon-based composite functional aggregate is 8-70 mesh.

[0023] Further, the length of the volcanic rock fiber is 4-8 mm, the length of the wollastonite whisker is 30-80 mu m, the diameter is 3-5 mu m, and the particle size of the fly ash microbead is 0.1-5 mu m.

[0024] Further, the additive is a high-efficiency polycarboxylic acid water reducing agent.

[0025] A preparation method of a high-strength and high-toughness low-shrinkage low-cost inspection well spraying repair material, comprising the following steps:

[0026] The ternary compounded cementitious material, the double-silicon-based composite functional aggregate and the macro-micro composite reinforced repair base material are uniformly mixed, then water is added, and uniform stirring is continued, so that the high-strength and high-toughness low-shrinkage low-cost inspection well spraying repair material is obtained.

[0027] Compared with the prior art, the advantages and beneficial effects of the present application are that:

[0028] 1. The macro-micro composite reinforced repair base material is introduced, the ternary compounded cementitious material and the double-silicon-based composite functional aggregate are matched, multi-scale reinforcement (millimeter+micron), energy dissipation synergy and interface optimization are realized, the repair material has high strength, high toughness and low shrinkage characteristics, a repair system with a bonding strength of greater than or equal to 3 MPa and a shrinkage of less than or equal to 0.05% is constructed, the compressive strength is simultaneously improved by more than 10 MPa, low-temperature and high-temperature curing and moisture surface adaptability are realized, and the technical bottlenecks of low adhesion, high brittleness, high shrinkage, easy peeling and cracking and collapse of sulphoaluminate cement late strength of general materials are overcome.

[0029] 2. The macro-micro composite reinforced repair base material is introduced, the ternary compounded cementitious material and the double-silicon-based composite functional aggregate are matched, the cement consumption is reduced by more than 30% under the premise of maintaining the same performance, the comprehensive cost of the repair material is reduced by 20%-30%, the functional aggregate is prepared from industrial solid wastes such as steel slag and slag, resource recycling is realized, and the consumption of natural sandstone is reduced by at least 0.8 tons per ton of material.

[0030] 3、The application breaks through the efficiency of trenchless repair and the environmental protection bottleneck of epoxy resin repair materials, and compared with epoxy resin and silicate cement repair materials, the material fast hardening property shortens the single well repair time by 6-10 hours, greatly reduces the influence of road closure on traffic, and is suitable for emergency repair; in terms of environmental protection, the carbon emission of single ton repair engineering is reduced by 20%-40%, which provides an innovative solution for green update of urban underground facilities. In addition, the application completely abandons the epoxy resin material system, and no irritating odor is released during the curing process of the repair material, which strengthens the environmental protection property from the material source and process link.

[0031] 4、The production process of the repair material is simple in operation, free of secondary pollution, and has strong implementability, and the spraying thickness can be controlled, so that the structure and functional reinforcement can be realized at the same time, and the repair purpose is achieved. BRIEF DESCRIPTION OF DRAWINGS

[0032] Figure 1 The on-site repair diagram of the high-strength and high-toughness low-shrinkage low-cost inspection well spraying repair material prepared for Example 1. DETAILED DESCRIPTION

[0033] In order to facilitate those skilled in the art to understand and implement the application, the application will be further described in detail below in combination with examples, and it should be understood that the examples described herein are only used to illustrate and explain the application, and are not used to limit the application.

[0034] Example 1

[0035] 1、Take 17 parts by mass of steel slag and 20 parts of blast furnace slag, take 25 parts by mass of quartz sand as siliceous material, and grind the quartz sand to 100 mesh, take 20 parts by mass of quicklime as calcareous material, take 0.4 parts by mass of H2O2 as gas generating agent, mix the steel slag, blast furnace slag, quartz sand, quicklime and gas generating agent uniformly, then add 16 parts by mass of water, stir uniformly, and obtain a slurry;

[0036] 2、The slurry is transported to a disc granulator, and is statically cured at room temperature for 5 hours, and then is put into a steam autoclave and is autoclaved at a steam pressure of 1.2 MPa for 8 hours, to obtain an autoclaved material;

[0037] 3、The autoclaved material is crushed and sieved to obtain a double-silicon-based composite functional aggregate with a particle size of 8-70 mesh.

[0038] 4. A high-toughness, low-shrinkage, low-cost repair material for manhole spraying, which is prepared from the following raw materials in parts by weight: 30 parts of ternary compound cementing material, wherein 24 parts of 625 sulphoaluminate cement, 4 parts of silica powder and 2 parts of phosphogypsum; 60 parts of double-silica-based composite functional aggregate; 0.5 part of high-efficiency polycarboxylic acid water reducer; 1.5 parts of macro-micro composite reinforcing repair base material, wherein 1 part of volcanic rock fiber (length 6 mm), 0.48 part of wollastonite whisker (length 30-40 μm, diameter 3-4 μm) and 0.02 part of fly ash microbead; and 13 parts of water.

[0039] The preparation method of the above-mentioned high-toughness, low-shrinkage, low-cost repair material for manhole spraying is as follows:

[0040] The cement, silica powder, phosphogypsum, double-silica-based composite functional aggregate, high-efficiency polycarboxylic acid water reducer, volcanic rock fiber, wollastonite whisker and fly ash microbead are stirred uniformly by a cement mortar stirrer, and then water is added, followed by slow stirring for 3-5 min (140 r / min) and fast stirring for 3-5 min (285 r / min) to form a uniform mortar without lumps, which is the high-toughness, low-shrinkage, low-cost repair material for manhole spraying.

[0041] Example 2

[0042] 1. A double-silica-based composite functional aggregate, which is prepared from the following raw materials in parts by weight: 20 parts of steel slag, 18 parts of blast furnace slag, 23 parts of quartz sand, 18 parts of quicklime, 0.35 part of H2O2 and 20 parts of water.

[0043] The preparation method of the above-mentioned double-silica-based composite functional aggregate is the same as that of Example 1.

[0044] 2. A high-toughness, low-shrinkage, low-cost repair material for manhole spraying, which is prepared from the following raw materials in parts by weight: 25 parts of ternary compound cementing material, wherein 21 parts of 625 sulphoaluminate cement, 2 parts of silica powder and 2 parts of phosphogypsum; 70 parts of double-silica-based composite functional aggregate; 1 part of high-efficiency polycarboxylic acid water reducer; 2 parts of macro-micro composite reinforcing repair base material, wherein 1.3 parts of volcanic rock fiber (length 4 mm), 0.65 part of wollastonite whisker (length 40-60 μm, diameter 3-4 μm) and 0.05 part of fly ash microbead; and 14 parts of water.

[0045] The preparation method of the above-mentioned high-toughness, low-shrinkage, low-cost repair material for manhole spraying is the same as that of Example 1.

[0046] Example 3

[0047] 1. A double-silica-based composite functional aggregate, which is prepared from the following raw materials in parts by weight: 15 parts of steel slag, 15 parts of blast furnace slag, 20 parts of quartz sand, 15 parts of quicklime, 0.2 part of H2O2 and 14 parts of water.

[0048] The preparation method of the double-silicon-based composite functional aggregate is the same as that of Example 1.

[0049] 2. A high-toughness, low-shrinkage, low-cost repair material for inspection well spraying, which is prepared from the following raw materials by weight: 35 parts of ternary compounded cementitious material, wherein 30 parts of 625 sulfoaluminate cement, 3 parts of silica powder, and 2 parts of phosphogypsum; 55 parts of double-silicon-based composite functional aggregate; 0.15 parts of high-efficiency polycarboxylic acid water reducer; 1 part of macro-micro composite reinforced repair base material, wherein 0.68 parts of volcanic rock fiber (length 8 mm), 0.31 parts of wollastonite whisker (length 30-40 μm, diameter 4-5 μm), and 0.01 parts of fly ash microbeads; and 12 parts of water.

[0050] The preparation method of the high-toughness, low-shrinkage, low-cost repair material for inspection well spraying is the same as that of Example 1.

[0051] Comparative Example 1

[0052] A repair material for inspection well spraying, which is prepared from the following raw materials by weight: 30 parts of ternary compounded cementitious material, wherein 24 parts of 625 sulfoaluminate cement, 4 parts of silica powder, and 2 parts of phosphogypsum; 60 parts of double-silicon-based composite functional aggregate; 0.5 parts of high-efficiency polycarboxylic acid water reducer; 1 part of volcanic rock fiber (length 6 mm); 0.02 parts of fly ash microbeads; and 13 parts of water.

[0053] The formula and preparation method of the double-silicon-based composite functional aggregate of the comparative example are the same as those of Example 1.

[0054] The preparation method of the repair material for inspection well spraying of the comparative example is the same as that of Example 1.

[0055] Comparative Example 2

[0056] A repair material for inspection well spraying, which is prepared from the following raw materials by weight: 30 parts of ternary compounded cementitious material, wherein 24 parts of 625 sulfoaluminate cement, 4 parts of silica powder, and 2 parts of phosphogypsum; 60 parts of double-silicon-based composite functional aggregate; 0.5 parts of high-efficiency polycarboxylic acid water reducer; 0.48 parts of wollastonite whisker (length 30-40 μm, diameter 3-4 μm); 0.02 parts of fly ash microbeads; and 13 parts of water.

[0057] The formula and preparation method of the double-silicon-based composite functional aggregate of the comparative example are the same as those of Example 1.

[0058] The preparation method of the repair material for inspection well spraying of the comparative example is the same as that of Example 1.

[0059] Comparative Example 3

[0060] A repair material for manhole spraying is prepared from the following raw materials by weight: 30 parts of ternary compounded cementitious material, wherein 24 parts of 625 sulfoaluminate cement, 4 parts of silica powder, and 2 parts of phosphogypsum; 60 parts of double-silica-based composite functional aggregate; 0.5 parts of high-efficiency polycarboxylate superplasticizer; 1 part of volcanic rock fiber (length 6 mm); 0.48 parts of wollastonite whisker (length 30-40 μm, diameter 3-4 μm); and 13 parts of water.

[0061] The formula and preparation method of the double-silica-based composite functional aggregate of the present comparative example are the same as those of Example 1.

[0062] The preparation method of the repair material for manhole spraying of the present comparative example is the same as that of Example 1.

[0063] Comparative Example 4

[0064] A repair material for manhole spraying is prepared from the following raw materials by weight: 30 parts of ternary compounded cementitious material, wherein 24 parts of 625 sulfoaluminate cement, 4 parts of silica powder, and 2 parts of phosphogypsum; 60 parts of double-silica-based composite functional aggregate; 0.5 parts of high-efficiency polycarboxylate superplasticizer; and 13 parts of water.

[0065] The formula and preparation method of the double-silica-based composite functional aggregate of the present comparative example are the same as those of Example 1.

[0066] The preparation method of the repair material for manhole spraying of the present comparative example is the same as that of Example 1.

[0067] Comparative Example 5

[0068] A repair material for manhole spraying is prepared from the following raw materials by weight: 30 parts of ternary compounded cementitious material, wherein 24 parts of 625 sulfoaluminate cement, 4 parts of silica powder, and 2 parts of phosphogypsum; 60 parts of 8-70 mesh quartz sand; 0.5 parts of high-efficiency polycarboxylate superplasticizer; 1.5 parts of macro-micro composite reinforced repair base material, wherein 1 part of volcanic rock fiber (length 6 mm), 0.48 parts of wollastonite whisker (length 30-40 μm, diameter 3-4 μm), and 0.02 parts of fly ash microbeads; and 13 parts of water.

[0069] The preparation method of the repair material for manhole spraying of the present comparative example is the same as that of Example 1.

[0070] Comparative Example 6

[0071] A repair material for manhole spraying is prepared from the following raw materials by weight: 30 parts of 625 sulfoaluminate cement; 60 parts of double-silica-based composite functional aggregate; 0.5 parts of high-efficiency polycarboxylate superplasticizer; 1.5 parts of macro-micro composite reinforced repair base material, wherein 1 part of volcanic rock fiber (length 6 mm), 0.48 parts of wollastonite whisker (length 30-40 μm, diameter 3-4 μm), and 0.02 parts of fly ash microbeads; and 13 parts of water.

[0072] The formula and preparation method of the double-silicon-based composite functional aggregate of the present comparative example are the same as those of Example 1.

[0073] The preparation method of the inspection well spraying repair material of the present comparative example is the same as that of Example 1.

[0074] Comparative Example 7

[0075] An inspection well spraying repair material is prepared from the following raw materials by weight: 30 parts of 625 sulfoaluminate cement; 60 parts of 8-70 mesh quartz sand; 0.5 parts of high-efficiency polycarboxylic acid water reducer; and 13 parts of water.

[0076] The preparation method of the inspection well spraying repair material of the present comparative example is the same as that of Example 1.

[0077] The repair materials prepared in Examples 1-3 and Comparative Examples 1-7 are cured under standard conditions, and after the curing is completed, the mechanical properties, high and low temperature resistance, bonding properties, and shrinkage properties and other related properties of the repair materials are tested, and the cost thereof is calculated, and the results are shown in Tables 1 and 2 below:

[0078] The properties of the high-strength and high-toughness low-shrinkage low-cost inspection well spraying repair materials prepared in Examples 1-3 are shown in Table 1 below:

[0079] Table 1

[0080]

[0081] The properties of the repair materials prepared in Example 1 and Comparative Examples 1-7 are shown in Table 2 below:

[0082] Table 2

[0083]

[0084] Note: The permeation resistance pressure is all 1.5 MPa because the maximum permeation resistance pressure of the laboratory detection equipment can only reach 1.5 MPa.

[0085] As can be seen from the above table, compared with traditional repair materials, the repair material of the present application has a significantly reduced cost and significantly improved other properties, especially the shrinkage properties and high and low temperature resistance, which ensures that the material does not burst and swell at extreme temperatures, and the ultra-low shrinkage rate reduces the material's hollowing and cracking, effectively reducing the full-cycle maintenance cost.

[0086] The repair material of the present application has a long service life in practical application and good durability, and at the same time, the material meets the performance requirements of cement-based materials for structural repair in the “Urban Drainage Pipeline Non-excavation Repair Engineering Construction and Acceptance Regulations”.

[0087] Taking the high-toughness low-shrinkage low-cost inspection well spraying repair material prepared in Example 1 as an example, a pipeline spraying repair experiment is carried out, spraying construction is carried out, the spraying thickness is 10 mm, the construction process is simple, the raw material is non-irritating, and the environmental protection is relatively strong, and the construction result is as shown in Figure 1 Figure 1 It can be known that the high-toughness low-shrinkage low-cost inspection well spraying repair material has good wall sticking property.​

Claims

1. A high tough, low shrinkage, low cost, manhole repair material for spraying, characterized in that It is prepared from the following raw materials by weight: 25-35 parts of ternary compound cementitious material, 50-80 parts of double-silicon-based composite functional aggregate, 0.1-1 part of additive, 1-3 parts of macro-micro composite reinforced repair base material, and 6-15 parts of water; The ternary compound cementitious material is composed of the following components by weight: 1-30 parts of sulphoaluminate cement, 2-5 parts of silicon powder, and 1-5 parts of phosphogypsum; The double-silicon-based composite functional aggregate is prepared from the following raw materials by weight through autoclaved curing method: 15-20 parts of steel slag, 15-20 parts of blast furnace slag, 20-30 parts of quartz sand, 10-20 parts of quicklime, and 0.1-1 part of gas evolution agent; The macro-micro composite reinforced repair base material is composed of the following components by weight: 0.5-2 parts of volcanic rock fiber, 0.25-1 part of wollastonite whisker, and 0.01-0.05 part of fly ash microbead.

2. The high tough, low shrinkage, low cost, manhole repair material for spray application of claim 1, wherein: The mass fraction of SiO2 in the silicon powder is not less than 95%.

3. The high tough, low shrinkage, low cost, manhole repair material of claim 1, wherein The preparation method of the double-silicon-based composite functional aggregate is as follows: 3.1, uniformly mix the steel slag, blast furnace slag, quartz sand, quicklime, and gas evolution agent, then add 12-25 parts by weight of water, stir uniformly, and obtain a slurry; 3.2, the slurry is statically cured at room temperature for 4-6 hours, and then placed in an autoclave for autoclaving at a steam pressure of 1-1.5 MPa for 6-10 hours to obtain autoclaved material; 3.3, crush and sieve the autoclaved material to obtain the double-silicon-based composite functional aggregate.

4. The high tough, low shrinkage, low cost, manhole repair material of claim 1, wherein: The gas evolution agent is H2O2.

5. The high tough, low shrinkage, low cost, manhole repair material of claim 1, wherein: The particle size of the double-silicon-based composite functional aggregate is 8-70 mesh.

6. The high tough, low shrinkage, low cost, manhole repair material of claim 1, wherein: The length of the volcanic rock fiber is 4-8 mm, the length of the wollastonite whisker is 30-80 μm, the diameter is 3-5 μm, and the particle size of the fly ash microbead is 0.1-5 μm.

7. The high tough, low shrinkage, low cost, manhole repair material of claim 1, wherein: The additive is a high-efficiency polycarboxylic acid water reducer.

8. A method for preparing the high-toughness, low-shrinkage, low-cost repair material for inspection well spraying according to any one of claims 1-7, characterized in that The steps include: Mix the ternary compound cementitious material, double-silicon-based composite functional aggregate, macro-micro composite reinforced repair base material, and additive uniformly, then add water, continue to stir uniformly, and obtain the high-strength and high-toughness low-shrinkage low-cost repair material for inspection well spraying.

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