Hot chamber wall self-compacting concrete one-time pouring forming construction method
By using a double-tube system and a segmented pouring method, the problem of pouring self-compacting concrete in hot chamber structures was solved, enabling continuous pouring under complex working conditions, ensuring the fluidity and compactness of the concrete, and reducing the cost of construction joint treatment and the risk of equipment deviation.
Patent Information
- Application Number
- CN202511626002.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-07
- Publication Date
- 2026-02-17
AI Technical Summary
In the construction of hot chamber structures, it is difficult to guarantee the compaction of self-compacting concrete through continuous pouring, and multiple pours increase the cost and time of construction joint treatment. Especially in ultra-high wall structures, ordinary concrete vibrators cannot be used, resulting in a high risk of equipment deviation.
A double-duct system and segmented pouring method were adopted. The concrete mix proportion and flow length were determined by combining simulation tests. The concrete was poured in segments through the first duct and chute and the second duct to gradually control the concrete pouring height, avoid the use of vibrators, and ensure fluidity and compactness.
It enables continuous pouring of self-compacting concrete under complex working conditions, reduces the risk of equipment deviation, reduces the cost and time of construction joint treatment, and ensures the filling and compactness of concrete.
Smart Images
Figure CN121539115A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of building construction technology, specifically to a method for one-time casting and molding of self-compacting concrete for hot chamber walls. Background Technology
[0002] In the construction industry, there is a demand for concrete pouring of ultra-high walls. To ensure pouring quality and safety, the conventional pouring process involves setting horizontal construction joints and pouring in multiple layers. However, multiple pours increase the construction cost and time required for construction joint treatment, and some construction joint treatments are not feasible due to operational conditions. Currently, there are existing construction methods for ultra-high structural members in China. However, since the pouring materials are all ordinary concrete and the applicable working conditions are relatively simple, they differ significantly from the complex hot chamber wall structure and cannot be applied to the continuous pouring of self-compacting concrete for hot chamber structures.
[0003] In the construction of hot chamber structures, due to the steel cladding on one or both sides of the walls and the large number and density of equipment and reinforcing bars embedded within them, ordinary concrete pouring requires the use of immersion vibrators for compaction. However, in cases where the space within the walls is limited, it is impossible to use immersion vibrators for sufficient compaction, making it difficult to guarantee the density of the concrete. Furthermore, using immersion vibrators increases the risk of deviation from the embedded equipment due to the increased vibration load. Therefore, using self-compacting concrete eliminates the need for immersion vibrators; only in more complex or specialized areas, external tapping of the formwork is needed to improve compaction. Summary of the Invention
[0004] The purpose of this invention is to provide a construction method for the continuous pouring of self-compacting concrete in ultra-high wall structures (such as hot chamber structures) with complex working conditions. The method adopts a comprehensive horizontal layering approach to solve the problems of excessively high pouring height, high pouring difficulty, and high density risk of self-compacting concrete, and to reduce the impact of deviations on the steel cladding and embedded equipment of the wall during the concrete pouring process.
[0005] This invention is achieved through the following technical solution: A method for one-time casting of self-compacting concrete for hot chamber walls includes the following steps: S1. Design the mix proportion of self-compacting concrete and verify its performance parameters to ensure that the flow length, initial setting time and filling properties of the concrete meet the design requirements. S2. Arrange concrete discharge points according to the flow length parameters. The distance between adjacent discharge points shall not be greater than twice the flow length, and avoid pre-embedded equipment in the wall. S3. Install a double-drum system for material feeding: including a first drum and chute on the outside of the wall, and a second drum on the inside of the wall; S4. Segmented casting: The wall is divided into three sections according to its height: lower, middle and upper. The lower, middle and upper sections of the wall are poured in sequence through the first chute and chute, the second chute and hopper and the top discharge, respectively. The casting is completed by controlling the thickness of each layer.
[0006] As one possible design, the performance parameters described in S1 above are determined through simulation tests, including actual ambient temperature, flow length at layer thickness, and initial setting time.
[0007] As one possible design, the arrangement of the unloading points in S2 above requires reserving space for the installation of the tremie pipe during the reinforcement binding process.
[0008] As one possible design, the first drum in the above-mentioned double drum system is made of corrugated pipe and has a first hopper at the top, which is connected to the first drum. The wall template has a feeding port for material feeding. The end of the chute closest to the wall is connected to the feeding port, and the end of the chute away from the wall is inclined upward. The bottom of the first cistern is set in the chute. The second spool is made of corrugated pipe and has a second hopper at the top. The second hopper is connected to the second spool, and the first hopper and the second hopper are installed at the same horizontal position.
[0009] As one possible design, the segmented casting in step S4 above specifically includes: S41. The lower 1 / 3 of the height is fed by the first chute and the sluice, and the material is poured in layers to the height of the lower edge of the inlet before the inlet is sealed. S42. The middle 1 / 3 of the height is poured using the second shunt. After pouring to the lower end of the second shunt, the second shunt is removed. S43, the upper 1 / 3 of the height is poured directly from the top of the wall.
[0010] As one possible design, the layer thickness is determined through calculation. The calculation formula includes factors such as the concrete pouring rate, initial setting time, length of the poured wall, and thickness. The calculation formula is as follows:
[0011] In the formula: H— Maximum layer height (m) for fully layered concrete pouring of the wall. S— The actual pouring speed per hour (m) using this method 3 When the wall is continuously poured in horizontal layers, the result can be determined through testing under actual working conditions. — The initial setting time (h) of concrete is determined by actual measurement. β—The risk correction coefficient to ensure continuous concrete pouring takes into account the impact of unforeseen circumstances during concrete pouring (such as pumping machinery failure, untimely concrete supply, etc.). β is taken as 0.8. If the construction conditions are complex, the coefficient value can be appropriately reduced.
[0012] l— Total length of the concrete wall to be poured in this instance (m); W— Wall thickness (m); Multiple inspection holes with vertical spacing equal to the layer thickness are set on the template. The completion of layering is determined by observing the overflow of slurry.
[0013] As one possible design, the upper inspection hole is located at the vertical spacing between the center lines of adjacent feeding points, and the layer thickness control accuracy is achieved through the coordinated operation of the upper and lower parts. This includes the upper-level operators controlling the material feeding time at each feeding point, with the feeding time calculated using the following formula. , Where: T—the duration of concrete feeding at each feeding point (min); H—Height of concrete layer pouring (m); w—wall thickness (m); — Concrete flow length (m); — Concrete pouring speed (m) 3 / min); In addition, the overflowing concrete slurry from the inspection hole is observed by the personnel at the bottom as an auxiliary criterion, and the personnel at the top are stopped from releasing material by using a walkie-talkie.
[0014] As one possible design, in areas with dense reinforcement or equipment, manual tapping or external plate vibrators can be used to assist in compaction.
[0015] As one possible design, when pouring the lower 1 / 3 of the height, when the pouring height reaches the lower edge of the inlet, the pouring at that point is paused, and the chute and the first tremie pipe at that point are immediately removed. Then, the inlet is sealed with a template, and the pouring is moved to the next inlet. This process is repeated until the overall height of the wall reaches the lower edge of the inlet, and all inlets are sealed, thus completing the pouring of the lower 1 / 3 of the height. When pouring the middle 1 / 3 of the height, after pouring to the lower end of the second tremie pipe, stop pouring at that point, then remove the second tremie pipe at that point, and move to the next pouring point for pouring. Continue in this manner until the concrete at all pouring points has been poured to the lower end of the corresponding second tremie pipe, thus completing the pouring of the middle 1 / 3 of the height.
[0016] As one possible design, the aforementioned layer thickness parameters are dynamically correlated with ambient temperature and concrete initial setting time, and the pouring speed and layer interval are adjusted through real-time monitoring.
[0017] Compared with the prior art, the present invention has the following advantages and beneficial effects: 1. By combining simulation tests with actual ambient temperature, layer thickness and other working conditions, the flow length and initial setting time of concrete are determined to ensure that the mix design is scientific and reasonable, avoid segregation, bleeding or insufficient fluidity caused by parameter deviation, and ensure the filling and compaction properties of self-compacting concrete.
[0018] 2. Determine the spacing between material discharge points based on the concrete flow length (not more than twice the flow length) to ensure that there are no blind spots in the concrete coverage area, reduce local accumulation or gaps, avoid areas with embedded equipment and dense reinforcement, avoid immersion vibration, and protect equipment from impact damage or increased deviation.
[0019] 3. By combining the first chute with the chute and the second chute, the concrete pouring height is controlled in sections (the first chute outside the wall is used for the lower part, and the second chute inside the wall is used for the middle part), which reduces concrete segregation caused by free fall height and avoids direct impact of concrete on high-precision embedded equipment. At the same time, the concrete is poured in three sections according to the height of the wall: lower, middle and upper, to gradually reduce the load of concrete lateral pressure on the formwork and equipment. Attached Figure Description
[0020] The accompanying drawings, which are included to provide a further understanding of embodiments of the invention and form part of this application, do not constitute a limitation thereof. In the drawings: Figure 1 This is a plan view of the wall material cutting point layout in an embodiment of this application; Figure 2 This is a schematic diagram of the dual-tube system layout according to an embodiment of this application; Figure 3 This is a schematic diagram of the wall elevation in an embodiment of this application; Figure 4 for Figure 3 Enlarged view of the structure at point A in the middle; Figure 5 This is a plan view of the chute according to an embodiment of this application; Figure 6 This is an isometric plan view of the chute according to an embodiment of this application; Figure 7 This is a schematic diagram of the hopper structure; Figure 8 This is a schematic diagram of the connection structure between the hopper and the feed hopper.
[0021] The attached diagram shows the markings and corresponding component names: 1-First sluice drum, 2-Cheet, 3-Second sluice drum, 4-First hopper, 5-Second hopper, 6-Wall, 7-Inspection hole, 8-Discharge point. Detailed Implementation
[0022] To make the objectives, technical solutions, and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the embodiments and accompanying drawings. The illustrative embodiments and descriptions of the present invention are only used to explain the present invention and are not intended to limit the present invention.
[0023] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.
[0024] It should be noted that when a component is referred to as being "fixed to" or "set on" another component, it can be directly or indirectly attached to that other component. When a component is referred to as being "connected to" another component, it can be directly or indirectly connected to that other component.
[0025] It should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention.
[0026] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.
[0027] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances. Example
[0028] Combined with reference Figures 1-8 As shown in the figure, this embodiment provides a method for one-time casting of self-compacting concrete for hot chamber walls, including the following steps: A method for one-time casting of self-compacting concrete for hot chamber walls includes the following steps: S1, design the mix proportion of self-compacting concrete and verify its performance parameters to ensure that the flow length, initial setting time and filling properties of the concrete meet the design requirements. For example, the specific settings are shown in Table 1 below: Table 1. Mix design data for shrinkage-compensating self-compacting concrete
[0029] S2, Concrete discharge points 8 are arranged according to the flow length parameters. The distance between adjacent discharge points 8 is no more than twice the flow length, and they avoid the pre-embedded equipment in the wall. S3, Install a double-drum system for material feeding: including a first drum 1 and a chute 2 on the outside of the wall 6, and a second drum 3 on the inside of the wall; S4, Segmented casting: The wall 6 is divided into three sections according to its height: lower, middle and upper. The lower, middle and upper sections of the wall 6 are poured in sequence through the first chute 1 and chute 2, the second chute 3 and hopper and the top discharge, respectively, and the casting is completed in combination with the layer thickness control.
[0030] Among them, by combining simulation tests with actual environmental conditions such as temperature and layer thickness, the flow length and initial setting time of concrete are determined to ensure that the mix design is scientific and reasonable, avoid segregation, bleeding or insufficient fluidity caused by parameter deviation, and ensure the filling and compaction properties of self-compacting concrete.
[0031] Furthermore, the spacing of the discharge points is determined based on the concrete flow length (not exceeding twice the flow length) to ensure that there are no blind spots in the concrete coverage area, reduce local accumulation or gaps, avoid areas with embedded equipment and dense reinforcement, prevent tool installation conflicts, and protect equipment from impact damage.
[0032] In this embodiment, the concrete pouring height is controlled in sections by combining the first chute 1 with the chute 2 and the second chute 3 (the first chute 1 outside the wall is used for the lower part, and the second chute 3 inside the wall is used for the middle part), which reduces the impact force of free fall and avoids damage to high-precision equipment. At the same time, the concrete is poured in three sections according to the height of the wall 6: lower, middle and upper, to gradually reduce the load of the concrete lateral pressure on the formwork and equipment.
[0033] In some embodiments, the performance parameters in step S1 are determined through simulation experiments, including actual ambient temperature, flow length at the layer thickness, and initial setting time. In some embodiments, the arrangement of the material feeding point 8 in step S2 requires reserving space for the installation of the tremie pipe during the reinforcement binding.
[0034] In some embodiments, the first drum 1 in the double-drum system is made of corrugated pipe and has a first hopper 4 at its top, which is connected to the first drum 1. The wall template has a feed inlet for material feeding. The end of the chute 2 closest to the wall 6 is connected to the feed inlet, and the end of the chute 2 furthest from the wall 6 is inclined upwards. The bottom end of the first cistern 1 is located on the upper side of the end of the chute 2 closest to the feed inlet. The second spool 3 is made of corrugated pipe and has a second hopper 5 at the top. The second hopper 5 is connected to the second spool 3, and the first hopper 4 and the second hopper 5 are installed at the same horizontal position.
[0035] In some embodiments, the segmented casting of step S4 specifically includes: the lower 1 / 3 height is fed by the first chute 1 and the chute 2, and the material is poured in layers to the lower edge of the inlet before the inlet is sealed. The middle 1 / 3 of the height is poured using the second duct 3. After pouring to the lower end of the second duct 3, the second duct 3 is removed. The upper 1 / 3 of the height was poured directly from the top of the wall.
[0036] In some embodiments, the layer thickness is determined by calculation. The calculation formula is based on the ultimate flow length of concrete, the supply speed and the initial setting time. Multiple inspection holes 7 with vertical spacing equal to the layer thickness are set on the template. The completion of the layer is judged by observing the overflow of grout. The layer thickness is calculated based on the ultimate flow length and the initial setting time, so as to control the pouring speed more accurately. The grout overflow is monitored in real time by the inspection holes 7, and the completion of the layer is judged intuitively, thus avoiding the formation of cold joints.
[0037] For example: the calculation formula is: , In the formula: H— Maximum layer height (m) for fully layered concrete pouring of the wall. S— The actual pouring speed per hour (m) using this method 3 When the wall is continuously poured in horizontal layers, the result can be determined through testing under actual working conditions. — The initial setting time (h) of concrete is determined by actual measurement. β—The risk correction coefficient to ensure continuous concrete pouring takes into account the impact of sudden situations that may occur during concrete pouring (such as pumping machinery failure, untimely concrete supply, etc.). β is taken as 0.8. If the construction conditions are complex, the coefficient value can be appropriately reduced. l— Total length of the concrete wall to be poured in this instance (m); W— Wall thickness (m); In some embodiments, the inspection hole 7 is located at the vertical spacing between the center lines of adjacent feeding points 8, thereby more accurately locating the layer boundary, and controlling the layer thickness through upper and lower linkage, further reducing the damage of lateral pressure to the template and equipment.
[0038] For example, the feeding time is calculated using the following formula: , Where: T—the duration of concrete feeding at each feeding point (min); H—Height of concrete layer pouring (m); w—wall thickness (m); — Concrete flow length (m); — Concrete pouring speed (m) 3 ( / min), and the overflow of concrete slurry from the inspection hole is used as an auxiliary judgment standard by the personnel at the bottom, and the personnel at the top are stopped from releasing material by calling the walkie-talkie.
[0039] In some embodiments, in areas with dense reinforcement or equipment, manual tapping or external plate vibrators are used to assist in compaction, thereby compensating for insufficient local fluidity of self-compacting concrete and eliminating defects such as hollow areas and honeycombing.
[0040] In some embodiments, when the lower 1 / 3 height is being poured, when the pouring height reaches the lower edge of the inlet, the pouring at that point is paused, and the chute 2 and the first cistern 1 at that point are immediately removed. Then, the inlet is sealed with a template, and the pouring is moved to the next inlet. This process continues until the overall height of the wall is poured to the lower edge of the inlet, and all inlets are sealed, thus completing the pouring of the lower 1 / 3 height. When pouring the middle 1 / 3 of the height, after pouring to the lower end of the second tremie pipe 3, the pouring at that point is paused, and then the second tremie pipe 3 at that point is removed. At the same time, the pouring is moved to the next pouring point. This process is continued until the concrete at all pouring points 8 has been poured to the lower end of the corresponding second tremie pipe 3, thus completing the pouring of the middle 1 / 3 of the height. In this embodiment, the removal and sealing of the tremie pipes are carried out in sequence, which makes the state of the concrete after pouring stable and avoids the flow disorder of the concrete caused by simultaneous removal. This maintains the continuity of the pouring at each stage and ensures the interlayer bonding strength.
[0041] In some embodiments, the layer thickness parameter is dynamically correlated with the ambient temperature and the initial setting time of the concrete. By monitoring and adjusting the pouring speed and layer interval in real time, the construction environment changes (such as temperature fluctuations) can be addressed, and cold joints or insufficient compactness caused by parameter solidification can be avoided.
[0042] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of the present invention. It should be understood that the above description is only a specific embodiment of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.
Claims
1. A method for one-time casting and molding of self-compacting concrete for hot chamber walls, characterized in that, Includes the following steps: S1. Design the mix proportion of self-compacting concrete and verify its performance parameters to ensure that the concrete's filling capacity, gap passage, slump flow, and initial setting time meet the design and construction requirements. S2. Arrange concrete feeding points (8) according to the flow length parameters. The distance between adjacent feeding points (8) shall not be greater than twice the flow length, and shall avoid pre-embedded equipment in the wall. S3. Install a double-drum system for material feeding: including a first drum (1) and a chute (2) on the outside of the wall (6), and a second drum (3) on the inside of the wall; S4. Segmented pouring: The wall (6) is divided into three segments according to its height: lower, middle and upper. The lower, middle and upper parts of the wall (6) are poured in sequence through the first chute (1) and the chute (2), the second chute (3) and the hopper and the top discharge, respectively, and the pouring is completed in combination with the layer thickness control.
2. The method according to claim 1, characterized in that: The performance parameters mentioned in step S1 are determined through simulation tests, including actual ambient temperature, flow length at layer thickness, and initial setting time.
3. The method according to claim 1, characterized in that: In step S2, the placement of the material feeding point (8) requires reserving space for the installation of the tremie pipe during the reinforcement binding process.
4. The method according to claim 1, characterized in that: The first drum (1) in the double drum system is made of corrugated pipe and has a first hopper (4) at the top, which is connected to the first drum (1). The wall template has a feeding port for feeding. The end of the chute (2) close to the wall (6) is connected to the feeding port. The end of the chute (2) away from the wall (6) is inclined upward. The bottom end of the first sluice tube (1) is set in the chute (2). The second spool (3) is made of corrugated pipe and has a second hopper (5) at the top. The second hopper (5) is connected to the second spool (3), and the first hopper (4) and the second hopper (5) are installed at the same horizontal position.
5. The method according to claim 4, characterized in that: Step S4, segmented casting, specifically includes: S41. The lower 1 / 3 of the height is fed by the first chute (1) and the chute (2), and the material is poured in layers to the height of the lower edge of the feed inlet before the feed inlet is sealed. S42. The middle 1 / 3 of the height is poured using the second shunt (3). After pouring to the lower end of the second shunt (3), the second shunt (3) is removed. S43, the upper 1 / 3 of the height is poured directly from the top of the wall.
6. The method according to claim 5, characterized in that: The layer thickness is determined through calculation. The calculation formula includes factors such as the concrete pouring rate, initial setting time, length of the poured wall, and thickness. The calculation formula is as follows: ， In the formula: H— Maximum layer height (m) for fully layered concrete pouring of the wall. S— The actual pouring speed per hour (m) using this method 3 When the wall is continuously poured in horizontal layers, the result can be determined through testing under actual working conditions. — The initial setting time (h) of concrete is determined by actual measurement. β— The risk correction coefficient to ensure continuous concrete pouring takes into account the impact of sudden situations that may occur during concrete pouring (such as pumping machinery failure, untimely concrete supply, etc.). β is taken as 0.
8. If the construction conditions are complex, the coefficient value can be appropriately reduced. l— Total length of the concrete wall to be poured in this instance (m); W— Wall thickness (m); Multiple inspection holes (7) with vertical spacing equal to the layer thickness are set on the template. The layering is judged by observing the overflow of slurry.
7. The method according to claim 6, characterized in that: The inspection hole (7) is located at the vertical spacing between the center lines of adjacent feeding points (8), and the layer thickness control accuracy is achieved through the coordinated action of the upper and lower parts. This includes the upper-level operators controlling the material feeding time at each feeding point, with the feeding time calculated using the following formula. ， Where: T—the duration of concrete feeding at each feeding point (min); H—Height of concrete layer pouring (m); w—wall thickness (m); — Concrete flow length (m); — Concrete pouring speed (m) 3 / min); In addition, the overflowing concrete slurry from the inspection hole is observed by the personnel at the bottom as an auxiliary criterion, and the personnel at the top are stopped from releasing material by using a walkie-talkie.
8. The method according to claim 7, characterized in that: In areas with dense reinforcement or equipment, manual tapping or external plate vibrators can be used to assist in compaction.
9. The method according to claim 5, characterized in that: When the lower 1 / 3 height is poured, when the pouring height reaches the lower edge of the feed inlet, the pouring of the feed point is paused, and the chute (2) and the first chute (1) at that point are immediately removed. Then the feed inlet is sealed with a template, and the pouring is moved to the next feed point. This process continues until the overall pouring height of the wall reaches the lower edge of the feed inlet, and the sealing of all feeds is completed, thus completing the pouring of the lower 1 / 3 height. When pouring the middle 1 / 3 height, after pouring to the lower end of the second truss (3), stop pouring at that point, then remove the second truss (3) at that point, and move to the next point for pouring. Continue in this manner until the concrete at all points (8) is poured to the lower end of the corresponding second truss (3), thus completing the middle 1 / 3 height pouring.
10. The method according to claim 9, characterized in that: The layer thickness parameter is dynamically correlated with the ambient temperature and the initial setting time of the concrete, and the pouring speed and layer interval are adjusted through real-time monitoring.