Airport fabricated pavement slab system and construction method

Abstract

The invention belongs to the technical field of airport assembly type pavements, and particularly relates to an airport assembly type pavement slab system and a construction method. An airport assembly type pavement slab system sequentially comprises a foundation layer, an assembly type foundation layer and an assembly type pavement slab from bottom to top, the assembly type foundation layer is fixedly connected with the foundation layer, the assembly type foundation layer is provided with an assembly type framework, the assembly type framework is filled with a foundation layer material, and the foundation layer material is flush with the top end of the assembly type framework after being compacted and leveled. And the assembly type pavement slab is connected with the assembly type framework through a positioning mechanism. The structure strength and construction efficiency of the airport pavement system can be effectively improved, the maintenance difficulty is reduced, and the maintenance quality is guaranteed.

Description

Technical Field

[0001] This invention belongs to the field of airport prefabricated pavement technology, specifically relating to an airport prefabricated pavement panel system and construction method. Background Technology

[0002] The structural system of prefabricated pavement panels for airports generally includes, from bottom to top: a base layer, a subbase, a flexible underlayment, and prefabricated pavement panels. To address the flatness issue during pavement panel installation, each layer needs to be leveled and compacted layer by layer from bottom to top. Finally, the pavement panels are assembled on the base layer. During assembly, the pavement panels are positioned using positioning structures placed on the flexible underlayment, and adjacent pavement panels are securely connected using connectors. For detailed information on the above prior art, please refer to patent document CN112746543B.

[0003] However, this construction method has the following drawbacks: 1. The leveling and compaction process is complicated, time-consuming, and difficult to implement; 2. Replacement of damaged track panels is a complicated and inefficient process. 3. The base material is at risk of cracking and freeze-thaw damage after long-term use. Summary of the Invention

[0004] This invention discloses an airport prefabricated pavement system and construction method, aiming to solve the problems described in prior art 1-3.

[0005] To achieve the above objectives, the technical solution of the present invention is as follows: An airport prefabricated pavement system comprises, from bottom to top, a ground base, a prefabricated base layer, and a prefabricated pavement panel. The prefabricated base layer is fixedly connected to the ground base layer. The prefabricated base layer is equipped with a prefabricated frame, and the prefabricated frame is filled with base material. After being compacted and leveled, the base material is flush with the top of the prefabricated frame. The prefabricated pavement panel is connected to the prefabricated frame through a positioning mechanism.

[0006] Preferably, the prefabricated frame includes several interlocking rectangular grid frames. The grid frame includes a rectangular frame and intersecting partitions disposed within the rectangular frame. The intersecting partitions form a filling space for filling with base material.

[0007] Preferably, the rectangular frame and partition are made of high-strength steel or reinforced concrete, the rectangular frame is anchored to the ground base by anchor rods, and adjacent grid frames are fixedly connected by high-strength bolts.

[0008] Preferably, the rectangular frame has a plurality of water-permeable holes evenly distributed on the bottom of its sidewalls, the water-permeable holes are equipped with metal filter screens, the rectangular frame has stepped holes for anchor rods to pass through, and the top four corners of the rectangular frame have conical positioning grooves; the conical positioning grooves are equipped with conical rubber plugs.

[0009] Preferably, the bottom end of the prefabricated pavement panel is equipped with a positioning rod that works in conjunction with a tapered positioning groove, and the positioning rod is made of metal; the top end of the prefabricated pavement panel has an internally threaded sleeve for hoisting; the positioning rod and the tapered positioning groove constitute a positioning mechanism.

[0010] Preferably, the base material is filled above the top of the grid skeleton and is compacted and leveled by a special compaction and leveling device. The base material is graded crushed stone.

[0011] Preferably, the dedicated compaction and leveling equipment includes a drive vehicle body, with a long-distance compaction unit and a long-distance leveling unit respectively located on both sides of the drive vehicle body. Each long-distance compaction and leveling unit comprises several boom segments, which are hinged together to form a W-shaped structure. A first hydraulic cylinder is installed on the inner side of the external corner formed by adjacent boom segments, and a second hydraulic cylinder is installed on the inner side of the internal corner. The two ends of the first and second hydraulic cylinders are rotatably connected to the adjacent boom segments. A third hydraulic cylinder is connected between the initial boom segment and the side wall of the drive vehicle body, with both ends rotatably connected to both the initial boom segment and the side wall of the drive vehicle body. A compaction roller is connected to the final boom segment of the long-distance compaction unit, and a fixed plate is connected to the final boom segment of the long-distance leveling unit. A scraping plate is connected to the bottom of the fixed plate via a pressure sensor. The drive vehicle body is equipped with a hydraulic station and a controller. The controller is connected to the pressure sensor signal and configured to control the long-distance compaction and leveling units.

[0012] Preferably, the top of the partition and the rectangular frame are flush, and the length of the scraper plate is at least greater than the width of one grid skeleton.

[0013] A construction method for an airport prefabricated pavement panel system includes the following steps: Step 1: Level and compact the subgrade, controlling the flatness to ≤1cm; Step 2: Assemble the grid skeleton on the surface of the base layer and correct the flatness of the top of the grid skeleton. For taller grid skeletons, apply pressure by static loading until the top height of the grid skeleton reaches the set standard. Continue this process until the tops of all grid skeletons are flush. Then, connect all grid skeletons into a whole using high-strength bolts. Step 3: Fill the grid skeleton with base material, making the base material higher than the set height of the grid skeleton and covering the entire prefabricated skeleton; Step 4: Move the dedicated compaction and leveling equipment to one side of the construction position using the drive vehicle. Compact the base material using the remote compaction unit. After compaction to the set standard, retract the remote compaction unit and steer the remote leveling unit toward the construction position. Insert the scraper plate into the base material and make the bottom of the scraper plate abut against the top of the grid skeleton. While maintaining contact between the scraper plate and the top of the grid skeleton within the set pressure range, push the scraper plate to scrape off the excess base material at the top of the grid skeleton. At this point, the base material at the top of the prefabricated skeleton is leveled and compacted. Step 5: The construction workers move along the rectangular frame of the grid skeleton to the conical positioning groove and remove the conical rubber plug; Step 6: Install the prefabricated pavement panels using lifting equipment, inserting the positioning rods into the corresponding conical positioning slots to achieve the assembly and positioning of the pavement panels.

[0014] Preferably, at the end of step four, after leveling and compaction, a flexible roll material is laid on the top of the prefabricated base layer to form a flexible pad, and the flexible pad is perforated at the position corresponding to the conical positioning groove.

[0015] Preferably, the construction method further includes a method for removing and installing prefabricated pavement panels during pavement maintenance, including the step of vertically lifting the prefabricated pavement panels directly from the prefabricated base layer using lifting equipment, and replacing the new prefabricated pavement panels by directly lifting them to the designated position using lifting equipment and inserting the positioning rod into the corresponding conical positioning groove.

[0016] The beneficial effects of the prefabricated airport pavement system and construction method of the present invention are as follows: 1. This invention proposes a structure and construction method for prefabricated base layers, which improves the original construction method of base layers. By constraining the base layer material through a grid skeleton, it avoids problems such as cracking and freeze-thaw damage after long-term use of the base layer material, and can withstand the load of aircraft take-off and landing, ensuring the stability of the position and structure of the prefabricated pavement panel.

[0017] 2. This invention uses a prefabricated frame connected by a grid skeleton to ensure that the top surface is coplanar and serves as a reference surface for leveling the base material. This can significantly reduce the difficulty of leveling and compacting the base material, improve construction efficiency, and ensure construction quality.

[0018] 3. This invention provides specialized equipment for the construction of prefabricated base layers, which can perform large-area, high-efficiency construction for compacting and leveling base materials in prefabricated base layers.

[0019] 4. This invention reduces the difficulty of installing prefabricated pavement panels, improves disassembly and assembly efficiency, ensures positioning accuracy, and facilitates maintenance of pavement panels in case of damage, through a reliable connection between the prefabricated frame and the prefabricated pavement panels. Attached Figure Description

[0020] Figure 1 A front cross-sectional view of the airport prefabricated pavement panel system of the present invention.

[0021] Figure 2 A top view of the prefabricated frame of the present invention.

[0022] Figure 3 A schematic diagram illustrating the construction principle of the special compaction and leveling equipment of this invention.

[0023] 1. Subbase; 2. Prefabricated pavement panel; 3. Prefabricated base layer; 31. Rectangular frame; 32. Partition plate; 33. Filling space; 34. Step hole; 35. High-strength bolt; 4. Anchor bolt; 5. Drainage hole; 6. Conical positioning groove; 7. Positioning rod; 8. Base material; 9. Drive vehicle body; 10. Arm segment; 11. Compaction roller; 12. Second hydraulic cylinder; 13. First hydraulic cylinder; 14. Fixing plate; 15. Pressure sensor; 16. Scraper plate; 17. Stiffening plate. Detailed Implementation

[0024] The following description is merely a preferred embodiment of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

[0025] The following embodiments can be understood as illustrating a part of the structure or method of the present invention individually, or as combining the embodiments to explain the broader structure or method of the present invention.

[0026] Example 1: An airport prefabricated pavement panel system, such as Figure 1-3 As shown, from bottom to top, it includes a ground base 1, a prefabricated base 3, and a prefabricated pavement panel 2. The prefabricated base 3 is fixedly connected to the ground base 1. The prefabricated base 3 is equipped with a prefabricated frame, and the prefabricated frame is filled with base material 8. After the base material 8 is compacted and leveled, it is flush with the top of the prefabricated frame. The prefabricated pavement panel 2 is connected to the prefabricated frame through a positioning mechanism.

[0027] The following defects exist when ordinary base materials are used for airport pavement: cracks and freeze-thaw damage may occur after long-term use of the base materials.

[0028] To address the aforementioned problems, this invention proposes a prefabricated base course. By filling the base course material within a prefabricated frame, the frame constrains the base course material, preventing cracks. Furthermore, the prefabricated frame transforms the previously easily loosened and cracked base course into a unified structure, significantly increasing its strength and resistance to freeze-thaw damage. Moreover, the prefabricated frame greatly reduces the difficulty of base course leveling, improves construction efficiency, and ensures leveling effectiveness. Simultaneously, the reliable connection between the prefabricated frame and the prefabricated pavement panels also improves the installation efficiency of the prefabricated pavement panels, reduces disassembly and assembly difficulty, and facilitates later maintenance.

[0029] Example 2: Figure 1-3 As shown, the prefabricated frame includes several interlocking rectangular grid frames. The grid frame includes a rectangular frame 31 and horizontally and vertically intersecting partitions 32 disposed within the rectangular frame 31. The horizontally and vertically intersecting partitions 32 form a filling space 33 for filling the base material 8.

[0030] like Figure 1-3 As shown, the rectangular frame 31 and partition 32 are constructed of high-strength steel or reinforced concrete. The rectangular frame 31 is anchored to the base layer 1 via anchor bolts 4, and adjacent grid frames are fixedly connected by high-strength bolts 35. After the grid frames are connected as a whole by high-strength bolts, it ensures that the tops of the grid frames are coplanar. Furthermore, the overall structure prevents base layer settlement, extends the service life of the airport pavement, and reduces the difficulty of leveling the base layer material, improving leveling efficiency. The base layer material is constrained within the filling space 33, preventing large-area displacement of the base layer material within the filling space due to the impact of aircraft takeoffs and landings.

[0031] like Figure 1 As shown, the bottom sidewall of the rectangular frame has a plurality of water-permeable holes 5 evenly distributed thereon, and each water-permeable hole 5 is equipped with a metal filter screen (not shown in the figure). Figure 2 As shown, the rectangular frame 31 has pre-drilled stepped holes 34 for anchor rods 4 to pass through, and conical positioning grooves 6 are pre-drilled at the four corners of the top of the rectangular frame 31; the conical positioning grooves 6 are equipped with conical rubber plugs (not shown in the figure). Airport runways have high drainage requirements, and the sidewalls of the rectangular frame have permeable holes 5 to quickly drain water that has passed through the base material, avoiding problems such as freeze-thaw damage, reduced structural strength, and reduced base strength due to water seepage.

[0032] like Figure 1As shown, the bottom of the prefabricated guide panel 2 is equipped with a positioning rod 7 that works in conjunction with the tapered positioning groove 6. The positioning rod 7 is made of metal. An internally threaded sleeve (not shown in the figure) is pre-embedded at the top of the prefabricated guide panel 2 for hoisting. By inserting the positioning rod 7 into the tapered positioning groove 6, the prefabricated guide panel 2 can be quickly installed and positioned.

[0033] Example 3: As Figure 3 As shown, the base material 8 fills the grid skeleton higher than the top of the grid skeleton and is compacted and leveled using specialized compaction and leveling equipment. The base material 8 is graded crushed stone. During the compaction process, the height of the graded crushed stone gradually decreases until it stops decreasing, but remains slightly higher than the top of the grid skeleton. At this point, the excess part at the top of the grid skeleton is scraped off, thus achieving rapid leveling and ensuring the compaction effect of the base material.

[0034] In this embodiment, base materials containing cement or lime are not used. Sufficient base strength can be ensured by using a grid skeleton and graded crushed stone, while simplifying the base material paving process.

[0035] Example 4: Figure 3 As shown, the dedicated compaction and leveling equipment includes a drive vehicle body 9, with a long-distance compaction unit and a long-distance leveling unit respectively located on both sides of the drive vehicle body 9. Each long-distance compaction unit and long-distance leveling unit includes several boom segments 10, which are hinged together to form a W-shaped structure. A first hydraulic cylinder 13 is installed on the inner side of the external corner formed by adjacent boom segments 10, and a second hydraulic cylinder 12 is installed on the inner side of the internal corner. The two ends of the first hydraulic cylinder 13 and the second hydraulic cylinder 12 are rotatably connected to adjacent boom segments 10. The initial boom segment 10 is connected to the drive vehicle body 9. A third hydraulic cylinder (not marked in the figure) is connected between the side walls of the motor car body 9. The two ends of the third hydraulic cylinder are respectively rotatably connected to the initial boom segment and the side wall of the driving car body 9. The last boom segment of the long-distance compaction unit is connected to a compaction roller 11, and the last boom segment 10 of the long-distance leveling unit is connected to a fixing plate 14. The bottom end of the fixing plate 14 is connected to a scraper plate 16 through a pressure sensor 15. The driving car body 9 is equipped with a hydraulic station and a controller. The controller is signal-connected to the pressure sensor 15 and configured to control the long-distance compaction unit and the long-distance leveling unit.

[0036] The tops of the partition 32 and the rectangular frame 31 are flush, and the length of the scraper plate 16 is at least greater than the width of one grid skeleton.

[0037] This embodiment provides a special equipment for the construction of prefabricated base layers in an airport prefabricated guide panel system, such as... Figure 3As shown, the remote compaction unit and remote leveling unit, configured with several segmented booms, can achieve compaction and leveling of large-area prefabricated base courses for airport pavements. During the compaction process, the remote compaction unit drives the compaction roller 11 to reciprocate, continuously compacting the base material into the grid framework. Ultimately, once the base material can withstand the load of the compaction roller, it reaches the compaction standard. Then, the remote leveling unit scrapes away excess base material from the top of the grid framework. Since the scraping process is based on the top of the grid framework, the flatness of the base material after leveling can be guaranteed.

[0038] When the scraper plate is in use, the cooperation of the first hydraulic cylinder and the second hydraulic cylinder ensures that the detection value of the pressure sensor is always within the set range, which ensures that the lower end of the scraper plate is in pressure contact with the top of the grid skeleton, thereby ensuring the scraping effect.

[0039] Example 5: Based on the above examples, this example discloses a construction method for an airport prefabricated pavement system, such as... Figure 1-3 As shown, it includes the following steps: Step 1: Level and compact the base layer 1, controlling the flatness to be accurate to ≤1cm; Step 2: Assemble the grid skeleton on the surface of the base layer 1, and correct the flatness of the top of the grid skeleton. For the taller grid skeletons, apply pressure by static loading until the top height of the grid skeleton reaches the set standard. Continue this process until the tops of all grid skeletons are flush. Then, connect all the grid skeletons into a whole using high-strength bolts. Step 3: Fill the grid skeleton with base material 8, making the base material 8 higher than the set height of the grid skeleton and covering the entire prefabricated skeleton; Step 4: Move the dedicated compaction and leveling equipment to one side of the construction position using the drive vehicle 9. Compact the base material 8 using the remote compaction unit. After compaction to the set standard, retract the remote compaction unit and steer the remote leveling unit toward the construction position. Insert the scraper plate 16 into the base material 8 and make the bottom of the scraper plate 16 abut against the top of the grid skeleton. While maintaining the contact between the scraper plate 16 and the top of the grid skeleton within the set pressure range, push the scraper plate 16 to scrape off the excess base material 8 at the top of the grid skeleton. At this point, the base material 10 at the top of the prefabricated skeleton is leveled and compacted; the top of the base material is flush with the top of the prefabricated skeleton. Step 5: The construction personnel move along the rectangular frame 31 of the grid skeleton to the conical positioning groove 6 and remove the conical rubber plug; if necessary, clean the hole of the conical positioning groove. Step 6: Install the prefabricated pavement panel 2 using lifting equipment, and insert the positioning rod 7 into the corresponding conical positioning groove 6 to achieve the assembly and positioning of the pavement panel.

[0040] In existing technologies (referencing patent document CN112746543B), it is still necessary to install a telescopic sleeve force transmission rod assembly to connect adjacent pavement panels, and also to install a bottom-mounted U-shaped tapered sleeve tie rod for positioning the pavement panels. This not only involves cumbersome construction procedures, high operational difficulty, and low efficiency, but also leads to difficulties in subsequent disassembly and assembly. This invention directly hoists the pavement panel so that the positioning rod engages with the tapered positioning groove, achieving one-time installation and positioning of the pavement panel. Since the position of the tapered positioning groove remains unchanged, the subsequent disassembly and assembly procedures of the pavement panel are also greatly simplified.

[0041] Example 6: As Figure 1-3 As shown, at the end of step four, after leveling and compaction, a flexible roll material is laid on top of the prefabricated base layer 3 to form a flexible pad (not shown in the figure). Holes are made at the positions corresponding to the conical positioning grooves 6 in the flexible pad to facilitate the insertion of the positioning rods. The flexible pad provides both anti-slip properties and cushioning, preventing hard impacts between the prefabricated pavement panels and the prefabricated frame.

[0042] Example 7: Figure 1-3 As shown, the construction method also includes a method for removing and installing the prefabricated pavement panel 2 during pavement maintenance. This includes the step of vertically lifting the prefabricated pavement panel 2 directly from the prefabricated base layer 3 using a lifting device. When replacing the prefabricated pavement panel 2, it is directly lifted to a designated position using a lifting device, and the positioning rod 7 is inserted into the corresponding conical positioning groove 6. It can be seen that, compared to the prior art (refer to patent document CN112746543B), the present invention provides simpler and more efficient maintenance for the subsequent prefabricated pavement panels, and eliminates concerns about assembly difficulties caused by displacement of the under-mounted U-shaped conical sleeve tie rod, as well as the need to connect adjacent pavement panels via a telescopic sleeve force transmission rod assembly.

Claims

1. A prefabricated pavement panel system for airports, characterized by: From bottom to top, it includes a ground base, a prefabricated base, and a prefabricated pavement panel. The prefabricated base is fixedly connected to the ground base. The prefabricated base is equipped with a prefabricated frame, and the prefabricated frame is filled with base material. After the base material is compacted and leveled, it is flush with the top of the prefabricated frame. The prefabricated pavement panel is connected to the prefabricated frame through a positioning mechanism.

2. The airport prefabricated pavement panel system as described in claim 1, characterized in that: The prefabricated frame includes several interlocking rectangular grid frames. The grid frame includes a rectangular frame and horizontally and vertically intersecting partitions within the rectangular frame. The horizontally and vertically intersecting partitions form a filling space for filling with base material. The rectangular frame and partition are made of high-strength steel or reinforced concrete. The rectangular frame is anchored to the ground base through anchor rods, and adjacent grid frames are fixedly connected by high-strength bolts. The rectangular frame has several water-permeable holes evenly distributed on the bottom of its side wall. Each water-permeable hole is equipped with a metal filter screen. The rectangular frame has stepped holes for anchor rods to pass through. The four corners of the top of the rectangular frame have tapered positioning grooves. Each tapered positioning groove is equipped with a tapered rubber plug.

3. The airport prefabricated pavement panel system as described in claim 2, characterized in that: The prefabricated pavement panel is equipped with a positioning rod at the bottom end that works in conjunction with a tapered positioning groove. The positioning rod is made of metal. An internally threaded sleeve for hoisting is pre-embedded at the top of the prefabricated pavement panel. The positioning rod and the tapered positioning groove constitute a positioning mechanism.

4. The airport prefabricated pavement panel system as described in claim 3, characterized in that: The base material is filled above the top of the grid skeleton and is compacted and leveled by a special compaction and leveling equipment. The base material is graded crushed stone.

5. The airport prefabricated pavement panel system as described in claim 4, characterized in that: The specialized compaction and leveling equipment includes a drive vehicle body, with a long-distance compaction unit and a long-distance leveling unit respectively located on both sides of the drive vehicle body. Each long-distance compaction and leveling unit comprises several boom segments, which are hinged together to form a "W"-shaped structure. A first hydraulic cylinder is installed on the inner side of the external corner formed by adjacent boom segments, and a second hydraulic cylinder is installed on the inner side of the internal corner. The two ends of the first and second hydraulic cylinders are rotatably connected to the adjacent boom segments. A third hydraulic cylinder is connected between the initial boom segment and the side wall of the drive vehicle body, with both ends rotatably connected to both the initial boom segment and the side wall of the drive vehicle body. A compaction roller is connected to the final boom segment of the long-distance compaction unit, and a fixed plate is connected to the final boom segment of the long-distance leveling unit. A scraper plate is connected to the bottom of the fixed plate via a pressure sensor. The drive vehicle body is equipped with a hydraulic station and a controller. The controller is connected to the pressure sensor signal and configured to control the long-distance compaction and leveling units.

6. The airport prefabricated pavement panel system as described in claim 5, characterized in that: The top of the partition and the rectangular frame are flush, and the length of the scraper plate is at least greater than the width of one grid skeleton.

7. The construction method of the airport prefabricated pavement system as described in claim 6, characterized in that, Includes the following steps: Step 1: Level and compact the subgrade, controlling the flatness to ≤1cm; Step 2: Assemble the grid skeleton on the surface of the base layer and correct the flatness of the top of the grid skeleton. For taller grid skeletons, apply pressure by static loading until the top height of the grid skeleton reaches the set standard. Continue this process until the tops of all grid skeletons are flush. Then, connect all grid skeletons into a whole using high-strength bolts. Step 3: Fill the grid skeleton with base material, making the base material higher than the set height of the grid skeleton and covering the entire prefabricated skeleton; Step 4: Move the dedicated compaction and leveling equipment to one side of the construction position using the drive vehicle. Compact the base material using the remote compaction unit. After compaction to the set standard, retract the remote compaction unit and steer the remote leveling unit toward the construction position. Insert the scraper plate into the base material and make the bottom of the scraper plate abut against the top of the grid skeleton. While maintaining contact between the scraper plate and the top of the grid skeleton within the set pressure range, push the scraper plate to scrape off the excess base material at the top of the grid skeleton. At this point, the base material at the top of the prefabricated skeleton is leveled and compacted. Step 5: The construction workers move along the rectangular frame of the grid skeleton to the conical positioning groove and remove the conical rubber plug; Step 6: Install the prefabricated pavement panels using lifting equipment, inserting the positioning rods into the corresponding conical positioning slots to achieve the assembly and positioning of the pavement panels.

8. A construction method for an airport prefabricated pavement system as described in claim 7, characterized in that: At the end of step four, after leveling and compaction, a flexible roll material is laid on the top of the prefabricated base layer to form a flexible pad, and holes are made at the positions corresponding to the conical positioning grooves in the flexible pad.

9. A construction method for an airport prefabricated pavement system as described in claim 7, characterized in that: The construction method also includes methods for removing and installing prefabricated pavement panels during pavement maintenance, including the step of vertically lifting the prefabricated pavement panels off the prefabricated base layer directly using lifting equipment, and replacing the new prefabricated pavement panels by directly lifting them to the designated position using lifting equipment and inserting the positioning rod into the corresponding conical positioning groove.

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