Fabricated pavement and construction method thereof

Abstract

The invention discloses a fabricated pavement and a construction method thereof.The fabricated pavement comprises a base layer and an intact pavement structure layer, the intact pavement structure layer is arranged above the base layer, an anchoring component is inserted into one side of the intact pavement structure layer, and a transverse prefabricated slab is arranged on one side of the intact pavement structure layer; the bottom of the prefabricated slab is fixedly connected with an abutment. The structure has the advantages that the structure is in anchoring connection with the peripheral pavement, so that the structure and the peripheral pavement form a complete system, and the overall bearing capacity is improved. Pavement loads are transmitted to the profile steel beams through the prefabricated plates and then transmitted to the abutments from the profile steel beams, the abutments disperse the loads to a lower-layer structure or a roadbed, the plate-girder effect is fully played, the loads borne by the prefabricated plates are effectively reduced, the bearing capacity of the pavement is improved in a disguised mode, and the service life of the structure is prolonged. Gaps are reserved between the prefabricated slabs for grouting, so that local damage caused by collision of the two adjacent prefabricated slabs due to plate dislocation in the later period can be avoided.

Description

Technical Field

[0001] This invention relates to the field of pavement structure technology, specifically to a prefabricated pavement and its construction method. Background Technology

[0002] In an era of rapid development in road construction and transportation, the proportion of damaged road surfaces is increasing year by year with rising traffic volume. Both cement concrete and asphalt pavements suffer varying degrees of damage. Currently, traditional road repair methods involve filling and repairing damaged road structures with ordinary concrete or asphalt. This process is generally lengthy, complex, and requires at least 14 days of closure for curing or reaching a certain percentage of the design strength before reopening to traffic. While using fast-setting repair materials can speed up repairs compared to traditional methods, it suffers from drawbacks such as low long-term strength development, demanding maintenance conditions, low durability, significant environmental impact, and high costs, making large-scale application difficult. Traditional road repair methods continue to have a significant impact on transportation.

[0003] Existing prefabricated pavement repair methods mostly use plate bolt connections during repair. This structure has low load-bearing capacity and insufficient anchoring to the surrounding area, making it prone to problems such as pavement slippage and misalignment in the later stages. In addition, there are no reserved drainage positions, making the pavement prone to water accumulation. The pavement still has defects and needs further improvement. Summary of the Invention

[0004] (a) Technical problems to be solved

[0005] In response to the problems of long construction cycles, complicated processes, and increased traffic pressure associated with traditional road repair technologies, as well as the issues of long-term strength and durability and cost associated with the use of fast-hardening materials, this invention improves upon existing prefabricated pavement repair methods. By utilizing this structure, the negative impacts of the aforementioned repair methods can be significantly reduced.

[0006] (II) Technical Solution

[0007] To achieve the goals of improving pavement bearing capacity, extending structural service life, avoiding slab misalignment, shortening construction cycle, and improving road repair efficiency, this invention provides the following technical solution: a prefabricated pavement, comprising a base layer and an intact pavement structure layer, wherein the intact pavement structure layer is located above the base layer, and an anchoring member is inserted into one side of the intact pavement structure layer;

[0008] A transverse precast slab is provided on one side of the intact road structure layer, and a pier is fixedly connected to the bottom of the precast slab. The pier is fixedly connected to the precast slab by precast slab fixing bolts.

[0009] The pier has grooves on both sides, one of which is used to attach an anchoring component, and the other is used to attach a steel beam. The top of the steel beam is attached to the bottom surface of the precast slab.

[0010] The steel beams are fixedly connected to the pier by steel beam fixing bolts, and the anchoring components are fixedly connected to the pier by steel beam fixing bolts.

[0011] Grouting layers are filled between the intact road surface structure and the precast slabs, and between the precast slabs themselves.

[0012] Preferably, the top of the base layer is a supporting pier, and the anchoring component is specifically an anchoring steel beam.

[0013] The above technical solution is adopted: the precast slab is a precast road slab used to replace the damaged road surface structure.

[0014] Preferably, the top surface of the precast slab is flush with the top surface of the intact road structure layer, and the precast slab has holes for inserting precast slab fixing bolts, with a grouting layer provided above the precast slab fixing bolts in the holes.

[0015] The above technical solution utilizes a system where piers, steel beams, and precast slabs form the main support structure, bearing the primary load of the road surface. This achieves a high degree of prefabrication, avoiding the drawbacks of on-site casting. The structure is anchored to the surrounding road surface, forming a complete system and increasing overall load-bearing capacity. Road loads are transferred through the precast slabs to the steel beams, and then from the steel beams to the piers. The piers distribute the load to the underlying structure or subgrade, fully utilizing the "slab-beam effect," effectively reducing the load borne by the precast slabs, indirectly increasing the road surface's load-bearing capacity, and extending the structure's service life. Grouting between precast slabs prevents damage caused by collisions between adjacent slabs due to later misalignment.

[0016] Preferably, the precast slab fixing bolts penetrate the precast slab and are threadedly connected to the pier.

[0017] Preferably, a plurality of steel beams are provided, and the arrangement direction of the steel beams is perpendicular to the direction of the pier.

[0018] Preferably, the bottom plate of the steel beam is penetrated by steel beam fixing bolts, and the vertical cross-sectional shape of the steel beam is I-shaped.

[0019] The greatest advantage of this invention compared to existing technologies lies in its convenient and rapid installation. It fully utilizes the "plate-beam effect," reducing the load on the precast slabs, increasing structural rigidity, and anchoring to the surrounding intact road surface structure on both sides, thus enhancing structural integrity. Furthermore, compared to the large-area use of fast-hardening repair materials, this structure requires less fast-hardening repair material, significantly reducing costs. The components directly influencing this invention are the piers, steel beams, and precast slabs, and the structural system formed by these components effectively highlights the advantages of this invention.

[0020] Preferably, the steel beam is located below a layer of crushed stone, and the steel beam fixing bolts penetrate the bottom plate of the steel beam and the anchoring member and are threadedly connected to the pier.

[0021] A construction method for prefabricated pavement includes the following steps:

[0022] 1. When repairing the road surface, the first step is to conduct inspection and measurement to determine the location and structure of the damage before excavation. Then, the foundation pit is backfilled and leveled, and the surrounding road surface is excavated at an inverted angle to facilitate subsequent anchoring.

[0023] 2. Anchor the anchoring components to one side of the pavement structure layer. The pier has a pre-reserved groove. The steel beam and the anchoring components are connected to the pier through the groove. Then, tighten the steel beam fixing bolts to connect the steel beam and the pier. Connect the anchoring components to the pier. At the same time, backfill one side of the pier and the bottom of the steel beam with crushed stone.

[0024] 3. The precast slabs are laid on top of the piers, completely covering the substructure. The precast slab fixing bolts are then tightened to connect and fix the precast slabs and the piers. After that, grouting layers are filled between the intact road structure and the precast slabs, and between the precast slabs themselves. Grouting layers are installed in the holes in the precast slabs where the precast slab fixing bolts are inserted. The grouting layer is specifically a fast-hardening self-leveling mortar layer.

[0025] (III) Beneficial Effects

[0026] Compared with the prior art, the present invention provides a prefabricated pavement and its construction method, which has the following beneficial effects:

[0027] 1. This prefabricated pavement and its construction method form the main support system through the connection of piers, steel beams, and precast slabs, bearing the main load of the pavement and achieving a high degree of prefabrication, avoiding the drawbacks of on-site casting. The anchored connection between this structure and the surrounding pavement creates a complete system, increasing the overall load-bearing capacity. The pavement load is transferred to the steel beams through the precast slabs, and then from the steel beams to the piers. The piers distribute the load to the underlying structure or subgrade, fully utilizing the "slab-beam effect," effectively reducing the load borne by the precast slabs, indirectly increasing the pavement's load-bearing capacity, and extending the structure's service life. Grouting between the precast slabs prevents localized damage caused by collisions between adjacent slabs due to later misalignment.

[0028] 2. This prefabricated pavement and its construction method allow all components to be prefabricated in the factory, resulting in a high degree of standardization and industrialization. This ensures uniform pavement flatness during later installation, while on-site excavation and filling are carried out simultaneously. On-site assembly achieves full bolt connection, effectively avoiding structural problems caused by inconsistent welding quality. The construction cycle is short, allowing for rapid repair and reopening to traffic, significantly improving road repair efficiency.

[0029] 3. In this prefabricated pavement and its construction method, the pavement load is not directly transferred to the base layer through the precast slabs, but is distributed to the base layer through the substructure support system. This effectively utilizes the bending resistance of the steel beams and reduces secondary damage to the pavement caused by the brittle failure of the precast slabs. In addition to backfilling, the gaps between the steel beams under the precast slabs can also be used for laying drainage pipes, embedding monitoring equipment, etc., making efficient use of the substructure space. In the event of disasters such as earthquakes, damaged components can be removed and replaced in a timely manner. Attached Figure Description

[0030] Figure 1 This is a structural front view of a prefabricated pavement and its construction method proposed in this invention;

[0031] Figure 2 This is a top view of the structure of a prefabricated pavement and its construction method proposed in this invention;

[0032] Figure 3 This is a schematic diagram of the precast slab fixing bolt connection structure of an assembled road surface and its construction method proposed in this invention.

[0033] Figure 4 This is a cross-sectional view of the pier connection method of a prefabricated pavement and its construction method proposed in this invention.

[0034] Figure 5 For the present invention Figure 1 Cross-sectional view at point 1-1;

[0035] Figure 6 For the present invention Figure 2Cross-sectional view at point 2-2;

[0036] Figure 7 This is a three-dimensional structural diagram of the pier structure in the prefabricated pavement and its construction method proposed in this invention.

[0037] In the diagram: 1-base layer, 2-intact pavement structure layer, 3-anchoring component, 4-precast slab, 5-pier, 6-precast slab fixing bolt, 7-groove, 8-steel beam, 9-steel beam fixing bolt, 10-grouting layer. Detailed Implementation

[0038] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0039] Please see Figure 1-7 A prefabricated pavement includes a base layer 1 and an intact pavement structure layer 2. The intact pavement structure layer 2 is located above the base layer 1, and an anchoring member 3 is inserted into one side of the intact pavement structure layer 2.

[0040] A transverse precast slab 4 is provided on one side of the intact road structure layer 2. A pier 5 is fixedly connected to the bottom of the precast slab 4. The pier 5 is fixedly connected to the precast slab 4 by precast slab fixing bolts 6.

[0041] The pier 5 has grooves 7 on both sides. An anchoring member 3 is connected in one groove 7, and a steel beam 8 is connected in the other groove 7. The top of the steel beam 8 is connected to the bottom surface of the precast slab 4.

[0042] The steel beam 8 is fixedly connected to the pier 5 by steel beam fixing bolts 9, and the anchoring component 3 is fixedly connected to the pier 5 by steel beam fixing bolts 9;

[0043] Grouting layer 10 is filled between the intact pavement structure 2 and the precast slab 4, and between the precast slabs 4 and each other.

[0044] Example 1: The top of the base layer 1 is supported by the abutment 5, and the anchoring component 3 is specifically an anchoring steel beam. The precast slab 4 is a precast pavement panel used to replace the damaged pavement structure.

[0045] Example 2: The top surface of the precast slab 4 is flush with the top surface of the intact pavement structure layer 2. Holes for inserting precast slab fixing bolts 6 are provided on the precast slab 4, and a grouting layer 10 is placed above the fixing bolts 6 in these holes. The piers 5, steel beams 8, and precast slabs 4 form the main support system, bearing the main load of the pavement and achieving a high degree of prefabrication, avoiding the drawbacks of on-site casting. The anchored connection between this structure and the surrounding pavement forms a complete system, increasing the overall load-bearing capacity. The pavement load is transferred through the precast slabs to the steel beams 8, and then from the steel beams 8 to the piers 6. The piers 6 distribute the load to the lower structure or subgrade, fully utilizing the "slab-beam effect," effectively reducing the load borne by the precast slabs 4, indirectly increasing the pavement's load-bearing capacity, and extending the structure's service life. Grouting between the precast slabs 4 prevents localized damage caused by collisions between adjacent slabs due to later misalignment.

[0046] Example 3: Precast slab fixing bolts 6 penetrate the precast slab 4 and are threadedly connected to the pier 5. Several steel beams 8 are provided, and the arrangement direction of the steel beams 8 is perpendicular to the direction of the pier 5. The bottom plate of the steel beams 8 is penetrated by steel beam fixing bolts 9, and the vertical cross-section of the steel beams 8 is I-shaped. The biggest advantage of this invention compared with the prior art is its convenient and fast installation, making full use of the "plate-beam effect", reducing the load borne by the precast slab 4, improving the structural rigidity, anchoring to the intact road surface structure on both sides, increasing the structural integrity, and compared with the large-area use of fast-hardening repair materials, the amount of fast-hardening repair materials used in this structure is smaller, which can significantly reduce costs. The components that directly affect this invention are the pier 5, the steel beams 8, and the precast slab 4, etc., and the structural system composed of the above components can highlight the advantages of the invention.

[0047] A construction method for prefabricated pavement includes the following steps:

[0048] 1. When repairing the road surface, the first step is to conduct inspection and measurement to determine the location and structure of the damage before excavation. Then, the foundation pit is backfilled and leveled, and the surrounding road surface is excavated at an inverted angle to facilitate subsequent anchoring.

[0049] 2. Anchor the anchoring component 3 to one side of the pavement structure layer 2. The pier 5 has a pre-reserved groove 7. The steel beam 8 and the anchoring component 4 are connected to the pier 5 through the groove 7. Then, tighten the steel beam fixing bolts 9 to connect the steel beam 8 and the pier 5, and connect the anchoring component 4 to the pier 5. At the same time, crushed stone is used for backfilling on one side of the pier 5 and under the steel beam 8.

[0050] 3. The precast slab 4 is laid on top of the pier 5, completely covering the lower structure, and the precast slab fixing bolts 6 are screwed on to connect and fix the precast slab 4 and the pier 5. Then, the grouting layer 10 is filled between the intact road structure 2 and the precast slab 4, and between the precast slabs 4. The grouting layer 10 is set in the holes in the precast slab 4 where the precast slab fixing bolts 6 are inserted. The grouting layer 10 is a fast-hardening self-leveling mortar layer.

[0051] In summary, this prefabricated pavement and its construction method form the main support system through the connection of piers 5 with steel beams 8 and precast slabs 4, bearing the main load of the pavement and achieving a high degree of prefabrication, avoiding the drawbacks of on-site casting. The anchored connection between this structure and the surrounding pavement creates a complete system, increasing the overall load-bearing capacity. The pavement load is transferred to the steel beams 8 through the precast slabs, and then from the steel beams 8 to the piers 6. The piers 6 distribute the load to the lower structure or subgrade, fully utilizing the "slab-beam effect," effectively reducing the load borne by the precast slabs 4, indirectly increasing the pavement's load-bearing capacity, and extending the structure's service life. Grouting between the precast slabs 4 prevents localized damage caused by collisions between adjacent slabs due to later misalignment.

[0052] All components can be pre-processed and produced in the factory, with a high degree of standardization and industrialization, ensuring uniform road surface flatness during later installation. On-site filling and excavation are carried out simultaneously, and on-site assembly achieves full bolted connection, effectively avoiding structural problems caused by inconsistent welding quality. The construction cycle is short, and roads can be quickly repaired and opened to traffic, greatly improving road repair efficiency.

[0053] The road load is not directly transferred to the base layer through the precast slab 4, but is distributed to the base layer through the subbase support system, effectively utilizing the bending resistance of the steel beams 8 and reducing secondary damage to the road surface caused by brittle failure of the precast slab 4; the gap area of ​​the steel beams 8 under the precast slab 4 can be used for backfilling, as well as for laying drainage pipes, pre-embedding monitoring equipment, etc., making efficient use of the subbase space. In the event of disasters such as earthquakes, damaged components can be removed and replaced in time.

[0054] Using other anchoring methods, such as anchor bolts or steel bar anchoring, to reinforce the surrounding road structure with this structure; using lightweight concrete or prestressed concrete slabs instead of ordinary precast concrete slabs for precast slabs; and replacing the backfill material between steel beams are all alternative solutions of this invention.

Claims

1. A built-up road pavement comprising a base layer (1) and a sound road pavement structure layer (2), above the base layer (1) is the sound road pavement structure layer (2), characterized in that, An anchoring member (3) is inserted into one side of the intact pavement structure layer (2); A transverse precast slab (4) is provided on one side of the intact road structure layer (2), and a pier (5) is fixedly connected to the bottom of the precast slab (4). The pier (5) is fixedly connected to the precast slab (4) by precast slab fixing bolts (6). The pier (5) has grooves (7) on both sides, one of the grooves (7) is connected to an anchoring member (3), and the other groove (7) is connected to a steel beam (8). The top of the steel beam (8) is connected to the bottom surface of the precast slab (4). The steel beam (8) is fixedly connected to the pier (5) by steel beam fixing bolts (9), and the anchoring component (3) is fixedly connected to the pier (5) by steel beam fixing bolts (9); Grouting layers (10) are filled between the intact road structure (2) and the precast slab (4), and between the precast slabs (4) and the precast slabs (4).

2. The assembled pavement of claim 1, wherein: The top of the base layer (1) is supported by a pier (5), and the anchoring component (3) is specifically an anchoring steel beam.

3. The assembled pavement of claim 1, wherein: The top surface of the precast slab (4) is flush with the top surface of the intact road structure layer (2). The precast slab (4) has holes for inserting precast slab fixing bolts (6) and a grouting layer (10) is provided above the precast slab fixing bolts (6) in the holes.

4. The assembled pavement of claim 1, wherein: The precast slab fixing bolt (6) passes through the precast slab (4) and is threadedly connected to the pier (5).

5. The assembled pavement of claim 1, wherein: The steel beams (8) are provided in several sections, and the arrangement direction of the steel beams (8) is perpendicular to the direction of the pier (5).

6. A prefabricated pavement according to claim 1, characterized in that: The bottom plate of the steel beam (8) is penetrated by the steel beam fixing bolts (9), and the vertical cross-section of the steel beam (8) is I-shaped.

7. A prefabricated pavement according to claim 1, characterized in that: The steel beam (8) is located below a layer of crushed stone. The steel beam fixing bolt (9) passes through the bottom plate of the steel beam (8) and the anchoring member (3) and is threadedly connected to the pier (5).

8. A construction method of a modular pavement, characterized by: Includes the following steps:

1. When repairing the road surface, the first step is to conduct inspection and measurement to determine the location and structure of the damage before excavation. Then, the foundation pit is backfilled and leveled, and the surrounding road surface is excavated at an inverted angle to facilitate subsequent anchoring.

2. Anchor the anchoring component (3) to one side of the road structure layer (2). The pier (5) has a pre-reserved groove (7). The steel beam (8) and the anchoring component (4) are connected to the pier (5) through the groove (7). Then, the steel beam fixing bolt (9) is screwed on to connect the steel beam (8) and the pier (5). The anchoring component (4) is connected to the pier (5). At the same time, the side of the pier (5) and the bottom of the steel beam (8) are backfilled with crushed stone.

3. The precast slab (4) is laid on top of the pier (5) to completely cover the lower structure. The precast slab fixing bolts (6) are screwed on to connect and fix the precast slab (4) and the pier (5). Then, grouting layer (10) is filled between the intact road structure (2) and the precast slab (4) and between the precast slabs (4). Grouting layer (10) is set in the holes in the precast slab (4) where the precast slab fixing bolts (6) are inserted. The grouting layer (10) is specifically a fast-hardening self-leveling mortar layer.

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