Bridge deck concrete tamping, defoaming and leveling integrated device and construction method

Abstract

The application relates to a bridge deck slab concrete ramming, defoaming and leveling integrated equipment and a construction method, and belongs to the technical field of bridge deck slab concrete construction. The top surface of the concrete to be treated in the same construction zone is divided into a ramming and vibrating area, a defoaming and gas releasing area and a re-vibrating and fine leveling area. The surface is continuously vibrated and rammed in a straight line by adopting first vibrating parameters. The defoaming component is used to break bubbles and release gas on the surface of the slurry film along an S-shaped path with a contact pressure smaller than that of the ramming and vibrating area. The bubbles are collected, broken and escaped on the slurry film carrier. The re-vibrating and fine leveling area is covered by a leveling beam, and the straight line fine leveling is implemented with the top surface of the side mold as the elevation reference. The surface holes after defoaming are closed and locked in elevation, cross slope and flatness in the re-vibration and fine leveling process. The problems that the beats of the bridge deck slab concrete vibration, ramming, defoaming, gas releasing, re-vibration and fine leveling in the same construction zone are difficult to match, the energy and operation track are difficult to control, and the apparent defects and flatness fluctuation are caused are solved.

Description

Technical Field

[0001] This invention belongs to the field of bridge deck concrete construction technology, specifically relating to an integrated equipment and construction method for bridge deck concrete grouting, defoaming, and leveling. Background Technology

[0002] Bridge deck concrete construction typically requires timely compaction, surface grouting, air bubble removal, and leveling after pouring and paving to achieve a finished surface that meets requirements for thickness, elevation, cross slope, and flatness. In existing technologies, bridge deck concrete is mostly compacted and roughly leveled using immersion vibrators or attached vibrating devices in conjunction with vibrating beams, truss vibrating leveling beams, roller levelers, or scrapers. Subsequently, air bubbles are removed and the final finish is achieved through manual troweling, grouting, or roller finishing. These processes are often completed in sections by different machines or work shifts, and compaction and leveling are achieved through repeated operations. During construction, the top surface of the side formwork, guide rails, or control lines are usually used as elevation benchmarks.

[0003] However, bridge deck concrete is characterized by its relatively thin slab thickness, the influence of reinforcing bars or embedded parts on vibration wave propagation, high requirements for appearance quality, and a short operable time window. The existing decentralized vibration, defoaming, and leveling processes are difficult to precisely coordinate in terms of time and space. On the one hand, asynchronous vibration and leveling can easily lead to leveling while the surface is still settling or leveling after the surface has lost its plasticity, resulting in defects such as ripples, depressions, cracks, and local segregation. On the other hand, the rise of air bubbles and the formation of slurry have a lag. If the defoaming action is too early, the air bubbles have not yet fully risen, and if it is too late, the slurry film is difficult to close, which can easily lead to pinholes, pitting, exposed aggregate, and loose surface. In addition, multiple operations with multiple machines lead to uneven energy input and repeated disturbances, which can easily cause local over-vibration, bleeding segregation, or local under-vibration voids. This is especially true in bridge deck construction where flatness is sensitive, where appearance defects and the difficulty in controlling the flatness are more likely to occur. Summary of the Invention

[0004] To address the aforementioned problems in the prior art, this invention provides an integrated equipment and construction method for grouting, defoaming, and leveling of bridge deck concrete. This solves the problems in the prior art where it is difficult to match the rhythm of vibration grouting, defoaming and air release, and re-vibration and fine leveling of bridge deck concrete within the same construction zone, and the energy and operation trajectory are difficult to control in stages, resulting in surface defects and fluctuations in flatness.

[0005] The objective of this invention can be achieved through the following technical solutions:

[0006] A method for integrated grouting, defoaming, and leveling of bridge deck concrete includes the following steps:

[0007] S1: Benchmark and template preparation, complete the installation and reinforcement of bridge deck side formwork, set elevation control benchmarks and clean, pre-wet or isolate the construction surface;

[0008] S2: Pouring and paving, pouring the bridge deck concrete to the design thickness and then spreading and leveling it initially;

[0009] S3: Select an integrated grouting, defoaming, and leveling equipment. Using the travel direction of the integrated grouting, defoaming, and leveling equipment as a reference, delineate the area on the concrete surface to be treated, located between the front and rear edges of the grouting beam and within the coverage of the grouting action on the grouting beam surface, as the grouting compaction zone. Delineate the area located between the rear edge of the grouting beam and the front edge of the leveling beam, within the coverage of the defoaming component, as the defoaming and air release zone. Delineate the area located between the front and rear edges of the leveling beam, within the coverage of the leveling beam's re-vibration and fine leveling action. The area within the coverage area is the re-vibration and fine leveling zone. In the grouting and compaction zone, the grouting beam is controlled to perform linear and continuous surface vibration and grouting on the concrete surface using the first vibration parameter. In the defoaming and degassing zone, a defoaming component is selected and the defoaming component is used to break bubbles on the surface of the grout film layer along an S-shaped path with a contact pressure lower than that in the grouting and compaction zone. In the re-vibration and fine leveling zone, the leveling beam is controlled to perform re-vibration on the concrete using a second vibration parameter lower than the first vibration parameter, and at the same time, the top surface of the side formwork is used as the elevation reference for linear fine leveling.

[0010] S4: Stability judgment and advancement. When working in the re-vibration and fine leveling area, make the leveling beam closely fit the top surface of the side formwork with the top surface of the side formwork as the elevation reference and maintain effective contact with the top surface of the concrete. Continue re-vibration and fine leveling until the surface grout appears and no longer sinks significantly. Then, control the equipment to move forward slowly at a preset low speed and repeat step S3 to achieve continuous construction.

[0011] S5: Finishing and maintenance. After the integrated treatment is completed, the final finish is applied, and after the maintenance conditions are met, the surface is covered with moisturizing agent and sprayed with maintenance agent for maintenance.

[0012] As a further aspect of the present invention, the vibration intensity corresponding to the first vibration parameter of the grouting compaction zone in step S3 is higher than the vibration intensity corresponding to the second vibration parameter of the re-vibration fine leveling zone, and the contact pressure of the defoaming component of the defoaming and gas release zone on the grout film layer is less than the pressure exerted by the grouting beam on the concrete surface.

[0013] As a further aspect of the present invention, by controlling the equipment travel speed and the longitudinal distance between the grouting beam and the defoaming component, a gas release time window is formed between the end of the grouting compaction zone and the beginning of the defoaming and gas release zone, so that the bubbles after grouting can float to the surface of the grout film before undergoing S-shaped defoaming treatment.

[0014] As a further aspect of the present invention, the S-shaped path of the defoaming and gas release zone is formed by the lateral reciprocating oscillation of the defoaming component, and the amplitude and frequency of the lateral reciprocating oscillation are matched with the thickness of the slurry film on the concrete surface.

[0015] As a further aspect of the present invention, the leveling beam in the vibratory leveling zone is fitted with the top surface of the side formwork as a reference while the cross slope or elevation is finely adjusted and controlled, so that the entire plane forms the target cross slope and avoids the formation of steps at the overlap of adjacent construction zones.

[0016] As a further aspect of the present invention, the integrated slurry defoaming and leveling equipment advances in a step-by-step manner of moving forward—stabilizing judgment—moving forward again, and the adjacent step operation sections are set with overlapping lengths in the longitudinal direction.

[0017] As a further aspect of the present invention, the final finishing treatment in step S5 includes one of roughening, grooving, or smoothing, and after the final finishing is completed, it is maintained by covering with a moisturizing agent, spraying, or applying a protective agent.

[0018] An integrated grouting, defoaming, and leveling device for bridge deck concrete includes a frame, a traveling assembly, a grouting beam, a defoaming assembly, and a leveling beam. The traveling assembly is mounted on the frame to drive the frame to move longitudinally along the bridge deck. The grouting beam is installed at the front of the frame along the traveling direction. The defoaming assembly is located between the grouting beam and the leveling beam. The leveling beam is installed at the rear of the frame along the traveling direction. Side mold fitting assemblies are provided at both ends of the leveling beam. During operation, the side mold fitting assemblies are tightly fitted to the top surface of the side mold and serve as a leveling elevation reference.

[0019] As a further embodiment of the present invention, the defoaming component further includes a trajectory generation mechanism, which is used to cause the defoaming component to generate periodic left and right displacements in the width direction of the bridge deck to form an S-shaped path defoaming trajectory.

[0020] As a further embodiment of the present invention, the edge mold bonding assembly includes bonding blocks disposed at both ends of the leveling beam, the bonding blocks being used to slide along the top surface of the edge mold and provide bonding guidance.

[0021] The beneficial effects of this invention are as follows:

[0022] This invention establishes a benchmark for the top surface elevation of the side formwork in steps S1 and S2, ensuring the concrete is in a plastic and consistent state. In step S3, using the equipment's travel direction as a benchmark, the top surface of the concrete to be treated within the same construction zone is divided into a grouting and compaction zone, a defoaming and degassing zone, and a re-vibration and fine-leveling zone according to the effective action range of the equipment components. The grouting and compaction zone is covered by a grouting beam, and surface vibration and grouting are performed in a linear and continuous manner using the first vibration parameter. This ensures sufficient energy input to the surface layer to promote air release from the mixture, form a continuous grout film, and complete preliminary compaction. The defoaming component then applies a contact pressure less than that of the grouting and compaction zone along the surface. The S-shaped path defoams and releases air from the slurry surface, causing air bubbles to collect, rupture, and escape on the slurry carrier. The re-vibration and fine-leveling zone is covered by a leveling beam, and re-vibration is performed using a second vibration parameter that is less than the first vibration parameter. The top surface of the side mold is used as the elevation reference for straight-line fine-leveling. This allows the surface pores after defoaming to close and lock the elevation, cross slope, and flatness during the re-vibration and fine-leveling process. This solves the problem in the existing technology where it is difficult to match the rhythm of bridge deck concrete vibration, slurrying, defoaming and air release, and re-vibration and fine-leveling within the same construction zone, and the energy and operation trajectory are difficult to control in stages, resulting in surface defects and flatness fluctuations. Attached Figure Description

[0023] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to the accompanying drawings.

[0024] Figure 1 This is a flowchart of the integrated construction method for grouting, defoaming, and leveling of bridge deck concrete according to the present invention.

[0025] Figure 2 This is a flowchart of step S3 of the present invention. Detailed Implementation

[0026] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided.

[0027] Please see Figure 1 — Figure 2 As shown in the figure, this embodiment provides an integrated construction method for grouting, defoaming, and leveling of bridge deck concrete, including the following steps:

[0028] S1: Benchmark and template preparation, complete the installation and reinforcement of bridge deck side formwork, set elevation control benchmarks and clean, pre-wet or isolate the construction surface;

[0029] S2: Pouring and paving, pouring the bridge deck concrete to the design thickness and then spreading and leveling it initially;

[0030] S3: Addressing the characteristics of thin-layered bridge deck concrete, its susceptibility to air inclusion, high appearance requirements, and the continued settling and delayed rising of air bubbles after vibration, the concrete surface to be treated within the same construction zone is divided into three continuous areas along the direction of travel, using the equipment's travel direction as a reference. These three areas are then subjected to interconnected and distinctly differentiated fine treatments. Specifically: the area on the concrete surface to be treated, located between the front and rear edges of the grouting beam and within the coverage of the grouting beam's vibration action, is designated as the grouting compaction zone; the area on the concrete surface to be treated, located between the rear edge of the grouting beam and the front edge of the leveling beam and within the coverage of the defoaming component, is designated as the defoaming and air release zone; and the area on the concrete surface to be treated, located between the front and rear edges of the leveling beam and within the coverage of the leveling beam's re-vibration and fine leveling action, is designated as the re-vibration and fine leveling zone.

[0031] Furthermore, the following treatments are performed in the three areas mentioned above: In the grouting and compaction zone, the grouting beam is controlled to perform linear and continuous surface vibration grouting on the concrete surface with the first vibration parameter, so that the surface mixture receives a high energy input to promote the rise of air bubbles and form a continuous grout film, while achieving a grouting and compaction state with continuous grout production and significantly reduced bubbling on the concrete surface; In the defoaming and degassing zone, while keeping the continuous grout film intact, the defoaming component is used to perform surface shearing or rolling defoaming on the grout film layer with a contact pressure lower than that in the grouting and compaction zone, and the effective contact trajectory of the defoaming component is in the width of the bridge deck. The equipment is periodically shifted left and right, thus forming an S-shaped defoaming path relative to the direction of travel during the straight-line movement of the equipment. This promotes the concentration and discharge of floating air bubbles through an S-shaped reciprocating pushing-gathering-rupture-escape mechanism, while avoiding excessive disturbance to the lower aggregate structure. In the re-vibration and fine-leveling zone, the leveling beam is controlled to re-vibrate the concrete with a second vibration parameter that is less than the first vibration parameter. At the same time, the top surface of the side formwork is used as the elevation reference for straight-line fine-leveling. This allows the surface pores after defoaming and air release to close and lock the elevation, cross slope, and flatness under the action of re-vibration and fine-leveling.

[0032] The continuous slurry film formed in the slurry compaction zone serves as the defoaming carrier of the defoaming and gas release zone and provides a channel for the escape of air bubbles. After the defoaming and gas release zone completes the gas release, the surface immediately enters the re-vibration and fine leveling zone to complete the closure of pores and fine leveling while the concrete is still plastic. Thus, through the coordinated treatment of the three zones, the overall appearance defects such as pinholes, exposed stones, ripples and depressions are reduced and the flatness stability is improved.

[0033] One point that needs further explanation is that the defoaming component uses a defoaming roller or defoaming scraper with micro-protrusions or textures on its surface. This is achieved through a vertical adjustment mechanism, which can be a pneumatic cylinder mounted on the frame, allowing independent adjustment of the contact pressure relative to the concrete surface. This ensures a light pressure contact with the grout film layer, lower than the pressure exerted by the grouting beam. The trajectory generation mechanism consists of a lateral movement mechanism, a drive unit, and a swing control unit. The lateral movement mechanism uses a rack and pinion transmission system and is arranged along the width of the bridge deck. The drive unit is a servo motor or a swing cylinder, which converts the rotational motion into the periodic lateral reciprocating motion of the defoaming component via a crank-connecting rod. The swing control unit can adjust the amplitude and frequency of the reciprocating motion to match the thickness and fluidity of the concrete slurry film. When the equipment moves along the longitudinal direction of the bridge, the defoaming component, driven by the trajectory generation mechanism, makes continuous and periodic left and right displacements in the width direction of the bridge deck. Its motion trajectory is combined with the forward direction of the equipment, thereby forming a continuous S-shaped defoaming path on the surface of the concrete slurry film. This path covers the entire construction bandwidth. Through the lateral reciprocating pushing and gathering action, the floating air bubbles are caused to migrate, merge and break out on the surface of the slurry film, while avoiding damage to the continuity of the slurry film, thus achieving a highly efficient and uniform defoaming and gas release effect.

[0034] S4: Stability judgment and advancement. When working in the re-vibration and fine leveling area, make the leveling beam closely fit the top surface of the side formwork with the top surface of the side formwork as the elevation reference and maintain effective contact with the top surface of the concrete. Continue re-vibration and fine leveling until the surface grout appears and no longer sinks significantly. Then, control the equipment to move forward slowly at a preset low speed and repeat step S3 to achieve continuous construction.

[0035] S5: Finishing and maintenance. After the integrated treatment is completed, the final finish is applied, and after the maintenance conditions are met, the surface is covered with moisturizing coating and sprayed for maintenance.

[0036] To address the issues of surface defects and smoothness fluctuations caused by the difficulty in matching the rhythm of vibration compaction, defoaming and degassing, and re-vibration leveling of bridge deck concrete within the same construction zone in existing technologies, and the difficulty in controlling energy and work trajectory in stages within the same construction zone, this embodiment establishes a benchmark for the top surface elevation of the side formwork in steps S1 and S2, ensuring the concrete is in a consistent plastic state. In step S3, using the equipment's travel direction as a benchmark, the top surface of the concrete to be treated within the same construction zone is divided into a grouting and compaction zone, a defoaming and degassing zone, and a re-vibration leveling zone according to the effective range of the equipment components. The grouting and compaction zone is covered by a grouting beam, and surface vibration compaction is performed continuously in a linear manner using the first vibration parameter, ensuring sufficient energy input to promote degassing of the mixture, form a continuous grout film, and complete preliminary compaction. The defoaming and degassing zone is located between the grouting beam and the leveling beam. During this process, the defoaming component applies a contact pressure lower than that of the grouting and compaction zone along an S-shaped path to defoam and release air from the slurry film surface. This causes the air bubbles to collect, rupture, and escape on the slurry film carrier. The re-vibration and fine-leveling zone is covered by a leveling beam, and re-vibration is performed using a second vibration parameter lower than the first vibration parameter. The top surface of the edge mold is used as the elevation reference for straight-line fine-leveling. This allows the surface pores after defoaming to close and lock the elevation, cross slope, and flatness during the re-vibration and fine-leveling process. Subsequently, in step S4, the stability is determined by the surface slurry emerging and no longer showing significant subsidence. The equipment is controlled to advance slowly at a low speed and repeat step S3. This achieves a continuous connection between vibration and grouting, defoaming and air release, and re-vibration and fine-leveling. From the three dimensions of process cycle time, energy classification, and trajectory differentiation, defects such as pinholes, exposed stones, ripples, depressions, and joint steps are suppressed simultaneously, and the flatness stability is improved.

[0037] It should be noted that, based on the objective construction characteristics of bridge deck concrete—thin, wide layers, high appearance requirements, dynamic settlement, and delayed air bubble rise—sufficient vibration energy needs to be input in the early stages to degas and form a grout film. In the middle stages, rising air bubbles need to be released without disrupting the continuity of the grout film. Furthermore, in the later stages, minimal disturbance is required to close the pores, lock the elevation, and ensure cross slope and flatness. Based on this process chain, the effective action boundaries of the equipment components are naturally divided into three zones: the grouting compaction zone, the defoaming and air release zone, and the re-vibration and fine-leveling zone. The grouting compaction zone corresponds to the action from the front edge to the rear edge of the grouting beam. The coverage area is used to complete the degassing and film formation and initial vibration compaction. The defoaming and gas release zone corresponds to the transition range from the rear edge of the grouting beam to the front edge of the leveling beam. It is used to break bubbles and release gas on the surface under the load of the grout film and expand the width direction of the coverage through an S-shaped path to form a treatment trajectory that is different from that of straight vibration. The re-vibration and fine leveling zone corresponds to the coverage range from the front edge to the rear edge of the leveling beam. It is used to complete the re-vibration closure and straight fine leveling with the top surface of the side formwork as the reference. This division is essentially to spatially segment the energy input intensity, surface shear mode, and elevation locking time point according to the sequence of concrete state evolution, thereby obtaining controllable and reproducible rhythmic coordination.

[0038] Since bridge deck concrete is a thin-layer structure, surface quality significantly contributes to the overall appearance and durability. During construction, there are objective constraints: sufficient vibration energy is needed initially to promote air removal, film formation, and compaction; the leveling stage requires controlling disturbance intensity to avoid surface slurry enrichment, bleeding segregation, and aggregate exposure. Simultaneously, defoaming operations directly act on the slurry film layer; excessive contact pressure directly disrupts the film's continuity, leading to secondary air entrainment and surface cracking. A single intensity and pressure approach cannot simultaneously satisfy all three constraints, resulting in fluctuations in surface structure and appearance quality. Therefore, in one embodiment, in step S3… The vibration intensity corresponding to the first vibration parameter in the grouting compaction zone is higher than that corresponding to the second vibration parameter in the re-vibration fine leveling zone. Moreover, the contact pressure of the defoaming component on the grout film layer in the defoaming and degassing zone is less than the pressure exerted by the grouting beam on the concrete surface. A clear energy and pressure gradient is established at the method level. The first section completes degassing, film formation, and initial compaction with higher energy. The middle section completes degassing on the grout film surface without breaking the film with lower contact pressure. The last section completes pore closure and fine leveling with lower energy. This directly inhibits the bleeding segregation, grout enrichment, and aggregate exposure caused by repeated strong disturbances in the thin-layer bridge deck, while avoiding the destruction of the grout film continuity during the defoaming process.

[0039] Furthermore, the time required for air bubbles to rise and for the grout film to stabilize after grouting the bridge deck concrete is significant. In continuous construction, the time interval between the end of the grouting beam's action and the start of the defoaming component's action is determined by both the equipment's travel speed and the longitudinal spacing. Existing procedures lack controllable constraints on this time interval. The phenomena of bubbles continuing to rise after grouting before defoaming, and bubbles only breaking after the grout film has largely closed, coexist in engineering projects. This results in unstable air release effectiveness and apparent pinhole control. In one embodiment, by controlling the equipment's travel speed and the longitudinal spacing between the grouting beam and the defoaming component... The spacing between the grouting and defoaming components creates a time window for air release between the end of the grouting and compaction zone and the beginning of the defoaming and degassing zone. This allows air bubbles to rise to the surface of the grout film after grouting before undergoing S-shaped defoaming treatment. By limiting the travel speed of the control equipment and the longitudinal spacing between the grouting beam and the defoaming component, a controllable time window for air release is created between the end of grouting and the beginning of defoaming. This binds the process of air bubbles rising to the surface of the grout film to the spatial location of the defoaming action, achieving rhythm matching and repeatable control. This improves the effectiveness of air release and reduces residual pinholes and apparent instability caused by time interval mismatch.

[0040] Furthermore, the bridge deck construction zone is quite wide, and differences in reinforcement distribution, paving uniformity, and vibration energy cause air bubbles to exhibit a non-uniform distribution along the width. A single straight-line defoaming path exhibits striped coverage across the width, with residual air bubbles and pinhole defects concentrated in the uncovered strip areas. Simultaneously, the concrete slump and surface film thickness vary with mix proportions, transportation, and paving conditions. When the lateral amplitude and frequency of the defoaming action are not properly matched, both insufficient defoaming and excessive shearing can occur, leading to inconsistencies between the defoaming effect and surface continuity. In one embodiment, an S-shaped path is used for defoaming in the defoaming and gas release zone. It is formed by the lateral reciprocating oscillation of the defoaming component. The amplitude and frequency of the lateral reciprocating oscillation are matched with the thickness of the slurry film on the concrete surface. The S-shaped path of the defoaming and gas release zone is defined as being formed by the lateral reciprocating oscillation of the defoaming component. Furthermore, the amplitude and frequency of the oscillation are matched with the thickness of the slurry film on the concrete surface. The process converges at both the coverage and adaptation levels. The S-shaped trajectory enables the defoaming to form a continuous coverage in the width direction, reducing the striping omissions caused by the straight path. The amplitude and frequency matching makes the defoaming shearing action correspond to different slurry film thicknesses, taking into account both the defoaming efficiency and the continuity and stability of the slurry film, and reducing the surface disturbance caused by insufficient defoaming and excessive shearing.

[0041] Furthermore, the bridge deck forming surface is simultaneously controlled by elevation, cross slope, and flatness. Construction often employs a segmented approach, with overlapping transitions between adjacent construction zones. The overlapping area is sensitive to minute deviations in elevation and cross slope. Insufficient leveling guidance and fine-tuning capabilities can lead to steps, ripples, and abrupt cross slope changes at the overlap, affecting driving comfort and drainage performance, and triggering subsequent pavement thickness compensation. In one embodiment, the leveling beam in the vibratory leveling zone is guided and fitted with the top surface of the edge formwork while undergoing cross slope or elevation fine-tuning control. This ensures the leveled surface forms the target cross slope and avoids steps at the overlap of adjacent construction zones. By limiting the leveling beam to be guided and fitted with the top surface of the edge formwork and undergoing cross slope or elevation fine-tuning control, key geometric elements of the bridge deck forming surface, such as elevation and cross slope, are incorporated into the proactive control of the leveling process. Simultaneously, the quality risks at the overlap transition are addressed at the process control stage, enabling a continuous transition between adjacent construction zones at the overlap under the same benchmark, reducing steps, abrupt cross slope changes, and ripples, thereby improving the consistency of flatness and drainage alignment.

[0042] In addition, the long continuous pouring distance of the bridge deck results in variations in the longitudinal state of the working surface due to differences in settlement and grout discharge over time. When the equipment advances at a constant speed, leveling and shaping occur at different material state stages, leading to fluctuations in compaction and leveling effects along the longitudinal direction. Simultaneously, construction organization typically involves segment connections and stop-start controls. Without repeated coverage at segment junctions, boundary effects on density and flatness are formed, manifesting as joint lines, local depressions, and surface differences. In one embodiment, the integrated grouting, defoaming, and leveling equipment advances in a step-by-step manner: forward movement – ​​stability judgment – ​​further forward movement. Adjacent step-by-step work sections have overlapping lengths in the longitudinal direction. By limiting the equipment to a forward-moving-stability judgment-further-moving-advancement step-by-step approach and limiting the overlapping lengths of adjacent step-by-step work sections in the longitudinal direction, the material state at the time of shaping is incorporated into the rhythm control. The stability judgment ensures that fine leveling and locking occur during the grout discharge and settlement stabilization stages. The overlapping provides secondary coverage and continuous compaction and leveling at the junctions, reducing longitudinal fluctuations and segment boundary effects caused by long-distance continuous construction and improving overall consistency.

[0043] Following the above embodiments, the bridge deck has a large exposed surface area and is constructed in an open-air environment. Wind speed, sunlight, and temperature and humidity conditions cause a significant rate of surface water loss. After the final finish is completed, the surface film is in a sensitive stage. Surface shrinkage and chalking caused by water loss directly reduce the appearance quality and affect impermeability and wear resistance. At the same time, the bridge deck also has functional texture requirements. Inconsistencies between the final finish method and the curing method will cause uneven texture, poor surface strength gradient, and differences in durability. In one embodiment, the final finish treatment in step S5 includes one of roughening, grooving, or smoothing. After the final finish is completed, curing is carried out by covering with moisturizing agents, spraying, or applying a curing agent. By limiting the final finish method and limiting the use of covering with moisturizing agents, spraying, or applying a curing agent after the final finish, the formation of functional texture and early moisturizing curing are formed into a set of constraints. This ensures that the surface layer is stably hardened under controlled water loss conditions after the texture process is completed, reducing surface shrinkage, chalking, and differences in strength gradient, and ensuring that appearance and durability simultaneously meet the engineering requirements of the bridge deck.

[0044] An integrated grouting, defoaming, and leveling device for bridge deck concrete includes a frame, a traveling assembly, a grouting beam, a defoaming assembly, and a leveling beam. The traveling assembly is mounted on the frame to drive the frame to move longitudinally along the bridge deck. The grouting beam is installed at the front of the frame along the traveling direction. The defoaming assembly is located between the grouting beam and the leveling beam. The leveling beam is installed at the rear of the frame along the traveling direction. Side formwork fitting assemblies are located at both ends of the leveling beam. During operation, the side formwork fitting assemblies are tightly fitted to the top surface of the side formwork and serve as a leveling elevation benchmark. In the scenario of thin-layer, wide-width, long-distance continuous construction of cast-in-place bridge decks, after concrete paving, the concrete continuously undergoes a state evolution within the same time period: surface vibration followed by sinking—air bubbles rising—grout film formation—surface closure—elevation locking. Simultaneously, the side formwork serves as a direct reference for bridge deck elevation control throughout the entire line. Existing construction methods combine vibration grouting and defoaming... The foaming treatment and leveling finishing are separated into different machines or different passes. The lack of structural constraints on the spatial distance, time interval and action sequence between the processes makes it difficult for the three core links to form a stable rhythm within the same construction zone. The connection between the front-stage degassing and film formation, the middle-stage air release and the rear-stage closed-cell fine leveling is unstable, which ultimately manifests as surface defects and fluctuations in flatness, such as pinholes, exposed aggregate, ripples, depressions and joint steps. Therefore, an integrated grouting, defoaming and leveling equipment for bridge deck concrete was designed. By integrating the grouting beam, defoaming component and leveling beam into the same frame and promoting them uniformly by the walking component, and setting side mold fitting components at both ends of the leveling beam, the top surface of the side mold is used as the leveling elevation benchmark. From a structural perspective, this provides a carrier for a continuous and rhythmic integrated process, solving the quality fluctuation problem caused by the instability of the connection between the dispersed processes.

[0045] Furthermore, the grouting beam, defoaming component, and leveling beam are arranged on the same frame in the forward, middle, and rear directions of travel. The entire machine is driven by the traveling component to move longitudinally along the bridge deck, allowing the three processes to be carried out continuously within the same stroke, forming a fixed sequence and stable relative spacing, thus solidifying the process rhythm into the structural relationship of the equipment. At the same time, the side mold bonding components at both ends of the leveling beam are tightly bonded to the top surface of the side mold, directly introducing the top surface of the side mold as the leveling elevation benchmark, reducing the accumulation of deviations introduced by manual control lines or temporary guide rails, and providing a stable geometric reference for fine leveling. In addition, the centralized arrangement of the three types of components transforms the construction organization from multiple tools and multiple passes to one tool and one pass, reducing surface grout enrichment, bleeding segregation, and striping defects caused by repeated disturbance and repeated travel, and improving the consistency of appearance and flatness.

[0046] Because bridge deck construction zones are typically quite wide, the concrete in the width direction is affected by factors such as paving uniformity, steel mesh distribution, edge formwork constraints, and differences in vibration propagation. This results in uneven bubble formation and aggregation in the width direction. When the defoaming action covers the area along a single straight path, the defoaming effect forms striped patterns in the width direction. Uncovered areas are prone to residual bubbles and pinhole-like pitting. To avoid these problems, in one embodiment, the defoaming component also includes a trajectory generation mechanism. This mechanism causes the defoaming component to periodically shift left and right in the width direction of the bridge deck, forming an S-shaped path for bubble breaking. The defoaming component is a working part that contacts the top surface of the concrete slurry film layer and performs bubble breaking and gas release. Its shape corresponds to the process requirements and can be understood as a defoaming scraper, defoaming roller, or equivalent contact-type bubble breaking element. The trajectory generation mechanism is a unit that drives or guides the defoaming component to periodically shift left and right in the width direction of the bridge deck. Its function is to... The forward superposition of lateral reciprocating motion creates an S-shaped bubble-breaking trajectory on the top surface of the concrete. The trajectory generation mechanism structurally corresponds to the lateral reciprocating drive and guide parts. Its goal is to stably and repeatedly generate periodic displacements rather than relying on manual oscillation. Here, the trajectory generation mechanism is used to make the defoaming component generate periodic left and right displacements in the width direction of the bridge deck, thereby forming an S-shaped bubble-breaking trajectory on the top surface of the concrete when the frame moves in a straight line. This improves the defoaming action from a single straight-line coverage to continuous coverage in the width direction. The defoaming component continuously reciprocates laterally during its forward movement, causing the bubble-breaking path to scan interlaced in the width direction. The defoaming action surface changes from striped to continuous. At the same time, the reciprocating pushing effect of the S-shaped path causes bubbles to converge and migrate on the surface of the slurry film, improving the effectiveness of bubble breaking and gas release and reducing the concentration of residual bubbles in local areas. Ultimately, at the equipment level, this method of using an S-shaped path for bubble breaking in the defoaming and gas release zone and continuously connecting it with the preceding and following processes is effective.

[0047] Bridge deck leveling uses the top surface of the side formwork as the elevation benchmark throughout the entire construction zone. When the equipment travels a long distance along the side formwork, the contact state between the end of the leveling beam and the top surface of the side formwork directly determines the guiding stability and elevation locking accuracy. Long-distance continuous construction brings continuous friction and wear; wear, scraping, and jumping of the end contact parts can cause unstable adhesion, leading to slight fluctuations in the leveling elevation and discontinuities in the edge alignment. To solve the problems of stability and wear-resistant maintenance in the adhesion guidance between the end of the leveling beam and the top surface of the side formwork, in one embodiment, the side formwork adhesion assembly includes adhesion blocks disposed at both ends of the leveling beam. The adhesion blocks are used to slide along the top surface of the side formwork and provide adhesion guidance. The side formwork adhesion assembly is a component assembly installed at both ends of the leveling beam, contacting the top surface of the side formwork and providing guidance or adhesion. The adhesion blocks are installed on both ends of the leveling beam. The end contact or sliding component is a solid block-shaped part that directly adheres to and slides along the top surface of the side mold. It serves to guide the bonding, bear friction, and protect the ends of the side mold and the leveling beam. Structurally, it corresponds to replaceable and wear-resistant contact elements. By defining the side mold bonding assembly, including bonding blocks set at both ends of the leveling beam, the bonding blocks are used to slide along the top surface of the side mold and provide bonding guidance. The contact interface between the leveling beam and the top surface of the side mold is defined as a controllable block bonding interface. The bonding blocks form a stable bonding contact surface, allowing the end of the leveling beam to slide smoothly along the top surface of the side mold. As a vulnerable end contact component, the bonding block bears friction and wear and is easy to maintain and replace, so that the bonding accuracy remains stable during long-distance operations. This improves the reliability of the leveling elevation benchmark and reduces the risk of discontinuity in edge alignment and local elevation fluctuations.

[0048] Working principle and usage process of this invention:

[0049] This invention uses an integrated device as a carrier, integrating the grouting beam, defoaming component, and leveling beam on the same frame in the forward, middle, and rear directions of travel. The traveling component drives the beam to move longitudinally along the bridge deck. The grouting beam uses high energy to continuously vibrate and grout the surface concrete, promoting air release, compaction, and the formation of a continuous grout film. The defoaming component acts on the grout film surface under relatively low contact pressure, and the trajectory generation mechanism drives it to periodically move left and right in the width direction, forming an S-shaped defoaming trajectory. This achieves the collection, rupture, and release of floating air bubbles while maintaining the continuity of the grout film. The leveling beam uses lower energy for re-vibration and simultaneous fine leveling. The bonding blocks at both ends slide along the top surface of the side mold and provide bonding guidance, making the top surface of the side mold a stable elevation benchmark. Thus, while the concrete is still plastic, the closure of pores, the locking of elevation and cross slope, and the shaping of flatness are completed.

[0050] During construction, the side formwork is first installed and reinforced, and a control system based on the top surface of the side formwork is established. After cleaning the construction surface and performing necessary pre-wetting or isolation treatment, the bridge deck concrete is poured, spread, and initially leveled. Then, the integrated equipment is placed at the starting point of the construction zone, and the working height and contact state of the grouting beam, defoaming component, and leveling beam are adjusted. The grouting and re-vibration parameters, as well as the S-shaped trajectory parameters of the defoaming component, are set. The equipment is started to move and continuously process the same stroke in the order of grouting and compaction zone to defoaming and degassing zone to re-vibration and fine leveling zone. During the re-vibration and fine leveling process, the top surface of the side formwork is used as a reference to fit and guide the equipment and maintain effective contact with the top surface of the concrete. After the stability judgment is completed based on the surface grouting and the sinking and stabilizing state, the equipment is slowly advanced to the next section and the operation is repeated until the entire bridge deck construction is completed. Finally, the final finishing treatment is carried out and the equipment is covered and moisturized or sprayed for curing.

[0051] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A method for integrated construction of bridge deck concrete by grouting, defoaming, and leveling, characterized in that, Includes the following steps: S1: Benchmark and template preparation, complete the installation and reinforcement of bridge deck side formwork, set elevation control benchmarks and clean, pre-wet or isolate the construction surface; S2: Pouring and paving, pouring the bridge deck concrete to the design thickness and then spreading and leveling it initially; S3: Select an integrated grouting, defoaming, and leveling equipment. Using the travel direction of the integrated grouting, defoaming, and leveling equipment as a reference, delineate the area on the concrete surface to be treated, located between the front and rear edges of the grouting beam and within the coverage of the grouting action on the grouting beam surface, as the grouting compaction zone. Delineate the area located between the rear edge of the grouting beam and the front edge of the leveling beam, within the coverage of the defoaming component, as the defoaming and air release zone. Delineate the area located between the front and rear edges of the leveling beam, within the coverage of the leveling beam's re-vibration and fine leveling action. The area within the coverage area is the re-vibration and fine leveling zone. In the grouting and compaction zone, the grouting beam is controlled to perform linear and continuous surface vibration and grouting on the concrete surface using the first vibration parameter. In the defoaming and degassing zone, a defoaming component is selected and the defoaming component is used to break bubbles on the surface of the grout film layer along an S-shaped path with a contact pressure lower than that in the grouting and compaction zone. In the re-vibration and fine leveling zone, the leveling beam is controlled to perform re-vibration on the concrete using a second vibration parameter lower than the first vibration parameter, and at the same time, the top surface of the side formwork is used as the elevation reference for linear fine leveling. S4: Stability judgment and advancement. When working in the re-vibration and fine leveling area, make the leveling beam closely fit the top surface of the side formwork with the top surface of the side formwork as the elevation reference and maintain effective contact with the top surface of the concrete. Continue re-vibration and fine leveling until the surface grout appears and no longer sinks significantly. Then, control the equipment to move forward slowly at a preset low speed and repeat step S3 to achieve continuous construction. S5: Finishing and maintenance. After the integrated treatment is completed, the final finish is applied, and after the maintenance conditions are met, the covering and moisturizing and spraying maintenance are carried out. In step S3, the vibration intensity corresponding to the first vibration parameter of the grouting and compaction zone is higher than the vibration intensity corresponding to the second vibration parameter of the re-vibration and fine leveling zone, and the contact pressure of the defoaming component of the defoaming and gas release zone on the grout film layer is less than the pressure exerted by the grouting beam on the concrete surface. By controlling the equipment's travel speed and the longitudinal distance between the grouting beam and the defoaming component, a time window for defoaming is created between the end of the grouting and compaction zone and the beginning of the defoaming and degassing zone, so that the bubbles after grouting can float to the surface of the grout film before undergoing S-shaped defoaming treatment. The S-shaped path of the defoaming and gas release zone is formed by the lateral reciprocating oscillation of the defoaming component, and the amplitude and frequency of the lateral reciprocating oscillation are matched with the thickness of the slurry film on the concrete surface.

2. The integrated construction method for grouting, defoaming, and leveling of bridge deck concrete according to claim 1, characterized in that, The leveling beams in the vibratory leveling zone are aligned with the top surface of the side formwork as a reference while undergoing fine-tuning control of the cross slope or elevation to form the target cross slope of the entire plane and avoid the formation of steps at the joints of adjacent construction zones.

3. The integrated construction method for grouting, defoaming, and leveling of bridge deck concrete according to claim 1, characterized in that, The integrated slurry defoaming and leveling equipment advances in a step-by-step manner of moving forward, determining stability, and then moving forward again, with adjacent step operation sections having an overlap length in the longitudinal direction.

4. The integrated construction method for grouting, defoaming, and leveling of bridge deck concrete according to claim 1, characterized in that, The final finishing treatment in step S5 includes one of roughening, grooving, or smoothing, and after the final finishing is completed, it is maintained by covering with a moisturizing agent, spraying, or applying a protective agent.

5. An integrated equipment for grouting, defoaming, and leveling bridge deck concrete, based on the integrated construction method for grouting, defoaming, and leveling bridge deck concrete according to any one of claims 1-4, characterized in that... The system includes a frame, a traveling assembly, a grouting beam, a defoaming assembly, and a leveling beam. The traveling assembly is mounted on the frame to drive the frame to move longitudinally along the bridge deck. The grouting beam is installed at the front of the frame along the traveling direction. The defoaming assembly is located between the grouting beam and the leveling beam. The leveling beam is installed at the rear of the frame along the traveling direction. The leveling beam has side mold bonding assemblies at both ends. During operation, the side mold bonding assemblies are tightly bonded to the top surface of the side mold and serve as a leveling elevation reference.

6. The integrated equipment for grouting, defoaming, and leveling bridge deck concrete according to claim 5, characterized in that, The defoaming component also includes a trajectory generation mechanism, which is used to cause the defoaming component to periodically shift left and right in the width direction of the bridge deck to form an S-shaped path defoaming trajectory.

7. The integrated equipment for grouting, defoaming, and leveling bridge deck concrete according to claim 5, characterized in that, The edge mold bonding assembly includes bonding blocks disposed at both ends of the leveling beam. The bonding blocks are used to slide along the top surface of the edge mold and provide bonding guidance.

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