Prefabricated polymer gravity block and preparation method thereof
By using prefabricated polymer gravity blocks with built-in block structures and reinforcing mesh structures, the problem of large amounts of cement, sand, and stone used in gravity blocks is solved, achieving the effects of reducing resource consumption, lowering heat of hydration, and improving safety.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- 北京峰筑工程技术研究院有限公司
- Filing Date
- 2024-03-14
- Publication Date
- 2026-04-17
AI Technical Summary
The use of existing gravity blocks in construction projects involves a large amount of cement, sand, and stone materials, resulting in significant resource and environmental pressures. It is necessary to reduce their usage to achieve energy conservation and environmental protection.
Precast polymer gravity blocks are used, which reduce the amount of cement, sand and stone used by building blocks and reinforcing mesh structure. The reinforcing mesh improves impact resistance and load-bearing capacity, and grooves and holes are set to adjust the center of gravity and weight.
It effectively reduces the use of cement, sand, and stone, lowers the heat of hydration, improves the safety and lifespan of gravity blocks, and facilitates construction and transportation.
Smart Images
Figure CN121875313A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of precast concrete technology, and specifically relates to a precast polymer gravity block and its preparation method. Background Technology
[0002] Gravity blocks are frequently used in construction projects, such as pile foundation testing and gravity energy storage power stations. Gravity blocks are an important component of these projects, primarily serving as counterweights and bearing their own loads as well as related dynamic loads. They are often precast concrete blocks, requiring large quantities of stone, sand, and cement. This places significant pressure on our resources and environment. Therefore, reducing the use of cement, sand, and stone in gravity blocks is of great importance for the construction of pile foundations and energy storage power stations in my country, as well as for energy conservation and environmental protection. Summary of the Invention
[0003] This invention provides a prefabricated polymer gravity block, primarily aimed at reducing the amount of cement, sand, and aggregate used in gravity blocks. By embedding block-shaped components within the gravity block, this invention effectively reduces the amount of cement, small-diameter sand, and aggregate used, thereby reducing heat of hydration and dust. This technology offers advantages such as reliable performance, simple construction, quick installation, and environmental friendliness.
[0004] To achieve the above objectives, the present invention adopts the following technical solution.
[0005] A prefabricated polymer gravity block includes a block, a polymer, and reinforcing ribs; the reinforcing ribs consist of transverse reinforcing ribs and longitudinal reinforcing ribs, forming a reinforcing rib mesh; the reinforcing rib mesh is located at the edge of the prefabricated polymer gravity block; the block is surrounded by the reinforcing rib mesh and arranged at intervals; the polymer wraps around the block and the reinforcing ribs.
[0006] Preferably, the reinforcing mesh is arranged horizontally and vertically to form a reinforcing cage; the reinforcing cage is closed or semi-closed; the closed reinforcing cage includes a lateral reinforcing mesh, a lower reinforcing mesh and an upper reinforcing mesh; the semi-closed reinforcing cage includes a lateral reinforcing mesh and a lower reinforcing mesh.
[0007] Preferably, the reinforcing cage has multiple sub-spaces; the sub-spaces are independent of each other and contain block-shaped objects.
[0008] Preferably, the reinforcing mesh has openings.
[0009] Preferably, the reinforcing ribs include steel bars, steel wires, or FRP bars; the blocky material includes stones, reinforced concrete blocks, concrete blocks, and mortar blocks; the particle size of the blocky material is not less than 80 mm. The polymer includes concrete, grouting material, cement mortar, and mortar; the concrete includes ordinary concrete, high-flowability concrete, heavy-duty concrete, and HEPA.
[0010] Preferably, the gravity block has a lifting device, with one end of the lifting device embedded in the gravity block and the other end protruding from the gravity block.
[0011] Preferably, the gravity block has a hole.
[0012] Preferably, the cavity contains filling material.
[0013] Preferably, the gravity block has a groove; the groove is located at the top and / or bottom of the gravity block.
[0014] A method for preparing prefabricated polymer gravity blocks includes the following steps:
[0015] Step 1: Prepare the raw materials for the block, polymer, and reinforcing ribs;
[0016] Step 2: Fabricate the reinforcing ribs into a reinforcing rib mesh; divide the raw material into blocks of predetermined size; remove dust from the blocks; place the blocks into a constraint cage to form pre-constrained blocks;
[0017] Step 3: Place the reinforcing mesh in the predetermined position, and place the block inside the reinforcing mesh; set up the template for the polymer gravity block.
[0018] Step 4: Mix the polymer raw materials according to the specified proportions to form a polymer.
[0019] Step 5: Pour the polymer into the mold so that the polymer wraps around the reinforcing mesh and blocks; cure to the predetermined strength.
[0020] Compared with the prior art, the present invention has the following features and beneficial effects.
[0021] 1. By strengthening the reinforcement cage, the impact resistance of the gravity block is improved, cracking is reduced, and the safety and service life of the gravity block are effectively enhanced.
[0022] 2. By placing block-shaped objects inside the gravity block, the amount of cement, sand, and stone used in the gravity block is reduced, and the heat of hydration of the gravity block is reduced during construction, thus saving energy and reducing emissions.
[0023] 3. By setting grooves and / or holes in the gravity block, its center of gravity and weight can be adjusted appropriately.
[0024] 4. Install lifting equipment to facilitate the transportation of gravity blocks. Attached image description:
[0025] The present invention will now be described in further detail with reference to the accompanying drawings.
[0026] Figure 1 This is a schematic diagram of the vertical cross-section of a prefabricated polymer gravity block.
[0027] Figure 2 This is a schematic diagram of a cross-section of a prefabricated polymer gravity block.
[0028] Figure 3 This is a schematic diagram of the vertical cross-section of a precast polymer gravity block with a steel mesh on top.
[0029] Figure 4 This is a schematic diagram of the vertical cross-section of a prefabricated polymer gravity block with lifting components.
[0030] Figure 5 This is a schematic diagram of the vertical cross-section of a prefabricated polymer gravity block with holes.
[0031] Reference numerals: 1 - block, 2 - polymer, 3 - reinforcing rib, 3.1 - transverse reinforcing rib, 3.2 - longitudinal reinforcing rib, 3.3 - reinforcing rib mesh, 4 - lifting component. Detailed implementation method:
[0032] To better understand the purpose, technical solution, and function of this invention, the invention will be described in further detail below with reference to the accompanying drawings. Here, illustrative embodiments and their descriptions are used to explain the invention, but are not intended to limit the invention.
[0033] In the description of this invention, it should be understood that the terms "comprising / including," "consisting of," or any other variations thereof are intended to cover a non-exclusive inclusion, such that a product, apparatus, process, or method that comprises a list of elements includes not only those elements but may also include, where necessary, other elements not expressly listed, or elements inherent to such a product, apparatus, process, or method. Without further limitation, an element defined by the phrase "comprising / including…" or "consisting of…" does not exclude the presence of additional identical elements in the product, apparatus, process, or method that includes said element.
[0034] In this invention, unless otherwise explicitly specified and limited, the term "fixed connection" should be interpreted broadly, for example, it can refer to a sleeve connection, an lap joint, a weld, a bolted connection, or a combination of the above connections; the terms "installation," "connection," and "linking" should also be interpreted broadly, for example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components; the term "continuous reinforcing bar" refers to a reinforcing bar that is continuous without breakage, or a reinforcing bar that is broken but with a fixed connection between the broken reinforcing bars. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.
[0035] The implementation of the present invention will be described in detail below with reference to the accompanying drawings and preferred embodiments.
[0036] like Figure 1 , Figure 2 As shown, a prefabricated polymer gravity block includes a block 1, a polymer 2, and reinforcing ribs 3. The reinforcing ribs 3 include transverse reinforcing ribs 3.1 and longitudinal reinforcing ribs 3.2, which together form a reinforcing rib mesh 3.3. The reinforcing rib mesh 3 is located at the edge of the prefabricated polymer gravity block. The block 1 is surrounded by the reinforcing rib mesh 3.3, and the blocks 1 are spaced apart. The polymer 2 wraps around the block 1 and the reinforcing ribs 2.
[0037] Because this invention uses block-shaped materials in precast polymer gravity blocks, it can replace the same volume of polymer. Compared to ordinary concrete gravity blocks, precast polymer gravity blocks can reduce the amount of cement, sand, and aggregate used, effectively saving energy and protecting the environment. The block shape reduces the amount of cement used in the polymer, lowering the heat of hydration generated during cement production, avoiding or reducing concrete cracking, and improving the durability of the gravity block. Furthermore, the block shape can effectively absorb the heat of hydration generated by the surrounding polymer, reducing the temperature difference with the surrounding environment and effectively avoiding or reducing cracks caused by temperature differences. The precast polymer gravity blocks are equipped with reinforcing ribs located around the perimeter, which can improve the load-bearing capacity and deformation capacity of the gravity block, enhance its impact resistance, and help prevent concrete cracking or damage during use, thereby improving its durability.
[0038] like Figure 1 , Figure 2 and Figure 3 As shown, in this invention, the prefabricated polymer gravity block has horizontal top and bottom reinforcing meshes 3.3 and laterally arranged reinforcing meshes 3.3, forming a reinforcing cage, and the stone blocks are placed in the reinforcing cage; wherein Figure 1 The semi-enclosed reinforcing cage shown includes a lateral reinforcing mesh and a lower reinforcing mesh. Figure 3 The diagram shows a closed reinforcing cage, which includes lateral reinforcing mesh, a lower reinforcing mesh, and an upper reinforcing mesh, forming a closed body. Block 1 is placed inside the reinforcing cage.
[0039] In this invention, the reinforcing mesh 3.3 has openings to facilitate the casting of polymer 2, further reducing the amount of reinforcing ribs used.
[0040] In this invention, the reinforcing rib 3 is a steel bar, steel wire, or FRP bar, and the diameter of the reinforcing rib 3 is 0.2mm to 40mm. The spacing of the reinforcing rib mesh is not less than 50mm, which facilitates the dense casting of the polymer. The spacing of the upper horizontal reinforcing rib mesh is greater than that of the lower horizontal reinforcing rib mesh, not less than 80mm, which is more conducive to polymer casting and reduces the amount of upper reinforcing ribs used.
[0041] In this invention, the reinforcing cage has multiple subspaces; the subspaces are independent of each other and are separated by the reinforcing mesh 3.3, and a block 1 is placed in the subspace.
[0042] In this invention, block 1 includes stone, reinforced concrete blocks, concrete blocks, and mortar blocks; the particle size of block 1 is not less than 80mm, which can reduce dust, etc. The polymer 2 includes concrete, grouting material, cement mortar, and mortar; the concrete includes ordinary concrete, high-flowability concrete, heavy concrete, fiber concrete, organic concrete, and ultra-high performance concrete (HEPA). High-flowability concrete includes self-compacting concrete and highly fluid concrete. High-flowability concrete requires a sufficient amount of powder content, and the coarse aggregate can use a particle size of 5-15mm or 5-25mm. High-flowability concrete is more conducive to filling the gaps between blocks, ensuring the overall compactness of the precast polymer gravity blocks.
[0043] The difference between the particle size of the block and the average particle size of the block should not exceed 20% of the average particle size. This ratio requirement ensures that the particle size of the block is relatively small, which makes it easier to control the contact mode between the blocks or reduce their contact area, and facilitates a more uniform distribution of the mass of the gravity block.
[0044] like Figure 4 As shown, in this invention, a lifting device 4 is mounted on the gravity block. One end of the lifting device is embedded in the gravity block, and the other end protrudes from the gravity block. The lifting device is made of steel bars, metal parts, etc., and is used to lift the gravity block. The gravity block can be a cube, cylinder, or ellipsoid.
[0045] like Figure 5 As shown, in this invention, the gravity block has a hole 5, and the hole 5 is filled with a filling material, such as cement mortar, concrete, metal block, or inorganic block, which is used to adjust the weight and center of gravity distribution of the gravity block.
[0046] In this invention, the gravity block has grooves; the grooves are located at the top and / or bottom of the gravity block. This facilitates transportation or use.
[0047] In this invention, the block 1 is at a certain distance from the outer surface of the polymer 2, not less than 5 mm, to facilitate the casting of the polymer.
[0048] In this invention, polymer 2 is composed of HEPA or high-strength concrete and ordinary concrete. The HEPA or high-strength concrete is located on the outside of the ordinary concrete. The HEPA or high-strength concrete can improve the impact resistance, load-bearing capacity and durability of the precast polymer gravity block.
[0049] A method for preparing prefabricated polymer gravity blocks includes the following steps:
[0050] Step 1: Prepare the raw materials for block 1, polymer 2 and reinforcing rib 3;
[0051] Step 2: Make the reinforcing rib 3 into a reinforcing rib mesh 3.3; divide the block material into blocks 1 of a predetermined size; remove the dust from the blocks 1; put the blocks 1 into the constraint cage 2 to form the pre-constrained blocks 5;
[0052] Step 3: Place the reinforcing mesh 3.3 in the predetermined position, and place the block 1 inside the reinforcing mesh 3.3; set up the template for supporting the polymer gravity block.
[0053] Step 4: Mix the polymer raw materials according to the specified proportions to form polymer 3;
[0054] Step 5: Pour polymer 3 into the template so that polymer 3 wraps around the reinforcing mesh 3.3 and block 1; cure to the predetermined strength.
[0055] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any modifications, equivalent substitutions and improvements made by those skilled in the art within the scope of the technology disclosed in the present invention should be covered within the scope of protection of the present invention.
Claims
1. A prefabricated polymer gravity block, characterized in that: The prefabricated polymer gravity block includes a block (1), a polymer (2), and reinforcing ribs (3); the reinforcing ribs (3) consist of transverse reinforcing ribs (3.1) and longitudinal reinforcing ribs (3.2), forming a reinforcing rib mesh (3.3); the reinforcing rib mesh (3) is located at the edge of the prefabricated polymer gravity block; the block (1) is surrounded by the reinforcing rib mesh (3.3) and arranged at intervals; the polymer (2) wraps around the block (1) and the reinforcing ribs (2).
2. The prefabricated polymer gravity block according to claim 1, characterized in that: The reinforcing mesh (3) is arranged horizontally and vertically to form a reinforcing cage; the reinforcing cage is closed or semi-closed; the closed reinforcing cage includes a lateral reinforcing mesh, a lower reinforcing mesh and an upper reinforcing mesh; the semi-closed reinforcing cage includes a lateral reinforcing mesh and a lower reinforcing mesh.
3. The prefabricated polymer gravity block according to claim 2, characterized in that: The reinforcing cage has multiple subspaces; each subspace is independent of the others and contains a block (1).
4. The prefabricated polymer gravity block according to claim 1, characterized in that: The reinforcing mesh (3.3) has openings.
5. The prefabricated polymer gravity block according to claim 1, characterized in that: The reinforcing bar (3) includes steel bars, steel wires or FRP bars; the block (1) includes stone, concrete blocks or mortar blocks; the particle size of the block (1) is not less than 80 mm; the polymer (2) includes concrete, grouting material, cement mortar or mortar.
6. The prefabricated polymer gravity block according to claim 1, characterized in that: The gravity block has a lifting device (4), one end of which is embedded in the gravity block and the other end is exposed.
7. The prefabricated polymer gravity block according to claim 1, characterized in that: The gravity block has a hole (5).
8. The prefabricated polymer gravity block according to claim 7, characterized in that: The hole (5) contains filling material.
9. The prefabricated polymer gravity block according to claim 1, characterized in that: The gravity block has grooves; the grooves are located at the top and / or bottom of the gravity block.
10. A method for preparing a prefabricated polymer gravity block, characterized in that... The steps are as follows: Step 1: Prepare the raw materials for the block (1), polymer (2) and reinforcing ribs (3); Step 2: Make the reinforcing rib (3) into a reinforcing rib mesh (3.3); divide the block material into blocks (1) of a predetermined size; remove the dust from the blocks (1); put the blocks (1) into the constraint cage (2) to form a pre-constrained block (5); Step 3: Place the reinforcing mesh (3.3) in the predetermined position, and place the block (1) inside the reinforcing mesh (3.3); set up the template for the polymer gravity block. Step 4: Mix the polymer raw materials together in proportion to form polymer (3); Step 5: Pour the polymer (3) into the template so that the polymer (3) wraps the reinforcing mesh (3.3) and the block (1); cure to the predetermined strength.