A method for quickly constructing a roadway super-hydrophobic mesh type sealing wall

Abstract

The application discloses a kind of roadway super-hydrophobic net type closure wall fast construction method, comprising: installing anchor rod;Flexible net is fixed with top anchor rod by steel band;Interval component is set between net layer to form cavity;Net bottom is fixed to bottom plate by locking device;Preparation includes hydrophobic treatment porous particle super-hydrophobic slurry;It is filled by adopting hanging and spraying synchronous process layer-by-layer injection;Maintenance wall body.The application combines flexible net with super-hydrophobic material, realizes closure wall fast construction and long-acting waterproof, adapts to surrounding rock deformation, especially suitable for water-rich roadway emergency closure engineering, the application can significantly improve construction efficiency, and can realize water infiltration in material essential level barrier, maintain the engineering goal of long-term dry and stable surrounding rock;The application has strong environmental adaptability, realizes reliable sealing, and has the advantages of light and fast construction, quick construction, low material loss, controllable cost, strong practicality and the like, which provides an economic and efficient solution for roadway closure wall construction engineering.

Description

Technical Field

[0001] This invention relates to the field of mine roadway support and sealing engineering, specifically to a method for rapid construction of a superhydrophobic mesh-type sealing wall suitable for water-rich roadways. Background Technology

[0002] In coal mine roadways, constructing sealing walls is a common engineering requirement, primarily used to achieve key functions such as separating ventilation systems, isolating hazardous areas, and sealing abandoned spaces. By setting up sealing walls in goaf or backfill areas, methane gas can be effectively isolated, fires suppressed, and harmful gases sealed to prevent their spread underground. Simultaneously, it ensures the stable solidification of backfill materials in designated areas, serving as a safety barrier for underground operations and playing an indispensable role in maintaining overall mine safety and production order.

[0003] However, as mining extends deeper into the region, water-rich environments in tunnels are becoming increasingly common, posing a severe challenge to the long-term performance of sealing walls. Existing traditional construction methods, such as masonry, monolithic concrete casting, or traditional spraying, generally suffer from the following adaptability problems: First, the rigid structure of the wall is ill-suited to the continuous deformation of the surrounding rock under dynamic pressure and hydration, easily leading to cracking at the contact surface and the formation of seepage channels. Second, existing walls primarily rely on complete sealing; their materials and structures lack the ability to actively guide infiltrated water, causing the risk of water inrush to shift from external sealing to accumulation within the wall or on the back side, exacerbating material erosion, reducing support strength, and potentially leading to structural instability. Furthermore, the long construction period, high labor intensity, the susceptibility of thick walls to internal defects, and poor adaptability to surrounding rock deformation also limit their emergency and routine application in deep, water-rich tunnels. In recent years, the "flexible mesh + shotcrete" technology has improved the construction speed, but the mesh hanging process still relies on point-by-point binding or welding, which limits the construction efficiency. Moreover, in deformable tunnels, rigid connection points are prone to failure, leading to loosening of the mesh and cracking of the wall, resulting in insufficient overall reliability.

[0004] Therefore, in the face of the increasing number of water-rich conditions in deep mines, there is an urgent need for a new type of closed wall construction method that can adapt to the deformation of the surrounding rock, can quickly install wire mesh, and has an active drainage function, in order to solve the engineering problems of construction efficiency and long-term stability. Summary of the Invention

[0005] To overcome the shortcomings of existing technologies, this invention provides a method for rapid construction of superhydrophobic mesh-type sealing walls in tunnels, which solves the problems of low construction efficiency, poor waterproofing, and weak structural adaptability in existing technologies.

[0006] The technical solution adopted by this invention to solve its technical problem is: A method for rapidly constructing a superhydrophobic mesh-type sealing wall for tunnels includes the following steps: S1. Install anchor bolts on the roof, sides and floor at the designed location of the tunnel; S2. The flexible mesh is fixed to the top plate and the two sides of the rock with fasteners to form a skeleton layer that fits the surrounding rock. S3. Spacing members are provided between adjacent skeleton layers to form cavities of a predetermined thickness; S4. Secure the bottom of the skeleton layer to the base plate using a locking device; S5. Prepare a spraying material containing porous microparticles with hydrophobic treatment; using a combined spraying and mesh hanging operation, spray the spraying material in layers to fill the cavity and surface of the skeleton layer to form a closed wall. S6. Maintain the formed wall structure.

[0007] Preferably, the fixing components in step S2 include a steel strip and fasteners; the steel strip is a W-shaped cross-section steel strip; the fasteners include washers and nuts; the anchor rod is a resin anchor rod, and the fixing specifically includes: S21. At the predetermined positions on the roof and sides of the tunnel, resin anchor bolts with W-shaped cross-section steel strips are initially installed, leaving room for adjustment. S22. Pass the top of the flexible mesh through the bottom of the W-shaped cross-section steel strip of the top plate, and extend it 50-100mm outward from the W-shaped cross-section steel strip before pre-bending it to make it fit tightly against the top plate; fix the side panels using the same fixing method as the top plate to make the mesh surface taut and flat. S23. Install spherical washers and locking nuts sequentially on the upper surface of the W-shaped cross-section steel strip; by tightening the nuts, the W-shaped cross-section steel strip presses the flexible netting firmly against the surrounding rock surface at its crest. After pre-tightening the flexible netting, the spherical washers and nuts are finally locked together, forming a layered integrated anchoring structure consisting of "surrounding rock - flexible netting - W-shaped cross-section steel strip - spherical washers - locking nuts - anchor bolts".

[0008] Preferably, the locking device in step S4 includes a locking seat fixed to the base plate, a slot provided on the locking seat, and a locking member passing through the slot and the skeleton layer, thereby pressing the bottom of the skeleton layer into the slot through the locking member.

[0009] Preferably, the spacer in step S3 is a prefabricated rigid pad, including two or more thickness specifications, arranged between adjacent skeleton layers at a predetermined interval to form a multi-layer cavity structure.

[0010] Preferably, the porous microparticles subjected to hydrophobic treatment in step S5 are fly ash cenospheres; the porous microparticles are subjected to surface hydrophobic treatment by at least one of silane coupling agent, fatty acid or its salt, and organosilicon resin.

[0011] Preferably, the spraying material in step S5 further includes at least one of a cementitious material, a polymer emulsion, a fiber, a water-reducing agent, and a thickener; the cementitious material is at least one of cement, gypsum, and lime.

[0012] Preferably, the layered spray filling in step S5 specifically includes: S51. After the partial skeleton layer is installed and the first cavity is formed, the inner lining layer is sprayed. S52. After the inner lining layer reaches the predetermined strength, the subsequent skeleton layer is hung to form a second cavity, and the cavity is sprayed and filled to form a core layer. S53. During the filling of the core layer, subsequent skeleton layers are hung in parallel to form a third cavity; S54. The third cavity is filled by spraying to form an outer protective layer.

[0013] Preferably, the maintenance in step S6 includes water retention maintenance, and after maintenance to the predetermined age, leveling and sealing spraying are performed.

[0014] Preferably, the wall surface formed after the sprayed material is cured has a micro-nano two-dimensional rough structure, a static water contact angle >150°, and a roll-off angle <10°.

[0015] The present invention also provides a rapid construction system for a superhydrophobic mesh-type sealing wall in a tunnel for implementing the above method, comprising: (1) Top and side fixing module, including anchor bolts, steel strips and fasteners; (2) Interlayer spacing control module, including spacing components; (3) Bottom locking module, including locking device; (4) Spraying material module, which includes a dry mix of hydrophobically treated porous microparticles and matrix material.

[0016] Beneficial effects: The construction method provided by this invention has the following advantages compared with the prior art: 1. This invention combines integrated top and side wall fixing, rapid bottom locking, and simultaneous hanging and spraying processes to form a systematic method for constructing closed walls, achieving lightweight and rapid construction of closed walls. The flexible mesh itself is easy to transport and relatively lightweight, allowing it to better adapt to the deformation of the surrounding rock in the tunnel during construction, shortening the construction period, effectively improving work efficiency, and making it more practical.

[0017] 2. This invention constructs a durable, actively hydrophobic sealed wall by filling it with a superhydrophobic spraying material based on modified fly ash cenospheres. During curing, this material forms a two-dimensional rough structure in situ, from micrometer to nanometer, giving the wall surface durable superhydrophobic properties similar to lotus leaves (contact angle >150°, roll-off angle <10°). This effectively blocks water vapor penetration and promotes rapid droplet roll-off, maintaining the wall's long-term dryness and stability, and significantly improving its resistance to water erosion and structural durability. Furthermore, using fly ash cenospheres, an industrial solid waste, as the key substrate not only achieves green recycling of resources but also reduces raw material costs. Based on these material characteristics, the sealed wall requires minimal maintenance and has low repair costs during its service life, exhibiting excellent long-term stability and economic efficiency.

[0018] 3. This invention combines biomimetic materials science, rapid support technology, and efficient construction process to provide a method for constructing a sealing wall for tunnels that is fast, effectively impermeable, long-lasting, durable, economical, and practical. Attached Figure Description

[0019] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0020] Figure 1 This is a schematic diagram of the tunnel enclosure wall mesh construction of the present invention.

[0021] Figure 2 This is a schematic diagram of the specially designed base plate anchoring type mesh locking device of the present invention.

[0022] Figure 3 This is a process flow diagram of the closed wall construction method of the present invention.

[0023] In the diagram: 1011-Pre-drilled hole for top and side anchor bolts, 103-Flexible mesh, 201-W-section steel strip, 301-Rigid spacer, 401-Special bottom plate anchoring mesh locking device, 4011-Locking seat base, 4012-U-shaped slot, 4013-High-strength through-locking bolt, 4014-Nut, 40111-Pre-drilled hole for anchor bolts. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of the present invention.

[0025] Example 1: This embodiment was carried out in a coal mine roadway. The roadway cross-section is a straight-walled semi-circular arch, 4.5m wide and 3.8m high. The roadway superhydrophobic mesh-type sealing wall rapid construction system described in this invention was used for construction. The system includes: (1) Top and side fixing module: including top and side anchor bolts (installed in the pre-drilled holes 1011 of the top and side anchor bolts), W-shaped cross-section steel strip 201, washers and nuts 203; (2) Layer spacing control module: includes rigid spacer 301, with two thicknesses of 150mm and 500mm; (3) Bottom locking module: includes a specially designed bottom plate anchoring type mesh locking device 401 (i.e., locking device, see Figure 2 The device consists of a locking seat base 4011, a U-shaped slot 4012, a high-strength through-locking bolt 4013, and a nut 4014. (4) Superhydrophobic slurry module: contains a dry mix of hydrophobically treated fly ash cenospheres, rapid-hardening sulfoaluminate cement, metakaolin, redispersible latex powder, polypropylene fiber, water-reducing agent, and hydroxypropyl methylcellulose ether in proportion.

[0026] See Figure 3 Construct a closed wall by following these steps: S1. Outline Positioning and Anchor Installation: The outline of the enclosed wall is marked using a laser positioning instrument well known to those skilled in the art. Pre-drilled holes 1011 (1.5m deep) for top and side anchors are drilled along the outline in the top slab and both sides. Top anchors are installed in the pre-drilled holes 1011, with 200mm of the threaded section exposed. Anchor holes (0.5m deep) are drilled in the bottom slab, and bottom anchors are installed, with 100mm of the threaded section exposed. In this embodiment, resin anchors well known to those skilled in the art are used.

[0027] S2. Roof and Side Anchor Net Fixing: The W-shaped cross-section steel strip 201 (in this embodiment, a three-hole W-shaped cross-section steel strip 201 with a hole spacing of 1.2m) is fitted onto the roof anchor rod. Initially tighten the washers and nuts, leaving adjustment allowance. Unroll the rolled flexible net, i.e., the flexible net 103. In this embodiment, the flexible net is a 30mm×30mm diamond-shaped mesh woven from polymer yarn well-known to those skilled in the art, with a width of 4.5m. The top passes under the W-shaped cross-section steel strip 201 and extends 80mm outwards before being pre-bent to ensure it fits tightly against the roof. Tighten the nuts to press the W-shaped cross-section steel strip 201 against the flexible net 103 to the surrounding rock surface, forming a fixation. The side walls are fixed using the same method to ensure the net surface is taut and flat.

[0028] S3. Rapid Control of Layer Spacing: Place 150mm thick rigid spacer members 301 at 1.0m x 1.0m intervals on the surface of the first layer of flexible mesh 103; hang the second layer of flexible mesh 103 and tension it, pressing it firmly onto the rigid spacer members 301. Place 500mm thick rigid spacer members 301 at the same intervals on the surface of the second layer of flexible mesh 103; hang the third layer of flexible mesh 103 and tension it. Then place 150mm thick rigid spacer members 301 on the surface of the third layer of flexible mesh 103; hang the fourth layer of flexible mesh 103 and tension it. This forms a three-layer cavity of 150mm-500mm-150mm, with a total thickness of 800mm.

[0029] S4. Bottom Flexible Mesh Locking: Specially designed bottom plate anchoring mesh locking devices 401 are arranged at 1.0m intervals along the outline of the bottom plate. The specially designed bottom plate anchoring mesh locking devices 401 are made of Q235 steel and include a locking seat base 4011, a U-shaped groove 4012, a high-strength through-locking bolt 4013 (M20), and a nut 4014. Anchor bolt pre-drilled holes 40111 are provided on both sides of the locking seat base 4011. Bottom plate anchor bolts pass through the anchor bolt pre-drilled holes 40111 to fix the locking seat base 4011 to the bottom plate. The bottom end of the flexible mesh 103 is inserted into the U-shaped groove 4012 until it touches the bottom. Then, the high-strength through-locking bolt 4013 is passed laterally through the U-shaped groove 4012 and the flexible mesh 103 layer. The nut 4014 is tightened to press and lock the bottom of the flexible mesh 103.

[0030] S5. Preparation of superhydrophobic slurry: (1) Hydrophobic treatment of fly ash cenospheres: fly ash cenospheres with a particle size of 75-150μm are immersed in an ethanol solution containing hexadecyltrimethoxysilane (3% of the weight of the cenospheres), stirred and refluxed at 70℃ for 5 hours, filtered, washed and dried to obtain hydrophobic cenospheres.

[0031] (2) Preparation of dry mix: Weigh 40 parts of fast-hardening sulfoaluminate cement, 12 parts of metakaolin, 5 parts of redispersible latex powder, 2 parts of polypropylene fiber, 1.0 part of water-reducing agent, 0.1 part of hydroxypropyl methylcellulose ether, and 10 parts of hydrophobic treated cenospheres by weight and mix them evenly.

[0032] (3) Slurry preparation: Add water at a water-cement ratio of 0.28 and stir during construction, then spray using a wet spraying machine.

[0033] "Synchronous spraying" layered spray filling: (1) After the first and second layers of flexible netting 103 are installed, the first cavity is immediately wet sprayed. First, an adhesion layer (thickness 50mm) is sprayed. After initial curing for 50 minutes, the coating is continued to 150mm to form an inner lining layer.

[0034] (2) After 24 hours, the compressive strength of the inner lining reaches 6.8 MPa. The third layer of flexible netting 103 is then installed, and the second cavity is filled by layered spraying, each layer being 250 mm, and the 500 mm core layer is filled in two stages.

[0035] (3) While filling the core layer, the fourth layer of flexible net 103 is installed in parallel.

[0036] (4) After the core layer is filled, the third cavity is sprayed and filled to form a 150mm outer protective layer.

[0037] S6. Wall Curing and Touch-up Spraying: 24 hours after spraying, begin water spraying for curing, keeping the wall surface moist and controlling the ambient temperature (temperature 20±5°C, relative humidity ≥60%). After 5 days of curing, perform final leveling and sealing touch-up spraying on all joints, corners, and discontinuous areas of the wall surface to achieve seamless structural closure. This completes the overall construction of the sealed wall (see...). Figure 1 ), and maintain for 7-14 days.

[0038] Example 2: The difference between this embodiment and Embodiment 1 is that the rigid spacer 301 is made of metal and the thickness is adjusted to 160mm and 480mm to verify the effect of different thicknesses on the wall performance.

[0039] Example 3: The difference between this embodiment and Embodiment 1 is that diatomaceous earth is used instead of fly ash cenospheres for hydrophobic treatment, and heptadecyltrimethoxysilane is used as the hydrophobic treatment agent. The amount of hydrophobic cenospheres used in the slurry formulation is 12 parts. After 14 days of curing, the wall structure was stable and the hydrophobic performance was good.

[0040] Example 4: The difference between this embodiment and Embodiment 1 lies in the structure of the specially designed base plate anchoring mesh locking device: the slot is a rectangular groove, and the locking element is a wedge-shaped pin, which is tightened by hammering. After construction, the wall structure is stable and there is no loosening.

[0041] Example 5: The difference between this embodiment and Embodiment 1 is that in step S2, a U-shaped steel strip is used, and its grooves also provide fitting space for subsequent spraying. The wall interface shows good bonding after construction.

[0042] The method provided by this invention has fast construction speed, strong structural adaptability and excellent waterproof performance. It can be widely used in the construction of tunnel sealing walls in underground engineering such as coal mines and metal mines. It is especially suitable for rapid sealing projects under complex conditions such as water-rich, soft rock and dynamic pressure.

[0043] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Any simple modifications and equivalent changes made to the above embodiments based on the technical essence of the present invention shall fall within the protection scope of the present invention.

Claims

1. A method for rapid construction of a superhydrophobic mesh-type sealing wall for tunnels, characterized in that, Includes the following steps: S1. Install anchor bolts on the roof, sides and floor at the designed location of the tunnel; S2. The flexible mesh is fixed to the top plate and the two sides of the rock with fasteners to form a skeleton layer that fits the surrounding rock. S3. Spacing members are provided between adjacent skeleton layers to form cavities of a predetermined thickness; S4. Secure the bottom of the skeleton layer to the base plate using a locking device; S5. Prepare a spraying material containing porous microparticles with hydrophobic treatment; using a combined spraying and mesh hanging operation, spray the spraying material in layers to fill the cavity and surface of the skeleton layer to form a closed wall. S6. Maintain the formed wall structure.

2. The method for rapid construction of a superhydrophobic mesh-type sealing wall for tunnels according to claim 1, characterized in that, In step S2, the fixing components include a steel strip and fasteners; the steel strip is a W-shaped cross-section steel strip; the fasteners include washers and nuts; the anchor rod is a resin anchor rod, and the specific fixing steps include: S21. At the predetermined positions on the roof and sides of the tunnel, resin anchor bolts with W-shaped cross-section steel strips are initially installed, leaving room for adjustment. S22. Pass the top of the flexible mesh through the bottom of the W-shaped steel strip of the top plate, and extend it 50-100mm outward from the W-shaped steel strip before pre-bending it to make it fit tightly against the top plate. The side panels are fixed using the same fixing method as the top plate to make the mesh surface taut and flat. S23. Install spherical washers and locking nuts sequentially on the upper surface of the W-shaped cross-section steel strip; by tightening the nuts, the W-shaped cross-section steel strip presses the flexible netting firmly against the surrounding rock surface at its crest. After pre-tightening the flexible netting, the spherical washers and nuts are finally locked together, forming a layered integrated anchoring structure consisting of "surrounding rock - flexible netting - W-shaped cross-section steel strip - spherical washers - locking nuts - anchor bolts".

3. The method for rapid construction of a superhydrophobic mesh-type sealing wall for tunnels according to claim 1, characterized in that, In step S4, the locking device includes a locking seat fixed to the base plate, a slot provided on the locking seat, and a locking member passing through the slot and the skeleton layer, thereby pressing the bottom of the skeleton layer into the slot through the locking member.

4. The method for rapid construction of a superhydrophobic mesh-type sealing wall for tunnels according to claim 1, characterized in that, In step S3, the spacer is a prefabricated rigid pad, including two or more thickness specifications, which are arranged between adjacent skeleton layers at a predetermined interval to form a multi-layer cavity structure.

5. The method for rapid construction of a superhydrophobic mesh-type sealing wall for tunnels according to claim 1, characterized in that, In step S5, the porous microparticles undergoing hydrophobic treatment are fly ash cenospheres; the porous microparticles are subjected to surface hydrophobic treatment by at least one of silane coupling agent, fatty acid or its salt, and organosilicon resin.

6. The method for rapid construction of a superhydrophobic mesh-type sealing wall for tunnels according to claim 5, characterized in that, In step S5, the spraying material also includes a cementitious material, a polymer emulsion, fibers, a water-reducing agent, and a thickener; the cementitious material is at least one of cement, gypsum, and lime.

7. The method for rapid construction of a superhydrophobic mesh-type sealing wall for tunnels according to claim 1, characterized in that, In step S5, the layered spray filling specifically includes: S51. After the partial skeleton layer is installed and the first cavity is formed, the inner lining layer is sprayed. S52. After the inner lining layer reaches the predetermined strength, the subsequent skeleton layer is hung to form a second cavity, and the cavity is sprayed and filled to form a core layer. S53. During the filling of the core layer, subsequent skeleton layers are hung in parallel to form a third cavity; S54. The third cavity is filled by spraying to form an outer protective layer.

8. The method for rapid construction of a superhydrophobic mesh-type sealing wall for tunnels according to claim 1, characterized in that, In step S6, maintenance includes water retention maintenance, and after maintenance to the predetermined age, leveling and sealing spraying are carried out.

9. The method for rapid construction of a superhydrophobic mesh-type sealing wall for tunnels according to claim 1, characterized in that, The wall surface formed after the sprayed material is cured has a micro-nano two-dimensional rough structure, with a static water contact angle >150° and a roll-off angle <10°.

10. A rapid construction system for a superhydrophobic mesh-type sealing wall in a tunnel, used for implementing the rapid construction method of the superhydrophobic mesh-type sealing wall according to any one of claims 1-9, characterized in that, include: (1) Top and side fixing module, including anchor bolts, steel strips and fasteners; (2) Interlayer spacing control module, including spacing components; (3) Bottom locking module, including locking device; (4) Spraying material module, which includes a dry mix of hydrophobically treated porous microparticles and matrix material.

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