A high-strength reinforced concrete segment and its manufacturing process

Abstract

This invention discloses a high-strength reinforced concrete segment, comprising a segment body with an extension portion and a reinforcing assembly. The reinforcing assembly includes multiple reinforcing holes penetrating the extension portion and a reinforcing cylinder fixedly installed inside any one of the reinforcing holes. A reinforcing column is fixedly installed inside the reinforcing cylinder. The beneficial effects of this invention are: by providing reinforcing holes in the extension portion of the segment body and installing the reinforcing cylinder, reinforcing column, and rib plate inside the reinforcing holes, a multi-layered reinforcement structure is formed at the segment connection. The reinforcing cylinder is tightly bonded to the concrete of the segment body, and the skeleton structure formed by the reinforcing column and rib plate can effectively transfer the stress at the segment connection, avoid stress concentration, and significantly improve the strength and impact resistance of the segment connection. At the same time, the filling reinforcing material further enhances the integrity between the reinforcing cylinder and the reinforcing column, achieving synergistic reinforcement of the segment body and the connection.

Description

Technical Field

[0001] This invention belongs to the technical field of tunnel construction components, specifically relating to a high-strength reinforced concrete segment and its manufacturing process. Background Technology

[0002] Reinforced concrete segments are the core components used in shield tunnel construction to assemble tunnel linings. Their performance directly determines the safety, durability, and service life of the tunnel structure. With the rapid development of urban rail transit and cross-river and cross-sea tunnel projects, the geological conditions faced by tunnel projects are becoming increasingly complex, such as high water pressure, soft soil strata, highly corrosive environments, and complex load conditions. This places higher demands on the mechanical strength, crack resistance, impermeability, and overall stability of the segments.

[0003] Currently, reinforced concrete tunnel segments generally adopt precast reinforced concrete structures, forming tunnel linings through factory prefabrication and on-site assembly. In existing technologies, various improvement schemes have emerged to enhance the performance of tunnel segments. For example, the crack-resistant reinforced concrete tunnel segment component with patent publication number CN120556937A sets the tunnel segment body as a composite structure of a matrix layer, a functional layer, and a surface layer. The matrix layer is made of ordinary concrete, the functional layer is made of composite fiber-reinforced resin mortar, and the surface layer is composed of a nano-waterproof coating. Through the short-cut carbon fiber reinforcement of the functional layer and the nano-waterproof coating of the surface layer, the crack resistance and waterproof performance of the tunnel segment are improved to a certain extent. The disclosed segment structure in this patent has a base layer thickness of 48mm to 52mm and a functional layer thickness of 8mm to 12mm. The composite fiber reinforced resin mortar, by weight, includes 1 to 3 parts of chopped carbon fiber and 100 to 120 parts of epoxy-modified polyurethane resin, with the chopped carbon fiber having a length of 5mm to 7mm. The nano-waterproof coating, by weight, includes 40 to 50 parts of silicone-based aqueous emulsion, 30 to 40 parts of nano-waterproof particles, and 5 to 10 parts of reinforcing agent. Its preparation method includes steps such as mold preparation, installation of steel mesh, pouring of base layer, formation of anti-slip texture, laying of functional layer, spraying of surface layer, curing and demolding.

[0004] However, the existing technologies still have the following drawbacks: insufficient connection strength of the tunnel segments; under high water pressure and heavy loads, stress concentration easily occurs at the joints of the segments, leading to cracking, water leakage, and even misalignment and loosening of the segments, seriously affecting the overall stability of the tunnel structure; limited improvement in the impact and crack resistance of the segments; the composite fiber reinforced resin mortar layer can only provide a certain crack resistance effect on the surface and cannot strengthen the internal stress structure of the segment body; under long-term alternating loads, the segment body is prone to internal micro-cracks, which gradually expand and destroy the overall structure of the segment, reducing its service life; in the existing manufacturing process, the bonding between the functional layer and the substrate layer depends on the anti-slip texture, and the bonding strength is greatly affected by the construction process, easily leading to interlayer peeling and detachment, and failing to maintain the performance of the composite structure in the long term. Summary of the Invention

[0005] The purpose of this invention is to provide a high-strength reinforced concrete segment and its manufacturing process, thereby improving the overall strength, crack resistance, impermeability, and connection stability of the segment.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a high-strength reinforced concrete segment, comprising a segment body, an extension portion provided on the segment body, and a reinforcing component, wherein the reinforcing component comprises a plurality of reinforcing holes through the extension portion and a reinforcing cylinder fixedly installed inside any one of the reinforcing holes, wherein a reinforcing column is fixedly installed inside the reinforcing cylinder, and a plurality of ribs spliced ​​with the reinforcing cylinder are provided on the reinforcing column, and reinforcing material can be filled between two adjacent ribs.

[0007] As a preferred technical solution of the present invention, the tube body is arc-shaped, the extension is integrally formed with the tube body, and the reinforcing holes are evenly distributed along the circumference of the tube body.

[0008] As a preferred embodiment of the present invention, the reinforcing cylinder is a hollow cylindrical structure with openings at both ends, and the outer wall of the reinforcing cylinder is tightly fitted with the inner wall of the reinforcing hole.

[0009] As a preferred technical solution of the present invention, the reinforcing material is epoxy resin mortar or micro-expansion concrete, the reinforcing material fills the gap between adjacent ribs, and the two ends of the reinforcing material are flush with the two end faces of the reinforcing cylinder.

[0010] This invention also discloses a manufacturing process for high-strength reinforced concrete segments, comprising the following steps: Step 1: Mold preparation: Clean and lubricate the segment mold to ensure that there are no impurities on the inner surface of the mold. According to the design dimensions of the segment body, locate the forming positions of the extension and reinforcement holes on the mold. Step 2: Rebar cage installation: Fix the precast rebar cage inside the mold according to the predetermined position, and pre-install the reinforcing cylinder at the forming position of the reinforcing hole in the mold, so that the reinforcing cylinder is welded and fixed to the rebar cage; Step 3: Concrete pouring and molding: High-strength concrete is poured into the mold. During the pouring process, a layered vibration process is used to ensure that the concrete is dense. Step 4: Segment curing: Place the cast segments in a standard curing environment for curing. When the concrete strength reaches more than 70% of the design strength, demold. After demolding, continue curing until the concrete strength reaches the design strength. Step 5: Install the reinforcement components: Insert the reinforcement column into the reinforcement cylinder and weld the ribs on the reinforcement column to the inner wall of the reinforcement cylinder. Step 6: Filling with reinforcement material: Inject reinforcement material into the gaps between adjacent ribs inside the reinforcement cylinder. Use pressure grouting to ensure that the reinforcement material fills the gaps. Cure until the reinforcement material reaches the design strength. Step 7: Quality Inspection and Acceptance: Inspect the dimensional accuracy of the segments, the concrete strength, the connection strength between the reinforcing cylinder and the reinforcing column, and the density of the reinforcing material. After passing the inspection, the segments are put into storage for future use.

[0011] As a preferred technical solution of the present invention, in step two, the inner wall of the reinforcing cylinder is coated with an anti-rust coating.

[0012] As a preferred technical solution of the present invention, in step three, the layered vibration process is divided into three vibrations. The first vibration is poured to 1 / 3 of the height of the segment body, the second vibration is poured to 2 / 3 of the height of the segment body, and the third vibration is poured to the top of the segment body. The vibration time for each vibration is 15-20 seconds, and the insertion point spacing of the vibrator is no more than 300 mm.

[0013] As a preferred technical solution of the present invention, in step four, the temperature of the standard curing environment is 18-22℃, the relative humidity is not less than 95%, the curing time is not less than 28 days, and a synchronous demolding process is adopted during demolding.

[0014] As a preferred technical solution of the present invention, in step six, the grouting pressure of the pressure grouting process is 0.3-0.5MPa, and multiple grouting is carried out during the grouting process.

[0015] Compared with the prior art, the beneficial effects of the present invention are: By setting reinforcement holes in the extension of the tunnel segment body and installing reinforcement cylinders, reinforcement columns, and ribs in the reinforcement holes, a multi-layered reinforcement structure is formed at the tunnel segment connection. The reinforcement cylinder is tightly bonded to the concrete of the tunnel segment body, and the skeleton structure formed by the reinforcement columns and ribs can effectively transfer the stress at the tunnel segment connection, avoid stress concentration, and significantly improve the strength and impact resistance of the tunnel segment connection. At the same time, the filling reinforcement material further enhances the integrity between the reinforcement cylinder and the reinforcement column, realizing the synergistic reinforcement of the tunnel segment body and the connection, and solving the problem of insufficient connection strength of existing tunnel segments. The reinforced structure formed by the reinforcing cylinder, reinforcing column, and reinforcing material of the present invention can effectively limit the generation and propagation of concrete cracks in the tunnel segment body, thereby improving the crack resistance of the tunnel segment. In the manufacturing process, steps such as pre-installing the reinforcing cylinder, layered vibration of concrete, and pressure grouting to fill the reinforcing material ensure the bonding strength between the reinforcing components and the segment body, avoiding problems such as interlayer peeling and detachment. At the same time, standard curing and synchronous demolding processes ensure the strength and dimensional accuracy of the segment concrete, improving the consistency and stability of the product. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is an exploded view of the reinforcement components and the segment body of the present invention. Figure 3 This is an exploded view of the reinforced column and reinforced cylinder of the present invention; Figure 4 This is a flowchart illustrating the manufacturing process of the high-strength reinforced concrete tunnel segments of the present invention. In the picture: 1. Segment body; 2. Extension; 3. Reinforcing cylinder; 4. Reinforcing column; 5. Rib; 6. Reinforcing hole. Detailed Implementation

[0017] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Example 1

[0018] Please see Figures 1 to 4This is the first embodiment of the present invention, which provides a high-strength reinforced concrete tunnel segment, including a tunnel segment body 1, an extension 2 provided on the tunnel segment body 1, and a reinforcement component. The reinforcement component includes multiple reinforcement holes 6 penetrating through the extension 2 and a reinforcement cylinder 3 fixedly installed inside any one of the reinforcement holes 6. A reinforcement column 4 is fixedly installed inside the reinforcement cylinder 3, and multiple ribs 5 spliced ​​with the reinforcement cylinder 3 are provided on the reinforcement column 4. This can form an internal three-dimensional reinforcement skeleton in the key stress area of ​​the tunnel segment splicing, which can evenly distribute the tunnel surrounding rock load and splicing extrusion stress, avoid stress concentration at the joint of the tunnel segment splicing, and significantly improve the overall structural strength, bending performance and deformation resistance of the reinforced concrete tunnel segment. Reinforcing material can be filled between two adjacent ribs 5 to realize the combination of structure and filling reinforcement, further strengthening the integrated connection of the reinforcement component and the tunnel segment body 1.

[0019] In this embodiment, the segment body 1 is arc-shaped, which is suitable for the assembly requirements of the tunnel ring lining and fits the stress conditions of the shield tunnel forming. The extension 2 and the segment body 1 are integrally formed, which has strong structural integrity, is not easy to crack or delaminate, and has better tensile and shear resistance. The reinforcement holes 6 are evenly distributed along the circumference of the segment body 1, which can realize the balanced stress of each part of the segment in the circumference, avoid local single-point overload damage, and ensure that the entire ring tunnel segment is subjected to uniform stress and has higher structural stability.

[0020] In this embodiment, the reinforcing cylinder 3 is a hollow cylindrical structure with openings at both ends, and the outer wall of the reinforcing cylinder 3 is tightly fitted to the inner wall of the reinforcing hole 6. The reinforcing cylinder 3 is designed as a hollow cylindrical structure with openings at both ends, which facilitates the internal installation of the reinforcing column 4 and the rib plate 5, and also provides a smooth working space for subsequent injection of reinforcing materials. The tight fit between the outer wall of the reinforcing cylinder 3 and the inner wall of the reinforcing hole 6 prevents relative slippage and loosening under stress, and at the same time blocks water vapor from seeping through the gaps in the hole wall, thereby improving the anti-seepage and waterproofing capabilities of the segment splicing position.

[0021] In this embodiment, the reinforcing material is epoxy resin mortar or micro-expansion concrete. The reinforcing material is filled in the gap between adjacent ribs 5, and both ends of the reinforcing material are flush with the two end faces of the reinforcing cylinder 3. Epoxy resin mortar or micro-expansion concrete is selected as the reinforcing material because it has the characteristics of high strength, micro-expansion, strong adhesion, corrosion resistance and aging resistance. When filled in the gap between adjacent ribs 5, it can bond and solidify the reinforcing column 4, ribs 5 and reinforcing cylinder 3 into an integral rigid structure, which greatly improves the collaborative load-bearing capacity of the reinforcing components. After the reinforcing material is filled, both ends are flush with the end faces of the reinforcing cylinder 3, which can ensure that the end face of the extension 2 is flat and does not affect the accuracy of the on-site assembly and docking of the segments.

[0022] A manufacturing process for high-strength reinforced concrete tunnel segments includes the following steps: Step 1: Mold preparation: Clean and lubricate the tube segment mold to ensure that there are no impurities on the inner surface of the mold. According to the design dimensions of the tube segment body 1, locate the forming positions of the extension 2 and the reinforcing hole 6 on the mold. Step 2: Reinforcing steel cage installation: Fix the precast reinforcing steel cage inside the mold according to the predetermined position, and pre-install the reinforcing cylinder 3 in the reinforcing hole forming position of the mold, so that the reinforcing cylinder 3 is welded and fixed to the reinforcing steel cage; the inner wall of the reinforcing cylinder 3 is coated with an anti-rust coating. Step 3: Concrete pouring and molding: High-strength concrete is poured into the mold. During the pouring process, a layered vibration process is adopted to ensure that the concrete is dense. The layered vibration process is divided into three vibrations. The first vibration is poured to 1 / 3 of the height of the segment body 1, the second vibration is poured to 2 / 3 of the height of the segment body 1, and the third vibration is poured to the top of the segment body 1. Each vibration lasts for 15 seconds, and the insertion point spacing of the vibrator is no more than 300mm. Step 4: Segment Curing: Place the cast segments in a standard curing environment for curing. Demold when the concrete strength reaches more than 70% of the design strength. Continue curing after demolding until the concrete strength reaches the design strength. The standard curing environment temperature is 18℃, the relative humidity is not less than 95%, and the curing time is not less than 28 days. Use a simultaneous demolding process to avoid impact damage to the segments. Step 5: Installation of reinforcement components: Insert the reinforcement column 4 into the reinforcement cylinder 3, and weld the rib plate 5 on the reinforcement column 4 to the inner wall of the reinforcement cylinder 3 for fixation; Step 6: Filling with reinforcement material: Inject reinforcement material into the gaps between adjacent ribs 5 inside the reinforcement cylinder 3. Use pressure grouting to ensure the reinforcement material fills the gaps. Cure until the reinforcement material reaches the design strength. The grouting pressure for the pressure grouting process is 0.3 MPa, and multiple grouting is used during the grouting process. Step 7: Quality Inspection and Acceptance: Inspect the dimensional accuracy of the segments, the concrete strength, the connection strength between the reinforcing cylinder 3 and the reinforcing column 4, and the density of the reinforcing materials. After passing the inspection, the segments are put into storage for future use. Example 2

[0023] Please see Figures 1 to 4 This is the second embodiment of the present invention, which is based on the previous embodiment, but differs in that: Concrete pouring and molding: High-strength concrete is poured into the mold. During the pouring process, a layered vibration process is adopted to ensure the concrete is dense. The layered vibration process is divided into three vibrations. The first vibration is poured to 1 / 3 of the height of the segment body 1, the second vibration is poured to 2 / 3 of the height of the segment body 1, and the third vibration is poured to the top of the segment body 1. Each vibration lasts for 18 seconds, and the insertion point spacing of the vibrator is no more than 300mm. Segment curing: Place the cast segments in a standard curing environment for curing. Demold when the concrete strength reaches more than 70% of the design strength. Continue curing after demolding until the concrete strength reaches the design strength. The standard curing environment temperature is 20℃, the relative humidity is not less than 95%, and the curing time is not less than 28 days. Use a simultaneous demolding process to avoid impact damage to the segments. Reinforcing material filling: Inject reinforcing material into the gap between adjacent ribs 5 inside the reinforcing cylinder 3. Use pressure grouting process to ensure that the reinforcing material fills the gap. Cure until the reinforcing material reaches the design strength. The grouting pressure of the pressure grouting process is 0.4MPa. Multiple grouting is used during the grouting process. Example 3

[0024] Please see Figures 1 to 4 This is the third embodiment of the present invention, which is based on the previous embodiment, but differs in that: Concrete pouring and molding: High-strength concrete is poured into the mold. During the pouring process, a layered vibration process is adopted to ensure the concrete is dense. The layered vibration process is divided into three vibrations. The first vibration is poured to 1 / 3 of the height of the segment body 1, the second vibration is poured to 2 / 3 of the height of the segment body 1, and the third vibration is poured to the top of the segment body 1. Each vibration lasts for 20 seconds, and the insertion point spacing of the vibrator is no more than 300mm. Segment curing: Place the cast segments in a standard curing environment for curing. Demold when the concrete strength reaches more than 70% of the design strength. Continue curing after demolding until the concrete strength reaches the design strength. The standard curing environment temperature is 22℃, the relative humidity is not less than 95%, and the curing time is not less than 28 days. Use a simultaneous demolding process to avoid impact damage to the segments. Reinforcing material filling: Inject reinforcing material into the gap between adjacent ribs 5 inside the reinforcing cylinder 3. Use pressure grouting process to ensure that the reinforcing material fills the gap. Cure until the reinforcing material reaches the design strength. The grouting pressure of the pressure grouting process is 0.5MPa. Multiple grouting is used during the grouting process.

[0025] Although embodiments of the invention have been shown and described (see the detailed description above), it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high-strength reinforced concrete segment, comprising a segment body (1), wherein an extension (2) is provided on the segment body (1), characterized in that: It also includes a reinforcement component, which includes multiple reinforcement holes (6) through which the extension (2) is opened, and a reinforcement cylinder (3) fixedly installed inside any one of the reinforcement holes (6). A reinforcement column (4) is fixedly installed inside the reinforcement cylinder (3), and multiple ribs (5) spliced ​​with the reinforcement cylinder (3) are provided on the reinforcement column (4). Reinforcement material can be filled between two adjacent ribs (5).

2. The high-strength reinforced concrete segment according to claim 1, characterized in that: The tube body (1) is arc-shaped, the extension (2) and the tube body (1) are integrally formed, and the reinforcing holes (6) are evenly distributed along the circumference of the tube body (1).

3. A high-strength reinforced concrete segment according to claim 1, characterized in that: The reinforcing cylinder (3) is a hollow cylindrical structure with openings at both ends, and the outer wall of the reinforcing cylinder (3) is tightly fitted to the inner wall of the reinforcing hole (6).

4. A high-strength reinforced concrete segment according to claim 1, characterized in that: The reinforcing material is epoxy resin mortar or micro-expansion concrete. The reinforcing material fills the gap between adjacent ribs (5), and the two ends of the reinforcing material are flush with the two end faces of the reinforcing cylinder (3).

5. A manufacturing process for high-strength reinforced concrete tunnel segments, characterized in that: The method for manufacturing high-strength reinforced concrete segments as described in any one of claims 1-4 comprises the following steps: Step 1: Mold preparation: Clean and lubricate the tube segment mold to ensure that there are no impurities on the inner surface of the mold. According to the design dimensions of the tube segment body (1), position the forming positions of the extension (2) and the reinforcing hole (6) on the mold. Step 2: Installation of the steel reinforcement cage: Fix the precast steel reinforcement cage inside the mold according to the predetermined position, and pre-install the reinforcing cylinder (3) at the forming position of the reinforcing hole of the mold, so that the reinforcing cylinder (3) is welded and fixed to the steel reinforcement cage; Step 3: Concrete pouring and molding: High-strength concrete is poured into the mold. During the pouring process, a layered vibration process is used to ensure that the concrete is dense. Step 4: Segment curing: Place the cast segments in a standard curing environment for curing. When the concrete strength reaches more than 70% of the design strength, demold. After demolding, continue curing until the concrete strength reaches the design strength. Step 5: Install the reinforcement components: Insert the reinforcement column (4) into the reinforcement cylinder (3) and weld the rib plate (5) on the reinforcement column (4) to the inner wall of the reinforcement cylinder (3). Step 6: Filling with reinforcement material: Inject reinforcement material into the gap between adjacent ribs (5) inside the reinforcement cylinder (3), and use pressure grouting process to ensure that the reinforcement material fills the gap, and cure until the reinforcement material reaches the design strength; Step 7 Quality Inspection and Acceptance: The dimensional accuracy of the segments, concrete strength, connection strength between the reinforcing cylinder (3) and the reinforcing column (4), and density of the reinforcing materials are inspected. After passing the inspection, the segments are put into storage for future use.

6. The manufacturing process for high-strength reinforced concrete tunnel segments according to claim 5, characterized in that: In step two, the inner wall of the reinforcing cylinder (3) is coated with an anti-rust coating.

7. The manufacturing process for high-strength reinforced concrete segments according to claim 5, characterized in that: In step three, the layered vibration process is divided into three vibrations. The first vibration is poured to 1 / 3 of the height of the segment body (1), the second vibration is poured to 2 / 3 of the height of the segment body (1), and the third vibration is poured to the top of the segment body (1). The vibration time for each vibration is 15-20s, and the insertion point spacing of the vibrator is no more than 300mm.

8. The manufacturing process for high-strength reinforced concrete segments according to claim 5, characterized in that: In step four, the standard curing environment temperature is 18-22℃, the relative humidity is not less than 95%, the curing time is not less than 28 days, and a synchronous demolding process is used during demolding.

9. The manufacturing process for high-strength reinforced concrete tunnel segments according to claim 5, characterized in that: In step six, the grouting pressure of the pressure grouting process is 0.3-0.5 MPa, and multiple grouting replenishments are used during the grouting process.

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