A comprehensive construction method of super-long and super-large area industrial plant emery wear-resistant solidified ground

Abstract

This invention discloses a comprehensive construction method for ultra-long and ultra-large area industrial plant corundum wear-resistant cured flooring, belonging to the field of floor construction technology, including the following steps: Step S1, setting compartment control lines on the base layer of the factory floor; Step S3, checking the flatness of the concrete surface layer through intermittent skip-compartment construction; Step S4, mixing aggregate with modified cement mortar, and spreading a portion of the aggregate mortar clumps on the base concrete according to the shape of compartment blocks; Step S5, spreading the remaining aggregate mortar clumps on the concrete again. This invention, by mixing corundum aggregate with modified cement mortar to form aggregate mortar clumps, utilizes the modified cement mortar to ensure firm adhesion of the aggregate, forming a high-strength wear-resistant surface layer, making the corundum aggregate evenly distributed in the concrete, while significantly improving the bonding force with the base concrete and with the aggregate, reducing porosity, improving impermeability, forming a dense wear-resistant surface layer, compacting pores and strengthening aggregate bonding.

Description

Technical Field

[0001] This invention relates to the field of ground construction technology, and in particular to a comprehensive construction method for ultra-long and ultra-large area industrial plant flooring with corundum abrasion-resistant and hardened surface. Background Technology

[0002] In modern industrial production systems, ultra-long and ultra-large industrial plants serve as core carriers for warehousing, heavy equipment installation, and large-scale production, placing stringent demands on the performance of their flooring systems. These plant floors must not only possess high strength and wear resistance to withstand long-term loads and frequent operational wear, but also meet requirements for high flatness, strong impermeability, and long service life. Simultaneously, they must adapt to the construction challenges arising from the large spans and open spaces of the plants.

[0003] With the development of intelligent and large-scale industrial development, the scale of factory construction continues to expand. Some projects have a single span length of over 30m and a floor area of ​​over 10,000㎡. In traditional industrial floor construction processes, ordinary concrete floors are prone to problems such as sanding, cracking, and insufficient wear resistance, resulting in high maintenance costs. Although single-layer corundum wear-resistant flooring has improved wear resistance, it is prone to cracking due to temperature stress and shrinkage deformation in ultra-large space construction. Moreover, its surface density and impermeability are difficult to meet the needs of high-end industries. Traditional construction methods for solidified floors in ultra-long and ultra-large industrial plants have limitations in terms of compartmentalized pouring control, flatness accuracy, and integrated wear-resistant curing construction. This leads to problems such as difficulty in controlling concrete shrinkage cracks, difficulty in controlling the flatness accuracy of large areas, surface cracks, hollow areas, surface sanding, peeling or pitting, poor compressive strength, and poor impermeability in the construction of ultra-long and ultra-large industrial plant floors. Summary of the Invention

[0004] The purpose of this invention is to provide a comprehensive construction method for ultra-long and ultra-large area industrial plant corundum wear-resistant and cured flooring, so as to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a comprehensive construction method for ultra-long and ultra-large area industrial plant corundum wear-resistant and cured flooring, comprising the following steps: Step S1: By cleaning the factory floor base, measure and mark the elevation control line and construction range line of the wear-resistant concrete floor of the room, and set the compartment control line; Step S2: Install anchors at intervals at the through joint, place the steel mesh in the upper middle part of the concrete slab, and break the steel mesh at the through joint and tie it to the implanted anchor hooks. Step S3: Pour concrete into the divided blocks, skip-pour construction, and use a steel roller to roll it repeatedly. At the same time, use an infrared laser detection device to check the concrete height, use a screed to level the concrete surface again, and use a level to check the levelness and flatness of the poured concrete surface. Step S4: Based on the unit area usage determined by the sample, calculate the weight of the diamond aggregate used in a single block in Step S3, divide the aggregate into two parts, mix them separately with modified cement mortar to form aggregate mortar clumps, and after the concrete surface reaches the initial setting state, spread a portion of the aggregate mortar clumps on the base concrete according to the shape of the block, press the aggregate into the concrete, and smooth it with a power trowel. Step S5: After the wear-resistant material absorbs moisture and darkens in color, spread the remaining aggregate slurry on the concrete again. As the concrete hardens, use a trowel to perform a crisscross grinding operation. Step S6: After the wear-resistant floor construction is completed and meets the standards, start the joint cutting operation, pour the joint filler into the joint, and after the floor curing is completed, the penetrating liquid hardener is sprayed into the interior of the floor through high pressure.

[0006] Preferably, the elevation control line measurement in step S1 includes the following steps: Step S11: Using the elevation lines pre-marked on the walls and columns as a reference, set steel rods at equal intervals. The elevation of the steel rods is the same as the elevation on the longitudinal joint template. At the same time, according to the drawings, accurately mark the boundary lines between the wear-resistant concrete area and other materials on the ground and wall, and repeatedly check them using an infrared laser level. Step S12: When the finished surfaces of adjacent rooms are at the same level, it is necessary to confirm the base treatment, gap treatment and finishing details. When there is a height difference, the transition method should be clarified. For the threshold and drainage ditch, draw simple node detail drawings to clarify the materials, thickness and finishing methods of each layer.

[0007] Preferably, the setting of the compartment control line in step S1 includes the following steps: Step S13: Based on the construction structure and concrete mix proportions, divide the concrete structure into multiple small-sized blocks and number the blocks in sequence. Step S14: Install wire mesh at the end of the first-cast block to create a barrier between adjacent blocks, and add additional crack-resistant steel mesh at the construction joint.

[0008] Preferably, the intermittent skip-cavity construction in step S3 includes the following steps: Step S31: Apply neat cement slurry to the cleaned concrete base, pour concrete into the designated block, pour concrete from one side along the width of the block, pour concrete in the predetermined skip-pour sequence, strictly control the pouring quality and interval time, and use a plate vibrator to vibrate, and use a steel roller to repeatedly roll the concrete. Step S32: The concrete is poured in a supplementary manner with the help of manual labor. The flatness of the concrete is adjusted and corrected, the edges of the poured concrete are trimmed, the construction joint of the concrete is left on the side, and the height of the concrete is checked with infrared laser detection equipment. Step S33: Use a long scraper to level the concrete surface again and remove the laitance. At the same time, use a level to check the levelness and flatness of the poured concrete surface. After the concrete is poured, use vacuum equipment to remove the bleed water.

[0009] Preferably, obtaining the aggregate usage per unit area of ​​the sample in step S4 includes the following steps: Step S41: Use the same type of corundum aggregate and cement raw materials as the main construction area. The concrete base of the sample area is the same as that of the main construction area, and the same construction process and equipment are used. Step S42: Use the concrete from step S41 to pour and level the concrete. During the initial setting stage, mix the carborundum aggregate and modified cement mortar evenly according to the pre-calculated weight to form aggregate mortar clumps. Spread the aggregate mortar clumps on the concrete in two layers. The weight of aggregate spread on each sample block is different. Press them in with a power trowel and smooth them with a steel trowel. Cure the sample blocks. Step S43: Test the wear resistance, surface appearance and color, and bonding strength of the sample blocks prepared in step S42 respectively, collect experimental data, record the aggregate usage of each sample block, select sample blocks that meet the construction standards, calculate the average aggregate usage of multiple sets of data by weighting, and calculate the usage per unit area based on the sample block area and the average aggregate usage.

[0010] Preferably, the calculation of the amount of corundum aggregate used in step S4 includes the following steps: Step S44: Calculate the top surface area of ​​the bin based on the dimensions of the bins divided in step S13. Calculate the weight of corundum aggregate required for a single bin by multiplying the top surface area of ​​the bin by the amount of aggregate used per unit area in step S43. Step S45: Determine the loss coefficient based on construction experience and management level, calculate the product of the weight of the corundum aggregate in a single silo block and the loss coefficient in step S44, determine the amount of corundum aggregate to be used in the silo block, weigh the aggregate according to the amount of corundum aggregate to be used in the silo block, and bag and label the aggregate, with the label being consistent with the silo block number.

[0011] Preferably, the construction of the corundum aggregate in step S4 includes the following steps: Step S46: Divide the weighed diamond aggregate in step S45 into two parts according to the proportion, and mix the two parts of diamond aggregate with modified cement mortar evenly to form aggregate mortar clumps. Step S47: Spread a large proportion of the aggregate mortar clumps on the surface of the initially set concrete, use a screed to level the aggregate mortar clumps according to the shape of the clumps, press the aggregate down into the concrete with a disc, use a level to check the levelness and flatness of the aggregate surface, and use a power trowel to smooth the aggregate surface.

[0012] Preferably, the aggregate slurry construction in step S5 includes the following steps: Step S51: After the diamond aggregate laid in step S47 absorbs water and turns darker in color, spread the remaining small proportion of aggregate mortar from step S46 on the surface of the aggregate, press the aggregate into the concrete, and smooth the concrete surface containing the diamond aggregate. Step S52: As the concrete cures and solidifies, adjust the tilt angle of the trowel blades and use the trowel to smooth and finish the concrete surface in a crisscross pattern. Use a manual steel trowel to smooth the edges and corners in an orderly and unidirectional manner to avoid trowel marks until the surface is free of trowel marks and has a certain gloss.

[0013] Preferably, the ground penetration construction in step S6 includes the following steps: Step S61: After the wear-resistant floor surface layer is completed, the joint cutting operation begins. Using joint cutting equipment, longitudinal and transverse joints are cut on the ground according to the construction standards. The debris inside the joints is removed, and the joints are kept dry. The joint filler is then poured into the joints, with the joint filler surface being lower than the concrete base surface. Step S62: Before applying the concrete sealant and hardener, use a multi-functional grinder with water to grind the surface, making the concrete surface porous and permeable. Step S63: After the wear-resistant floor curing is completed, the penetrating liquid curing agent is sprayed under high pressure to penetrate into the interior of the floor, where it reacts chemically with the free calcium and magnesium ions in the concrete to generate water-insoluble calcium silicate hydrate, which fills the pores and densifies the gaps between the aggregates.

[0014] Preferably, in step S45, the aggregate packaging is pre-weighed and packaged according to the amount of aggregate used in a single silo block. The silo block number, planned usage, and usage location are clearly marked on the packaging bag. Furthermore, the actual amount of aggregate used in each silo block is recorded during construction and compared with the theoretical calculation to analyze whether the loss is normal.

[0015] The technical effects and advantages of this invention are as follows: This invention calculates the amount of diamond aggregate used based on the area of ​​each storage block, divides the aggregate into two parts, and mixes the diamond aggregate with modified cement mortar to form aggregate mortar clumps. The modified cement mortar ensures that the aggregate adheres firmly and forms a high-strength wear-resistant surface layer. The two aggregate mortar clumps are then evenly spread on the concrete, and the aggregate is pressed down to sink into the concrete, so that the diamond aggregate is evenly distributed in the concrete. The adhesiveness of the mortar ensures that the diamond aggregate is set flat, while significantly improving the bonding force with the base concrete and with the aggregate, reducing porosity, improving impermeability, forming a dense and wear-resistant surface layer, compacting the pores and strengthening the aggregate bonding, and ensuring that the diamond aggregate is spread flatly on the ground surface, improving the flatness of the factory floor. Attached Figure Description

[0016] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the embodiments of the invention to explain the invention, but do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic diagram of the integrated construction method for industrial plant grounds according to the present invention; Figure 2 This is a schematic diagram of the elevation control line measurement process of the present invention; Figure 3 This is a schematic diagram of the compartment control line setting process of the present invention; Figure 4 This is a schematic diagram of the interval skip-containment construction process of the present invention; Figure 5 This is a schematic diagram of the process for obtaining the amount of aggregate per unit area in the sample according to the present invention; Figure 6 This is a schematic diagram of the calculation process for the amount of corundum aggregate used in the bins according to the present invention; Figure 7 This is a schematic diagram of the construction process of the corundum aggregate of the present invention; Figure 8 This is a schematic diagram of the aggregate slurry construction process of the present invention; Figure 9 This is a schematic diagram of the ground penetration construction process of the present invention. 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.

[0018] This invention provides, for example Figures 1-9The method for constructing a comprehensive, ultra-long, ultra-large area industrial plant floor with corundum abrasion-resistant and hardened surface, as shown, includes the following steps: Step S1: By cleaning the factory floor base, measure and mark the elevation control line and construction range line of the wear-resistant concrete floor of the room, and set the compartment control line; Step S2: Install anchors at intervals at the through joint, place the steel mesh in the upper middle part of the concrete slab, and break the steel mesh at the through joint and tie it to the implanted anchor hooks. Step S3: Pour concrete into the divided blocks, skip-pour construction, and use a steel roller to roll it repeatedly. At the same time, use an infrared laser detection device to check the concrete height, use a screed to level the concrete surface again, and use a level to check the levelness and flatness of the poured concrete surface. Step S4: Based on the unit area usage determined by the sample, calculate the weight of the diamond aggregate used in a single block in Step S3, divide the aggregate into two parts, mix them separately with modified cement mortar to form aggregate mortar clumps, and after the concrete surface reaches the initial setting state, spread a portion of the aggregate mortar clumps on the base concrete according to the shape of the block, press the aggregate into the concrete, and smooth it with a power trowel. Step S5: After the wear-resistant material absorbs moisture and darkens in color, spread the remaining aggregate slurry on the concrete again. As the concrete hardens, use a trowel to perform a crisscross grinding operation. Step S6: After the wear-resistant floor construction is completed and meets the standards, start the joint cutting operation, pour the joint filler into the joint, and after the floor curing is completed, the penetrating liquid hardener is sprayed into the interior of the floor through high pressure.

[0019] By setting control lines on the factory floor base, the floor base to be constructed is divided into multiple blocks. Concrete is poured into the divided blocks, with intermittent skip-block construction. After checking the levelness and flatness of the poured concrete surface, the amount of diamond aggregate is calculated based on the area of ​​each block. The aggregate is divided into two parts and mixed separately with modified cement mortar to form aggregate mortar clumps. After the concrete surface reaches the initial setting state, a portion of the aggregate mortar clumps is spread on the base concrete according to the block shape, and the aggregate is pressed into the concrete. After the wear-resistant material absorbs water and darkens in color, the remaining aggregate mortar clumps are spread on the concrete again according to the block shape. A level instrument is used to check the levelness and flatness of the poured concrete surface, ensuring that the diamond aggregate is evenly distributed in the concrete, improving the bonding force between the base concrete and the aggregate, reducing porosity, improving impermeability, forming a dense and wear-resistant surface layer, compacting pores and strengthening aggregate bonding, and ensuring that the diamond aggregate is spread evenly on the ground surface, improving the flatness of the factory floor.

[0020] The elevation control line measurement in step S1 includes the following steps: Step S11: Using the elevation lines pre-marked on the walls and columns as a reference, set steel rods at equal intervals. The elevation of the steel rods is the same as the elevation on the longitudinal joint template. At the same time, according to the drawings, accurately mark the boundary lines between the wear-resistant concrete area and other materials on the ground and wall, and repeatedly check them using an infrared laser level. Step S12: When the finished surfaces of adjacent rooms are at the same level, it is necessary to confirm the base treatment, gap treatment and finishing details. When there is a height difference, the transition method should be clarified. For the threshold and drainage ditch, draw simple node detail drawings to clarify the materials, thickness and finishing methods of each layer.

[0021] Using a level, and looking at the original elevation line provided by the surveying unit on the back wall or column with the highest accuracy, calculate the design elevation of the concrete surface in the current area. This serves as the benchmark for all subsequent work. According to the compartment drawing, install longitudinal templates and repeatedly calibrate the top of the templates using a level to ensure they accurately reach the design elevation of the concrete surface. Based on the width of the compartments, measure and mark the insertion points of steel rods at equal intervals between the templates. Drive the steel rods into the marked points to ensure they do not loosen during concrete vibration. Set up the level again and observe each steel rod. Adjust its height by hammering until the elevation reading at the top of the steel rod is completely consistent with the elevation of the top of the longitudinal joint template that has been checked. Construct an invisible guide rail network with the same elevation as the boundary template within the pouring area using steel rods. This achieves high-precision and high-efficiency control of the concrete elevation. By drawing detailed node drawings and strictly implementing them, common quality defects such as cracking, water accumulation, and tripping hazards at the ground junction can be avoided to the greatest extent.

[0022] The setting of the sub-warehouse control line in step S1 includes the following steps: Step S13: Based on the construction structure and concrete mix proportions, divide the concrete structure into multiple small-sized blocks and number the blocks in sequence. Step S14: Install wire mesh at the end of the first-cast block to create a barrier between adjacent blocks, and add additional crack-resistant steel mesh at the construction joint.

[0023] Above and below the construction joint, an additional layer of steel mesh is installed. According to the dividing line, anchors are installed at 1-meter intervals in the steel skeleton. The anchors are inserted 5cm into the lower poured floor slab. The steel mesh is placed in the upper middle part of the poured block and tied to the anchors to ensure that it is vertical and stable. The concrete structure of the factory floor is divided into multiple small blocks, which facilitates the intermittent adjustment of the factory floor. After the concrete has initially set, the exposed wire mesh is cut off and a clear interface is created.

[0024] Step S3, the interval skip-construction construction, includes the following steps: Step S31: Apply neat cement slurry to the cleaned concrete base, pour concrete into the designated block, pour concrete from one side along the width of the block, pour concrete in the predetermined skip-pour sequence, strictly control the pouring quality and interval time, and use a plate vibrator to vibrate, and use a steel roller to repeatedly roll the concrete. Step S32: The concrete is poured in a supplementary manner with the help of manual labor. The flatness of the concrete is adjusted and corrected, the edges of the poured concrete are trimmed, the construction joint of the concrete is left on the side, and the height of the concrete is checked with infrared laser detection equipment. Step S33: Use a long scraper to level the concrete surface again and remove the laitance. At the same time, use a level to check the levelness and flatness of the poured concrete surface. After the concrete is poured, use vacuum equipment to remove the bleed water.

[0025] Remove mortar and adhering materials from the concrete surface. Clean the surface with water before pouring the top layer. Soak the base surface in water for 24 hours before the actual top layer pour. Once the surface is dry, apply a layer of neat cement slurry with the concrete pouring process, using P.O42.5 cement mixed with 8% construction adhesive. Pour the ready-mixed concrete into the designated sections. The concrete slump should be approximately 160mm. Pour concrete from one side along the width of the section, dividing the section into 20-30m sections. For the construction of the intermittent concrete slab, a plate vibrator is used for compaction, and a special steel roller is used for repeated rolling. The columns, corners and other parts are troweled with a wooden trowel. After the concrete is leveled, the cement slurry rises to the surface to a thickness of at least 3mm. At the same time, an infrared laser detection device is used to check the concrete height. A long screed is used to level the concrete surface again and remove the laitance. Meanwhile, a level is used to check the levelness and flatness of the poured concrete surface. The surface error is controlled within 1mm. After the concrete is poured, the process is repeated more than twice before the wear-resistant flooring construction begins.

[0026] Obtaining the aggregate usage per unit area of ​​the sample in step S4 includes the following steps: Step S41: Use the same type of corundum aggregate and cement raw materials as the main construction area. The concrete base of the sample area is the same as that of the main construction area, and the same construction process and equipment are used. Step S42: Use the concrete from step S41 to pour and level the concrete. During the initial setting stage, mix the carborundum aggregate and modified cement mortar evenly according to the pre-calculated weight to form aggregate mortar clumps. Spread the aggregate mortar clumps on the concrete in two layers. The weight of aggregate spread on each sample block is different. Press them in with a power trowel and smooth them with a steel trowel. Cure the sample blocks. Step S43: Test the wear resistance, surface appearance and color, and bonding strength of the sample blocks prepared in step S42 respectively, collect experimental data, record the aggregate usage of each sample block, select sample blocks that meet the construction standards, calculate the average aggregate usage of multiple sets of data by weighting, and calculate the usage per unit area based on the sample block area and the average aggregate usage.

[0027] By selecting the same type of diamond aggregate and cement raw materials as the factory floor construction, and following the same construction process, cement concrete was first poured. The pre-selected and weighed diamond aggregate was divided into two parts, and the two parts were mixed evenly with modified cement mortar. The aggregate mortar clumps were then spread evenly on the concrete in two stages, and the aggregate mortar clumps were pressed into the concrete to prepare multiple sample panels. The amount of diamond aggregate used in different sample panels was different, while keeping the amount of concrete constant. The ratio of the average amount of diamond aggregate used in the sample panels to the area of ​​the sample panels was calculated. This ratio is the diamond aggregate content. The material usage per unit area is determined after the sample plate has been cured. An abrasion resistance testing machine is used to test the abrasion resistance of the sample plate surface. A small hammer is used to gently tap the sample plate to check for hollow areas. The bonding strength is tested, and the smoothness and aggregate particle density of the sample plate surface are observed. Experimental data from multiple sample plates are obtained. The experimental data from multiple sample plates are processed, and the sample plate that best meets the construction standards in terms of abrasion resistance, surface appearance and color, and bonding strength is selected. The average value of the diamond aggregate usage per sample plate is calculated, and the material usage per unit area is calculated based on the sample block area and the average aggregate usage.

[0028] The calculation of the amount of corundum aggregate used in step S4 includes the following steps: Step S44: Calculate the top surface area of ​​the bin based on the dimensions of the bins divided in step S13. Calculate the weight of corundum aggregate required for a single bin by multiplying the top surface area of ​​the bin by the amount of aggregate used per unit area in step S43. Step S45: Determine the loss coefficient based on construction experience and management level, calculate the product of the weight of the corundum aggregate in a single silo block and the loss coefficient in step S44, determine the amount of corundum aggregate to be used in the silo block, weigh the aggregate according to the amount of corundum aggregate to be used in the silo block, and bag and label the aggregate, with the label being consistent with the silo block number.

[0029] Combining the top surface area of ​​the silo block in step S13 and the unit area usage in step S43, the amount of diamond aggregate used for each silo block is calculated. The aggregate is bagged and labeled according to the silo block number to determine the amount of diamond aggregate required for the construction of each silo block. This facilitates the compartmentalized construction of the factory floor and ensures the wear resistance and flatness of the factory floor.

[0030] Step S4, the application of corundum aggregate, includes the following steps: Step S46: Divide the weighed diamond aggregate in step S45 into two parts according to the proportion, and mix the two parts of diamond aggregate with modified cement mortar evenly to form aggregate mortar clumps. Step S47: Spread a large proportion of the aggregate mortar clumps on the surface of the initially set concrete, use a screed to level the aggregate mortar clumps according to the shape of the clumps, press the aggregate down into the concrete with a disc, use a level to check the levelness and flatness of the aggregate surface, and use a power trowel to smooth the aggregate surface.

[0031] The weighed carborundum aggregate is divided into two parts, with one part accounting for 60% and the other part accounting for 40%. The two parts are mixed separately with modified cement mortar to form carborundum aggregate slurry. After the concrete base layer has initially solidified, the large proportion of carborundum aggregate slurry is spread evenly on the concrete base layer according to the block size. A disc is used to press the aggregate downwards into the concrete to ensure that the carborundum aggregate is evenly embedded in the concrete. The surface flatness of the aggregate is measured and smoothed using a power trowel. The modified cement mortar is prepared by adding a polymer emulsion to the cement mortar. The polymer emulsion is one of styrene-butadiene latex (SBR), acrylic emulsion, or VAE emulsion.

[0032] The aggregate slurry construction in step S5 includes the following steps: Step S51: After the diamond aggregate laid in step S47 absorbs water and turns darker in color, spread the remaining small proportion of aggregate mortar from step S46 on the surface of the aggregate, press the aggregate into the concrete, and smooth the concrete surface containing the diamond aggregate. Step S52: As the concrete cures and solidifies, adjust the tilt angle of the trowel blades and use the trowel to smooth and finish the concrete surface in a crisscross pattern. Use a manual steel trowel to smooth the edges and corners in an orderly and unidirectional manner to avoid trowel marks until the surface is free of trowel marks and has a certain gloss.

[0033] By spreading the other part of the diamond aggregate mortar clump from step S46 evenly on the concrete and aggregate surface according to the block size, and pressing the aggregate downwards to sink it into the concrete, the diamond aggregate is mixed with modified cement mortar to form an aggregate mortar clump. The modified cement mortar ensures that the aggregate adheres firmly and forms a high-strength wear-resistant surface layer. The aggregate mortar clump is evenly spread on the concrete in two parts and the aggregate is pressed downwards to sink it into the concrete, so that the diamond aggregate is evenly distributed in the concrete. The adhesiveness of the mortar ensures that the diamond aggregate is set flat, while significantly improving the bonding force with the base concrete and the aggregate, reducing porosity, improving impermeability, forming a dense and wear-resistant surface layer, compacting the pores and strengthening the aggregate bonding.

[0034] The surface is smoothed and finished multiple times using a trowel. The flatness requirement for the wear-resistant floor is a maximum deviation of 2mm for a 2m square, and the maximum deviation between the highest and lowest points at the same elevation is no more than 5mm. To eliminate trowel marks remaining on the surface after troweling, a thin steel trowel is used to manually smooth the surface in an orderly and unidirectional manner to complete the finishing process. The wear-resistant hardened floor should be cured on the surface for 4 to 6 hours after construction to prevent rapid evaporation of surface moisture and ensure the stable growth of the strength of the wear-resistant material.

[0035] Step S6, the ground penetration construction, includes the following steps: Step S61: After the wear-resistant floor surface layer is completed, the joint cutting operation begins. Using joint cutting equipment, longitudinal and transverse joints are cut on the ground according to the construction standards. The debris inside the joints is removed, and the joints are kept dry. The joint filler is then poured into the joints, with the joint filler surface being lower than the concrete base surface. Step S62: Before applying the concrete sealant and hardener, use a multi-functional grinder with water to grind the surface, making the concrete surface porous and permeable. Step S63: After the wear-resistant floor curing is completed, the penetrating liquid curing agent is sprayed under high pressure to penetrate into the interior of the floor, where it reacts chemically with the free calcium and magnesium ions in the concrete to generate water-insoluble calcium silicate hydrate, which fills the pores and densifies the gaps between the aggregates.

[0036] Joint cutting can begin 10-15 hours after the wear-resistant floor surface layer is completed. Depending on the site temperature, if the temperature inside the factory is high, joint cutting should be completed within 24 to 48 hours. If the temperature in the basement area is low, joint cutting should be completed around 48 hours. Cut joints 5mm wide and 20mm deep according to the column spacing, with a 6*6 grid pattern to prevent irregular cracking. Cutting should be done with a uniform chalk line to ensure neat and straight joints. Then fill the joints with sealant, ensuring the sealant is 1-3mm lower than the concrete base surface, with no leaks or overflows. Avoid contact with water for 4 hours after construction. Before applying the concrete sealant, the floor should be ground using a multi-functional grinder with resin grinding discs and water to further improve the flatness of the floor. After grinding, clean the surface to ensure there is no laitance or other debris. After 7 days of curing, the penetrating liquid curing agent will penetrate 3-5mm into the floor through high-pressure spraying, reacting chemically with free calcium and magnesium ions in the concrete.

[0037] In step S45, aggregate packaging involves pre-weighing and repackaging the aggregate according to the usage of each individual silo. The silo number, planned usage, and application location are clearly marked on the packaging bags. During construction, the actual aggregate usage for each silo is recorded and compared with the theoretical calculation to analyze whether the loss is normal. The difference between the actual and theoretical usage is calculated, and the ratio of this difference to the actual usage is the loss rate. A loss rate within the range of 3-5% indicates a stable process; a loss rate between 5-10% indicates excessive loss, requiring analysis of the cause. A negative loss rate indicates an anomaly, necessitating immediate on-site inspection of the silo to check for areas with significant aggregate sparseness. Simultaneously, the accuracy of material requisition and return records is verified. This meticulous control of cost and quality management reflects whether the loss is normal and reveals problems in the construction process.

[0038] Principle of this invention: By setting control lines on the factory floor base, the floor base to be constructed is divided into multiple blocks. Concrete is poured into the divided blocks, with intermittent skip-block construction. After checking the levelness and flatness of the poured concrete surface, the amount of diamond aggregate is calculated based on the area of ​​each block. The aggregate is divided into two parts. The diamond aggregate is mixed with modified cement mortar to form aggregate mortar clumps. The modified cement mortar ensures that the aggregate adheres firmly and forms a high-strength wear-resistant surface layer. The two aggregate mortar clumps are evenly spread on the concrete, and the aggregate is pressed down to sink into the concrete, so that the diamond aggregate is evenly distributed in the concrete. The adhesiveness of the mortar ensures that the diamond aggregate is set flat, while significantly improving the bonding force with the base concrete and the aggregate, reducing porosity, improving impermeability, forming a dense and wear-resistant surface layer, compacting the pores and strengthening the aggregate bonding, and ensuring that the diamond aggregate is spread flat on the ground surface, improving the flatness of the factory floor.

[0039] Although embodiments of the invention have been shown and described, 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 comprehensive construction method for ultra-long and ultra-large area industrial plant corundum wear-resistant and cured flooring, characterized in that, Includes the following steps: Step S1: By cleaning the factory floor base, measure and mark the elevation control line and construction range line of the wear-resistant concrete floor of the room, and set the compartment control line; Step S2: Install anchors at intervals at the through joint, place the steel mesh in the upper middle part of the concrete slab, and break the steel mesh at the through joint and tie it to the implanted anchor hooks. Step S3: Pour concrete into the divided blocks, skip-pour construction, roll with a steel roller, and level the concrete surface again with a screed. At the same time, use testing equipment to check the concrete height, levelness and flatness. Step S4: Based on the unit area usage of the sample, calculate the amount of corundum aggregate used in a single block in Step S3. Divide the aggregate into two parts and mix them with modified cement mortar to form aggregate mortar clumps. After the concrete surface reaches the initial setting state, spread a portion of the aggregate mortar clumps on the base concrete and press the aggregate into the concrete. Step S5: After the wear-resistant material absorbs moisture and darkens in color, spread the remaining aggregate slurry on the concrete again. As the concrete hardens, use a trowel to perform a crisscross grinding operation. Step S6: After the wear-resistant floor construction is completed and meets the standards, start the joint cutting operation, pour the joint filler into the joint, and after the floor curing is completed, the penetrating liquid hardener is sprayed into the interior of the floor through high pressure.

2. The comprehensive construction method for ultra-long and ultra-large area industrial plant corundum wear-resistant and cured flooring according to claim 1, characterized in that, The elevation control line measurement in step S1 includes the following steps: Step S11: Using the elevation lines pre-marked on the walls and columns as a reference, set steel rods at equal intervals. The elevation of the steel rods is the same as the elevation on the longitudinal joint template. At the same time, according to the drawings, accurately mark the boundary lines between the wear-resistant concrete area and other materials on the ground and wall, and repeatedly check them using an infrared laser level. Step S12: When the finished surfaces of adjacent rooms are at the same elevation, it is necessary to confirm the base treatment, gap treatment and finishing details. When there is a height difference, draw detailed drawings of the nodes for the threshold and drainage ditch areas to determine the materials, thickness and finishing methods of each layer.

3. The comprehensive construction method for ultra-long and ultra-large area industrial plant corundum wear-resistant and cured flooring according to claim 2, characterized in that, The setting of the compartment control line in step S1 includes the following steps: Step S13: Based on the construction structure and concrete mix proportions, divide the concrete structure into multiple small-sized blocks and number the blocks in sequence. Step S14: Set up wire mesh at the end of the first-cast block to form a barrier between adjacent blocks, and add additional crack-resistant steel mesh at the construction joint.

4. The comprehensive construction method for ultra-long and ultra-large area industrial plant corundum wear-resistant and cured flooring according to claim 3, characterized in that, The interval skip-containment construction in step S3 includes the following steps: Step S31: Apply neat cement slurry to the cleaned concrete base, pour concrete into the designated block, pour concrete from one side along the width of the block, pour concrete in the predetermined skip-pour sequence, strictly control the pouring quality and interval time, and use a plate vibrator to vibrate, and use a steel roller to repeatedly roll the concrete. Step S32: The concrete is poured in a supplementary manner with the help of manual labor. The flatness of the concrete is adjusted and corrected, the edges of the poured concrete are trimmed, the construction joint of the concrete is left on the side, and the height of the concrete is checked with infrared laser detection equipment. Step S33: Use a long scraper to level the concrete surface again and remove the laitance. At the same time, use a level to check the levelness and flatness of the poured concrete surface. After the concrete is poured, use vacuum equipment to remove the bleed water.

5. The comprehensive construction method for ultra-long and ultra-large area industrial plant corundum wear-resistant and cured flooring according to claim 4, characterized in that, Obtaining the aggregate usage per unit area of ​​the sample in step S4 includes the following steps: Step S41: Use the same type of corundum aggregate and cement raw materials as the main construction area. The concrete base of the sample area is the same as that of the main construction area, and the same construction process and equipment are used. Step S42: Use the concrete from step S41 to pour and level the concrete. During the initial setting stage, mix the carborundum aggregate and modified cement mortar evenly according to the pre-calculated weight to form aggregate mortar clumps. Spread the aggregate mortar clumps on the concrete in two layers. The weight of aggregate spread on each sample block is different. Press them in with a power trowel and smooth them with a steel trowel. Cure the sample blocks. Step S43: Test the wear resistance, surface appearance and color, and bonding strength of the sample blocks prepared in step S42 respectively, collect experimental data, record the aggregate usage of each sample block, select sample blocks that meet the construction standards, calculate the average aggregate usage of multiple sets of data by weighting, and calculate the usage per unit area based on the sample block area and the average aggregate usage.

6. The comprehensive construction method for ultra-long and ultra-large area industrial plant corundum wear-resistant cured flooring according to claim 5, characterized in that, The calculation of the amount of corundum aggregate used in step S4 includes the following steps: Step S44: Calculate the top surface area of ​​the bin based on the dimensions of the bins divided in step S13. Calculate the weight of corundum aggregate required for a single bin by multiplying the top surface area of ​​the bin by the amount of aggregate used per unit area in step S43. Step S45: Determine the loss coefficient based on construction experience and management level, calculate the product of the weight of the corundum aggregate in a single silo block and the loss coefficient in step S44, determine the amount of corundum aggregate to be used in the silo block, weigh the aggregate according to the amount of corundum aggregate to be used in the silo block, and bag and label the aggregate, with the label being consistent with the silo block number.

7. The comprehensive construction method for ultra-long and ultra-large area industrial plant corundum wear-resistant cured flooring according to claim 6, characterized in that, The construction of the corundum aggregate in step S4 includes the following steps: Step S46: Divide the weighed diamond aggregate in step S45 into two parts according to the proportion, and mix the two parts of diamond aggregate with modified cement mortar evenly to form aggregate mortar clumps. Step S47: Spread a large proportion of the aggregate mortar clumps on the surface of the initially set concrete, use a screed to level the aggregate mortar clumps according to the shape of the clumps, press the aggregate down into the concrete with a disc, use a level to check the levelness and flatness of the aggregate surface, and use a power trowel to smooth the aggregate surface.

8. The comprehensive construction method for ultra-long and ultra-large area industrial plant corundum wear-resistant and cured flooring according to claim 7, characterized in that, The aggregate slurry construction in step S5 includes the following steps: Step S51: After the diamond aggregate laid in step S47 absorbs water and turns darker in color, spread the remaining small proportion of aggregate mortar from step S46 on the surface of the aggregate, press the aggregate into the concrete, and smooth the concrete surface containing the diamond aggregate. Step S52: As the concrete cures and hardens, adjust the tilt angle of the trowel blades and use the trowel to smooth and finish the concrete surface in a crisscross pattern. Use a manual steel trowel to smooth the edges and corners in an orderly and unidirectional manner to remove the trowel marks from the surface.

9. The comprehensive construction method for ultra-long and ultra-large area industrial plant corundum wear-resistant and cured flooring according to claim 8, characterized in that, The ground penetration construction in step S6 includes the following steps: Step S61: After the wear-resistant floor surface layer is completed, the joint cutting operation begins. Using joint cutting equipment, longitudinal and transverse joints are cut on the ground according to the construction standards. The debris inside the joints is removed, the joints are dried, and the joint filler is poured into the joints. The joint filler surface is lower than the concrete base surface. Step S62: Before applying the concrete sealant and hardener, use a multi-functional grinder with water to grind the surface, making the concrete surface porous and permeable. Step S63: After the wear-resistant floor curing is completed, the penetrating liquid curing agent is sprayed under high pressure to penetrate into the interior of the floor, where it reacts chemically with the free calcium and magnesium ions in the concrete to generate water-insoluble calcium silicate hydrate, which fills the pores and densifies the gaps between the aggregates.

10. The comprehensive construction method for ultra-long and ultra-large area industrial plant corundum wear-resistant and cured flooring according to claim 9, characterized in that, In step S45, the aggregate packaging is pre-weighed and packaged according to the amount of aggregate used in a single silo block. The silo block number, planned usage, and usage location are clearly marked on the packaging bag. During construction, the actual amount of aggregate used in each silo block is recorded and compared with the theoretical calculation to analyze the amount of loss.

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