A reinforcing method for a punched steel plate combined with an HPA coating for a new energy power structure

Abstract

A reinforcing method for punching steel plate combined with HPA paint of new energy power structure, comprising the following steps: step 1: the outer surface of the new energy power structure to be reinforced is cleaned and roughened, and if there are cracks or defects on the surface, they are repaired in advance; step 2: according to the shape of the structure to be reinforced, a punching steel plate with a predetermined thickness is selected and a through hole is processed on it, and then the surface of the punching steel plate is treated; step 3: the area to be reinforced is drilled and chemical bolts are implanted; step 4: structural steel adhesive is applied to the bonding surface of the new energy power structure to be reinforced and the bonding surface of the punching steel plate, and after curing, a steel adhesive layer is formed; step 5: after the structure is reinforced, HPA high-performance paint is continuously sprayed on the surface of the structure to form a protective layer wrapping the punching steel plate and the chemical bolts. The present application can repair and reinforce the structure in time during the long-term use of the power structure, thereby enhancing the bearing capacity, toughness and durability of the structure.

Description

Technical Field

[0001] This invention relates to the field of new energy structure reinforcement technology, specifically to a reinforcement method for new energy power structures that combines perforated steel plates with HPA coating. Background Technology

[0002] With prolonged use, structures are prone to aging and corrosion, affecting their durability and ultimately leading to a loss of original load-bearing capacity and toughness. For example, concrete, subjected to long-term freeze-thaw cycles, acid rain erosion, and carbonation, often experiences problems such as protective layer peeling, longitudinal cracks, and steel reinforcement corrosion, resulting in severe degradation of bending stiffness. The interior of pumping and storage pipes is also prone to concrete wear due to prolonged erosion. For wind turbine towers, the outer layer gradually wears away under constant wind and rain, especially in coastal salt spray or industrial acid rain areas, leading to frequent corrosion and thinning of members, loose bolts, and even node plate fractures. As massive structures bearing high-cycle dynamic loads, tower welds and flange connections are highly susceptible to fatigue cracks. Simultaneously, to improve transmission efficiency, power grid companies commonly implement "capacity-increasing conductors" or "multi-circuit tower" upgrades, significantly increasing the load on towers and their wind-receiving area, often exceeding the original design's load-bearing limits. These factors can lead to transmission line interruptions. Furthermore, the sheer number of photovoltaic support structures necessitates extensive reconstruction and dismantling, resulting in substantial social impact and economic losses. Compared with demolition and reconstruction, strengthening the original structure can not only reduce economic costs, but also does not affect the normal operation of the power grid during the strengthening process, thus minimizing the impact on power supply. He Minjuan, Xiao Yufei. Development and prospect of repair and strengthening technology for concrete wind power tower structure [J]. Special Structures, 2026, 43(1):33-38. DOI:10.19786 / j.tzjg.2026.01.007. Traditional strengthening technology requires high-altitude on-site welding under the existing high stress state, which can lead to local material embrittlement and induce initial cracks; The bolt connection and hole enlargement reinforcement method directly reduces the effective cross-sectional area of ​​the original tower, and stress concentration is very likely to occur at the edge of the hole. Under the action of reciprocating dynamic loads such as wind load, fatigue failure is easily accelerated. Traditional FRP bonding reinforcement technology mainly relies on the bonding of structural adhesives such as epoxy resin to the surface of steel pipes. At the ends or where the load changes abruptly, it is very easy to cause brittle peeling failure due to excessive interlayer shear stress. Traditional resin matrix is ​​very easy to age and become brittle under ultraviolet radiation, large temperature difference and alternating dry and wet conditions, resulting in an exponential decline in the reinforcement effect after a few years. Internal grouting with concrete will significantly increase the self-weight of the tower, which will not only increase the load on the foundation, but also significantly increase the inertial force of the structure under seismic action, which is detrimental to the overall seismic performance. Summary of the Invention

[0003] In order to overcome the shortcomings of the existing technology, the purpose of this invention is to provide a reinforcement method for new energy power structures by combining perforated steel plates with HPA coatings. This method can promptly repair and reinforce the power structure to prevent damage caused during long-term use, thereby enhancing the load-bearing capacity, toughness, and durability of the structure.

[0004] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A reinforcement method for perforated steel plates used in new energy power structures, combining them with HPA coating, includes the following steps; This method is applied to the reinforcement and repair of new energy power structures, and includes the following steps: Step 1: Surface treatment of the original structure: Clean and roughen the outer surface of the area to be reinforced in the new energy power structure. If there are cracks or defects on the surface, repair them in advance. Step 2: Perforated steel plate fabrication: Based on the shape of the structure to be reinforced, select a perforated steel plate 2 of predetermined thickness and process through holes on it, then remove rust from the surface of the steel plate. Step 3: Chemical bolt 3 anchoring: Plan the bolt positions on the surface of the area to be reinforced in the new energy power structure, avoiding the original internal steel bars, drill holes and insert chemical bolts 3; Step 4: Steel plate installation and bonding: Apply structural steel bonding adhesive to the bonding surface of the area to be reinforced in the new energy power structure and the bonding surface of the perforated steel plate 2. Fix the perforated steel plate 2 to the chemical bolts 3 and press it firmly so that the steel bonding adhesive is squeezed out from the holes of the perforated steel plate 2 under pressure. After curing, a steel bonding adhesive layer 4 is formed. Step 5: Spraying HPA high-performance coating 5: After the adhesive layer 4 has cured, use a high-pressure spraying device to continuously spray HPA high-performance coating 5 onto the reinforced structural surface to form a protective layer covering the perforated steel plate and chemical bolts 3.

[0005] In step 1, the roughening treatment specifically refers to chiseling, which involves removing 20-30mm of the original structure surface layer to expose the new surface of the aggregate, and removing surface dust and oil stains to keep the base surface dry. This aims to increase the mechanical bonding force between the steel bonding adhesive and the surface of the utility pole structure 1, increase the bonding area, ensure the bonding strength of the reinforced structure, and prevent cross-sectional peeling.

[0006] In step 2, the thickness of the perforated steel plate 2 is no more than 8mm; the holes on the perforated steel plate 2 are arranged in a quincunx pattern, with a hole diameter of 20mm-50mm and a hole spacing of 100mm-300mm, to prevent stress concentration in the steel plate, making the shear force more evenly distributed in the plane and also reducing the overall weight of the structure; the rust removal treatment of the steel plate must reach the standard of revealing the metallic luster.

[0007] The perforated steel plate 2 must undergo further rust removal before subsequent operations, and oil stains should be wiped off with propionate and kept dry. In step 3, the diameter of the chemical bolt 3 is selected between 14mm and 20mm based on the thickness of the perforated steel plate 2; the drilling depth of the chemical bolt 3 is determined according to the bolt specifications, preferably around 110mm; the distance between the center of the outermost chemical bolt 3 and the upper and lower edges of the perforated steel plate 2 is controlled between 30mm and 350mm, preferably 50mm to 250mm, to avoid stress concentration.

[0008] Before construction, the chemical bolts 3 should be planned according to the original position of the reinforcing bars to avoid damage to the original reinforcing bars. The appropriate drill bit should be selected according to the bolt size to drill holes in the original structural surface and anchor them to the surface of the perforated steel plate.

[0009] In step 4, the adhesive for bonding the steel is applied in a way that is thicker in the middle and thinner at the edges. During the compaction process, pressure is applied by tightening the nuts of the chemical bolts 3, causing the adhesive to overflow from the quincunx-shaped holes. The overflowing adhesive is then smoothed with a trowel to cover the area around the holes, forming an adhesive nail structure embedded in the holes of the steel plate. This effectively transfers the pressure of the concrete to the steel plate, ensuring that the perforated steel plate 2 deforms in tandem with the original structure, and preventing the reinforcement layer from peeling off or slipping from the original structure. The curing time of the adhesive layer 4 is approximately 24 hours.

[0010] The adhesive is applied tightly and evenly to the concrete bonding surface and the steel plate bonding surface that have been cleaned using a scraper, forming adhesive layer 4. The curing time is approximately 24 hours. After the curing time is completed, the bonding quality is checked, and the steel plate can only be subjected to force after passing the inspection.

[0011] In step 5, the HPA high-performance coating 5 is a modified high-performance anti-corrosion coating with low water absorption, strong impermeability, and salt spray resistance. The HPA high-performance coating 5 can be cured at room temperature, incorporating the advantages of various polymer resin materials such as polybutadiene, polyurethane, and polycarbonate. It features low water absorption, strong impermeability, excellent anti-corrosion performance, and salt spray resistance. In step 5, a high-pressure airless sprayer is preferred for spraying, with the spraying pressure controlled at around 10.3 MPa. Appropriate nozzles are selected, and filters are used to prevent nozzle clogging. The HPA high-performance coating 5 has a spraying thickness of approximately 8 mm, and the protective film formed after spraying completely covers the perforated steel plate, chemical bolts 3, and the original structure.

[0012] The HPA high-performance coating 5 is applied outside the perforated steel plate 2 because the material has good adsorption properties and can be cured at room temperature. It is not easily hydrolyzed during use and has stable performance, which can ensure that the coating is not damaged and ensure the durability of the original structure and the reinforced structure.

[0013] A reinforcement structure for power structures is a structure formed using the method described above, comprising, from the inside out: The base surface of the utility pole structure is roughened, a perforated steel plate 2 is anchored by chemical bolts 3 and bonded by structural steel adhesive, and an HPA high-performance coating 5 completely covers the perforated steel plate 2 and chemical bolts 3 as a protective layer; the perforated steel plate 2 forms a mechanical interlock with the original structure through the pin effect formed by the steel adhesive in the holes.

[0014] The power structure includes a concrete power pole structure 1 and photovoltaic pipe piles or pumped water pipes 11; When applied to concrete utility pole structure 1, the perforated steel plate 2 is arranged around the circumference of the pole body of utility pole structure 1. The perforated steel plate 2 is 4mm thick, the hole diameter is 30mm, and the hole spacing is 150mm.

[0015] The HPA high-performance coating 5 protective layer is a continuous, seamless, and dense film. When applied to photovoltaic pipe piles, the perforated steel plate 2 is prefabricated into two semi-circular clamp-type units; it has pre-drilled overflow holes 6 arranged in a plum blossom pattern with a diameter of 20mm and a spacing of 100mm to accommodate the high curvature of the small-diameter photovoltaic pipe pile; the inner side of the perforated steel plate 2 is roughened; the two semi-circular steel plates are interlocked and wrapped around the area of ​​the photovoltaic pipe pile to be reinforced, and a 10-15mm joint is reserved at the end of the semi-circular steel plates for injecting structural adhesive and adjusting installation errors; The perforated steel plate 2 is connected to the photovoltaic pipe pile through the through chemical anchor 3. The chemical anchor 3 is embedded in the concrete of the pipe wall. For pipe piles with thin walls, the anchor embedment depth is controlled at 40mm-50mm. Salt and alkali resistant structural adhesive is filled in the annular gap between the perforated steel plate 2 and the photovoltaic column 7. Under the pressure of the bolt pre-tightening force, the adhesive bursts out from the overflow hole 6 and forms a high-density group of mechanical pins after curing.

[0016] When applied to the inner wall of the pumping and storage pipe 11, the components from the pipe wall to the center of the pipe include: the original inner wall base surface of the pumping and storage pipe 11 after roughening treatment, the steel bonding adhesive layer 4 which fills and acts as an adhesive, the perforated steel plate 2 which is mechanically anchored, and the HPA high-performance coating 5 which completely covers the innermost water-facing surface. The perforated steel plate 2 is pre-rolled into an arc-shaped covering unit in the factory according to the inner diameter of the original water storage pipe 11; its surface is covered with reserved through holes arranged in a plum blossom pattern; multiple arc-shaped perforated steel plates (2) are assembled inside the pipe to form a continuous steel cylinder that is tightly attached to the inner wall of the water pipe. The perforated steel plate 2 is anchored to the concrete wall of the original pumping and storage pipe 11 by chemical bolts 3; the steel bonding adhesive layer 4 not only fills the annular gap between the original pumping and storage pipe 11 and the perforated steel plate 2, but also overflows from the reserved through hole 6 towards the center of the pipe under the action of anchoring extrusion pressure.

[0017] The beneficial effects of this invention are: This invention significantly improves the durability and corrosion resistance of power structures by employing HPA high-performance coating as the outermost protective layer for the reinforced structure. This coating possesses excellent anti-corrosion, anti-permeability, and salt spray resistance properties, with extremely low water absorption. It effectively solves the problems of easy rusting of steel plates and high maintenance costs associated with traditional steel-clad reinforcement methods. It is particularly suitable for wind turbine towers, transmission towers, and utility poles that are exposed to outdoor, coastal, or humid environments for extended periods, forming a dense protective layer that blocks the intrusion of corrosive media and significantly extends the service life of power facilities.

[0018] The reinforced structure constructed in this invention exhibits strong overall integrity and reliable stress transfer. Through the synergistic effect of chemical bolt anchoring and perforated steel plates, a stable connection between the reinforced layer and the original structure is achieved. The perforated design on the steel plate, with its quincunx-shaped holes (20-50mm in diameter), not only reduces the self-weight of the reinforced components but also facilitates the expulsion of air from the adhesive (steel bonding glue) during the compression process, creating a mechanical pin effect. This enhances the shear resistance of the steel plate and the concrete substrate, preventing hollowing or peeling of the reinforced layer. Chemical bolts: Anchoring with chemical bolts results in less stress on the substrate compared to traditional expansion bolts. Furthermore, by avoiding the original reinforcement bars during construction, strong pull-out resistance is provided without damaging the original structural reinforcement, ensuring that the perforated steel plate and the original electrical structure share the load.

[0019] The construction method provided by this invention is safe and convenient, adaptable to the special working conditions of power facilities, and avoids a large amount of on-site welding work. Firstly, it offers high safety by using chemical bolts and adhesive to fix the steel, eliminating the safety hazards of hot work welding in flammable and high-voltage environments such as transmission towers or wind turbine towers. Secondly, it is highly adaptable by using perforated steel plates with a thickness of no more than 8mm and an appropriate width, possessing good toughness, which allows it to fit well onto curved or irregular surfaces such as power poles and towers, solving the problem of rigid thick steel plates being unable to cover irregularly shaped power components.

[0020] This invention emphasizes both repair and reinforcement, aiming to restore structural toughness and load-bearing capacity. The reinforced structure not only improves the load-bearing capacity of components through the external steel cladding, but also provides comprehensive repair to the aging power structure through surface roughening, crack repair, and HPA coating application. The combination of high-performance coating and steel plate gives the reinforced structure better toughness and impact resistance, effectively resisting damage to power facilities caused by wind loads and external impacts.

[0021] With rapid curing, long maintenance cycles, and significant economic benefits, the selected HPA coating cures at room temperature and exhibits stable performance and resistance to hydrolysis. Combined with a steel bonding process that cures in approximately 24 hours, it shortens the construction period and reduces the impact on power grid operation. The reinforced structure exhibits "maintenance-free" or "low-maintenance" characteristics, significantly reducing the operation and maintenance costs of power facilities throughout their entire lifecycle. It effectively repairs cracks in the original structure, prevents concrete aging and steel plate corrosion, and effectively prevents secondary damage to the reinforced structure. No cracks appear on the structural surface after using HPA high-performance coating, effectively improving structural durability.

[0022] The reinforcement structure and construction method adopted in this invention are simple to manufacture, convenient to construct, and have low requirements for environmental and site conditions. It can adapt to various environments where power structures are located. The perforated steel plates, chemical bolts, and HPA high-performance coatings involved do not involve complex processing methods or construction techniques, facilitating mass production and processing, improving on-site construction efficiency, and bringing considerable economic benefits. Attached Figure Description

[0023] Figure 1 This is an overall schematic diagram of the wind turbine tower reinforcement according to Embodiment 1 of the present invention.

[0024] Figure 2 This is a cross-sectional view of the reinforced structure of the present invention.

[0025] Figure 3 This is a cross-sectional view of the structure after the photovoltaic support is reinforced according to the present invention.

[0026] Figure 4 This is a schematic diagram of the structure of the wind turbine tower reinforced by the present invention.

[0027] Figure 5 This is a schematic diagram of the internal structure of the reinforced pumping and storage pipe of the present invention.

[0028] Figure 6 It is a cross-sectional view of the internal structure of the reinforced pumping and storage pipe.

[0029] Number: 1-Pole structure, 2-Perforated steel plate, 3-Chemical bolt, 4-Steel bonding adhesive layer, 5-HPA high-performance coating, 6-Pre-drilled through hole. Detailed Implementation

[0030] The present invention will now be described in further detail with reference to the accompanying drawings.

[0031] Example 1: A reinforcement method for concrete utility poles using perforated steel plates combined with HPA coating, such as... Figure 1As shown, most existing utility poles are concrete poles, which have been in use for a long time, resulting in exposed carbonized steel reinforcement in the concrete. With increasing electricity demand, the load they bear far exceeds the original design load, leading to a decrease in their load-bearing capacity and durability, necessitating reinforcement or direct replacement. Directly replacing the pole is extremely wasteful; therefore, reinforcement is chosen. However, if only external steel plate reinforcement is used, the durability of both the concrete and the steel plate will remain a serious issue with increasing service life.

[0032] Therefore, this invention is applied to the reinforcement of concrete utility poles and key stress areas. The structure adopts a combined structure reinforcement. In this embodiment, the components used include the original utility pole structure 1, perforated steel plate 2, chemical bolts 3, steel bonding adhesive 4, HPA high-performance coating 5, and reserved through holes 6.

[0033] In this embodiment, the cross-sectional shape of the concrete utility pole is typically circular or near-circular (such as a top-end pole). The perforated steel plate 2 is also rolled or cold-bent into an arc shape according to the curvature of the pole body, and each plate has pre-drilled glue overflow holes 6 arranged in a staggered pattern. The inner side of the perforated steel plate 2 has a roughened bonding surface treated by sandblasting to remove rust. The perforated steel plate 2 wraps around the outside of the area to be reinforced in the original utility pole structure 1, leaving a certain gap, and is usually arranged around the circumference of the pole body. The height of the perforated steel plate 2 can be determined according to the damage range of the utility pole and the bending reinforcement requirements, and usually covers the critical stress area or crack distribution area 2-3 meters above the root.

[0034] In this embodiment, the perforated steel plate 2 is connected to the original concrete utility pole structure 1 via a group of chemical anchors 3. The group of chemical anchors 3 passes through the anchor holes on the perforated steel plate 2, is inserted into the pole wall of the concrete utility pole, and is anchored to the outside of the perforated steel plate 2. The structural adhesive layer 4 fills the gap between the perforated steel plate 2 and the original concrete structure 1, and overflows from the adhesive overflow hole 6 under pressure, forming a group of pins penetrating the steel plate after curing.

[0035] In this embodiment, the HPA high-performance protective coating 5 is arranged on the outermost layer of the perforated steel plate 2, continuously covering and wrapping the chemical anchor group composed of the perforated steel plate 2 and the chemical anchor 3.

[0036] The coating adheres tightly to the perforated steel plate 2 and the surface of the original concrete utility pole, forming a complete closed protective system that prevents secondary damage to the original structure and the reinforced structure.

[0037] This invention also provides a construction method for the above-mentioned reinforcement structure, which mainly includes: cleaning and micro-repairing the surface of the original concrete utility pole; fabricating and pre-treating perforated steel plates; welding-free mechanical anchoring installation; pressure injection and pin forming; and HPA protective layer spraying.

[0038] Specifically, the steps for cleaning and minimally invasive repair of the existing concrete utility pole surface include: Before laying the reinforcement components, the surface of the area to be reinforced on the utility pole (usually 2-3 meters above the base) must first be cleaned. Given that most existing concrete utility poles have been in use for a long time, the concrete is severely carbonized and some even have exposed reinforcing bars, so surface preparation is necessary.

[0039] Use a manual chisel or high-pressure water jet to remove the aged, loose, and carbonized concrete from the original structure's surface. Chisel to a depth of 20-30mm until a fresh, solid aggregate surface is exposed. This step aims to remove the damaged outer layer and establish a reliable load-bearing base. If structural cracks wider than 0.2mm are found on the original surface, pressure grouting with low-viscosity modified epoxy resin is required to restore the integrity of the pole. For larger pits, honeycomb, or spalling areas, high-strength non-shrink repair mortar is used for leveling. After the base surface repair is complete, use a high-pressure air gun to blow away dust and debris, and wipe the surface with acetone or a special cleaning agent to remove oil stains, keeping the base surface clean and dry to prepare for subsequent steel bonding adhesive application.

[0040] Specifically, the steps for fabricating and pre-processing the perforated steel plate include: selecting a Q235B grade or higher strength carbon structural steel plate based on the perimeter and reinforcement height of the utility pole structure 1. In this embodiment, the thickness of the perforated steel plate 2 is selected as 4mm. This thickness was chosen after balancing mechanical calculations and construction convenience: on the one hand, a 4mm thickness provides sufficient tensile strength to share the bending moment of the utility pole; on the other hand, this thickness has good toughness, facilitating cold bending operations on-site, allowing it to fit tightly against the circular or conical cross-section of the utility pole and avoiding large gaps. The perforated steel plate 2 needs to be mechanically punched, with the holes arranged in a staggered, quincunx pattern. According to the specific implementation case, the diameter of the overflow through-hole 12 is set to 30mm, and the hole spacing is set to 150mm.

[0041] As one implementation method, the combination of aperture and spacing is optimized to ensure that the effective net cross-section of the steel plate is not less than 85% of the original cross-section, while also ensuring that the adhesive material can smoothly expel air and form shear pins of effective diameter after extrusion deformation. After the steel plate is fabricated, it must be derusted using a sandblasting process to Sa2.5 grade until a silver-gray metallic luster is exposed. Immediately afterwards, a thin layer of rust inhibitor or primer is applied to prevent secondary oxidation before installation.

[0042] Specifically, the steps for welding-free mechanical anchoring installation include: drilling holes in the original concrete structure and inserting anchor bolts. First, a rebar detector is used to scan and locate the existing main reinforcement bars (usually prestressed steel bars) and spiral stirrups inside the utility pole. The bolt hole locations are planned on the original structural surface, strictly avoiding the existing structural reinforcement bars to prevent damage to the pole's prestressing system during drilling. Based on the selected chemical anchor bolt specifications (in this example, 14mm diameter chemical anchor bolts are used), a drill bit of appropriate diameter is selected for drilling, with a drilling depth of approximately 110mm (determined based on anchoring force calculations). After drilling, the holes are repeatedly cleaned of dust at least three times using an air pump and brush to ensure no dust adheres to the hole walls. Then, anchoring adhesive is injected, the chemical anchor bolt is screwed in, and the installation is allowed to cure. Disturbing the bolts during the curing period is strictly prohibited.

[0043] Specifically, the pressure injection and pin forming steps include: After the anchors have cured, a special structural steel bonding adhesive is prepared. Using a "thicker in the middle, thinner at the edges" application process, the adhesive is applied with a scraper to the joint surface of the concrete pole and the inner joint surface of the perforated steel plate 2. The thickness of the adhesive layer at the ridge is controlled at 5-8mm, gradually thinning at the edges. The perforated steel plate 2 is aligned with the pre-embedded chemical anchors 3 and installed, and the bolts are inserted. Subsequently, the nuts are tightened sequentially and symmetrically using an electric wrench, applying normal pressure to the steel plate. During tightening, the steel plate gradually approaches the concrete surface, and the steel bonding adhesive accumulated in the middle flows outwards and into the holes under pressure. At this time, the thixotropic steel bonding adhesive will be squeezed out from the plum blossom-shaped overflow holes 6 of the steel plate under pressure. Construction workers need to use a trowel to smooth the adhesive squeezed out of the holes, covering the area around the holes and forming rivet-like "adhesive nails" embedded in the holes of the steel plate. These adhesive anchors cure, thus achieving a dual anchoring effect of mechanical interlocking and chemical bonding between the steel plate and the concrete. It should be noted that the distance between the center of the first chemical anchor at the outermost edge and the edge of the steel plate should be controlled at approximately 50mm to prevent warping or peeling of the steel plate edge under stress.

[0044] Specifically, the steps for applying the HPA protective layer include: after the adhesive has cured for 24 hours and passed a void check, the outermost protective layer is applied. Using specialized two-component high-temperature, high-pressure spraying equipment, the perforated steel plate 2, chemical bolts 3, and the surrounding concrete surface are coated with HPA high-performance coating. In this embodiment, modified polyurea elastomer is used as the HPA coating, with a coating thickness of approximately 8 mm. The spraying operation should be continuous to ensure a uniform coating thickness, free of runs and pinholes.

[0045] This invention can effectively repair and reinforce aging or overloaded concrete utility poles, and significantly improve the load-bearing capacity and durability of the structure.

[0046] Specifically, the structure of the perforated steel plate 2 combined with HPA high-performance coating used in this invention achieves a balance of rigidity and flexibility in mechanical properties. The perforated steel plate 2 provides extremely high tensile stiffness, and together with the original utility pole structure 1 through chemical bolts 3, they form a combined section to jointly bear the bending moment generated by wind load and conductor tension. After reinforcement, the bending load-bearing capacity of the utility pole can be increased by more than 40%.

[0047] HPA high-performance coating 5 has high impact resistance. This thickness (8mm) of HPA material not only provides corrosion protection, but also forms a tough "armor" that prevents the internal concrete of the utility pole from breaking and collapsing when it is hit by a vehicle or by an external force.

[0048] Specifically, this invention changes the interface force transmission mechanism of traditional reinforcement: traditional steel-bonded reinforcement relies solely on the chemical bonding force of the adhesive layer, and once the adhesive layer ages, the steel plate is easily peeled off. In this invention, the adhesive is extruded from the holes in the perforated steel plate 2 and solidifies, forming numerous "micro-concrete pins." This structure achieves mechanical interlocking between the steel plate and the pole. Even if the chemical bonding force weakens in the future due to environmental factors, these physical pins can continue to transmit shear force, ensuring the steel plate does not detach, greatly improving the safety redundancy of the reinforcement structure. Furthermore, the perforated holes on the steel plate are natural venting channels, effectively expelling air from the adhesive layer during the extrusion process, ensuring the density of the adhesive layer and solving the problem of easy delamination in traditional large-area steel bonding.

[0049] Specifically, this invention significantly improves the durability of the structure. HPA high-performance coatings (such as polyurea) have extremely low water absorption and excellent impermeability and salt spray resistance, and can cure rapidly after spraying (<1 hour at room temperature), forming a continuous, seamless, and dense protective film. This protective film completely encapsulates the perforated steel plate 2, chemical bolts 3, and the original reinforced structure, completely cutting off the path of water vapor, oxygen, and corrosive media to the internal reinforcing bars and steel plates. Its expected corrosion resistance life can be extended by more than 30 years, effectively solving the problems of easy loosening and corrosion of metal parts and accelerated carbonization of concrete surfaces in traditional clamp reinforcement methods, achieving the economic goal of "maintenance-free" or "low-maintenance".

[0050] Furthermore, none of the components and construction steps of this reinforcement structure involve complex on-site processing techniques (such as welding of plates). It employs a cold-work method combining mechanical connections and chemical bonding, eliminating the risk of open flame during field construction and minimizing environmental and site requirements. The perforated steel plates can be prefabricated in the factory, facilitating on-site installation; the HPA coating cures quickly, resulting in a short construction cycle. This efficient and safe construction method is suitable for power grid upgrades in various complex terrains and environments, facilitating mass production and processing, improving on-site construction efficiency, and effectively reducing the total life-cycle operation and maintenance costs, thus bringing considerable economic benefits.

[0051] It should be noted that this embodiment describes the crack-resistant and toughening reinforcement of concrete utility poles, but it does not mean that the present invention is limited to utility poles. In fact, regardless of whether the original structure is a concrete transmission tower, substation frame or other power concrete structure with a circular / annular cross section, the perforated steel plate and HPA coating composite method described in this invention can be used for reinforcement to improve the load-bearing capacity and durability of the structure.

[0052] The foregoing basic examples and their further alternative examples of the present invention can be freely combined to form multiple embodiments, all of which are embodiments that can be adopted and are claimed by the present invention. In the present invention, each alternative example can be arbitrarily combined with any other basic example and alternative example. Those skilled in the art will recognize numerous combinations.

[0053] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

[0054] Example 2: like Figure 3 As shown, this invention is applicable not only to power transmission and distribution towers but also to concrete support structures in the field of new energy photovoltaic power generation. Existing large-scale ground-mounted photovoltaic power stations are mostly built in Gobi deserts, tidal flats, or coal mining subsidence areas, and their support structures often use prestressed concrete pipe piles (PHC piles). Due to long-term exposure to saline-alkali soils or water surfaces, these pipe piles are highly susceptible to severe freeze-thaw erosion and steel corrosion in areas with fluctuating water levels and above the mud surface. Simultaneously, as the power of the modules increases (e.g., from 400W to 600W+), the pull-out bearing capacity and overturning stiffness of the original support foundation are often insufficient, necessitating minimally invasive and durable reinforcement.

[0055] Therefore, this embodiment provides a composite reinforcement structure for photovoltaic support concrete pipe piles, mainly applied to the stress-critical section of the pipe pile exposed above the ground (or water surface). The components used in this structure include: the original photovoltaic pipe pile structure 1, perforated steel plate 2, through-hole chemical bolts 3, structural adhesive 4, HPA high-performance coating 5, reserved through holes 6, photovoltaic column 7, photovoltaic support 8, and photovoltaic panel 9.

[0056] In this embodiment, considering the small diameter of the photovoltaic pile (typically 300mm-500mm), the perforated steel plate 2 is prefabricated into two semi-circular "clamp-type" units. These units have pre-drilled, densely arranged adhesive overflow holes 6 (20mm diameter, 100mm spacing) in a plum blossom pattern to accommodate the high curvature of the small-diameter pile. The inner side of the perforated steel plate 2 is roughened. The two semi-circular steel plates are interlocked and wrapped around the area of ​​the photovoltaic pile to be reinforced, with a 10-15mm seam left at the ends of the plates for injecting structural adhesive and adjusting for installation errors.

[0057] In this embodiment, the perforated steel plate 2 is connected to the original photovoltaic pipe pile 1 via through-hole chemical anchors 3. Unlike solid poles, this embodiment employs a specially designed "through-hole anchoring" or "single-sided wall chemical anchoring" technique for hollow PHC pipe piles. The chemical anchors 3 are implanted into the concrete pipe wall. For pipe piles with thin walls, the anchor implantation depth must be strictly controlled to avoid penetrating the pipe wall, typically controlled at 40mm-50mm. The salt and alkali resistant structural adhesive 4 is filled in the annular gap between the perforated steel plate 2 and the photovoltaic column 7. Under the pressure of the bolt pre-tightening force, it bursts out from the overflow hole 6, and after curing, forms a high-density group of mechanical pins.

[0058] In this embodiment, the HPA high-performance coating 5 is designed for the special environment of photovoltaic power plants. Considering that photovoltaic fields are often subject to wind and sand erosion or water level fluctuations, the HPA high-performance coating 5 is wrapped around the outermost layer of the reinforced structure to form a protective layer. This coating not only prevents corrosion but also resists the continuous abrasion from Gobi winds and sand and the alternating wet and dry erosion of saline water.

[0059] This invention also provides a construction method for the above-mentioned photovoltaic support reinforcement structure. The process flow strictly follows the core technical route of this invention, but has been optimized for the characteristics of batch operations in photovoltaic fields. Specifically, the steps for batch cleaning and repairing the surface of existing photovoltaic (PV) pipe piles include: during PV array power outage maintenance or without power outage, using a portable angle grinder to grind the deteriorated concrete in the water level fluctuation zone of the pipe piles or within 0.5m above ground level. Remove the loose surface layer caused by freeze-thaw cycles until the solid aggregate is exposed. For pipe piles with circumferential cracks, first inject low-viscosity epoxy resin to restore integrity. Then use a high-pressure air gun to blow away dust and wipe with alcohol to ensure the base surface is dry and clean.

[0060] Specifically, the steps for fabricating and pre-treating the semi-circular perforated steel plate 2 include: selecting weathering steel or Q355B steel plate with a thickness of 3mm. Thinner steel plates are easier to fit small-diameter pipe piles and reduce weight. The steel plate is uniformly stamped in the factory with a 20mm hole diameter and pre-bent into a semi-circular arc with a diameter slightly larger than the outer diameter of the pipe pile by 5mm. After shot blasting to remove rust from the inner and outer surfaces of the perforated steel plate 2, it is coated with a zinc-rich primer and ready for use. This factory prefabrication method is very suitable for the batch reinforcement needs of tens of thousands of pile foundations in photovoltaic power plants.

[0061] Specifically, the steps for welding-free mechanical anchoring installation include: drilling holes on the surface of the pipe pile, avoiding the prestressed main reinforcement. For hollow pipe piles, a limiting drill bit must be used to prevent drilling through. Insert short, high-strength chemical anchors. Attach two pairs of semi-circular perforated steel plates to the pipe pile, using temporary clamps to secure the joints. Insert the anchors and initially tighten the nuts.

[0062] Specifically, the pressure injection and dowel forming steps include: Due to the small gap in the photovoltaic pipe pile reinforcement, this embodiment uses a combination of "grouting method" or "adhesive application method". Salt-alkali resistant structural adhesive 4' is pre-applied before steel plate installation, and then radial clamping force is applied to the steel plate by tightening the anchor bolt nuts. As the steel plate tightens, the adhesive is evenly squeezed out from the dense overflow holes 6'. Construction personnel quickly smooth out the overflowing adhesive, covering the hole openings. The cured adhesive-filled dowels and chemical anchors together form a strong shear force transmission system, effectively preventing vertical slippage of the steel plate when the pipe pile is subjected to pull-out force.

[0063] Specifically, the steps for applying the HPA protective layer include: after the structural adhesive has cured, using a backpack or vehicle-mounted spraying device, spraying an HPA polyurea coating onto the reinforced area. The coating thickness is approximately 3-5 mm. This coating cures extremely quickly (<10 minutes) and does not affect subsequent cleaning and maintenance of the photovoltaic modules.

[0064] The beneficial effects of this embodiment are as follows: First, it significantly improves the uplift and bending bearing capacity of the photovoltaic support structure. The steel hoop effect formed by the perforated steel plate puts the concrete of the pipe pile in a triaxial compression state, greatly improving the compressive strength. At the same time, the mechanical pin group ensures that the steel plate and the pipe pile can share the uplift force and bending moment caused by wind load, solving the hidden danger of the foundation being "top-heavy" after the module is enlarged.

[0065] Secondly, the HPA coating solves the problem of salt and alkali corrosion. Photovoltaic power plants are mostly located in saline soil areas, where concrete corrosion is the biggest challenge. The dense protective film formed by the HPA coating completely isolates salt intrusion, extending the design life of the pipe piles by more than 20 years and ensuring the operational benefits of the photovoltaic power plant throughout its entire lifecycle.

[0066] Finally, this construction method involves no open flames or welding, making it particularly suitable for photovoltaic fields with dry vegetation and extremely high fire prevention requirements. It also allows for fast construction speeds and streamlined operations, significantly reducing labor costs.

[0067] It should be noted that although this embodiment uses concrete pipe piles as an example, this method can also be applied to PHC solid square piles or short columns in strip foundations of photovoltaic supports by adjusting the shape of the perforated steel plate (such as making it into an L-shaped interlocking or U-shaped wrapping). For example Figure 4 The diagram shows the reinforcement of the wind turbine tower.

[0068] Example 3: like Figure 5 and Figure 6 As shown in the cross-sectional view of the internal structure of the reinforced pumped storage pipe, the composite reinforcement method of the present invention is also extremely applicable to the internal reinforcement of large hydraulic fluid transport structures (i.e., pumped storage pipes) such as water intake pipes and tailrace pipes of pumped storage power stations.

[0069] Pumped storage power station pipes are subjected to extremely high internal water pressure and frequent erosion and cavitation from bidirectional high-speed water flow over long periods. With increasing service life, the inner walls of the original concrete pipes are prone to severe wear, exposed aggregate, peeling of the protective layer, and longitudinal tensile cracks, seriously threatening the operational safety of the power station. Furthermore, the interior of pumped storage pipes is a typical narrow, confined space. Traditional external steel reinforcement methods require extensive splicing and welding work inside the pipes, which not only makes ventilation and smoke extraction difficult and creates an extremely harsh construction environment, but also greatly increases the risk of fire and suffocation accidents within the confined space.

[0070] Therefore, this embodiment provides a composite reinforcement structure and construction method for the interior of pumped storage pipelines. The structure is applied to the inner wall of the original pumped storage pipe 11 and includes, from the pipe wall to the center (i.e. from the outside to the inside): the inner wall base surface of the original pumped storage pipe 11 after roughening, a steel bonding adhesive layer 4 for filling and bonding, a perforated steel plate 2 for mechanical anchoring, and an HPA high-performance coating 5 that completely covers the innermost water-facing surface.

[0071] In this embodiment, the perforated steel plate 2 is pre-rolled into an arc-shaped covering unit at the factory according to the inner diameter of the original pumping and storage pipe 11. Its surface is covered with reserved through holes 6 arranged in a quincunx pattern. Multiple arc-shaped perforated steel plates 2 are assembled inside the pipe to form a continuous steel cylinder that fits tightly against the inner wall of the water pipe to resist the huge internal water splitting pressure.

[0072] In this embodiment, the perforated steel plate 2 is anchored to the concrete wall of the original pumping and storage pipe 11 by chemical bolts 3. The adhesive layer 4 not only fills the annular gap between the original pumping and storage pipe 11 and the perforated steel plate 2, but also overflows from the reserved through hole 6 towards the center of the pipe under the action of anchoring pressure. After the overflowing adhesive solidifies, it forms a high-density group of mechanical pins, realizing a strong mechanical interlock between the steel plate and the concrete pipe wall.

[0073] In this embodiment, the HPA high-performance coating 5 serves as the innermost protective layer that directly contacts the high-speed water flow. This coating is continuously and densely sprayed onto the perforated steel plate 2, the exposed ends of the chemical bolts 3, and the surface of the mechanical pins, forming a smooth, erosion-resistant flow channel.

[0074] This invention also provides a construction method for the internal reinforcement structure of the above-mentioned pumping and storage pipe. Taking into account the characteristics of operations in confined spaces, the specific steps include: Specifically, the pipe cleaning and surface treatment steps include: draining the accumulated water in the original pumping and storage pipe 11 and performing forced ventilation. Using high-pressure water jets or small milling equipment, thoroughly remove the attachments, moss, and aged concrete surface layer from the inner wall of the pipe until the solid aggregate is exposed. For deep structural cracks in the pipe wall, use high-pressure injection of epoxy resin to seal and prevent subsequent high-pressure water flow from seeping inward.

[0075] Specifically, the assembly steps for the perforated steel plate pipe include: transporting the prefabricated arc-shaped perforated steel plates 2 into the pipe in batches using a hoisting device; drilling a grid pattern of holes in the inner wall of the original pumping and storage pipe 11, avoiding the original reinforcement, and inserting chemical bolts 3; applying a water-resistant steel adhesive layer 4 to the inner side of the perforated steel plate 2, and then fitting in the chemical bolts 3 for assembly.

[0076] Specifically, the weld-free anchoring and pin extrusion molding steps include: No welding is permitted inside the pipe throughout the entire process. Construction workers use pneumatic or electric wrenches to tighten the nuts of the chemical bolts 3 sequentially, pressing the steel plate against the pipe wall. The adhesive layer 4 "bursts" out from the pre-drilled through-hole 6, which is quickly smoothed out by the construction workers. After curing, it forms shear-resistant bonds, completely resolving the "hollowing" hazard that easily occurs when large areas of steel plate are bonded inside the pipe.

[0077] Specifically, the impact and abrasion resistant HPA coating spraying process includes, after the steel-bonded system inside the pipe has cured and the surface has been cleaned, continuously spraying HPA high-performance coating 5 onto the entire reinforced inner wall of the pipe using a high-pressure airless spraying device. Special attention is paid to covering and leveling the ends of the chemical bolts 3 and the pre-drilled through holes 6.

[0078] The significant advantages of this embodiment are as follows: Firstly, it completely solves the safety concerns associated with reinforcing confined spaces. The entire process employs a combination of chemical anchoring and physical pinning, eliminating the need for open-pore welding inside the pipe and removing the risks of flammable, explosive, and toxic gas accumulation, thus significantly improving the safety of underwater or underground pipeline construction.

[0079] Secondly, it significantly improves the pipeline's resistance to internal pressure and abrasion. The closed perforated steel plate 2 acts like a high-strength steel sleeve inside the pipe, greatly enhancing the circumferential tensile stiffness of the pipe body; while the innermost HPA high-performance coating 5 (such as special polyurea) not only has excellent wear resistance and anti-cavitation properties, effectively resisting the damage of sand-laden water flow, but its surface is also extremely smooth (roughness far lower than that of the original concrete), which can significantly reduce water flow friction resistance and improve the overall hydropower generation and pumping efficiency of the pumped storage power station.

Claims

1. A reinforcement method for perforated steel plates combined with HPA coating for new energy power structures, characterized in that, Includes the following steps; Step 1: Clean and roughen the outer surface of the area to be reinforced in the new energy power structure. If there are cracks or defects on the surface, repair them in advance. Step 2: Select a perforated steel plate (2) of a predetermined thickness according to the shape of the structure to be reinforced and process through holes on it. Then, remove rust from the surface of the perforated steel plate (2). Step 3: Plan the bolt positions on the surface of the area to be reinforced in the new energy power structure, avoiding the original internal steel bars, drill holes and insert chemical bolts (3). Step 4: Apply structural steel bonding adhesive to the bonding surface of the new energy power structure to be reinforced and the bonding surface of the perforated steel plate (2), fix the perforated steel plate (2) on the chemical bolt (3) and press it down, so that the steel bonding adhesive is squeezed out from the hole of the perforated steel plate (2) under pressure, and after curing, a steel bonding adhesive layer (4) is formed. Step 5: After the adhesive layer (4) has cured, use a high-pressure spraying device to continuously spray HPA high-performance coating (5) onto the reinforced structural surface to form a protective layer that wraps around the perforated steel plate (2) and chemical bolts (3).

2. The reinforcement method for perforated steel plates combined with HPA coating for new energy power structures according to claim 1, characterized in that, In step 1, the roughening treatment specifically refers to chiseling, which involves removing 20-30mm of the original structure surface layer to expose the new aggregate surface, and removing surface dust and oil stains to keep the base surface of the new energy power structure to be reinforced dry.

3. The reinforcement method for perforated steel plates combined with HPA coating for new energy power structures according to claim 1, characterized in that, In step 2, the thickness of the perforated steel plate (2) is no more than 8mm; the holes on the perforated steel plate (2) are arranged in a plum blossom pattern, with a hole diameter of 20mm-50mm and a hole spacing of 100mm-300mm; The perforated steel plate (2) must undergo further rust removal before subsequent operations, and oil stains should be wiped off with acetal and kept dry.

4. The reinforcement method for perforated steel plates combined with HPA coating for new energy power structures according to claim 1, characterized in that, In step 3, the diameter of the chemical bolt (3) is between 14mm and 20mm depending on the thickness of the perforated steel plate (2); the drilling depth of the chemical bolt (3) is determined according to the bolt specification; the distance between the center of the outermost chemical bolt (3) and the upper and lower edges of the perforated steel plate (2) is controlled between 30mm and 350mm.

5. The reinforcement method for perforated steel plates combined with HPA coating for new energy power structures according to claim 1, characterized in that, In step 4, the adhesive for bonding the steel is applied in a way that is thicker in the middle and thinner at the edges. During the compaction process, pressure is applied by tightening the nuts of the chemical bolts (3), causing the adhesive to overflow from the plum blossom-shaped holes. The overflowing adhesive is then smoothed with a trowel to cover the perimeter of the holes, forming an adhesive nail structure embedded in the holes of the steel plate. The curing time of the adhesive layer (4) is 24 hours. The adhesive is applied tightly and evenly with a scraper to the concrete bonding surface and the perforated steel plate (2) bonding surface that has been cleaned, forming an adhesive layer (4), which takes about 24 hours to cure.

6. The reinforcement method for perforated steel plates combined with HPA coating for new energy power structures according to claim 1, characterized in that, In step 5, the HPA high-performance coating (5) is a modified high-performance anti-corrosion coating; In step 5, a high-pressure airless sprayer is used for spraying, the spraying pressure is controlled at 10.3 MPa, and the appropriate nozzle is selected. A filter screen is used to prevent the nozzle from clogging. The spraying thickness of HPA high-performance coating (5) is 8 mm. The protective film formed after spraying completely wraps the perforated steel plate (2), chemical bolts (3) and the original structure.

7. A reinforcement structure for power structures, comprising a structure formed by the method described in any one of claims 1-6, characterized in that, The reinforced structure, from the inside out, includes: The base surface of the utility pole structure after roughening, the perforated steel plate (2) anchored by chemical bolts (3) and bonded by structural adhesive, and the HPA high-performance coating (5) completely covering the perforated steel plate (2) and chemical bolts (3) are used as a protective layer; the perforated steel plate (2) forms a mechanical interlock with the original structure through the pin effect formed by the adhesive in the holes.

8. A reinforcement structure for power structures according to claim 7, characterized in that, The power structure includes concrete power pole structure (1) and photovoltaic pipe pile or pumped water pipe (11). When applied to a concrete utility pole structure (1), the perforated steel plate (2) is arranged around the circumference of the pole body of the utility pole structure (1). The perforated steel plate (2) is 4mm thick, the hole diameter is 30mm, and the hole spacing is 150mm.

9. A reinforcement structure for power structures according to claim 8, characterized in that, The HPA high-performance coating (5) protective layer is a continuous, seamless, and dense film; When applied to photovoltaic pipe piles, the perforated steel plate (2) is prefabricated into two semi-circular arc-shaped clamp-type units; it is pre-reserved with overflow holes (6) arranged in a plum blossom pattern with a high density, the hole diameter is 20mm and the spacing is 100mm, in order to adapt to the high curvature of the small diameter pile body of the photovoltaic pipe pile; the inner side of the perforated steel plate (2) is roughened; the two semi-circular arc steel plates are interlocked and wrapped around the area of ​​the photovoltaic pipe pile to be reinforced, and a 10-15mm joint is reserved at the end of the semi-circular arc steel plate for injecting structural adhesive and adjusting installation errors; The perforated steel plate (2) is connected to the photovoltaic pipe pile through the through chemical anchor (3). The chemical anchor (3) is implanted into the concrete of the pipe wall. For pipe piles with thin walls, the anchor implantation depth is controlled at 40mm-50mm. Salt and alkali resistant structural adhesive is filled in the annular gap between the perforated steel plate (2) and the photovoltaic column (7). Under the pressure of the bolt pre-tightening force, the adhesive bursts out from the overflow hole (6) and forms a high-density group of mechanical pins after curing.

10. A reinforcement structure for power structures according to claim 8, characterized in that, When applied to the inner wall of the pumping and storage pipe (11), the following components are included from the pipe wall to the center of the pipe: the inner wall base surface of the original pumping and storage pipe (11) after roughening treatment, the steel bonding adhesive layer (4) that fills and acts as an adhesive, the perforated steel plate (2) that is mechanically anchored, and the HPA high-performance coating (5) that completely covers the innermost water-facing surface. The perforated steel plate (2) is pre-rolled into an arc-shaped covering unit in the factory according to the inner diameter of the original pumping and storage pipe (11); its surface is covered with reserved through holes (6) arranged in a plum blossom pattern; multiple arc-shaped perforated steel plates (2) are assembled inside the pipe to form a continuous steel cylinder that is tightly attached to the inner wall of the water pipe. The perforated steel plate (2) is anchored to the concrete wall of the original pumping and storage pipe (11) by chemical bolts (3); the adhesive layer (4) not only fills the annular gap between the original pumping and storage pipe (11) and the perforated steel plate (2), but also overflows from the reserved through hole (6) towards the center of the pipe under the action of anchoring extrusion pressure.

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