A method of de-laminating and vibrating a bridge deck

Abstract

The application discloses a layered mold-entering vibration method for a bridge deck slab, relates to the technical field of bridge engineering prefabricated component construction, and is suitable for the prefabricated construction of a coarse aggregate reactive powder concrete bridge deck slab. The method divides a mold cavity into at least two layers of mold-entering vibration layers along the thickness direction by acquiring the thickness of the bridge deck slab, a reinforcement grid, embedded parts, a dovetail area and the spread, temperature, mold-entering time and material level of the coarse aggregate reactive powder concrete, and divides the plane of the mold cavity into a plurality of vibration grids. After segmented material distribution of a material distribution device along the long edge direction of the bridge deck slab, arrayed insertion vibration devices respectively perform bottom layer insertion vibration and upper layer overlapping insertion vibration, and partitioned supplementary vibration is performed on the dovetail area, the adjacent area of the embedded parts and the adjacent area of the side mold. Finally, re-vibration, leveling and film covering are performed. The method reduces the risk of vibration leakage, over-vibration, segregation and non-densification of the edge of the coarse aggregate reactive powder concrete bridge deck slab, and improves the densification, edge forming quality and batch prefabrication consistency of the bridge deck slab.

Description

Technical Field

[0001] This invention relates to the field of precast component construction technology for bridge engineering, and in particular to a method for layered placement and vibration of bridge deck panels, specifically applicable to the automated placement, vibration, leveling, and coating construction of precast bridge deck panels made of coarse aggregate reactive powder concrete. Background Technology

[0002] CA-RPC (Coarse Aggregate Reactive Powder Concrete) is a high-performance cement-based composite material, typically characterized by high powder content, strong fluidity, high fiber distribution requirements, rapid early hydration reaction, and a short construction window. For precast bridge deck construction, bridge decks generally feature large lengths, thin thicknesses, dense steel mesh, numerous embedded parts, and dovetail joints or similar interlocking structures at the edges. After concrete is poured into the formwork, improper control of placement, vibration, and leveling can easily lead to quality problems such as localized air bubbles, loose compaction at the bottom or edges, insufficient material in the dovetail joint areas, localized enrichment of steel fibers, uneven surface slurry, over-vibration segregation, and insufficient interlayer bonding.

[0003] In the construction of existing bridge decks or precast components, concrete vibration is typically accomplished using manual immersion vibrators, attached vibrators, or ordinary fixed vibration equipment. These methods generally only specify rigid requirements such as layered pouring, layered vibration, rapid insertion and slow withdrawal, and vibration until the surface is covered with slurry. The insertion depth, vibration time, and vibration frequency rely heavily on the operator's experience to determine. For ordinary concrete components, this method can meet general construction requirements; however, for coarse aggregate reactive powder concrete bridge decks, the material fluidity, initial setting time, slab thickness, reinforcement mesh density, and irregularly shaped areas at the edges all affect the vibration effect. Relying solely on manual experience makes it difficult to guarantee the consistency of batch precast components.

[0004] Meanwhile, under factory-automated prefabrication conditions, the placement, insertion, vibration, leveling, and coating of bridge deck materials need to be completed in a continuous rhythm. If the travel path of the vibrating equipment, the insertion point of the vibrator, the layer thickness, the insertion depth, and the sequence of leveling are not matched, local under-vibration or repeated vibration may easily occur. If the same vibration method is used for the dovetail tenon area, the area adjacent to the embedded part, and the area adjacent to the edge mold as for the central area, insufficient compaction at the edges may easily occur due to edge mold constraints, local grooves, and obstruction by the embedded part.

[0005] In summary, the existing technology has at least the following technical problems: there is a lack of a layered vibration compaction method for the precast construction of coarse aggregate reactive powder concrete bridge decks. This method can match the layer thickness, vibration grid, vibration frequency, insertion depth, pull-out speed, and re-vibration leveling sequence according to the bridge deck thickness, reinforcement mesh, embedded parts, dovetail joint area, as well as the spread, temperature, placement time, and height of the coarse aggregate reactive powder concrete. This would improve the compactness of the bridge deck, the edge forming quality, and the consistency of batch precasting. Summary of the Invention

[0006] The purpose of this invention is to provide a method for vibrating bridge deck panels in layers during the prefabrication process, in order to solve the problems of under-vibration, over-vibration, segregation, loose edges, and insufficient interlayer bonding caused by the high fluidity of the material, rapid initial setting, thin panel, dense reinforcement, and complex edge structure of coarse aggregate reactive powder concrete bridge deck panels.

[0007] The preferred technical solutions among the many technical solutions provided by this invention can produce a variety of technical effects, which are described in detail below.

[0008] To address the aforementioned technical problems, the present invention provides the following technical solution: This invention provides a method for layered formwork vibration compaction of bridge deck concrete, comprising: a control system acquiring the thickness, length and width dimensions, reinforcing mesh, embedded parts and dovetail joint positions of the bridge deck concrete to be precast, as well as the spread, placement time, material temperature and material level of the coarse aggregate reactive powder concrete; dividing the mold cavity into at least two layers of formwork vibration compaction according to the thickness and material level, and dividing the mold cavity plane into multiple vibration grids according to the reinforcing mesh, embedded parts and dovetail joints, and locating the vibrator insertion point in each vibration grid; controlling the concrete placement equipment to place the concrete into the mold in segments along the long side of the bridge deck concrete, and according to the spread, placement time, material temperature and material level of the coarse aggregate reactive powder concrete; The material level height is selected using a first vibration parameter and a second vibration parameter; after the material of the first layer of the mold-insertion vibration layer is placed into the mold, the array-type insertion vibration device is controlled to perform bottom layer insertion vibration of the mold cavity according to the first vibration parameter; after the material of the second layer or subsequent layer of the mold-insertion vibration layer is placed into the mold, the array-type insertion vibration device is controlled to perform interlayer overlap insertion vibration according to the second vibration parameter, and the vibrator of the insertion vibration device enters the preset overlap depth of the already compacted lower layer; the array-type insertion vibration device is used to perform zoned supplementary vibration on the dovetail tenon area, the adjacent area of ​​the embedded part and the adjacent area of ​​the side mold; after the zoned supplementary vibration is completed, the surface of the bridge deck is re-vibrated and leveled and covered with a film.

[0009] As one alternative implementation, when the thickness H of the bridge deck is not greater than 220mm, the mold cavity is divided into a bottom layer for in-mold vibration and a top layer for in-mold vibration along the thickness direction. The thickness of the bottom layer for in-mold vibration is 0.40H to 0.60H, and the thickness of the top layer for in-mold vibration is 0.40H to 0.60H.

[0010] As one optional implementation, when the thickness H of the bridge deck is greater than 220mm, the mold cavity is divided into three or more layers of the in-mold vibration layer along the thickness direction, and the stacking height of a single material placement in any of the in-mold vibration layers is not greater than 0.5m.

[0011] As one optional implementation, when the spread of the coarse aggregate reactive powder concrete is 380mm to 420mm, the coarse aggregate reactive powder concrete is determined to be in a state to be vibrated; when the spread is less than 380mm or more than 420mm, the automatic vibration program of the array-type insertion vibrator is paused, and a verification prompt for the mix proportion, transportation settling time or material placement speed is output.

[0012] In one optional implementation, the vibratory grid is established based on the arrangement of the vibrators in the array-type insertion vibratory device. The insertion spacing of the vibrators in the array-type insertion vibratory device along both the long and short sides of the bridge deck is 200mm ± 5mm, and the vibrators in the array-type insertion vibratory device are inserted from the center of the reinforcing steel grid.

[0013] In one optional implementation, the first vibration parameters include a first vibration frequency, a first insertion depth, and a first pull-out speed; the first vibration frequency is 150Hz to 200Hz; the first insertion depth is 5mm to 20mm from the tip of the vibrating rod of the array-type insertion vibrating device to the bottom mold; and the first pull-out speed is 0.8cm / s to 1.2cm / s.

[0014] In one optional implementation, the second vibration parameters include a second vibration frequency, a second insertion depth, and a second pull-out speed; the second vibration frequency is 100Hz to 200Hz; the second insertion depth is 20mm to 80mm into the already compacted lower layer by the vibrating rod of the array-type insertion vibrating device, and the depth of the vibrating rod into the already compacted lower layer is not greater than 1 / 2 of the thickness of the already compacted lower layer; the second pull-out speed is 0.8cm / s to 1.2cm / s.

[0015] As one of the optional implementation methods, both the bottom insertion vibration and the overlapping insertion vibration are carried out by starting the vibration first and then inserting, with fast insertion and slow withdrawal. The vibrator of the array-type insertion vibration device is kept vibrating during the withdrawal process until the tip of the vibrator of the array-type insertion vibration device leaves the surface of the coarse aggregate reactive powder concrete.

[0016] As one optional implementation, when performing the partitioned vibration on the dovetail joint area, first control the local material feeding port of the material feeding device to feed material to the dovetail joint area, and then start the independent vibrating rod group corresponding to the dovetail joint area in the array-type insertion vibrating device for vibration supplementation, and maintain a safe distance of 50mm to 100mm between the vibrating rod of the array-type insertion vibrating device and the side mold.

[0017] As one optional implementation, the operation time from the unloading of the coarse aggregate reactive powder concrete into the placing equipment to the completion of the insertion vibration, the re-vibration leveling and the covering is no more than 15 minutes; when the coarse aggregate reactive powder concrete is left to stand in the transport equipment or the placing equipment for more than 3 minutes, the control system outputs a standing timeout alarm.

[0018] Compared with the prior art, the present invention has the following beneficial effects: This invention incorporates the thickness of the coarse aggregate reactive powder concrete bridge deck, the steel mesh, the embedded parts, the dovetail area, as well as the spread, temperature, placement time, and height of the coarse aggregate reactive powder concrete into the same vibration control logic, forming a matching relationship between layer thickness, insertion point, vibration frequency, insertion depth, and pull-out speed, thus avoiding reliance solely on manual experience for vibration.

[0019] This invention employs a combination of thickness-direction layering and a mold cavity planar vibration grid to ensure that the insertion point of the vibrator is compatible with the steel reinforcement grid, embedded parts, and dovetail tenon areas, thereby reducing the risks of missed vibration, repeated vibration, collision with steel reinforcement, and collision with the side mold.

[0020] For thin-slab structures of coarse aggregate reactive powder concrete bridge decks, a bottom layer insertion vibration and an upper layer overlapping insertion vibration are adopted to ensure that the upper layer of concrete can form an effective bond with the already vibrated lower layer, while avoiding excessive insertion that could cause disturbance of the bottom layer, over-vibration segregation, or steel fiber settlement.

[0021] By setting up zoned vibration compensation for the dovetail tenon area, the area adjacent to the embedded part, and the area adjacent to the edge mold, the complex edge areas can receive independent material replenishment and targeted vibration compaction, which is beneficial to improving the fullness of the dovetail tenon forming and the density of the bridge deck edge.

[0022] This invention incorporates the processes of material placement, insertion and vibration, re-vibration and leveling, and film covering into continuous time control, thereby adapting to the short construction time window of coarse aggregate reactive powder concrete and reducing the risk of cold joints, surface defects, and insufficient interlayer bonding caused by excessive waiting time. Attached Figure Description

[0023] To more clearly illustrate the technical solution of the present invention, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a schematic flowchart of the bridge deck layer-by-layer formwork vibration compaction method of the present invention; Figure 2 This is a schematic diagram of the vibration grid division of the present invention; Figure 3 This is a schematic diagram of the layered molding process of the bridge deck cavity according to the present invention; Figure 4 This is a schematic diagram of the array-type insertion vibratory compaction device of the present invention in conjunction with the bridge deck mold platform; Figure 5 This is a schematic diagram of independent material replenishment and vibration control in the dovetail tenon area of ​​the present invention; Figure 6 This is a schematic diagram of the vibration parameter matching control logic of the present invention; Figure 7 This is a schematic diagram of the production line combination structure of the bridge deck mold table, material laying equipment, array-type insertion vibrating equipment, re-vibration leveling equipment and film coating mechanism of the present invention; Figure 8 This is a schematic diagram of the timing control of vibration leveling and coating in this invention.

[0025] The accompanying figure is labeled as follows: 1. Bridge deck formwork; 2. Side mold; 3. Reinforcing mesh; 4. Coarse aggregate reactive powder concrete; 5. The bottom layer is placed in the mold and vibrated; 6. Surface layer compacted in mold; 7. Vibrate the grid; 8. Vibrator; 9. Array-type insertion vibratory compaction equipment; 10. Fabric laying equipment; 11. Dovetail joint area; 12. Embedded parts; 13. Re-vibration leveling equipment; 14. Control system; 15. Material level sensor; 16. Walking and positioning unit; 17. Expansion input module; 18. Time counting module; 19. Coating mechanism. Detailed Implementation

[0026] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings.

[0027] This specific implementation provides a layered formwork vibration method for bridge decks, applicable to the precast construction of CA-RPC (coarse aggregate reactive powder concrete) bridge decks. By acquiring the bridge deck thickness, reinforcing mesh, embedded parts, dovetail areas, and the spread, temperature, placement time, and height of the coarse aggregate reactive powder concrete, the mold cavity is divided into at least two vibration layers along the thickness direction, and the mold cavity plane is divided into multiple vibration grids. After the material placing equipment places the material in segments along the long side of the bridge deck, an array-type insertion vibration device performs bottom layer insertion vibration and upper layer overlap insertion vibration respectively, and also performs vibration on the dovetail areas. The tail tenon area, the area adjacent to the embedded parts, and the area adjacent to the edge formwork are subjected to zoned vibration supplementation, and finally re-vibration leveling and film covering are carried out; this reduces the risk of under-vibration, over-vibration, segregation, and loose edges in the prefabrication process of CA-RPC (coarse aggregate reactive powder concrete) bridge decks, and improves the density of bridge decks, edge forming quality, and batch prefabrication consistency; it effectively solves the problems of under-vibration, over-vibration, segregation, loose edges, and insufficient interlayer bonding caused by the high fluidity of the material, rapid initial setting, thin plate, dense reinforcement, and complex edge structure in the prefabrication process of coarse aggregate reactive powder concrete bridge decks.

[0028] Example 1 like Figures 1 to 4 As shown, this embodiment provides a layered formwork vibration method for bridge decks, applicable to the precast construction of CA-RPC (coarse aggregate reactive powder concrete) bridge decks. A side mold 2 is set on the bridge deck formwork platform 1, forming a cavity for pouring coarse aggregate reactive powder concrete 4. A reinforcing mesh 3, embedded parts 12, and dovetail tenon areas 11 along the edge of the bridge deck are provided within the cavity. A concrete placing device 10, an array-type insertion vibration device 9, a re-vibration leveling device 13, and a film covering mechanism 19 are set on one side or above the bridge deck formwork platform 1. Each device can move sequentially along the long side of the bridge deck or act sequentially on the bridge deck formwork cavity according to the production rhythm.

[0029] In application, the control system 14 first acquires the structural parameters of the CA-RPC (coarse aggregate reactive powder concrete) bridge deck to be precast. These parameters include the bridge deck thickness, the dimensions along the long side of the bridge deck, the dimensions along the short side of the bridge deck, the position of the reinforcing mesh 3, the position of the embedded parts 12, the position of the dovetail tenon area 11, and the position of the side formwork 2. These structural parameters are imported into the control system 14 based on the bridge deck's 3D model, construction drawings, formwork positioning references, or a pre-established production parameter table.

[0030] Simultaneously, the control system 14 acquires the state parameters of the coarse aggregate reactive powder concrete 4. The state parameters include the spread of the coarse aggregate reactive powder concrete 4, the time from discharge to placement in the formwork, and the material temperature and height.

[0031] The expansion degree is manually detected and entered into the expansion degree input module 17 of the control system 14, or detected by an online detection device and then transmitted to the control system 14; the material level height is detected by the material level sensor 15 installed on the material distribution equipment 10 or the bridge deck mold table 1; the time from material discharge to mold entry is counted by the time counting module 18 of the control system 14; the material temperature is detected by the temperature sensor or uploaded by the mixing system.

[0032] The control system 14 divides the mold cavity into at least two vibratory compaction layers along the thickness direction based on the bridge deck thickness and the current material level. When the bridge deck thickness H is not greater than 220mm, it is preferably divided into a bottom vibratory compaction layer 5 and a top vibratory compaction layer 6. The thickness of the bottom vibratory compaction layer 5 is 0.40H to 0.60H, and the thickness of the top vibratory compaction layer 6 is 0.40H to 0.60H. For example, for a CA-RPC (coarse aggregate reactive powder concrete) bridge deck with a thickness of 180mm, the target thickness of the bottom vibratory compaction layer 5 is set to 80mm to 100mm, and the target thickness of the top vibratory compaction layer 6 is set to 80mm to 100mm.

[0033] Furthermore, the control system 14 divides the mold cavity plane into multiple vibration grids 7 according to the positions of the reinforcing mesh 3, the embedded parts 12, and the dovetail joint area 11. Each vibration grid 7 corresponds to one or more insertion points of the vibrator 8. The insertion point of the vibrator 8 is preferably set in the central area of ​​the reinforcing mesh, avoiding the intersections of the reinforcing bars, the embedded parts 12, and the side mold 2. In this way, the vibrator 8 can effectively transmit vibration energy after entering the coarse aggregate reactive powder concrete 4 without directly colliding with the reinforcing mesh 3, the embedded parts 12, or the side mold 2.

[0034] The concrete placing device 10 inserts concrete into the formwork in segments along the long side of the bridge deck. For each section, the bottom layer of coarse aggregate reactive powder concrete 4 is first placed into the formwork and vibrated. When the material level sensor 15 detects that the bottom layer of the formwork and vibrated layer 5 has reached the target height, the control system 14 controls the concrete placing device 10 to pause the placement of the current bottom layer and controls the array-type insertion vibrating device 9 to move to the corresponding vibration grid 7. The array-type insertion vibrating device 9 includes multiple vibrating rods 8, which can be raised, lowered, stopped, and frequency adjusted independently or in groups.

[0035] During the bottom layer vibration compaction, the control system 14 selects the first vibration parameters based on the spread, temperature, placement time, and height of the coarse aggregate reactive powder concrete 4. The first vibration parameters include the first vibration frequency, the first insertion depth, the first vibration time, and the first withdrawal speed. After starting and reaching the set first vibration frequency, the vibrator 8 is quickly inserted into the bottom layer of the compaction 5 and reaches the first insertion depth. The first vibration frequency is preferably 150Hz to 200Hz, and the first insertion depth is preferably inserted to a position where the tip of the vibrator is 5mm to 20mm from the bottom mold. When the surface of the bottom layer of the compaction 5 no longer sinks significantly, the air bubbles are significantly reduced, and uniform slurry appears, the vibrator 8 maintains its vibration state and is withdrawn at the set first withdrawal speed, preferably 0.8cm / s to 1.2cm / s.

[0036] After the bottom layer insertion vibration is completed, the material placement device 10 continues to place the top layer material into the mold on the same material section, forming the top layer vibration layer 6. After the top layer material placement is completed, the control system 14 controls the array-type insertion vibration device 9 to perform overlapping insertion vibration according to the second vibration parameters. The second vibration parameters include the second vibration frequency, the second insertion depth, the second vibration time, and the second pull-out speed.

[0037] During the overlapping insertion and vibration compaction, the vibrator 8, after starting and reaching the set second vibration frequency, is quickly inserted into the surface layer compaction layer 6 and then into the already compacted bottom layer compaction layer 5, reaching the set second insertion depth, so that the surface layer compaction layer 6 and the bottom layer compaction layer 5 form an effective bond. The second vibration frequency is preferably 100Hz to 200Hz, and the second insertion depth is preferably 20mm to 80mm deep into the already compacted bottom layer by the tip of the vibrator 8, and not greater than 1 / 2 of the thickness of the already compacted bottom layer. After compaction, the vibrator 8 is pulled out at a set second pull-out speed while maintaining vibration, preferably 0.8cm / s to 1.2cm / s, to reduce rod hole residue and avoid disturbing the already compacted bottom layer.

[0038] After immersion vibration is completed, the re-vibration leveling equipment 13 re-vibrates and levels the surface of the bridge deck, further eliminating micro-air bubbles and forming a smooth surface in the surface coarse aggregate reactive powder concrete 4. After the re-vibration leveling is completed, the coating mechanism 19 coats the surface of the bridge deck to reduce the risk of surface water loss and early shrinkage cracks.

[0039] Example 2 like Figure 6 As shown, this describes the matching control method between the state parameters and vibration parameters of coarse aggregate reactive powder concrete.

[0040] A vibration parameter database is pre-established within the control system 14. This database includes at least the corresponding relationships between bridge deck thickness, target layer thickness, spread, material temperature, time from discharge to mold entry, material level, vibration frequency, insertion depth, vibration time, rod extraction speed, and equipment travel speed. Before the start of each material placement section, the control system 14 reads data from the spread input module 17, the time counting module 18, and the material level sensor 15, and selects the vibration parameters for the current section accordingly.

[0041] When the spread of the coarse aggregate reactive powder concrete 4 is between 380mm and 420mm, the control system 14 determines that the coarse aggregate reactive powder concrete 4 is in a state awaiting vibration and allows the placing equipment 10 and the array-type insertion vibrating equipment 9 to enter the automatic construction program. When the spread is less than 380mm, the control system 14 determines that the coarse aggregate reactive powder concrete 4 has insufficient fluidity and outputs a prompt to check the mixing status, transportation time, or material temperature. When the spread is greater than 420mm, the control system 14 determines that the coarse aggregate reactive powder concrete 4 has a risk of bleeding or segregation and outputs a prompt to check the mix proportion, admixture dosage, or placing speed.

[0042] For the bottom vibratory layer 5, the first vibration frequency is preferably 150Hz to 200Hz, more preferably 180Hz to 200Hz. The first insertion depth is preferably 5mm to 20mm between the tip of the vibrator 8 and the bottom mold, which can both expel air bubbles at the bottom and prevent the vibrator 8 from directly touching the bottom mold. The first withdrawal speed is preferably 0.8cm / s to 1.2cm / s, so that the coarse aggregate reactive powder concrete 4 can fully backfill the rod hole during the withdrawal of the vibrator 8, reducing voids.

[0043] For the surface layer vibrating layer 6 or subsequent vibrating layers, the second vibration frequency is preferably 100Hz to 200Hz. If the spread of the coarse aggregate reactive powder concrete 4 is close to 380mm and the material temperature is low, the control system 14 needs to increase the second vibration frequency or extend the vibration time; if the spread is close to 420mm and the surface slurry rises quickly, the control system 14 needs to decrease the second vibration frequency or shorten the vibration time to reduce the risk of over-vibration and segregation.

[0044] When the material temperature is higher than 30℃ or the time from discharge to placement in the formwork exceeds the preset time threshold, the control system 14 shortens the length of a single material placement section and increases the vibration priority of the area already in the formwork, so that the coarse aggregate reactive powder concrete 4 completes insertion vibration and re-vibration leveling before the fluidity decreases significantly.

[0045] Example 3 like Figures 2 to 4 As shown, this describes the coordinated control method of the vibratory grid 7 and the array-type insertion vibratory device 9.

[0046] The vibratory grid 7 is established based on the bridge deck mold cavity plane, the mesh spacing of the reinforcing mesh 3, the arrangement position of the embedded parts 12, and the arrangement spacing of the vibrators 8 in the array-type insertion vibratory device 9. The insertion spacing of the vibrators 8 along both the long and short sides of the bridge deck is preferably 200mm ± 5mm. For areas with denser reinforcing mesh 3, the control system 14 preferentially selects the center of the reinforcing mesh as the insertion point; for areas adjacent to the embedded parts 12, the control system 14 sets a clearance zone according to the outer contour of the embedded parts 12, and no insertion points are set in the clearance zone.

[0047] An array-type insertion vibratory compactor 9 is mounted on a traveling and positioning unit 16. The traveling and positioning unit 16 can move along the long side of the bridge deck and position the array-type insertion vibratory compactor 9 above the vibratory grid 7 corresponding to each fabric section. The control system 14 controls the vibratory rod 8 to be inserted, vibrated, and pulled out within the corresponding vibratory grid 7 based on the position data fed back by the traveling and positioning unit 16.

[0048] During vibration, the control system 14 causes the vibrator 8 to operate in a manner of starting first and then inserting, with rapid insertion and slow withdrawal. Specifically, the vibrator 8 is started and reaches the set vibration frequency before entering the coarse aggregate reactive powder concrete 4, and then quickly inserted into the corresponding layer thickness range; after vibration is completed, the vibrator 8 is slowly withdrawn while maintaining vibration until the tip leaves the surface of the coarse aggregate reactive powder concrete 4. This method can reduce air holes, voids, and rod hole residues during the insertion and withdrawal process of the vibrator 8.

[0049] The control system 14 also records the working status of each vibrator 8. When a vibrator 8 fails to reach the set frequency, fails to reach the set insertion depth, or has an abnormal start / stop, the control system 14 outputs an abnormal alarm and can control the adjacent vibrators 8 to perform compensatory vibration, or prompt manual verification of the compaction status of the corresponding vibration grid 7.

[0050] Example 4 like Figure 5 As shown, this relates to a method for vibration compensation in special regions.

[0051] The edges of CA-RPC (coarse aggregate reactive powder concrete) bridge decks are typically designed with dovetail joints 11. These dovetail joints 11 are characterized by localized unevenness, strong edge formwork constraint, and complex concrete flow paths. If uniform vibration parameters are used only in the central area, material shortages, air bubbles, or incomplete molding can easily occur in the dovetail joints 11. Therefore, this embodiment divides the dovetail joints 11 into independent vibration-supplemented areas.

[0052] When the concrete placing device 10 moves to the position corresponding to the dovetail tenon area 11, the control system 14 first opens the partial concrete placing port of the concrete placing device 10, allowing the coarse aggregate reactive powder concrete 4 to preferentially enter the dovetail tenon groove or the irregular edge area. After the partial material replenishment is completed, the control system 14 starts the independent vibrator group corresponding to the dovetail tenon area 11 for supplementary vibration. The independent vibrator group includes one or more vibrators 8, and the start / stop, vibration frequency, and insertion depth of the independent vibrator group are independently controlled by the central vibrator group.

[0053] When performing vibration reinforcement in the dovetail joint area 11, a safe distance of 50mm to 100mm, preferably 80mm, should be maintained between the vibrator 8 and the side mold 2 to avoid direct collision between the vibrator 8 and the side mold 2 or the dovetail joint core mold. When performing vibration reinforcement on the bottom layer, the vibrator 8 should be inserted to a position where the tip of the rod is 5mm to 20mm away from the bottom mold; when performing vibration reinforcement on the surface layer, the vibrator 8 should be inserted 20mm to 50mm into the already compacted lower layer to enhance the interlayer bonding.

[0054] For the area adjacent to the embedded part 12, the control system 14 sets an embedded part avoidance zone according to the outer contour and height of the embedded part 12, and sets surrounding vibration compensation points outside the avoidance zone. The vibrator 8 is inserted from the center of the steel mesh adjacent to the embedded part 12, without directly inserting into the area where the embedded part 12 is located, so that the vibration energy is transmitted around the embedded part 12, thereby improving the density of the coarse aggregate reactive powder concrete 4 around the embedded part 12.

[0055] For the area adjacent to the edge mold 2, the control system 14 sets an edge vibration reinforcement band according to the position of the edge mold 2. The vibration frequency in the edge vibration reinforcement band is higher than the vibration frequency of the central surface layer, and the vibration time is appropriately extended according to the bubble discharge situation. By performing zoned vibration reinforcement on the dovetail tenon area 11, the area adjacent to the embedded part 12, and the area adjacent to the edge mold 2, the quality of the bridge deck edge and the molding reliability of complex areas can be improved.

[0056] Example 5 like Figure 7 and Figure 8 As shown, this relates to the timing control methods for vibration leveling and coating.

[0057] The concrete placing device 10, the array-type insertion vibratory compactor 9, the re-vibration leveling device 13, and the film covering mechanism 19 are arranged in sequence along the long side of the bridge deck. The time counting module 18 starts timing when the coarse aggregate reactive powder concrete 4 is unloaded into the concrete placing device 10. The control system 14 controls the total time from the unloading of the coarse aggregate reactive powder concrete 4 into the concrete placing device 10 to the completion of insertion vibration, re-vibration leveling, and film covering to within 15 minutes.

[0058] In application, after the fabric laying device 10 completes the bottom layer of fabric for a fabric section, the array-type insertion vibrating device 9 immediately enters the fabric section to perform bottom layer insertion vibration; the fabric laying device 10 then completes the top layer of fabric for the fabric section, and the array-type insertion vibrating device 9 then performs overlapping insertion vibration; the re-vibration leveling device 13 enters the fabric section after the insertion vibration is completed to perform surface re-vibration leveling; the film coating mechanism 19 then applies a film to the fabric section.

[0059] When the control system 14 detects that a certain placement section has been completed but the waiting time for vibration exceeds a preset threshold, it pauses subsequent placement and prioritizes controlling the array-type insertion vibrating device 9 to complete the vibration of that placement section. When the coarse aggregate reactive powder concrete 4 remains in the transport equipment or placement equipment 10 for more than 3 minutes, the control system 14 outputs a timeout alarm and prompts a check on the spread and temperature of the coarse aggregate reactive powder concrete 4.

[0060] The re-vibration leveling equipment 13 adopts either a plate vibratory leveling equipment or an axe-type vibratory leveling equipment. When the re-vibration leveling equipment 13 acts on the surface of the bridge deck, the condition for stopping is that the slurry on the bridge deck surface is uniform, there is no more obvious sinking, and the surface is flat. After the re-vibration leveling is completed, the film coating mechanism 19 rolls the film coating on the surface of the bridge deck to make the film adhere to the surface of the bridge deck to reduce the risk of surface water loss.

[0061] Example 6 The present invention relates to the parameter solidification method in the first prefabrication construction.

[0062] During the prefabrication of the first bridge deck, the control system 14 records the expansion, material temperature, time from material discharge to mold entry, start time of bottom layer material laying, start time of bottom layer vibration, start time of top layer material laying, start time of top layer vibration, completion time of re-vibration and leveling, and completion time of film coating for each material laying section. Simultaneously, it records the vibration frequency, insertion depth, vibration time, extraction speed, start / stop status, and abnormal alarm information for each vibrator 8.

[0063] After the bridge deck is formed, the appearance quality, flatness, fullness of the dovetail tenon forming, position of embedded parts 12, thickness of the steel reinforcement protective layer, deck thickness, and strength are tested. When the test results meet the design and acceptance requirements, the corresponding layer thickness, vibration frequency, insertion depth, rod extraction speed, equipment travel speed, zoned vibration compensation parameters, and film covering sequence are solidified as standard construction parameters for subsequent batch prefabrication.

[0064] When the inspection detects localized air bubbles, missing material at the edges, incomplete dovetail joints, or abnormal surface slurry, the control system 14 reverse-locates the corresponding vibration grid 7 based on the defect location and adjusts the material distribution, vibration time, insertion depth, or vibration frequency of that vibration grid 7 or adjacent vibration grids 7. Thus, this invention can transform empirical vibration processes into standardized construction parameters that are recordable, traceable, and reusable through the first-piece construction, thereby precisely improving the consistency and reliability of subsequent batch prefabrication of CA-RPC (coarse aggregate reactive powder concrete) bridge decks.

[0065] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described.

Claims

1. A method for layered compaction of bridge deck panels, characterized in that, include: The control system acquires the thickness, length and width dimensions, steel mesh, embedded parts and dovetail joint locations of the bridge deck to be precast with coarse aggregate reactive powder concrete, as well as the expansion of the coarse aggregate reactive powder concrete, the time from discharge to placement, material temperature and material level. The control system has a pre-established vibration parameter database, which includes at least the correspondence between bridge deck thickness, target layer thickness, expansion, material temperature, time from discharge to mold entry, material level height, vibration frequency, insertion depth, vibration time, rod pulling speed, and equipment travel speed. Before the start of each material laying section, the control system reads the data from the expansion input module, time counting module, and material level sensor, and selects the vibration parameters for the current material laying section accordingly. The mold cavity is divided into at least two layers of in-mold vibration layers along the thickness direction according to the plate thickness and the material level height, and the mold cavity plane is divided into multiple vibration grids according to the steel mesh, the embedded parts and the dovetail area, and the vibrator insertion point in each vibration grid is located. The fabric feeding device is controlled to enter the mold in segments along the long side of the bridge deck, and the first vibration parameter and the second vibration parameter are selected according to the expansion, the time from material discharge to mold entry, the material temperature and the material level height. When the material temperature is higher than 30°C or the time from material discharge to mold entry exceeds a preset time threshold, the control system shortens the length of a single material distribution segment and increases the vibration priority of the area already in the mold. When the control system detects that a certain fabric section has been completed but the waiting time for vibration exceeds a preset threshold, it pauses the subsequent fabric laying and prioritizes the control of the array-type insertion vibration device to complete the vibration of the fabric section. After the first layer of material is placed into the mold, the array-type insertion vibrating device is controlled to perform bottom layer insertion vibration of the mold cavity according to the first vibration parameters; after the second or subsequent layer of material is placed into the mold, the array-type insertion vibrating device is controlled to perform interlayer overlap insertion vibration according to the second vibration parameters, and the vibrator of the array-type insertion vibrating device enters the preset overlap depth of the already compacted lower layer; the array-type insertion vibrating device is used to perform zoned supplementary vibration of the dovetail joint area, the adjacent area of ​​the embedded part, and the adjacent area of ​​the side mold. After the partitioned vibration is completed and the vibration is inserted, the surface of the bridge deck is re-vibrated, leveled, and covered with a film.

2. The method for layered placement and vibration compaction of bridge deck panels according to claim 1, characterized in that, When the thickness H of the bridge deck is not greater than 220mm, the mold cavity is divided into a bottom layer for in-mold vibration and a top layer for in-mold vibration along the thickness direction. The thickness of the bottom layer for in-mold vibration is 0.40H to 0.60H, and the thickness of the top layer for in-mold vibration is 0.40H to 0.60H.

3. The method for layered placement and vibration compaction of bridge deck panels according to claim 1, characterized in that, When the thickness H of the bridge deck is greater than 220mm, the mold cavity is divided into three or more layers along the thickness direction, and the stacking height of a single material placement in any of the layers is not greater than 0.5m.

4. The method for layered placement and vibration compaction of bridge deck panels according to claim 1, characterized in that, When the spread of the coarse aggregate reactive powder concrete is 380mm to 420mm, the coarse aggregate reactive powder concrete is determined to be in a state of waiting to be vibrated. When the expansion is less than 380mm or greater than 420mm, the automatic vibration program of the array-type insertion vibrator is paused, and a verification prompt for the mix ratio, transportation settling time, or fabric laying speed is output.

5. The method for layered placement and vibration compaction of bridge deck panels according to claim 1, characterized in that, The vibratory grid is established based on the arrangement of the vibrators in the array-type insertion vibratory device. The insertion spacing of the vibrators in the array-type insertion vibratory device along the long and short sides of the bridge deck is 200mm±5mm, and the vibrators in the array-type insertion vibratory device are inserted from the center of the reinforcing steel grid.

6. The method for layered placement and vibration compaction of bridge deck panels according to claim 1, characterized in that, The first vibration parameters include a first vibration frequency, a first insertion depth, and a first pull-out speed; the first vibration frequency is 150Hz to 200Hz; the first insertion depth is 5mm to 20mm from the tip of the vibrating rod of the array-type insertion vibrating device to the bottom mold; and the first pull-out speed is 0.8cm / s to 1.2cm / s.

7. The method for layered placement and vibration compaction of bridge deck panels according to claim 1, characterized in that, The second vibration parameters include a second vibration frequency, a second insertion depth, and a second pull-out speed; the second vibration frequency is 100Hz to 200Hz; the second insertion depth is 20mm to 80mm into the already compacted lower layer by the vibrating rod of the array-type insertion vibrating device, and the depth of the vibrating rod into the already compacted lower layer is not greater than 1 / 2 of the thickness of the already compacted lower layer; the second pull-out speed is 0.8cm / s to 1.2cm / s.

8. The method for layered placement and vibration compaction of bridge deck panels according to claim 1, characterized in that, Both the bottom insertion vibration and the overlapping insertion vibration are carried out by starting the vibration first and then inserting, with fast insertion and slow withdrawal. The vibrator of the array-type insertion vibration device is kept vibrating during the withdrawal process until the tip of the vibrator of the array-type insertion vibration device leaves the surface of the coarse aggregate reactive powder concrete.

9. The method for layered compaction of bridge deck panels according to claim 1, characterized in that, When performing the partitioned vibration on the dovetail joint area, first control the local material feeding port of the material feeding device to feed the material to the dovetail joint area, and then start the independent vibrating rod group corresponding to the dovetail joint area in the array-type insertion vibrating device to perform vibration, and maintain a safe distance of 50mm to 100mm between the vibrating rod of the array-type insertion vibrating device and the side mold. For the area adjacent to the embedded part, the control system sets an embedded part avoidance zone according to the outer contour and height of the embedded part, and sets surrounding vibration points outside the embedded part avoidance zone; the vibrator of the array-type insertion vibrating device is inserted from the center of the steel mesh adjacent to the embedded part, and does not directly insert into the area where the embedded part is located.

10. The method for layered placement and vibration compaction of bridge deck panels according to claim 1, characterized in that, The operation time from the unloading of the coarse aggregate reactive powder concrete into the placing equipment to the completion of the insertion vibration, the re-vibration leveling and the covering film shall not exceed 15 minutes; When the coarse aggregate reactive powder concrete is left to stand in the transport equipment or the placing equipment for more than 3 minutes, the control system outputs a standing timeout alarm.

Images