Concrete tower section, ultra high performance concrete and method of manufacture

Abstract

The application discloses a concrete tower drum, ultra-high performance concrete and a manufacturing method, and relates to the technical field of concrete tower drums, and more particularly to an ultra-high performance concrete comprising dry powder material and liquid admixtures, wherein the dry powder material further comprises pre-tension anchoring fibers, the pre-tension anchoring fibers exert pressure on the ultra-high performance concrete matrix in the ultra-high performance concrete, and the component proportion of cement, silica fume, fly ash, microbeads, basalt machine-made sand and steel fibers is accurately controlled through the grading optimization of the cementing system and the aggregate system to construct a dense matrix with multi-scale close packing; on the other hand, the pre-tension anchoring fibers are built in the matrix to break through the passive toughening limitation of traditional steel fibers by means of active prestress enhancement mechanism, and the comprehensive mechanical properties of the ultra-high performance concrete are comprehensively improved.

Description

Technical Field

[0001] This invention relates to a technology in the field of new energy, specifically a concrete tower, ultra-high performance concrete, and a manufacturing method thereof. Background Technology

[0002] Ultra-High Performance Concrete (UHPC), formerly known as Reactive Powder Concrete (RPC), is defined according to the national standard GB / T 31387-2025 "Ultra-High Performance Concrete" as a fiber-reinforced cementitious composite material with four core characteristics: ultra-high strength, high toughness, ultra-low porosity, and ultra-long durability. It is formulated with high-grade silicate cement and ultra-fine mineral active admixtures as the composite cementitious system, combined with fine aggregates, high-performance polycarboxylate superplasticizers, high-volume-fraction reinforcing fibers, and extremely low water-cement ratio.

[0003] Driven by the "dual-carbon" strategy, onshore wind turbines are continuously upgrading towards larger capacity, taller towers, and longer blades. Currently, the hub height of mainstream models has reached 170 meters, with some models in low-wind-speed areas exceeding 200 meters. The rotor diameter generally exceeds 200 meters, and a single blade weighs over 30 tons. The total load of the nacelle and rotor can reach hundreds of tons. As the core load-bearing structure of the wind turbine, the concrete tower must bear the combined effects of the superstructure's self-weight, alternating wind loads, seismic loads, and temperature loads throughout its entire life cycle. The bottom section of a 200-meter-high tower must withstand extremely high combined compressive and bending stresses, while also resisting long-term wind-induced fatigue and environmental erosion. This places extremely stringent requirements on the mechanical strength, crack resistance, and durability of concrete materials.

[0004] Although ultra-high performance concrete (UHPC) has become the core technology for lightweighting and high-strength wind turbine concrete towers, it still suffers from the inherent limitation of cement-based materials, where compressive strength is much higher than tensile strength. While existing conventional UHPC achieves strain hardening and multi-crack toughening through the addition of steel fibers, resulting in tensile strength several times higher than ordinary concrete, its tensile strength is typically only 5-8 MPa due to the passive crack-inhibiting mechanism of the fibers. The tension-to-compression ratio is less than 1 / 20, and the match between tensile and compressive strength remains low. This fails to adequately offset the tensile and shrinkage stresses in the tension zone of the tower, making macroscopic cracks prone to appear on the tension side, thus deteriorating the long-term durability of the structure and making it difficult to fully meet the high-strength, high-crack-resistance service requirements of 200-meter-class wind turbine concrete towers. Summary of the Invention

[0005] This invention addresses the shortcomings of existing ultra-high performance concrete, such as its low tensile-to-compression ratio and limited tensile strength enhancement due to passive toughening mechanisms, which make it difficult to meet the high strength, high crack resistance, and high durability requirements of 200-meter-class wind power concrete towers. It proposes a concrete tower, ultra-high performance concrete, and its manufacturing method. On one hand, this invention optimizes the gradation of the cementitious and aggregate systems, precisely controlling the component ratios of cement, silica fume, fly ash, microspheres, basalt manufactured sand, and steel fibers to construct a dense matrix with multi-scale close packing. On the other hand, it incorporates pre-tensioned anchoring fibers within the matrix, using an active prestressing enhancement mechanism to overcome the limitations of traditional passive toughening with steel fibers, thus comprehensively improving the overall mechanical properties of ultra-high performance concrete.

[0006] The pre-tensioned anchoring fiber includes a fiber body, an anchor body, and a tensioning body. The anchor bodies are fixedly set at the set positions of the fiber body, and the tensioning bodies are set between adjacent anchor bodies. Through the axial support of the tensioning bodies on both sides of the anchor bodies, the corresponding fiber body is pre-tensioned and stably maintained in an axial tensile state, thereby storing stable pre-tension stress inside the fiber and forming a prestressed reinforcement unit at the single fiber level.

[0007] Both the anchor body and the tension body of the pre-tensioned anchoring fiber have pozzolanic reactivity on their surfaces. During the setting and hardening process of ultra-high performance concrete, the active components on its surface can undergo a secondary hydration reaction with the calcium hydroxide released by cement hydration to generate hydrated calcium silicate gel homologous to the matrix. This reaction can achieve chemical fusion and interfacial compaction between the anchor body, the tension body and the concrete matrix, eliminate defects in the interfacial transition zone between the fiber and the matrix, ensure interfacial bond strength, and avoid the interfacial slippage and debonding problems that are common in traditional reinforcing fibers. On the other hand, relying on the strong interfacial bond, the pre-tension stress stored inside the fiber body can be uniformly and continuously transferred to the surrounding concrete matrix, generating an active axial and radial pre-compression effect on the matrix.

[0008] By optimizing the matrix materials and actively reinforcing with pre-tensioned anchoring fibers, the ultra-high performance concrete of this invention can significantly improve tensile strength, initial crack strength, and fatigue resistance while maintaining ultra-high compressive strength. The stress in the tensile zone under external loads significantly improves the tensile-compression ratio and structural crack resistance reserve of the material. Wind power concrete towers made with this ultra-high performance concrete can better adapt to the high-pressure bending loads, long-term alternating wind loads, and complex corrosive environments of 200-meter-class high towers, effectively delaying structural cracking, improving durability, extending the service life of the structure, and reducing the total life cycle maintenance cost.

[0009] According to one aspect of the present invention, an ultra-high performance concrete is provided, comprising:

[0010] Dry powder, wherein the dry powder comprises the following components in parts by weight:

[0011] 65-71 parts cement;

[0012] 14-19 parts silica fume;

[0013] 6-9 parts fly ash;

[0014] 5-8 parts of microbeads;

[0015] 115-127 parts of basalt manufactured sand, wherein the particle size of the basalt manufactured sand is 0.35-0.5 mm;

[0016] 44-60 parts steel fiber;

[0017] A liquid admixture, wherein the liquid admixture comprises the following components in parts by weight:

[0018] 16-18 parts water;

[0019] 3-10 parts of carboxylic acid water-reducing agent;

[0020] The dry powder and the liquid admixture are mixed and solidified to form the ultra-high performance concrete.

[0021] Preferably, the dry powder material further includes pre-tensioned anchoring fibers, which apply pressure to the ultra-high performance concrete matrix within the ultra-high performance concrete.

[0022] Preferably, the pre-tensioned anchoring fiber comprises:

[0023] Fiber body;

[0024] The first end anchor is fixedly disposed at one end of the fiber body;

[0025] The end anchor is fixedly disposed at the other end of the fiber body;

[0026] Multiple tension bodies are provided, which are closely attached between the first end anchor body and the last end anchor body of the fiber body;

[0027] The tensioning body compresses the first and last anchor bodies to elongate the fiber body.

[0028] Preferably, the first anchor body is a spherical quartz, and the last anchor body is a spherical quartz.

[0029] Preferably, the tensioning body is Microspheres.

[0030] Preferably, the tensioning body comprises:

[0031] Quartz sphere;

[0032] A hydration reaction layer is formed on the outer surface of the quartz sphere.

[0033] According to one aspect of the present invention, a method for manufacturing ultra-high performance concrete is provided, comprising the following steps:

[0034] Cement, silica fume, fly ash, microspheres, basalt manufactured sand, and steel fibers are mixed to form a dry powder.

[0035] Water and carboxylic acid water-reducing agent are mixed to form a liquid admixture;

[0036] The dry powder material and the liquid admixture are mixed to form the ultra-high performance concrete.

[0037] in:

[0038] The dry powder comprises the following components in parts by weight:

[0039] 65-71 parts cement;

[0040] 14-19 parts silica fume;

[0041] 6-9 parts fly ash;

[0042] 5-8 parts of microbeads;

[0043] 115-127 parts of basalt manufactured sand, wherein the particle size of the basalt manufactured sand is 0.35-0.5 mm;

[0044] 44-60 parts steel fiber;

[0045] The liquid admixture comprises the following components in parts by weight:

[0046] 16-18 parts water;

[0047] 3-10 parts of carboxylic acid water-reducing agent.

[0048] Preferably, it further includes: adding pre-tensioned anchoring fibers to the dry powder, wherein the pre-tensioned anchoring fibers apply pressure to the ultra-high performance concrete matrix within the ultra-high performance concrete.

[0049] Preferably, the pre-tensioned anchoring fiber comprises:

[0050] Fiber body;

[0051] The first end anchor is fixedly disposed at one end of the fiber body;

[0052] The end anchor is fixedly disposed at the other end of the fiber body;

[0053] Multiple tension bodies are provided, which are closely attached between the first end anchor body and the last end anchor body of the fiber body;

[0054] The tensioning body compresses the first and last anchor bodies to elongate the fiber body.

[0055] According to one aspect of the present invention, a concrete tower is provided, the main body of which is formed by the setting of ultra-high performance concrete, wherein the ultra-high performance concrete is formed by mixing and setting dry powder and liquid admixture.

[0056] The dry powder comprises the following components in parts by weight:

[0057] 65-71 parts cement;

[0058] 14-19 parts silica fume;

[0059] 6-9 parts fly ash;

[0060] 5-8 parts of microbeads;

[0061] 115-127 parts of basalt manufactured sand, wherein the particle size of the basalt manufactured sand is 0.35-0.5 mm;

[0062] 44-60 parts steel fiber;

[0063] The liquid admixture comprises the following components in parts by weight:

[0064] 16-18 parts water;

[0065] 3-10 parts of carboxylic acid water-reducing agent;

[0066] The dry powder material also includes pre-tensioned anchoring fibers, which apply pressure to the ultra-high performance concrete matrix within the ultra-high performance concrete.

[0067] The pre-tensioned anchoring fiber includes:

[0068] Fiber body;

[0069] The first end anchor is fixedly disposed at one end of the fiber body;

[0070] The end anchor is fixedly disposed at the other end of the fiber body;

[0071] Multiple tension bodies are provided, which are closely attached between the first end anchor body and the last end anchor body of the fiber body;

[0072] The tensioning body compresses the first and last anchor bodies to elongate the fiber body.

[0073] The beneficial effects of the above technical solution are:

[0074] On the one hand, this invention optimizes the gradation of the cementitious system and aggregate system to precisely control the component ratio of cement, silica fume, fly ash, microspheres, basalt manufactured sand and steel fiber, thereby constructing a dense matrix with multi-scale close packing. On the other hand, by embedding pre-tensioned anchoring fibers in the matrix, it breaks through the passive toughening limitation of traditional steel fibers with an active prestressing enhancement mechanism, thereby comprehensively improving the overall mechanical properties of ultra-high performance concrete.

[0075] The pre-tensioned anchoring fiber includes a fiber body, an anchor body, and a tensioning body. The anchor bodies are fixedly set at the set positions of the fiber body, and the tensioning bodies are set between adjacent anchor bodies. Through the axial support of the tensioning bodies on both sides of the anchor bodies, the corresponding fiber body is pre-tensioned and stably maintained in an axial tensile state, thereby storing stable pre-tension stress inside the fiber and forming a prestressed reinforcement unit at the single fiber level.

[0076] Both the anchor body and the tension body of the pre-tensioned anchoring fiber have pozzolanic reactivity on their surfaces. During the setting and hardening process of ultra-high performance concrete, the active components on its surface can undergo a secondary hydration reaction with the calcium hydroxide released by cement hydration to generate hydrated calcium silicate gel homologous to the matrix. This reaction can achieve chemical fusion and interfacial compaction between the anchor body, the tension body and the concrete matrix, eliminate defects in the interfacial transition zone between the fiber and the matrix, ensure interfacial bond strength, and avoid the interfacial slippage and debonding problems that are common in traditional reinforcing fibers. On the other hand, relying on the strong interfacial bond, the pre-tension stress stored inside the fiber body can be uniformly and continuously transferred to the surrounding concrete matrix, generating an active axial and radial pre-compression effect on the matrix.

[0077] By optimizing the matrix materials and actively reinforcing with pre-tensioned anchoring fibers, the ultra-high performance concrete of this invention can significantly improve tensile strength, initial crack strength, and fatigue resistance while maintaining ultra-high compressive strength. The stress in the tensile zone under external loads significantly improves the tensile-compression ratio and structural crack resistance reserve of the material. Wind power concrete towers made with this ultra-high performance concrete can better adapt to the high-pressure bending loads, long-term alternating wind loads, and complex corrosive environments of 200-meter-class high towers, effectively delaying structural cracking, improving durability, extending the service life of the structure, and reducing the total life cycle maintenance cost.

[0078] Other features and advantages of the present invention, as well as the structure and operation of various embodiments thereof, will be described in detail below with reference to the accompanying drawings. It should be noted that the present invention is not limited to the specific embodiments described herein. The embodiments given herein are merely illustrative. Attached Figure Description

[0079] Other features, objects, and advantages of the invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings.

[0080] Figure 1 This is a schematic diagram of the matrix of the ultra-high performance concrete of the present invention;

[0081] Figure 2 This is a schematic diagram of the pre-tensioned anchoring fiber structure of the present invention;

[0082] Figure 3 This is a schematic diagram of the tension body structure of the present invention;

[0083] Figure 4 This is a schematic diagram of the state of the pre-tensioned anchoring fiber of the present invention solidified in the ultra-high performance concrete matrix;

[0084] Figure 5 This is a schematic diagram of the ultra-high performance concrete manufacturing method of the present invention;

[0085] Figure 6 This is a schematic diagram of a wind turbine generator structure according to the present invention.

[0086] Figure label:

[0087] 110 matrix

[0088] 120 pre-tensioned anchoring fiber

[0089] 121 fiber body

[0090] 122 Head Anchor Solid

[0091] 123 End Anchor Solid

[0092] 124 tension bodies

[0093] 1241 hydration reaction layer

[0094] 1242 Quartz Sphere

[0095] 210 wind turbine generator set

[0096] 220 motor

[0097] 230 blades

[0098] 240 Concrete Tower

[0099] The features and advantages of the invention will become more apparent from the following detailed description taken in conjunction with the accompanying drawings. Throughout the drawings, the same reference numerals identify corresponding elements. In the drawings, the same reference numerals generally indicate the same, functionally similar, and / or structurally similar elements. Detailed Implementation

[0100] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0101] The terms "first," "second," and similar words used in this application do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Words such as "including" or "comprising" mean that the element or object preceding the word encompasses the elements or objects listed after the word and their equivalents, without excluding other elements or objects. Words such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as "upper," "lower," "left," and "right" are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0102] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other.

[0103] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, but this is not intended to limit the scope of the invention.

[0104] According to one aspect of the present invention, an ultra-high performance concrete is provided.

[0105] The ultra-high performance concrete of the present invention comprises two parts: dry powder and liquid admixture, which are stored separately. When preparing the ultra-high performance concrete, the dry powder and liquid admixture are mixed and stirred.

[0106] The dry powder material comprises the following components in parts by weight: 65-71 parts cement, 14-19 parts silica fume, 6-9 parts fly ash, and 5-8 parts microspheres; 115-127 parts basalt manufactured sand with a particle size of 0.35-0.5 mm; and 44-60 parts steel fiber. The liquid admixture comprises the following components in parts by weight: 16-18 parts water and 3-10 parts carboxylic acid water-reducing agent. The dry powder material and liquid admixture are mixed and solidified to form ultra-high performance concrete. The dry powder material also includes pre-tensioned anchoring fibers 120, which apply pressure to the ultra-high performance concrete matrix 110 within the ultra-high performance concrete.

[0107] Figure 1 A schematic diagram of the matrix of the ultra-high performance concrete of the present invention. Figure 1The matrix 110 shown is a dense cement-based matrix formed by mixing, molding, and curing ultra-high performance concrete. Multiple pre-tensioned anchoring fibers 120 are uniformly distributed within the matrix 110. Each pre-tensioned anchoring fiber 120 is in a three-dimensional, disordered, dispersed state, tightly bonded to the surrounding matrix 110 without significant interfacial gaps. In working condition, each pre-tensioned anchoring fiber 120 is under axial tension and can apply active pre-stress to the surrounding matrix 110 through interfacial bonding. The synergistic effect of multiple pre-tensioned anchoring fibers 120 forms a three-dimensional pre-stress field covering the entire matrix 110, effectively counteracting the internal tensile stress generated by hydration shrinkage and temperature deformation of the matrix 110, while simultaneously improving the tensile bearing capacity and crack resistance of the matrix 110 under external loads.

[0108] Figure 2 A schematic diagram of the pre-tensioned anchoring fiber structure of the present invention. Figure 2 The pre-tensioned anchoring fiber 120 shown includes a fiber body 121, a first-end anchor 122, a second-end anchor 123, and a tensioning body 124. The first-end anchor 122 is fixedly disposed at one end of the fiber body 121, forming a stable axial anchor with the fiber body 121, with no relative slippage between them. The second-end anchor 123 is fixedly disposed at the other end of the fiber body 121, and is coaxially arranged with the first-end anchor 122 along the axis of the fiber body 121. The tensioning body 124 is tightly disposed against the fiber body 121, can be inserted into the fiber body 121, and is axially clamped between the first-end anchor 122 and the second-end anchor 123. The two end faces of the tensioning body 124 are tightly fitted with the inner end faces of the first-end anchor 122 and the second end face of the second-end anchor 123, respectively. Figure 2 The diagram shows the assembled state, in which the tensioning body 124 exerts a continuous outward squeezing support on the first anchor body 122 and the last anchor body 123 along the axial direction, pushing the two end anchor bodies to cause the two ends of the fiber body 121 to separate from each other along the axial direction, thereby causing the fiber body 121 to produce elastic elongation and stably maintain the tensioned state, storing a preset pre-tension stress inside the fiber body 121.

[0109] In some embodiments, the first anchor 122 is a spherical quartz, and the last anchor 123 is a spherical quartz. The tensioning body 124 is... Microspheres. The first-end anchor 122, the last-end anchor 123, and the tensioning body 124 are coaxially mounted on the fiber body 121. The tensioning body 124 is sandwiched between the first-end anchor 122 and the last-end anchor 123, forming a single pre-tensioned anchor fiber 120 with rigid anchoring at both ends and active tensioning in the middle. The spherical quartz used for the first-end anchor 122 and the last-end anchor 123 is made of crystalline silicon dioxide, with a complete and ordered quartz crystal phase structure. It is chemically stable and does not undergo significant dissolution in the highly alkaline porous solution environment of cement hydration, possessing high compressive strength and structural stiffness. In the assembled state, the spherical quartz at both ends can stably bear the axial compressive force applied by the tensioning body 124, providing a reliable end anchoring support for the fiber body 121, ensuring the stable maintenance of the fiber pre-tension stress during the tensioning stage, and preventing anchor slippage or structural collapse due to hydration erosion. Meanwhile, the spherical shape of the first anchor body 122 and the last anchor body 123 can mechanically interlock with the surrounding concrete matrix 110. Combined with the encapsulation effect of hydration products, this ensures the interfacial bond strength between the fiber and the matrix 110, providing a stable interfacial foundation for prestress transfer. The SiO2 microspheres used in the tension body 124 have a glassy amorphous silica structure as their main body, and the surface layer possesses pozzolanic reactivity, allowing for a secondary hydration reaction with calcium hydroxide generated during cement hydration. The SiO2 microspheres are stacked between the two spherical quartz crystals at a set particle size and in corresponding quantities. Their rigidity allows them to maintain the axial distance between the first anchor body 122 and the last anchor body 123, causing the fiber body 121 to produce a corresponding elastic elongation, achieving precise control of the prestress. By adjusting the particle size and number of SiO2 microspheres, the total elongation and prestress level of the fiber body 121 can be flexibly adjusted to suit different strength grades of matrix 110 formulations and service scenarios.

[0110] Figure 3 A schematic diagram of the tensioned body structure of the present invention. (Reference) Figure 3 In some embodiments, the tension body 124 includes: a quartz sphere 1242; and a hydration reaction layer 1241, which covers the outer surface of the quartz sphere 1242. The quartz sphere 1242, serving as the core support of the tension body 124, is composed of crystalline silicon dioxide with a regular and dense internal lattice arrangement. It is chemically stable in the highly alkaline porous solution environment of cement hydration, does not participate in secondary hydration reactions, and possesses high compressive strength and long-term dimensional stability. During the assembly stage of the pre-tensioned anchoring fiber 120, the quartz sphere 1242 can stably bear the axial compressive load, providing a rigid support reference for the tensioning of the fiber body 121, ensuring precise control and stability of the pre-tension stress.

[0111] Figure 4 A schematic diagram showing the state of the pre-tensioned anchoring fiber of the present invention cured within the ultra-high performance concrete matrix 110. (Reference) Figure 4The hydration reaction layer 1241, covering the outer surface of the quartz sphere 1242, is made of amorphous silica with pozzolanic activity. Its thickness is uniform and controllable. It can undergo a secondary hydration reaction with calcium hydroxide released during cement hydration, generating hydrated calcium silicate gel homologous to the concrete matrix 110. Thus, gaps exist between the first anchor body 122, the last anchor body 123, and the tension body 124 of the pre-tensioned anchoring fiber 120, which are filled by concrete. As the active functional layer of the tension body 124, the hydration reaction layer 1241 can, on the one hand, chemically fuse with the surrounding concrete matrix 110 through hydration, eliminating interfacial gaps between the tension body 124 and the matrix 110, strengthening interfacial adhesion, and providing a stable interfacial foundation for the uniform transfer of prestress; on the other hand, as the hydration reaction continues, the hydration reaction layer 1241 is gradually consumed, and its thickness gradually decreases with the hydration process. During the setting and hardening process of ultra-high performance concrete, the hydration reaction layer 1241 gradually participates in the secondary hydration reaction within the system and undergoes dissolution and consumption. The overall radial dimension and axial length of the tension body 124 decrease slightly, and its axial compressive support force on the first anchor body 122 and the last anchor body 123 gradually decreases. This slowly releases the tension constraint on the fiber body 121, allowing the fiber body 121 to gradually shrink and reset, continuously transferring the stored prestress to the surrounding concrete matrix 110, transforming it into an active pre-compression effect on the matrix 110. Meanwhile, the internal quartz spheres 1242 maintain structural integrity, preventing the complete collapse of the tension body 124, maintaining the axial positioning and basic anchoring function of the fiber in the matrix 110, ensuring a stable and controllable prestress release process, and simultaneously ensuring the long-term structural stability of the fiber in the matrix 110.

[0112] In some embodiments, the cement is P.II52.5 silicate cement, the silica fume is SF90 grade, and the fly ash is Grade I fly ash, forming a dense cementitious system with multi-scale particle size distribution. The P.II52.5 silicate cement is the core hydration component, meeting the requirements of GB175-2007 "General Silicate Cement" standard, exhibiting high early hydration activity and stable strength development, providing a basic strength framework for the matrix. The SF90 grade silica fume... With a mass fraction of not less than 90% and an average particle size reaching the submicron level, it fills the fine voids between cement particles, improving the packing density of the system. Simultaneously, it undergoes a secondary hydration reaction with calcium hydroxide generated during cement hydration, producing a dense hydrated calcium silicate gel. This eliminates calcium hydroxide-rich areas within the matrix 110, refines the pore structure, and strengthens the performance of the interfacial transition zone. The fly ash is Grade I fly ash, meeting the requirements of GB / T1596-2017 "Fly Ash for Cement and Concrete". Utilizing the morphological effect of spherical particles, it reduces frictional resistance within the slurry, improving workability. Simultaneously, its active silica-alumina components participate in subsequent secondary hydration, forming a synergistic hydration effect with silica fume, further optimizing the microstructure and reducing heat of hydration and autogenous shrinkage. The microspheres are spherical ultrafine glassy powders that can exert a ball-bead effect to further improve the rheological properties of the slurry under low water-cement ratios. Combined with water-reducing agents, they achieve good flowability with ultra-low water consumption, while simultaneously filling the nanoscale voids in the cementitious system, further enhancing the density of the matrix 110.

[0113] In some embodiments, the basalt manufactured sand preferably has an average particle size of 0.35~0.5mm, corresponding to a medium sand gradation with a fineness modulus of approximately 2.5. Basalt aggregate itself has high Mohs hardness and excellent mechanical properties. This particle size range forms a good match with the particle gradation of cementitious materials, achieving close packing of aggregate and paste. At the same time, it eliminates the coarse aggregate component of traditional concrete, eliminating the weak interface transition zone caused by coarse aggregate, and ensuring the homogeneity and strength stability of the ultra-high strength matrix 110.

[0114] In some embodiments, the steel fibers are copper-plated hooked steel fibers with a length of 14 mm, added at a mass ratio of 44-60 parts, corresponding to a volumetric admixture of 2% of the total concrete volume. The steel fibers are three-dimensionally disordered and uniformly distributed within the matrix 110, forming a continuous reinforcing network, which can effectively bridge microcracks, inhibit crack propagation, significantly improve the tensile and flexural toughness of concrete, and improve the brittle failure characteristics of the ultra-high strength matrix 110.

[0115] In some embodiments, the specific mass ratio of cement: silica fume: fly ash: microspheres: basalt manufactured sand: water: steel fiber: carboxylic acid water-reducing agent can be 1:0.24:0.11:0.1:0.13:1.5:0.42:0.05, the water-cement ratio is controlled between 0.16 and 0.18, and the steel fiber content is 6% by volume.

[0116] According to one aspect of the present invention, a method for manufacturing ultra-high performance concrete is provided.

[0117] Figure 5 A schematic diagram of the process for manufacturing ultra-high performance concrete according to the present invention. Figure 5 The method for manufacturing ultra-high performance concrete shown includes steps S101, S102 and S103.

[0118] Step S101: Cement, silica fume, fly ash, microspheres, basalt manufactured sand, and steel fibers are mixed to form dry powder.

[0119] Step S102: Mix water and carboxylic acid water-reducing agent to form a liquid additive.

[0120] Step S103: The dry powder and liquid admixture are mixed to form ultra-high performance concrete.

[0121] The dry powder material comprises the following components in parts by weight: 65-71 parts cement; 14-19 parts silica fume; 6-9 parts fly ash; 5-8 parts microspheres; 115-127 parts basalt manufactured sand with a particle size of 0.35-0.5 mm; and 44-60 parts steel fiber. The liquid admixture comprises the following components in parts by weight: 16-18 parts water; and 3-10 parts carboxylic acid water-reducing agent. The method further includes adding pre-tensioned anchoring fibers 120 to the dry powder material, wherein the pre-tensioned anchoring fibers 120 apply pressure to the ultra-high performance concrete matrix 110 within the ultra-high performance concrete. The pre-tensioned anchoring fiber 120 includes: a fiber body 121; a first-end anchor 122 fixedly disposed at one end of the fiber body 121; a second-end anchor 123 fixedly disposed at the other end of the fiber body 121; and a plurality of tensioning bodies 124, which are tightly disposed between the first-end anchor 122 and the second-end anchor 123 of the fiber body 121. The tensioning bodies 124 compress the first-end anchor 122 and the second-end anchor 123 to elongate the fiber body 121.

[0122] According to one aspect of the present invention, a concrete tower is provided.

[0123] Figure 6 A schematic diagram of a motor-driven wind turbine generator set according to the present invention. Figure 6The illustrated wind turbine generator set 210 includes a motor 220, blades 230, and a concrete tower 240. The main body of the concrete tower 240 is formed by the setting of ultra-high performance concrete, which is formed by mixing and setting dry powder and liquid admixtures. The dry powder includes the following components in parts by weight: 65-71 parts cement; 14-19 parts silica fume; 6-9 parts fly ash; 5-8 parts microspheres; 115-127 parts basalt manufactured sand with a particle size of 0.35-0.5 mm; and 44-60 parts steel fiber. The liquid admixture includes the following components in parts by weight: 16-18 parts water; 3-10 parts carboxylic acid water-reducing agent; the dry powder also includes pre-tensioned anchoring fibers 120, which apply pressure to the ultra-high performance concrete matrix 110 within the ultra-high performance concrete. The pre-tensioned anchoring fiber 120 includes: a fiber body 121; a first-end anchor 122 fixedly disposed at one end of the fiber body 121; a second-end anchor 123 fixedly disposed at the other end of the fiber body 121; and a plurality of tensioning bodies 124, which are tightly disposed between the first-end anchor 122 and the second-end anchor 123 of the fiber body 121. The tensioning bodies 124 compress the first-end anchor 122 and the second-end anchor 123 to elongate the fiber body 121.

[0124] In summary, this invention optimizes the gradation of the cementitious system and aggregate system to precisely control the component ratios of cement, silica fume, fly ash, microspheres, basalt manufactured sand, and steel fibers, thereby constructing a dense matrix with multi-scale close packing. On the other hand, by embedding pre-tensioned anchoring fibers in the matrix, it overcomes the limitations of passive toughening of traditional steel fibers through an active prestressing enhancement mechanism, thus comprehensively improving the overall mechanical properties of ultra-high performance concrete.

[0125] The pre-tensioned anchoring fiber includes a fiber body, an anchor body, and a tensioning body. The anchor bodies are fixedly set at the set positions of the fiber body, and the tensioning bodies are set between adjacent anchor bodies. Through the axial support of the tensioning bodies on both sides of the anchor bodies, the corresponding fiber body is pre-tensioned and stably maintained in an axial tensile state, thereby storing stable pre-tension stress inside the fiber and forming a prestressed reinforcement unit at the single fiber level.

[0126] Both the anchor body and the tension body of the pre-tensioned anchoring fiber have pozzolanic reactivity on their surfaces. During the setting and hardening process of ultra-high performance concrete, the active components on its surface can undergo a secondary hydration reaction with the calcium hydroxide released by cement hydration to generate hydrated calcium silicate gel homologous to the matrix. This reaction can achieve chemical fusion and interfacial compaction between the anchor body, the tension body and the concrete matrix, eliminate defects in the interfacial transition zone between the fiber and the matrix, ensure interfacial bond strength, and avoid the interfacial slippage and debonding problems that are common in traditional reinforcing fibers. On the other hand, relying on the strong interfacial bonding effect, the pre-tension stress stored inside the fiber body can be uniformly and continuously transferred to the surrounding concrete matrix, generating an active axial and radial pre-compression effect on the matrix.

[0127] By optimizing the matrix materials and actively reinforcing with pre-tensioned anchoring fibers, the ultra-high performance concrete of this invention can significantly improve tensile strength, initial crack strength, and fatigue resistance while maintaining ultra-high compressive strength. The stress in the tensile zone under external loads significantly improves the tensile-compression ratio and structural crack resistance reserve of the material. Wind power concrete towers made with this ultra-high performance concrete can better adapt to the high-pressure bending loads, long-term alternating wind loads, and complex corrosive environments of 200-meter-class high towers, effectively delaying structural cracking, improving durability, extending the service life of the structure, and reducing the total life cycle maintenance cost.

[0128] The above description, in conjunction with specific preferred embodiments, provides a further detailed explanation of the present invention. It should not be construed that the specific implementation of the present invention is limited to these descriptions. For those skilled in the art, various simple deductions or substitutions can be made without departing from the concept of the present invention, and all such modifications and substitutions should be considered within the scope of protection of the present invention.

Claims

1. A type of ultra-high performance concrete, characterized in that, include: Dry powder, wherein the dry powder comprises the following components in parts by weight: 65-71 parts cement; 14-19 parts silica fume; 6-9 parts fly ash; 5-8 parts of microbeads; 115-127 parts of basalt manufactured sand, wherein the particle size of the basalt manufactured sand is 0.35-0.5 mm; 44-60 parts steel fiber; A liquid admixture, wherein the liquid admixture comprises the following components in parts by weight: 16-18 parts water; 3-10 parts of carboxylic acid water-reducing agent; The dry powder and the liquid admixture are mixed and solidified to form the ultra-high performance concrete.

2. The ultra-high performance concrete according to claim 1, characterized in that, The dry powder material also includes pre-tensioned anchoring fibers, which apply pressure to the ultra-high performance concrete matrix within the ultra-high performance concrete.

3. The ultra-high performance concrete according to claim 2, characterized in that, The pre-tensioned anchoring fiber includes: Fiber body; The first end anchor is fixedly disposed at one end of the fiber body; The end anchor is fixedly disposed at the other end of the fiber body; Multiple tension bodies are provided, which are closely attached between the first end anchor body and the last end anchor body of the fiber body; The tensioning body compresses the first and last anchor bodies to elongate the fiber body.

4. The ultra-high performance concrete according to claim 3, characterized in that, The first anchor body is a spherical quartz, and the last anchor body is a spherical quartz.

5. The ultra-high performance concrete according to claim 3, characterized in that, The tension body is Microspheres.

6. The ultra-high performance concrete according to claim 3, characterized in that, The tensioning body includes: Quartz sphere; A hydration reaction layer is formed on the outer surface of the quartz sphere.

7. A method for manufacturing ultra-high performance concrete, characterized in that, Includes the following steps: Cement, silica fume, fly ash, microspheres, basalt manufactured sand, and steel fibers are mixed to form a dry powder. Water and carboxylic acid water-reducing agent are mixed to form a liquid admixture; The dry powder material and the liquid admixture are mixed to form the ultra-high performance concrete. in: The dry powder comprises the following components in parts by weight: 65-71 parts cement; 14-19 parts silica fume; 6-9 parts fly ash; 5-8 parts of microbeads; 115-127 parts of basalt manufactured sand, wherein the particle size of the basalt manufactured sand is 0.35-0.5 mm; 44-60 parts steel fiber; The liquid admixture comprises the following components in parts by weight: 16-18 parts water; 3-10 parts of carboxylic acid water-reducing agent.

8. The method according to claim 7, characterized in that, Also includes: Pre-tensioned anchoring fibers are added to the dry powder, and the pre-tensioned anchoring fibers apply pressure to the ultra-high performance concrete matrix within the ultra-high performance concrete.

9. The method according to claim 8, characterized in that, The pre-tensioned anchoring fiber includes: Fiber body; The first end anchor is fixedly disposed at one end of the fiber body; The end anchor is fixedly disposed at the other end of the fiber body; Multiple tension bodies are provided, which are closely attached between the first end anchor body and the last end anchor body of the fiber body; The tensioning body compresses the first and last anchor bodies to elongate the fiber body.

10. A concrete tower, characterized in that, The main body of the concrete tower is formed by the setting of ultra-high performance concrete, which is formed by mixing and setting dry powder and liquid admixtures. The dry powder comprises the following components in parts by weight: 65-71 parts cement; 14-19 parts silica fume; 6-9 parts fly ash; 5-8 parts of microbeads; 115-127 parts of basalt manufactured sand, wherein the particle size of the basalt manufactured sand is 0.35-0.5 mm; 44-60 parts steel fiber; The liquid admixture comprises the following components in parts by weight: 16-18 parts water; 3-10 parts of carboxylic acid water-reducing agent; The dry powder material also includes pre-tensioned anchoring fibers, which apply pressure to the ultra-high performance concrete matrix within the ultra-high performance concrete. The pre-tensioned anchoring fiber includes: Fiber body; The first end anchor is fixedly disposed at one end of the fiber body; The end anchor is fixedly disposed at the other end of the fiber body; Multiple tension bodies are provided, which are closely attached between the first end anchor body and the last end anchor body of the fiber body; The tensioning body compresses the first and last anchor bodies to elongate the fiber body.

Images