A new type of hydraulic self-compacting rock-filled concrete wall material and construction method

Abstract

The application provides a new type of hydraulic self-compacting rockfill concrete wall material and a construction method, and relates to a geopolymer non-dispersed self-compacting concrete for the underwater part of the wall material and a geopolymer self-compacting concrete for the overwater part of the wall material.The wall material is composed of a composite precursor of slag powder, retired wind turbine blade micro powder, fly ash and water-quenched manganese slag micro powder, and a composite alkali activator of potassium hydroxide and water glass, and is modified by sodium polyacrylate and polyacrylamide as modifiers to improve the cohesiveness of the concrete, reduce the loss of cementitious materials, use sand and gravel as aggregates, improve the crack resistance by the retired wind turbine blade fiber, shorten the final setting time of the geopolymer concrete by increasing the content of the composite alkali activator, increase the cohesive strength of the hardened concrete, and increase the cohesiveness of the mixture and the cohesive strength of the hardened concrete by the stone powder.The water-quenched manganese slag micro powder and the fly ash can generate more hydrated calcium carbonate gel to better fill the voids and improve the later strength.

Description

Technical Field

[0001] This invention relates to the field of geopolymer concrete wall materials technology, and in particular to a novel hydraulic self-compacting riprap concrete wall material and its construction method. Background Technology

[0002] Currently, the concrete wall materials industry is facing an unprecedented development crisis, mainly reflected in two key aspects. Firstly, there is a resource crisis. The main raw materials for cement production are limestone and clay, and a large amount of natural aggregate is also used in the production of concrete wall materials. However, these natural resources are not inexhaustible; with the passage of time and large-scale exploitation, their scarcity is becoming increasingly prominent. Secondly, there is an environmental crisis. The cement industry accounts for 5%-7% of global anthropogenic carbon emissions, second only to the combustion of chemical fuels. In addition, the cement production process also releases large amounts of harmful gases and dust, causing serious environmental pollution and posing a significant challenge to ecological balance. To solve these problems, the development of wall materials must follow a sustainable development path that is resource-saving, environmentally friendly, and utilizes resources comprehensively. Geopolymer concrete is undoubtedly a rapidly developing direction in this regard.

[0003] To date, concrete remains one of the most important and widely used building materials in hydraulic wall engineering, and its performance directly affects the quality and progress of hydraulic walls. Traditional hydraulic walls mostly use cast-in-place ordinary concrete or precast concrete blocks, which have the following problems: (1) Ordinary concrete wall construction requires vibration, which is complex and has low construction efficiency; (2) Large-volume concrete walls have high heat of hydration and are prone to temperature cracks; (3) Large cement consumption and high carbon emissions; (4) Traditional wall materials have insufficient freeze-thaw resistance and cannot meet the durability requirements of hydraulic walls in cold regions. Cement-based composite materials usually use flocculants and other additives to increase the cohesion between concrete particles to improve the anti-dispersion properties. However, due to the special nature of hydraulic wall engineering, especially in the construction of hydraulic walls in cold regions, it is necessary to consider the self-compacting properties of the concrete mixture, the anti-dispersion properties, the early strength, freeze-thaw resistance, and other factors, which makes the construction process too complicated and difficult to effectively control the quality and progress of hydraulic walls. Summary of the Invention

[0004] To address the problems existing in the prior art, this invention provides a novel self-compacting riprap concrete wall material and construction method. By using geopolymer concrete technology, geopolymers replace traditional silicate cement, while fully utilizing emerging solid waste (retired wind turbine blades, water-quenched manganese slag, etc.). Polymer modifiers are used to modify the materials, significantly improving the cohesiveness of the geopolymer concrete and reducing the loss of cementitious materials. This results in geopolymer concrete with underwater non-dispersible self-compacting ability, as well as early strength and excellent freeze-thaw resistance. Because it replaces traditional silicate cement, it effectively reduces production energy consumption and carbon emissions. Simultaneously, it consumes a large amount of solid waste, solving problems such as waste disposal and environmental degradation. It is a novel green wall material. The resulting riprap concrete wall structure utilizes large stones, saving concrete usage, reducing heat of hydration and shrinkage, simplifying the construction process, accelerating construction progress, and shortening the construction period. This achieves a dual improvement in environmental and economic benefits. The technical solution is as follows: On one hand, the present invention provides a novel hydraulic self-compacting riprap concrete wall material, the wall material comprising an underwater portion and an above-water portion, wherein the underwater portion is a geopolymer non-dispersible self-compacting concrete, and the geopolymer non-dispersible self-compacting concrete raw material comprises the following components by weight: Slag powder 380-420 parts, decommissioned wind turbine blade powder 60-80 parts, fly ash 40-50 parts, water-quenched manganese slag powder 30-40 parts, potassium hydroxide 10-12 parts, water glass solution 70-90 parts, sodium polyacrylate 8-10 parts, polyacrylamide 1-2 parts, decommissioned wind turbine blade fiber 1-2 parts, manufactured sand 620-650 parts, stone powder 80-90 parts, crushed stone 690-730 parts, water 180-200 parts, potassium hydroxide 10-12 parts, water glass solution 70-90 parts; The above-water portion is made of geopolymer self-compacting concrete. The raw materials for geopolymer self-compacting concrete include the following components by weight: 360-380 parts slag powder, 50-60 parts decommissioned wind turbine blade powder, 30-40 parts fly ash, 20-30 parts water-quenched manganese slag powder, 6-10 parts potassium hydroxide, 66-72 parts water glass solution, 1-2 parts decommissioned wind turbine blade fiber, 680-700 parts manufactured sand, 96-102 parts stone powder, 740-780 parts crushed stone, 180-200 parts water, 6-10 parts potassium hydroxide, and 66-72 parts water glass solution.

[0005] Preferably, the slag powder is of grade S95 and has a specific surface area of ​​400 m² / kg or more.

[0006] Preferably, the decommissioned wind turbine blade powder is produced by grinding and screening decommissioned wind turbine blades, with a fineness of 200 mesh.

[0007] Preferably, the diameter of the single fiber filament of the decommissioned wind turbine blade is 5μm and the length is 3-5mm.

[0008] Preferably, the fly ash is Grade I or Grade II.

[0009] Preferably, the fineness of the water-quenched manganese slag powder is 200 mesh.

[0010] Preferably, the modulus of the water glass solution is 1.5-3.5.

[0011] Of the remaining raw materials, potassium hydroxide is industrial-grade flakes with a purity greater than 98% (mass fraction); sodium polyacrylate is industrial-grade white powder with a molecular weight of 8 million; polyacrylamide is anionic type 1200; the sand is manufactured sand with a fineness modulus of 2.4-2.8; the crushed stone has a particle size of 5-10 mm; and the stone powder has a particle size of less than 0.16 mm.

[0012] On the other hand, the present invention provides a construction method for a novel self-compacting riprap concrete wall material for hydraulic engineering. Using the aforementioned novel self-compacting riprap concrete wall material, the construction method is divided into two parts: underwater pouring of non-dispersible self-compacting concrete and above-water pouring of self-compacting concrete. Specifically, it includes the following steps: Step 1: Underwater excavation and trenching. After excavation, the water level in the trench should be controlled to not exceed 500mm, and the water flow velocity should not exceed 0.5m / s. Step 2, slab construction of the storage area. The storage area uses natural barriers and does not require templates. After excavation and shaping, the slabs are manually laid out. Step 3: Preparation of underwater partial geopolymer non-dispersible self-compacting concrete premix: Put 380-420 parts of slag powder, 60-80 parts of decommissioned wind turbine blade powder, 40-50 parts of fly ash, 30-40 parts of water-quenched manganese slag powder, 8-10 parts of sodium polyacrylate, 1-2 parts of polyacrylamide, 1-2 parts of decommissioned wind turbine blade fiber, 620-650 parts of manufactured sand, 80-90 parts of stone powder, 690-730 parts of crushed stone, and 180-200 parts of water into a mixer and mix using forced mixing for more than 3 minutes. Step 4: Alkali activation of non-dispersible self-compacting concrete at the pouring site. After transporting the premixed material obtained in Step 3 to the pouring site, dissolve 10-12 parts of potassium hydroxide in 70-90 parts of water glass solution. After fully dissolving, add it to the mixer and stir with forced stirring for more than 3 minutes. Step 5: Underwater part of the non-dispersible self-compacting concrete of the geopolymer is poured. The pouring method is underwater self-flowing grouting. At each pouring point, the geopolymer self-compacting concrete must be filled before it can be moved to the adjacent pouring point. Secondary pouring is not allowed. The pouring sequence should be unidirectional and the pouring should not be repeated on the surface. Step 6: Preparation of premixed self-compacting concrete for the above-water portion: 360-380 parts slag powder, 50-60 parts decommissioned wind turbine blade powder, 30-40 parts fly ash, 20-30 parts water-quenched manganese slag powder, 1-2 parts decommissioned wind turbine blade fiber, 680-700 parts manufactured sand, 96-102 parts stone powder, 740-780 parts crushed stone, and 180-200 parts water are added to a mixer and forced mixing is carried out for more than 3 minutes.

[0013] Step 7: Alkali activation of self-compacting concrete at the pouring site. After transporting the premixed material obtained in Step 6 to the pouring site, dissolve 6-10 parts of potassium hydroxide in 66-72 parts of water glass solution. After fully dissolving, add it to the mixer and stir with forced stirring for more than 3 minutes. Step 8: Pouring the above-water portion of the self-compacting concrete with aggregate. First, roughen the top surface of the underwater portion of the non-dispersible self-compacting concrete with aggregate. Then, start building a formwork along the top surface of the underwater portion of the non-dispersible self-compacting concrete with aggregate. Send the rubble into the roughened underwater concrete top surface and pour it according to the pouring method in Step 5 until it reaches the top edge of the formwork. Smooth the concrete surface and polish it before initial setting. Step 9: Curing of the geopolymer concrete. The underwater part is allowed to cure naturally while the above-water part is left unformed for 6 hours after pouring and then water curing can begin. Preferably, in step 4, the construction control parameters are as follows: the slump expansion of the mixture is controlled at 550-650mm, the expansion time T500 is controlled at 10-20s, the hopper emptying time is controlled at 12-25s, and the loss of cementitious materials is less than 1.5%.

[0014] Preferably, in step 6, the construction control parameters are: the slump expansion of the mixture is controlled at 600-750mm, the expansion time T500 is controlled at 5-15s, and the hopper emptying time is controlled at 5-18s.

[0015] The beneficial effects of the technical solutions provided in the embodiments of the present invention include at least the following: This invention utilizes a composite precursor composed of slag powder, decommissioned wind turbine blade powder, fly ash, and water-quenched manganese slag powder. A composite alkali activator is formed using potassium hydroxide and water glass. Modification with sodium polyacrylate and polyacrylamide improves concrete adhesion and reduces cementitious material loss. Sand and stone powder are used as aggregates, and decommissioned wind turbine blade fibers enhance crack resistance. Increasing the dosage of the composite alkali activator shortens the final setting time of the polymer concrete and increases its hardened bond strength. Stone powder also increases the cohesiveness of the mixture and the hardened bond strength. The combination of water-quenched manganese slag powder and fly ash generates more hydrated calcium carbonate gel, which better fills voids and improves later-stage strength.

[0016] Underwater non-dispersible self-compacting concrete is used for underwater riprap grouting, bonding the underwater non-dispersible self-compacting concrete with the riprap to form a new type of riprap concrete structural wall. In addition to being used for hydraulic engineering walls, it can also be used for the reinforcement of the underwater parts of various water conservancy projects. This new structure makes extensive use of large stones, saves on concrete usage, reduces heat of hydration, and minimizes shrinkage. The technical solution provided by this invention simplifies the construction process, eliminates the traditional vibration step, and removes the need for cooling water pipe laying, roughening, and other procedures, thus accelerating the construction progress and shortening the construction period, achieving a dual improvement in environmental protection and economic benefits. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying 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.

[0018] Figure 1 A flowchart illustrating a construction method for a novel self-compacting rockfill concrete wall material for hydraulic engineering, provided by the present invention, is shown.

[0019] Figure 2 The water-to-land strength ratio of geopolymer-non-dispersible self-compacting concrete according to Embodiments 1-3 of the present invention is shown. Detailed Implementation

[0020] The technical solution of the present invention will now be described with reference to the accompanying drawings.

[0021] In embodiments of the present invention, words such as "exemplarily," "for example," etc., are used to indicate that something is an example, illustration, or description. Any embodiment or design described as "exemplary" in the present invention should not be construed as being more preferred or advantageous than other embodiments or designs. Specifically, the use of the word "exemplary" is intended to present the concept in a concrete manner. Furthermore, in embodiments of the present invention, the meaning expressed by "and / or" can be both, or either one.

[0022] In the embodiments of this invention, the terms "image" and "picture" may sometimes be used interchangeably. It should be noted that, without emphasizing the distinction between them, they convey the same meaning. Similarly, the terms "of," "corresponding (relevant)," and "corresponding" may sometimes be used interchangeably. It should be noted that, without emphasizing the distinction between them, they convey the same meaning.

[0023] In this embodiment of the invention, sometimes a subscript such as W1 may be written in a non-subscript form such as W1. When the difference is not emphasized, the meaning they express is the same.

[0024] To make the technical problems, technical solutions and advantages of the present invention clearer, a detailed description will be given below in conjunction with the accompanying drawings and specific embodiments. Example 1

[0025] This invention provides a novel self-compacting riprap concrete wall material for hydraulic engineering. The wall material includes an underwater part and an above-water part. The underwater part is a geopolymer non-dispersible self-compacting concrete. The raw materials of the geopolymer non-dispersible self-compacting concrete include the following components by weight: 380 parts slag powder, 60 parts decommissioned wind turbine blade powder, 40 parts fly ash, 30 parts water-quenched manganese slag powder, 8 parts sodium polyacrylate, 1 part polyacrylamide, 1 part decommissioned wind turbine blade fiber, 650 parts manufactured sand, 90 parts stone powder, 730 parts crushed stone, 180 parts water, 10 parts potassium hydroxide, and 70 parts water glass solution.

[0026] The above-water portion is made of geopolymer self-compacting concrete. The raw materials for geopolymer self-compacting concrete include the following components by weight: 370 parts slag powder, 55 parts decommissioned wind turbine blade powder, 35 parts fly ash, 25 parts water-quenched manganese slag powder, 8 parts potassium hydroxide, 69 parts water glass solution, 1.5 parts decommissioned wind turbine blade fiber, 690 parts manufactured sand, 99 parts stone powder, 760 parts crushed stone, and 190 parts water.

[0027] Of the above raw materials: The slag powder is grade S95 with a specific surface area of ​​over 400 m² / kg.

[0028] The decommissioned wind turbine blade powder is produced by grinding and screening decommissioned wind turbine blades, with a fineness of 200 mesh.

[0029] The fly ash is either Grade I or Grade II.

[0030] The fineness of the water-quenched manganese slag powder is 200 mesh.

[0031] The potassium hydroxide is industrial grade in flake form with a purity greater than 98% (mass fraction).

[0032] The modulus of the water glass solution is any value between 1.5 and 3.5.

[0033] The diameter of the single filament of the retired wind turbine blade is 5μm, and the length is any value between 3-5mm.

[0034] The polyvinyl alcohol is a dry powder mixture with a fineness of 160 mesh.

[0035] The polyacrylamide is anionic type 1200.

[0036] The sand is manufactured sand with a fineness modulus of any value between 2.4 and 2.8.

[0037] The particle size of the crushed stone is any value between 5 and 10 mm.

[0038] The stone powder is powder with a particle size of less than 0.16 mm.

[0039] This invention also provides a construction method for the above-mentioned novel self-compacting riprap concrete wall material for hydraulic engineering. Step 1: Underwater excavation and trenching. The foundation of the project to be reinforced is excavated using an excavator. After excavation, when the water depth in the trench exceeds 500mm, water is pumped out to control the water level to not exceed 500mm and ensure that the water flow velocity does not exceed 0.5m / s. If the flow velocity exceeds this, diversion measures can be taken upstream of the river.

[0040] Step 2, Construction of the storage surface boulders. The storage surface is naturally isolated and does not require formwork. After excavation and shaping, the boulders are laid manually. Before large boulders are put into the storage, they must be transported separately and laid out in a dispersed manner, and must not be laid in a concentrated manner. The boulders should be placed in the storage with larger ones at the bottom and smaller ones at the top, and larger ones in the middle and smaller ones at the outside. Unqualified materials in the storage should be cleaned up. Concrete pouring can only be carried out after inspection and acceptance. Step 3: Preparation of underwater geopolymer non-dispersible self-compacting concrete premix. Weigh the following materials in the above proportions: slag powder, decommissioned wind turbine blade powder, fly ash, water-quenched manganese slag powder, sodium polyacrylate, polyacrylamide, decommissioned wind turbine blade fiber, manufactured sand, stone powder, crushed stone, and water, and put them into a mixer. Use forced mixing for more than 3 minutes. Step 4: Alkali activation of non-dispersible self-compacting concrete at the pouring site. After transporting the premixed material obtained in Step 3 to the pouring site, dissolve 10 parts of potassium hydroxide in 70 parts of water glass solution. After fully dissolving, add it to the mixer and use forced mixing for more than 3 minutes. In step 4, the construction control parameters are as follows: the slump expansion of the mixture is controlled at 550-650mm, the expansion time T500 is controlled at 10-20s, the hopper emptying time is controlled at 12-25s, and the loss of cementitious materials is less than 1.5%.

[0041] Step 5: Underwater concrete pouring. The pouring method employs underwater self-compacting grouting, using a pump to deliver the concrete. Flexible hoses are used for placement, with a spacing of no more than 500mm between placement points. Each pouring point must be completely filled with self-compacting concrete before moving to the next point; secondary pouring is prohibited. Pouring points should be continuously arranged to ensure the compactness of the concrete within the stones. The pouring sequence should be unidirectional; repetitive pouring on the surface is not allowed. After placement, a steel rod can be inserted along the gaps between the stones to clear blockages, accelerating the self-flow of concrete and ensuring the gaps are fully filled. Finally, the concrete on top of the stones is leveled.

[0042] Step 6: Preparation of premixed geopolymer self-compacting concrete for the above-water portion. Weigh the raw materials of the premixed geopolymer self-compacting concrete according to the above proportions and put them into the mixer. Use forced mixing for more than 3 minutes.

[0043] Step 7: Alkali activation of self-compacting concrete at the pouring site. After transporting the premixed material obtained in Step 6 to the pouring site, dissolve 6-10 parts of potassium hydroxide in 66-72 parts of water glass solution. After fully dissolving, add it to the mixer and stir with forced stirring for more than 3 minutes. In step 7, the construction control parameters are as follows: the slump expansion of the mixture is controlled at 600-750mm, the expansion time T500 is controlled at 5-15s, and the hopper emptying time is controlled at 5-18s.

[0044] Step 8: First, roughen the top surface of the underwater concrete and start building the formwork along the top surface of the underwater concrete. Send the rubble into the roughened compartment and place it on the top surface of the underwater concrete. The rubble placement process is the same as in Step 2. Place the rubble to 10mm from the top edge of the formwork. Each layer should not exceed 650mm. Follow the pouring method in Step 5. The spacing between the placement points should not be greater than 700mm until the concrete reaches the top edge of the formwork. Smooth the concrete surface and polish it before initial setting. Step 9: Curing of the geopolymer concrete. The underwater part is allowed to cure naturally while remaining still. The above-water part can be demolded 6 hours after pouring and water curing can begin. Example 2

[0045] Unlike Example 1, in this example, the geopolymer non-dispersible self-compacting concrete raw material includes the following components by weight: 400 parts slag powder, 70 parts decommissioned wind turbine blade powder, 45 parts fly ash, 35 parts water-quenched manganese slag powder, 9 parts sodium polyacrylate, 1 part polyacrylamide, 1 part decommissioned wind turbine blade fiber, 635 parts manufactured sand, 85 parts stone powder, 710 parts crushed stone, 190 parts water, 11 parts potassium hydroxide, and 80 parts water glass solution.

[0046] The raw material composition and proportion of the geopolymer self-compacting concrete are the same as in Example 1.

[0047] The parameters and grades of each raw material are the same as in Example 1.

[0048] The construction method and steps of the above-mentioned hydraulic self-compacting riprap concrete new wall material are the same as those in Example 1. The difference is that in step 3, the underwater part of the preparation of the polymer non-dispersible self-compacting concrete premix involves weighing the slag powder, decommissioned wind turbine blade powder, fly ash, water-quenched manganese slag powder, sodium polyacrylate, polyacrylamide, decommissioned wind turbine blade fiber, manufactured sand, stone powder, crushed stone, and water in the raw materials of the polymer non-dispersible self-compacting concrete according to the proportions provided in this example, and then putting them into a mixer and using forced mixing for more than 3 minutes.

[0049] In step 4, the premixed material obtained in step 3 is transported to the pouring site and then 11 parts of potassium hydroxide are dissolved in 80 parts of water glass solution. After the solution is fully dissolved, it is added to the mixer and stirred for more than 3 minutes using forced stirring. Example 3

[0050] Unlike Example 1, in this example, the geopolymer non-dispersible self-compacting concrete raw material includes the following components by weight: 420 parts slag powder, 80 parts decommissioned wind turbine blade powder, 50 parts fly ash, 40 parts water-quenched manganese slag powder, 10 parts sodium polyacrylate, 2 parts polyacrylamide, 2 parts decommissioned wind turbine blade fiber, 620 parts manufactured sand, 80 parts stone powder, 690 parts crushed stone, 200 parts water, 12 parts potassium hydroxide, and 90 parts water glass solution.

[0051] The raw material composition and proportion of the geopolymer self-compacting concrete are the same as in Example 1.

[0052] The parameters and grades of each raw material are the same as in Example 1.

[0053] The construction method and steps of the above-mentioned hydraulic self-compacting riprap concrete new wall material are the same as those in Example 1. The difference is that in step 3, the underwater part of the preparation of the polymer non-dispersible self-compacting concrete premix involves weighing the slag powder, decommissioned wind turbine blade powder, fly ash, water-quenched manganese slag powder, sodium polyacrylate, polyacrylamide, decommissioned wind turbine blade fiber, manufactured sand, stone powder, crushed stone, and water in the raw materials of the polymer non-dispersible self-compacting concrete according to the proportions provided in this example, and then putting them into a mixer and using forced mixing for more than 3 minutes.

[0054] In step 4, the premixed material obtained in step 3 is transported to the pouring site to activate the self-compacting concrete with non-dispersible polymer. After the premixed material is transported to the pouring site, 12 parts of potassium hydroxide are dissolved in 90 parts of water glass solution. After the solution is fully dissolved, it is added to the mixer and forced to mix for more than 3 minutes. Example 4

[0055] Unlike Example 1, in this example, the geopolymer self-compacting concrete raw material includes the following components by weight: 360 parts slag powder, 50 parts decommissioned wind turbine blade powder, 30 parts fly ash, 20 parts water-quenched manganese slag powder, 1 part decommissioned wind turbine blade fiber, 700 parts manufactured sand, 102 parts stone powder, 780 parts crushed stone, 180 parts water, 6 parts potassium hydroxide, and 66 parts water glass solution.

[0056] The parameters and grades of each raw material are the same as in Example 1.

[0057] The construction method and steps of the above-mentioned hydraulic self-compacting riprap concrete new wall material are the same as those in Example 1. The difference is that in step 6, the preparation of the premixed aggregate self-compacting concrete for the above-water part involves weighing the slag powder, decommissioned wind turbine blade powder, fly ash, water-quenched manganese slag powder, decommissioned wind turbine blade fiber, manufactured sand, stone powder, crushed stone and water in the aggregate self-compacting concrete raw materials according to the proportions provided in this example, and then putting them into a mixer and using forced mixing for more than 3 minutes.

[0058] In step 7, the premixed material obtained in step 3 is transported to the pouring site and then 6 parts of potassium hydroxide are dissolved in 66 parts of water glass solution. After the solution is fully dissolved, it is added to the mixer and stirred for more than 3 minutes using forced stirring. Example 5

[0059] Unlike Example 1, in this example, the geopolymer self-compacting concrete raw material includes the following components by weight: 370 parts slag powder, 55 parts decommissioned wind turbine blade powder, 35 parts fly ash, 25 parts water-quenched manganese slag powder, 1 part decommissioned wind turbine blade fiber, 690 parts manufactured sand, 99 parts stone powder, 760 parts crushed stone, 190 parts water, 8 parts potassium hydroxide, and 69 parts water glass solution.

[0060] The parameters and grades of each raw material are the same as in Example 1.

[0061] The construction method and steps of the above-mentioned hydraulic self-compacting riprap concrete new wall material are the same as those in Example 1. The difference is that in step 6, the preparation of the premixed aggregate self-compacting concrete for the above-water part involves weighing the slag powder, decommissioned wind turbine blade powder, fly ash, water-quenched manganese slag powder, decommissioned wind turbine blade fiber, manufactured sand, stone powder, crushed stone and water in the aggregate self-compacting concrete raw materials according to the proportions provided in this example, and then putting them into a mixer and using forced mixing for more than 3 minutes.

[0062] In step 7, the premixed material obtained in step 3 is transported to the pouring site and then 8 parts of potassium hydroxide are dissolved in 69 parts of water glass solution. After the solution is fully dissolved, it is added to the mixer and stirred for more than 3 minutes using forced stirring. Example 6

[0063] Unlike Example 1, in this example, the geopolymer self-compacting concrete raw material includes the following components by weight: 380 parts slag powder, 60 parts decommissioned wind turbine blade powder, 40 parts fly ash, 30 parts water-quenched manganese slag powder, 2 parts decommissioned wind turbine blade fiber, 680 parts manufactured sand, 96 parts stone powder, 740 parts crushed stone, 200 parts water, 10 parts potassium hydroxide, and 72 parts water glass solution.

[0064] The parameters and grades of each raw material are the same as in Example 1.

[0065] The construction method and steps of the above-mentioned hydraulic self-compacting riprap concrete new wall material are the same as those in Example 1. The difference is that in step 6, the preparation of the premixed aggregate self-compacting concrete for the above-water part involves weighing the slag powder, decommissioned wind turbine blade powder, fly ash, water-quenched manganese slag powder, decommissioned wind turbine blade fiber, manufactured sand, stone powder, crushed stone and water in the aggregate self-compacting concrete raw materials according to the proportions provided in this example, and then putting them into a mixer and using forced mixing for more than 3 minutes.

[0066] In step 7, the premixed material obtained in step 3 is transported to the pouring site and then 10 parts of potassium hydroxide are dissolved in 72 parts of water glass solution. After the solution is fully dissolved, it is added to the mixer and stirred for more than 3 minutes using forced stirring.

[0067] Performance testing: Underwater portion: Geopolymer non-dispersible self-compacting concrete raw materials were placed into a mixer according to the proportions of Example 1, Example 2 and Example 3, and forced mixing was carried out for more than 3 minutes to obtain premixed materials.

[0068] The above premixed material was alkali activated according to the method in step 4. The potassium hydroxide and water glass solution were mixed with the premixed powder in the proportions specified in step 4 of Examples 1, 2 and 3, respectively. After being fully dissolved, the mixture was added to a mixer and stirred for at least 3 minutes using forced stirring.

[0069] Alkali activation process control parameters: slump expansion of the mixture is controlled at 550-650mm, expansion time T500 is controlled at 10-20s, hopper emptying time is controlled at 12-25s, and cementitious material loss is less than 1.5%.

[0070] Place the compressive strength test molds into a water tank (450mm high, with dimensions sufficient to accommodate the required number of molds). Fill the tank with water to 150mm from the top. After adding the material, the water level should rise no more than 50mm. Use a shovel to drop the underwater portion of the self-compacting, non-dispersible concrete mixture into the molds. Each addition should be approximately 1 / 10 of the mold's volume. Adding should be continuous, with the amount exceeding the mold's surface. Each addition should take approximately 0.5-1 minute. Allow the concrete to self-level and self-compact until it reaches a stable state. Remove the molds from the water and let them stand for 5-10 minutes. Gently tap the two sides of the molds with a wooden mallet to promote drainage. Smooth any excess concrete with a trowel before initial setting. Then place the molds in a standard curing room. Demold after one day and place in a 20℃ curing room. +Continue curing in water at 3°C ​​for 6 and 27 days, and then conduct compressive strength tests for 7 and 28 days.

[0071] The underwater self-compacting non-dispersible concrete mix is ​​formed directly in the air and then placed in a standard curing room for 28 days after being formed according to the compressive strength of ordinary concrete.

[0072] The test for loss of cementitious materials shall be conducted in accordance with the anti-dispersion test of DL / T5117-2021.

[0073] Above-water portion: Geopolymer self-compacting concrete raw materials were placed into a mixer according to the proportions of Examples 4, 5 and 6, and forced mixing was carried out for more than 3 minutes to obtain premixed materials.

[0074] The premixed material was alkali-activated according to step 7. The potassium hydroxide and water glass solution were mixed with the premixed powder in the proportions specified in step 7 of Examples 4, 5, and 6, respectively. After being fully dissolved, the mixture was added to a mixer and stirred for at least 3 minutes using forced stirring.

[0075] Alkali-activated construction control parameters: slump expansion of the mixture is controlled at 600-750mm, expansion time T500 is controlled at 5-15s, and hopper emptying time is controlled at 5-18s.

[0076] The self-compacting concrete mixture was molded to the compressive strength of ordinary concrete and then placed in a standard curing room for 28 days.

[0077] The test results for each embodiment are shown in Table 1 and Figure 2 .

[0078]

[0079] Table 1 shows the test results. Regarding the workability of the underwater geopolymer self-compacting concrete, the slump spread of Examples 1-3 was 600 mm-640 mm, and the spread time was 15 s-18 s, indicating that the mixture not only had good fluidity but also good anti-segregation properties. The V-funnel emptying time was 17 s-20 s, all not exceeding 20 s, indicating good gap permeability. The underwater cementitious material loss was 0.9%-1.4%, all not exceeding 1.5%, indicating good underwater anti-dispersion properties. After alkali activation at the pouring site, the setting time was 20 min-25 min, meeting the requirements for underwater rockfill grouting construction. The 28-day compressive strength in water was 48.2 MPa-55.2 MPa, fully meeting the needs of underwater engineering. The 7-day compressive strength in water was 38.6 MPa-43.6 MPa, showing good early strength, suitable for emergency repairs and flood control in water conservancy projects.

[0080] Figure 2 The graph shows the water-to-land strength ratio of geopolymer-non-dispersible self-compacting concrete in Examples 1-3. Figure 2 The results show that the underwater geopolymer self-compacting concrete has a water-to-land strength ratio of 91.3%-93.2%, all of which are not less than 70%, indicating that the underwater geopolymer self-compacting concrete has good mechanical properties.

[0081] Regarding the workability of the self-compacting concrete with polymers in the aquatic region, the slump spread of Examples 4-6 was 680 mm-730 mm, with a spread time of 7-12 seconds, indicating excellent fluidity and anti-segregation properties of the mixture. The V-funnel emptying time was 8-14 seconds, none exceeding 20 seconds, indicating good gap permeability. After alkali activation at the pouring site, the setting time was 25-30 minutes, meeting the requirements for aquatic rockfill grouting construction. The 28-day compressive strength was 49.3 MPa-52.1 MPa, fully meeting the needs of underwater engineering, and the 7-day compressive strength in water was 42.6 MPa-47.4 MPa, showing good early strength, suitable for emergency repairs and flood control in water conservancy projects.

[0082] Examples 1-6 demonstrate that the solution provided by this invention can impart excellent scalability, filling properties, and gap-passing ability to the mixture. It can significantly reduce the porosity of riprap concrete and effectively increase its overall density. Notably, in all six examples, the efflorescence phenomenon commonly seen in geopolymer concrete did not occur.

[0083] This invention effectively improves the adhesion of underwater self-compacting concrete and reduces the loss of cementitious materials, thereby significantly enhancing the anti-dispersion properties of underwater geopolymer self-compacting concrete. Simultaneously, the addition of decommissioned wind turbine blade fibers further improves the crack resistance of the concrete; the use of a composite alkali activator shortens the final setting time of the geopolymer concrete, and significantly improves its early strength, particularly that of underwater geopolymer concrete. This characteristic provides strong technical support for flood control and emergency repair work in water conservancy projects, and also provides a solid guarantee for the safe operation of water conservancy projects in cold regions.

[0084] Furthermore, this solution makes full use of emerging solid waste, successfully replacing traditional silicate cement. This initiative not only effectively reduces energy consumption during the production process but also significantly reduces carbon emissions. It can be said that this is a highly innovative new type of green concrete material with extremely broad application prospects in the future.

[0085] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A novel self-compacting riprap concrete wall material for hydraulic engineering, characterized in that, The wall material includes an underwater portion and an above-water portion. The underwater portion is geopolymer non-dispersible self-compacting concrete, and the raw materials for geopolymer non-dispersible self-compacting concrete include the following components by weight: Slag powder 380-420 parts, decommissioned wind turbine blade powder 60-80 parts, fly ash 40-50 parts, water-quenched manganese slag powder 30-40 parts, potassium hydroxide 10-12 parts, water glass solution 70-90 parts, sodium polyacrylate 8-10 parts, polyacrylamide 1-2 parts, decommissioned wind turbine blade fiber 1-2 parts, manufactured sand 620-650 parts, stone powder 80-90 parts, crushed stone 690-730 parts, water 180-200 parts, potassium hydroxide 10-12 parts, water glass solution 70-90 parts; The above-water portion is made of geopolymer self-compacting concrete. The raw materials for geopolymer self-compacting concrete include the following components by weight: 360-380 parts slag powder, 50-60 parts decommissioned wind turbine blade powder, 30-40 parts fly ash, 20-30 parts water-quenched manganese slag powder, 6-10 parts potassium hydroxide, 66-72 parts water glass solution, 1-2 parts decommissioned wind turbine blade fiber, 680-700 parts manufactured sand, 96-102 parts stone powder, 740-780 parts crushed stone, 180-200 parts water, 6-10 parts potassium hydroxide, and 66-72 parts water glass solution.

2. The novel self-compacting riprap concrete wall material for hydraulic engineering according to claim 1, characterized in that, The slag powder is grade S95 with a specific surface area of ​​over 400 m² / kg.

3. The novel self-compacting riprap concrete wall material for hydraulic engineering according to claim 1, characterized in that, The decommissioned wind turbine blade powder is produced by grinding and screening decommissioned wind turbine blades, with a fineness of 200 mesh.

4. The novel self-compacting riprap concrete wall material for hydraulic engineering according to claim 1, characterized in that, The retired wind turbine blades have fiber monofilaments with a diameter of 5μm and a length of 3-5mm.

5. A novel self-compacting riprap concrete wall material for hydraulic engineering according to claim 1, characterized in that, The fly ash is either Grade I or Grade II.

6. The novel self-compacting riprap concrete wall material for hydraulic engineering according to claim 1, characterized in that, The fineness of the water-quenched manganese slag powder is 200 mesh.

7. A novel self-compacting riprap concrete wall material for hydraulic engineering according to claim 1, characterized in that, The modulus of the water glass solution is 1.5-3.

5.

8. A construction method for a novel self-compacting riprap concrete wall material for hydraulic engineering, using the novel self-compacting riprap concrete wall material as described in any one of claims 1-7, characterized in that, The construction method consists of two parts: underwater pouring of non-dispersible self-compacting concrete and above-water pouring of self-compacting concrete. Specifically, it includes the following steps: Step 1: Underwater excavation and trenching. After excavation, the water level in the trench should be controlled to not exceed 500mm, and the water flow velocity should not exceed 0.5m / s. Step 2, slab construction of the storage area. The storage area uses natural barriers and does not require templates. After excavation and shaping, the slabs are manually laid out. Step 3: Preparation of underwater partial geopolymer non-dispersible self-compacting concrete premix: Put 380-420 parts of slag powder, 60-80 parts of decommissioned wind turbine blade powder, 40-50 parts of fly ash, 30-40 parts of water-quenched manganese slag powder, 8-10 parts of sodium polyacrylate, 1-2 parts of polyacrylamide, 1-2 parts of decommissioned wind turbine blade fiber, 620-650 parts of manufactured sand, 80-90 parts of stone powder, 690-730 parts of crushed stone, and 180-200 parts of water into a mixer and mix using forced mixing for more than 3 minutes. Step 4: Alkali activation of non-dispersible self-compacting concrete at the pouring site. After transporting the premixed material obtained in Step 3 to the pouring site, dissolve 10-12 parts of potassium hydroxide in 70-90 parts of water glass solution. After fully dissolving, add it to the mixer and stir with forced stirring for more than 3 minutes. Step 5: Underwater part of the non-dispersible self-compacting concrete of the geopolymer is poured. The pouring method is underwater self-flowing grouting. At each pouring point, the geopolymer self-compacting concrete must be filled before it can be moved to the adjacent pouring point. Secondary pouring is not allowed. The pouring sequence should be unidirectional and the pouring should not be repeated on the surface. Step 6: Preparation of premixed self-compacting concrete for the above-water portion: 360-380 parts slag powder, 50-60 parts decommissioned wind turbine blade powder, 30-40 parts fly ash, 20-30 parts water-quenched manganese slag powder, 1-2 parts decommissioned wind turbine blade fiber, 680-700 parts manufactured sand, 96-102 parts stone powder, 740-780 parts crushed stone, and 180-200 parts water are added to a mixer and forced to mix for at least 3 minutes. Step 7: Alkali activation of self-compacting concrete at the pouring site. After transporting the premixed material obtained in Step 6 to the pouring site, dissolve 6-10 parts of potassium hydroxide in 66-72 parts of water glass solution. After fully dissolving, add it to the mixer and stir with forced stirring for more than 3 minutes. Step 8: Pouring the above-water portion of the self-compacting concrete with aggregate. First, roughen the top surface of the underwater portion of the non-dispersible self-compacting concrete with aggregate. Then, start building a formwork along the top surface of the underwater portion of the non-dispersible self-compacting concrete with aggregate. Send the rubble into the roughened underwater concrete top surface and pour it according to the pouring method in Step 5 until it reaches the top edge of the formwork. Smooth the concrete surface and polish it before initial setting. Step 9: Curing of the geopolymer concrete. The underwater part is allowed to cure naturally while remaining still. The above-water part can be demolded 6 hours after pouring and water curing can begin.

9. The construction method of a novel self-compacting riprap concrete wall material for hydraulic engineering according to claim 8, characterized in that, In step 4, the construction control parameters are as follows: the slump of the mixture is controlled at 550-650mm, and the expansion time T... 500 The time should be controlled within 10-20 seconds, the hopper emptying time should be controlled within 12-25 seconds, and the loss of cementitious material should be less than 1.5%.

10. The construction method of a novel self-compacting riprap concrete wall material for hydraulic engineering according to claim 8, characterized in that, In step 6, the construction control parameters are as follows: the slump of the mixture is controlled at 600-750mm, and the expansion time T... 500 Control the time to 5-15 seconds, and control the time to empty the funnel to 5-18 seconds.

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