Method for jump pouring of a wear-resistant floor without cutting joints

Abstract

The application discloses a kind of wear-resistant floor skip pouring methods of free cutting joint, including S1, the construction area is divided into interval arrangement first pouring bin and post-pouring bin;S2, first pouring bin formwork is supported and is poured, and the inside face of formwork has tenon, so that first pouring bin side wall is shaped and is provided with set interface shape;S3, first pouring bin concrete initial condensation after laying wear-resistant aggregate;S4, first pouring bin reaches preset strength after formwork is dismantled;S5, stress buffer layer is set in first pouring bin side wall, and its top is installed extractable type stop formwork;S6, pours post-pouring bin concrete, so that it is closely attached stress buffer layer and stop formwork;S7, post-pouring bin concrete initial condensation after laying wear-resistant aggregate;S8, post-pouring bin reaches preset strength after stop formwork is extracted, and forms reserved joint groove;S9, to joint groove fills sealing material.The method is free cutting joint protection carborundum surface layer;First pouring bin groove and post-pouring bin form mechanical engagement;Stress buffer layer and surface sealant joint constitute double stress release system, and layered digestion shrinkage displacement, and floor quality and life are significantly improved.

Description

Technical Field

[0001] This invention relates to the field of building floor construction technology, specifically to a method for pouring wear-resistant flooring without cutting joints. Background Technology

[0002] Large-area corundum wear-resistant concrete floors have stringent requirements for integrity, crack resistance, and interlayer bond strength due to their large loads and high usage frequency; they have long faced the challenge of crack control and joint treatment.

[0003] Traditional construction methods employ a process of integral pouring followed by mechanical cutting. This cutting directly damages the surface layer of abrasive aggregate, leading to defects such as chipping, water seepage, and sandblasting at the cut locations. Furthermore, through-cracks cannot be completely avoided. To reduce the risk of cracking, sequential pouring in sections is widely adopted. However, the interface between the first and subsequent pours is flat, with the new and old concrete only bonded by an interface agent. This results in weak mechanical bonding, making long-term use prone to delamination, hollowing, and cracking along the joints. Existing skip-pour pouring techniques only optimize the pouring sequence but do not structurally strengthen the interface between sections, resulting in low interface strength and failing to address the root causes of section cracking defects.

[0004] Therefore, to solve the above problems, a no-cutting method for pouring wear-resistant flooring in skip-pour sections is needed. This method can strengthen the bonding between sections while eliminating the need for cutting joints, thereby reducing the occurrence of flooring cracks, delamination, and hollow areas from the root. Summary of the Invention

[0005] In view of this, the purpose of the present invention is to overcome the defects in the prior art and provide a method for skip-pouring of wear-resistant flooring without cutting joints. This method can strengthen the bonding between the sections while eliminating the need for cutting joints, thereby reducing the occurrence of flooring cracks, delamination, and hollow areas from the root.

[0006] The present invention provides a method for pouring wear-resistant flooring without cutting seams, comprising the following steps:

[0007] S1. Divide the construction area into pre-cast sections and post-cast sections arranged at intervals according to the skip-casting method;

[0008] S2. Erect the formwork for the pre-cast section and pour the concrete.

[0009] The precast mold has an inwardly protruding tenon, so that a predetermined interface shape is formed on the side wall after the precast mold is formed.

[0010] S3. Before the final setting of the first-poured concrete, after the initial setting of the first-poured concrete, lay the wear-resistant aggregate.

[0011] S4. After the concrete in the pre-poured section reaches the preset strength, remove the formwork of the pre-poured section.

[0012] S5. A stress buffer layer is set on the side wall of the pre-casting chamber, and a removable baffle is installed on the top of the stress buffer layer. The top elevation of the baffle is not lower than the surface elevation of the adjacent pre-casting chamber.

[0013] S6. Pour the post-construction concrete to ensure that the concrete adheres tightly to the stress buffer layer and formwork.

[0014] S7. After the initial setting and before the final setting of the post-cast concrete, wear-resistant aggregate is laid, and the formwork provides a forming boundary for the edge of the post-cast concrete.

[0015] S8. After the concrete in the post-cast section reaches the preset strength, the formwork is removed to form the reserved groove.

[0016] S9. Fill the groove with sealant.

[0017] Furthermore, in step S2, the top elevation of the pre-cast template is higher than the designed surface elevation, and the excess height is not less than the laying thickness of the wear-resistant aggregate; in step S3, the part of the pre-cast template that extends above the surface layer serves as an edge baffle when laying the wear-resistant aggregate.

[0018] Furthermore, in step S2, the tenon is a protrusion that is continuously or intermittently distributed along the height direction of the template, so that the side wall of the pre-casting chamber forms a groove structure of the corresponding shape.

[0019] Furthermore, the stress buffer layer includes a core skeleton and a functional layer covering the core skeleton. The core skeleton has elasticity and / or deformability so that the stress buffer layer can continuously fill the adjacent compartments.

[0020] Furthermore, the core skeleton has pre-reserved deformation energy absorption holes.

[0021] Furthermore, the core layer skeleton is provided with supporting ribs, and the stiffness of the supporting ribs is greater than that of the core layer skeleton.

[0022] Furthermore, the baffle is a rigid component with a lifting operation end on its top, so that adjacent compartments can be pulled out by lifting.

[0023] Furthermore, the outer surface of the retaining mold has a lubricating layer.

[0024] Furthermore, the stress buffer layer is fixed to the side wall of the pre-cast chamber by adhesive bonding, and the baffle supports the top of the stress buffer layer.

[0025] Furthermore, in step S9, the sealing material is a sealant, which is flush with the floor surface after filling.

[0026] The beneficial effects of this invention are as follows: The present invention discloses a method for skip-pour pouring of wear-resistant flooring without cutting joints. By using a raised toothed template that also serves as a retaining edge and a removable rigid retaining formwork to directly form grooves, the traditional mechanical cutting process is completely eliminated, fundamentally preventing damage to the abrasive surface layer caused by cutting joints. The tenon-shaped groove on the side wall of the first pouring section forms a mechanical interlock with the concrete of the subsequent pouring section, significantly improving the bonding strength between the sections and effectively eliminating the risk of delamination and hollow areas. The built-in stress buffer layer and the surface sealant joint constitute a dual stress release system, which absorbs and dissipates temperature and shrinkage displacement in layers, comprehensively inhibiting surface cracking. The template and retaining edge functions are integrated, and both the retaining formwork and the template can be recycled. Skip-pour construction allows multiple work surfaces to be advanced simultaneously, eliminating the cutting joint process and significantly saving construction time and equipment costs. The raised template and retaining formwork work together to provide double edge protection, ensuring that the edges of the abrasive aggregate are full and straight, and the joints are neat and beautiful, significantly improving the overall quality and service life of the flooring. Attached Figure Description

[0027] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0028] Figure 1 This is a schematic diagram of the pre-cast layer construction of the present invention;

[0029] Figure 2 This is a structural schematic diagram of the post-cast layer construction of the present invention;

[0030] Figure 3 For the present invention Figure 2 A schematic diagram of the groove structure formed by the pre-reserved retaining mold at point A;

[0031] Figure 4 For the present invention Figure 2 A schematic diagram of the structure in which sealing material is filled at point A in the groove;

[0032] Figure 5 This is a schematic diagram of the stress buffer layer of the present invention. Detailed Implementation

[0033] Figures 1-5 As shown in the figure, the no-cut-joint wear-resistant flooring skip-pour casting method in this embodiment includes the following steps:

[0034] S1. The construction area is divided into pre-cast sections 1 and post-cast sections 2 using the skip-casting method. Pre-cast sections 1 and post-cast sections 2 are arranged in a checkerboard pattern, with the separation positions between adjacent sections forming an interlocking and closed interface connection system. The skip-casting method allows each section to shrink independently, fully releasing the early hydration heat and shrinkage stress of the concrete, reducing the risk of through cracks from the source. The checkerboard layout ensures that each post-cast section 2 is surrounded and constrained by the pre-cast sections 1, with the interfaces connected into a network, resulting in stronger overall structural integrity.

[0035] S2. Erect the precast formwork 001 for the precast section 1 and pour concrete. The precast formwork 001 is a universal precast template with a preset shape, which can be reused. The precast formwork 001 has an inwardly protruding tenon 101, so that the precast section 1 forms a predetermined interface shape on the side wall after molding. The tenon 101 is a protrusion that is continuously or intermittently distributed along the height direction of the template, so that the side wall of the precast section 1 forms a groove structure of corresponding shape. The predetermined interface shape is preferably a continuous tooth shape, an intermittent tooth shape, or an irregular structure, so as to meet the purpose of the subsequent section 2 being able to interlock with the precast section 1. This will not be elaborated further. In this embodiment, the tenon 101 is a continuous trapezoidal tooth along the height direction of the template. This allows the precast section 1 and the subsequent section 2 to form a multi-layered mechanical interlocking structure in the height direction after construction, with the interlocking range covering the entire height of the section wall, thereby enhancing the shear bearing capacity of the interface.

[0036] S3. Before the final setting of the concrete in the pre-cast section 1, wear-resistant aggregate, namely corundum wear-resistant aggregate, is laid. In step S2, the top elevation of the pre-cast section template 001 is higher than the design surface elevation, and the excess height is not less than the laying thickness of the wear-resistant aggregate. This allows the pre-cast section template 001 to also serve as an edge retainer when corundum is subsequently spread in the pre-cast section 1, confining the corundum to a designated area, simplifying the process and improving construction quality.

[0037] S4. After the concrete in the pre-cast section 1 reaches the preset strength, the pre-cast section formwork 001 is removed. The preset strength is determined according to the construction standards. Generally, the pre-cast section formwork 001 is removed after the concrete in the pre-cast section 1 has been cured to more than 70% of the design strength, so as to ensure that the pre-cast section 1 is formed into the preset interface structure.

[0038] S5. A stress buffer layer 3 is provided on the side wall of the pre-casting chamber 1. A removable baffle 4 is installed on the top of the stress buffer layer 3, and the top elevation of the baffle 4 is not lower than the surface elevation of the adjacent pre-casting chamber 1.

[0039] In this embodiment, the stress buffer layer 3 includes a core skeleton 31 and a functional layer 32 covering the core skeleton 31. The core skeleton 31 has elasticity and / or deformability, so that the stress buffer layer 3 can continuously fill the space between adjacent compartments. "And / or" means that the core skeleton 31 can independently possess elasticity or deformability, or it can possess both elasticity and deformability, which will not be elaborated further here. For example, for elasticity, a rubber material can be used; for deformability, a sandwich filled with a deformable material can be used, such as a sandwich filled with sand, soil, or gravel, or the rubber material can have a predetermined area for filling with deformable material, forming a composite layer structure, which will not be elaborated further here.

[0040] In this embodiment, the core layer skeleton 31 is provided with supporting ribs 33, and the stiffness of the supporting ribs 33 is greater than that of the core layer skeleton 31. These supporting ribs 33 provide support, giving the core layer skeleton 31 a certain degree of stiffness. In this design, the core layer skeleton 31 is made of rubber, and its built-in supporting ribs 33 are steel mesh, manufactured as a single unit. Furthermore, the core layer skeleton 31 has pre-reserved deformation energy-absorbing holes 34, providing deformation space when relative displacement occurs between the compartments, thus enhancing the overall functionality of the core layer skeleton 31. It possesses both corresponding stiffness and elasticity and deformation capacity, allowing the stress buffer layer 3 to continuously fill the adjacent compartments, absorbing displacement between them and ensuring the reliability of the connection between adjacent compartments.

[0041] In this embodiment, the functional layer 32 is a geotextile covering the core skeleton 31, which is easy to obtain and has better functionality.

[0042] In this embodiment, the baffle 4 is a rigid component to ensure the reserved slot size. The top of the baffle 4 is provided with a lifting operation end so that the adjacent compartment can be pulled out by lifting, which is convenient to operate. In addition, the outer surface of the baffle 4 has a lubricating layer to reduce resistance and facilitate pulling out from the reserved slot.

[0043] In this embodiment, the stress buffer layer 3 is fixed to the side wall of the pre-casting chamber 1 by adhesive bonding, and the baffle 4 is supported on the top of the stress buffer layer 3. The two work together to position the baffle 4 securely. Specifically, an insertion joint is provided at the top of the stress buffer layer 3 so that the baffle 4 can be inserted into the joint and integrated with the stress buffer layer 3 during use. When removing the baffle 4, it can be simply pulled out. Of course, the baffle 4 can also be temporarily fixed to the side wall of the pre-casting chamber 1, such as by nailing at multiple points or by gluing, as long as the weak connection is easy to remove. This will not be elaborated further here.

[0044] S6. After pouring the concrete for the post-pouring section 2, the concrete fully fills the space outside the stress buffer layer 3, making the concrete adhere tightly to the stress buffer layer 3 and the formwork 4. The continuous toothed interface shape of the pre-pouring section 1 is mechanically interlocked through the stress buffer layer 3, resulting in a bond strength between sections that is much higher than that of a traditional flat interface. In this state, the stress buffer layer 3 is moderately compressed under the pouring pressure, which enhances the contact density with the concrete on both sides and eliminates the risk of voids. The elasticity of the stress buffer layer 3 allows it to continue to adhere to the interfaces on both sides when the concrete hardens and shrinks, compensating for the small gaps caused by shrinkage and reducing the occurrence of defects such as floor cracking, delamination, and hollowing from the root.

[0045] S7. After the initial setting and before the final setting of the concrete in the post-casting compartment 2, wear-resistant aggregate is laid. The formwork 4 provides a forming boundary for the edge of the post-casting compartment 2, ensuring the surface quality of the post-casting compartment 2. The isolation effect of the formwork 4 allows the surface of the two compartments to be formed independently, with clear and neat boundaries at the joints, avoiding aggregate breakage and corner chipping caused by traditional cutting.

[0046] S8. After the concrete in post-cast chamber 2 reaches the preset strength, the formwork 4 is removed to form the reserved groove. According to the construction standard, the preset strength is generally achieved after the concrete in post-cast chamber 2 has been cured to more than 70% of the design strength. The formwork 4 is then removed to directly form the groove, completely eliminating the traditional mechanical cutting process and preventing the damage to the diamond abrasive surface layer caused by cutting from the source. The groove size is precise and uniform, and no secondary repair is required.

[0047] S9. Fill the groove with sealant 5, which is a sealant. After filling, it is flush with the floor surface, forming a surface-sealed stress relief joint. The sealant acts as a surface stress relief strip, forming a dual stress relief system with the built-in stress buffer layer 3. This system effectively resolves internal deformation and surface displacement of the floor in layers, significantly reducing the risk of surface cracking.

[0048] This solution completely eliminates the need for traditional mechanical cutting by using a raised toothed template that also serves as an edge retainer and a removable rigid retainer 4 to directly form the groove, thus fundamentally preventing damage to the diamond aggregate surface layer caused by cutting. The tenon 101 on the side wall of the first pouring section 1 forms a groove that mechanically interlocks with the concrete of the subsequent pouring section 2, significantly improving the bonding strength between the sections and effectively eliminating the risk of delamination and hollow areas. The built-in stress buffer layer 3 and the surface sealant joint constitute a dual stress release system, absorbing and dissipating temperature and shrinkage displacement in layers, comprehensively suppressing surface cracking. The template and edge retainer functions are integrated, and both the retainer 4 and the template can be reused. Skip-pour construction allows multiple work surfaces to be advanced simultaneously, eliminating the need for cutting and significantly saving construction time and equipment costs. The raised template and retainer 4 work together to provide double edge protection, ensuring that the edges of the diamond aggregate are full and straight, and the joints are neat and beautiful, significantly improving the overall quality and service life of the floor.

[0049] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A method for pouring wear-resistant flooring without cutting joints, characterized in that: Includes the following steps: S1. Divide the construction area into pre-cast sections and post-cast sections arranged at intervals according to the skip-casting method; S2. Erect the formwork for the pre-cast section and pour the concrete. The precast mold has an inwardly protruding tenon, so that a predetermined interface shape is formed on the side wall after the precast mold is formed. S3. Before the final setting of the first-poured concrete, after the initial setting of the first-poured concrete, lay the wear-resistant aggregate. S4. After the concrete in the pre-poured section reaches the preset strength, remove the formwork of the pre-poured section. S5. A stress buffer layer is set on the side wall of the pre-casting chamber, and a removable baffle is installed on the top of the stress buffer layer. The top elevation of the baffle is not lower than the surface elevation of the adjacent pre-casting chamber. S6. Pour the post-construction concrete to ensure that the concrete adheres tightly to the stress buffer layer and formwork. S7. After the initial setting and before the final setting of the post-cast concrete, wear-resistant aggregate is laid, and the formwork provides a forming boundary for the edge of the post-cast concrete. S8. After the concrete in the post-cast section reaches the preset strength, the formwork is removed to form the reserved groove. S9. Fill the groove with sealant.

2. The method for skip-pouring pouring of wear-resistant flooring without cutting seams according to claim 1, characterized in that: In step S2, the top elevation of the pre-cast template is higher than the design surface elevation, and the excess height is not less than the laying thickness of the wear-resistant aggregate; in step S3, the part of the pre-cast template that extends above the surface layer serves as an edge baffle when laying the wear-resistant aggregate.

3. The method for skip-pouring pouring of wear-resistant flooring without cutting seams according to claim 1, characterized in that: In step S2, the tenon is a protrusion that is continuously or intermittently distributed along the height direction of the template, so that the side wall of the pre-casting compartment forms a groove structure of the corresponding shape.

4. The method for skip-pouring pouring of wear-resistant flooring without cutting seams according to claim 1, characterized in that: The stress buffer layer includes a core skeleton and a functional layer covering the core skeleton. The core skeleton has elasticity and / or deformability so that the stress buffer layer can continuously fill the space between adjacent compartments.

5. The method for skip-pouring of wear-resistant flooring without cutting seams according to claim 4, characterized in that: The core skeleton has pre-reserved deformation energy absorption holes.

6. The method for skip-pouring of wear-resistant flooring without cutting seams according to claim 4, characterized in that: The core layer skeleton is provided with supporting ribs, and the stiffness of the supporting ribs is greater than that of the core layer skeleton.

7. The method for skip-pouring of wear-resistant flooring without cutting seams according to claim 1, characterized in that: The baffle is a rigid component with a lifting operation end on its top, so that adjacent compartments can be pulled out by lifting.

8. The method for skip-pouring of wear-resistant flooring without cutting seams according to claim 6, characterized in that: The outer surface of the retaining mold has a lubricating layer.

9. The method for skip-pouring pouring of wear-resistant flooring without cutting seams according to claim 1, characterized in that: The stress buffer layer is fixed to the side wall of the pre-cast chamber by adhesive bonding, and the baffle supports the top of the stress buffer layer.

10. The method for skip-pouring of wear-resistant flooring without cutting seams according to claim 1, characterized in that: In step S9, the sealing material is a sealant, which is flush with the floor surface after filling.

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