Prefabricated airport pavement three-dimensional interlocking interface structure system and rapid construction method thereof

Abstract

The application provides an assembled airport pavement three-dimensional interlocking interface structure system and a rapid construction method thereof, a structural adhesive layer is arranged between preset interlocking components and a base layer, and the base layer, the structural adhesive layer and the preset interlocking components are connected through anchor bolts; the preset interlocking components comprise a bottom plate and a plurality of regularly arranged trapezoidal protrusions arranged on the bottom plate; micro interlocking structures are arranged on surfaces of the trapezoidal protrusions; and a surface layer is filled on the preset interlocking components with the micro interlocking structures in a pouring form. The application realizes full-area bonding and stress diffusion through the structural adhesive layer, point mechanical anchoring is realized through the anchor bolts, a composite connection system of surface bonding and point anchoring is formed, the close combination of the components and the base layer is ensured, loads are efficiently and uniformly transmitted to the base layer, the array of protrusions on the working surface of the components is filled and wrapped by the paving surface layer material, and mechanical interlocking is formed after solidification, and the integrated macro protrusion anchoring body and the micro textured surface provided by the prefabricated components realize interface locking.

Description

Technical Field

[0001] This invention relates to the field of road interface enhancement technology, and in particular to a prefabricated airport pavement three-dimensional interlocking interface structure system and its rapid construction method. Background Technology

[0002] Multi-layer composite structural systems (such as asphalt overlay on old cement concrete pavement, steel bridge deck paving, and airport composite pavement) are widely used in the construction and maintenance of civil engineering infrastructure. The overall performance, load-bearing capacity, and service life of such structures largely depend on whether their interlayer interfaces can efficiently and persistently transfer shear stress, tensile stress, and bending moment.

[0003] Currently, improving the performance of interlayer interfaces mainly relies on the following two types of technologies, both of which have shortcomings that are not compatible with the requirements of rapid and industrialized construction:

[0004] The first type is the on-site bonding layer technology, which mainly uses organic materials such as emulsified asphalt, polymer-modified asphalt, or epoxy resin. Its drawbacks are that the materials are prone to aging, and the construction quality is significantly affected by the temperature and humidity of the on-site environment, the dryness of the base layer, and the skill level of the workers. The process is time-consuming, the strength is formed slowly, and it is difficult to meet the needs of rapid traffic opening.

[0005] The second category is on-site mechanical processing technology, including methods such as chiseling, sandblasting, and grooving that are performed directly on the existing base layer. The problems are: (1) it is a destructive construction that damages the original structure and generates a lot of waste during the renovation project; (2) the construction efficiency is low, the vibration and noise are high, and it is difficult to arrange long-term operations in busy traffic sections or operating sites; (3) the processing quality (such as texture depth and uniformity) depends on the equipment and operation, the homogeneity is poor, and the performance is highly discrete; (4) the interface formed is an integral structure with the base layer, and it is difficult to repair after local damage. It often requires large-scale renovation, resulting in high maintenance costs and long cycles.

[0006] Therefore, there is an urgent need to provide an interface structure system and construction method that can separate the production and installation of high-quality interface structures. Summary of the Invention

[0007] To address the shortcomings of existing technologies, this invention provides a prefabricated airport pavement three-dimensional interlocking interface structure system and its rapid construction method, thereby solving the technical problems existing in the background art.

[0008] In a first aspect, the technical solution provided by the present invention is: a prefabricated airport pavement three-dimensional interlocking interface structure system, including a base layer, a surface layer, a structural adhesive layer, and pre-installed interlocking components; the pre-installed interlocking components and the base layer are provided with a structural adhesive layer, and the base layer, the structural adhesive layer, and the pre-installed interlocking components are connected by anchor bolts;

[0009] The pre-set interlocking component includes a base plate and a plurality of regularly arranged trapezoidal protrusions on the base plate; a micro-interlocking structure is also provided on the surface of the trapezoidal protrusions.

[0010] The micro-interlocking structure is a micron-level surface texture set on the surface of the trapezoidal protrusion; the surface layer is filled on the pre-installed interlocking component with the micro-interlocking structure by casting.

[0011] Preferably, the pre-installed interlocking components are prefabricated using fiber-reinforced concrete, polymer concrete, or high-performance composite materials.

[0012] Preferably, the base plate has multiple mounting holes, and the anchor bolts are connected to the base layer, structural adhesive layer, and pre-installed interlocking components through the mounting holes.

[0013] Preferably, the two adjacent pre-installed interlocking components are connected by a mortise and tenon structure provided at their edges.

[0014] Preferably, all the edges of the trapezoidal protrusion and the bottom of the groove of the protrusion key are rounded, and the radius of the rounded arc is... It is 3-8mm.

[0015] Preferably, the trapezoidal protrusions are arranged on the base plate in a parallel stripe or grid pattern.

[0016] Preferably, the trapezoidal protrusion is divided into a standard trapezoidal protrusion and an enhanced trapezoidal protrusion.

[0017] Preferably, the height of the standard trapezoidal protrusion is... It is 15-20mm;

[0018] The sidewall inclination angle of the standard trapezoidal protrusion The angle is 20°-30°.

[0019] The top width of the standard trapezoidal protrusion is greater than the bottom width; and the top width... 40-45mm; bottom width It is 25-30mm.

[0020] Preferably, the height of the enhanced trapezoidal protrusion is... It is 20-25mm;

[0021] The sidewall inclination angle of the enhanced trapezoidal protrusion The angle is 25°-35°.

[0022] The top width of the enhanced trapezoidal protrusion is greater than the bottom width; and the top width 40-45mm; bottom width It is 15-20mm.

[0023] Preferably, the center distance between two adjacent trapezoidal protrusions is twice the width of the top of the trapezoidal protrusion.

[0024] Preferably, the surface roughness of the micron-level surface texture The size is 2-12μm, formed by sandblasting.

[0025] Preferably, the structural adhesive layer is an epoxy resin layer or a polymer mortar layer.

[0026] Preferably, the bottom of the base plate is further provided with a striped structure or a grooved structure to increase the contact area with the structural adhesive layer.

[0027] Secondly, the technical solution provided by this invention is: a rapid construction method for a prefabricated airport pavement three-dimensional interlocking interface structure system, comprising the following steps:

[0028] S1) The pre-set interlocking components are pre-set according to their type and geometric parameters, and micron-level surface textures are prepared on the trapezoidal protrusions of the pre-set interlocking components by sandblasting, with a surface roughness of... 2-12μm;

[0029] S2) Transport the pre-installed interlocking components to the construction site; clean the base layer, and mark the installation outline and control points of each pre-installed interlocking component on the base layer using a total station and a 3D laser scanner;

[0030] S3) Use lifting equipment to hoist the coded pre-installed interlocking components to the corresponding installation position; use a laser level, level and jack to adjust the three-dimensional posture of the pre-installed interlocking components to ensure that the flatness and elevation of the top surface fully meet the design requirements.

[0031] S4) Apply a layer of structural adhesive evenly to the bottom of the pre-installed interlocking component that has been adjusted and to the treated base surface; then accurately position the pre-installed interlocking component on the base surface coated with structural adhesive, and install the anchor bolt through the pre-set mounting holes; during the tightening of the anchor bolt, the adhesive is squeezed and forms a uniform, air-free thin layer at the interface, thus completing both chemical bonding and mechanical anchoring.

[0032] S5) Install connecting bolts, prestressing tendons or fitting tenons of adjacent pre-installed interlocking components to connect all pre-installed interlocking components into a whole.

[0033] S6) Pour the asphalt mixture or cement mixture onto the pre-installed interlocking components, and then compact it after leveling. During the compaction process, the raised array area should be compacted with overlapping, slow, and multiple passes.

[0034] S7) Inspect the construction. When the installation accuracy, interface density, and interface bonding quality all meet the preset standards, the construction quality of the prefabricated three-dimensional interlocking interface is deemed qualified.

[0035] Preferably, in step S7), the inspection includes:

[0036] A handheld 3D laser scanner was used to scan the area where the pre-installed interlocking components were installed. The point cloud data was compared with the design model to verify the positional deviation, flatness, and geometric integrity of the protrusion array of the pre-installed interlocking components.

[0037] High-frequency ground-penetrating radar was used to scan the interface area, and the signals were analyzed to determine the filling density of the surface material in the gaps between the protrusions and to identify voids.

[0038] In key areas, the pre-installed interlocking components are scanned using a tapping method, an impact echo method, or an ultrasonic detector to check for area-wide void defects and ensure the quality of interface bonding.

[0039] When the installation accuracy, interface density, and interface bonding quality all meet the preset standards, the construction quality of the prefabricated three-dimensional interlocking interface is deemed qualified.

[0040] The beneficial effects of this invention are as follows:

[0041] 1. The pre-installed interlocking component of this invention uses a base plate as the main load-bearing body. A high-performance structural adhesive layer is fully coated between the base plate and the substrate to achieve full-area bonding and stress diffusion. Point-type mechanical anchoring is used with anchor bolts to form a composite connection system of surface bonding and point anchoring, which ensures the tight connection between the component and the substrate, effectively eliminates the risk of separation, and efficiently and evenly transfers the load to the substrate.

[0042] 2. The surface material of this invention fills and wraps the raised array on the working surface of the component, and forms a mechanical interlock after curing; the interface is locked by providing integrated macroscopic raised anchor solids and microscopic textured surfaces through prefabricated components. Attached Figure Description

[0043] Figure 1 This is a schematic diagram of the system structure in Embodiment 1 of the present invention;

[0044] Figure 2 This is a schematic diagram of the structure of different types of trapezoidal protrusions in Embodiment 1 of the present invention;

[0045] Figure 3 This is a schematic diagram of different arrangements of the trapezoidal protrusions in Embodiment 1 of the present invention;

[0046] Figure 4This is a schematic diagram of the connection between adjacent pre-set interlocking components in Embodiment 1 of the present invention;

[0047] Figure 5 This is a top view of the assembled multiple pre-installed interlocking components in Embodiment 1 of the present invention;

[0048] Figure 6 This is a flowchart illustrating the method of Embodiment 2 of the present invention.

[0049] In the diagram, 1-base layer; 2-surface layer; 3-structural adhesive layer; 4-pre-installed interlocking components; 5-base plate; 6-trapezoidal protrusion; 7-anchor bolt; 8-mortise and tenon structure; 9-positioning pin. Detailed Implementation

[0050] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings:

[0051] Example 1

[0052] like Figure 1 As shown, this embodiment provides a prefabricated airport pavement three-dimensional interlocking interface structure system, including a base layer 1, a surface layer 2, a structural adhesive layer 3, and a pre-installed interlocking component 4; the pre-installed interlocking component 4 and the base layer 1 are provided with a structural adhesive layer 3, and the base layer 1, the structural adhesive layer 3, and the pre-installed interlocking component 4 are connected by anchor bolts 7.

[0053] The pre-installed interlocking component 4 includes a base plate 5 and a plurality of regularly arranged trapezoidal protrusions 6 disposed on the base plate 5; a micro-interlocking structure is also disposed on the surface of the trapezoidal protrusions 6.

[0054] The micro-interlocking structure is a micron-level surface texture set on the surface of the trapezoidal protrusion 6; the surface layer 2 is filled on the pre-installed interlocking component 4 with the micro-interlocking structure by casting.

[0055] In this embodiment, the pre-installed interlocking component 4 is prefabricated using fiber-reinforced concrete, polymer concrete, or high-performance composite materials.

[0056] In this embodiment, the base plate 5 is provided with multiple mounting holes, and the anchor bolt 7 is connected to the base layer 1, the structural adhesive layer 3, and the pre-installed interlocking component 4 through the mounting holes.

[0057] In this embodiment, as Figure 4 As shown, two adjacent pre-installed interlocking components 4 are connected by a mortise and tenon structure 8 provided on their edges; in this embodiment, the mortise and tenon structure 8 includes a hook provided on one of the pre-installed interlocking components 4 and a groove provided on the other pre-installed interlocking component 4.

[0058] like Figure 5As shown, the connection points of the multiple pre-installed interlocking components 4 can be connected by positioning pins 9.

[0059] In this embodiment, all the edges and corners of the trapezoidal protrusion 6 and the bottom of the groove of the protrusion key are rounded, and the radius of the rounded arc is... It is 3-8mm.

[0060] In this embodiment, as Figure 3 As shown, the trapezoidal protrusions 6 are arranged on the base plate 5 in a parallel stripe or grid pattern.

[0061] In this embodiment, the trapezoidal protrusion 6 is divided into a standard trapezoidal protrusion 6 and an enhanced trapezoidal protrusion 6, such as... Figure 2 As shown.

[0062] In this embodiment, the height of the standard trapezoidal protrusion 6 is... It is 15-20mm;

[0063] The side wall inclination angle of the standard trapezoidal protrusion 6 The angle is 20°-30°.

[0064] The top width of the standard trapezoidal protrusion 6 is greater than the bottom width; and the top width 40-45mm; bottom width It is 25-30mm.

[0065] In this embodiment, the height of the standard trapezoidal protrusion 6 is... It is 20-25mm;

[0066] The side wall inclination angle of the standard trapezoidal protrusion 6 The angle is 25°-35°.

[0067] The top width of the standard trapezoidal protrusion 6 is greater than the bottom width; and the top width 40-45mm; bottom width It is 15-20mm.

[0068] In this embodiment, the center distance between two adjacent trapezoidal protrusions 6 It is twice the width of the top of the trapezoidal protrusion 6.

[0069] In this embodiment, the surface roughness of the micron-level surface texture... The size is 2-12μm, formed by sandblasting.

[0070] In this embodiment, the structural adhesive layer 3 is an epoxy resin layer or a polymer mortar layer, and the bottom of the base plate 5 is also provided with a striped structure or a groove structure to increase the interlocking area with the structural adhesive layer 3.

[0071] Example 2

[0072] like Figure 6 As shown in the figure, this embodiment provides a rapid construction method for a prefabricated airport pavement three-dimensional interlocking interface structure system, including the following steps:

[0073] S1) The pre-set interlocking component 4 is pre-set according to its type and geometric parameters, and a micron-level surface texture is prepared on the surface of the trapezoidal protrusion 6 of the pre-set interlocking component 4 by sandblasting, and its surface roughness is... 2-12μm;

[0074] In this embodiment, the pre-installed interlocking component 4 is prefabricated using fiber-reinforced concrete, polymer concrete, or high-performance composite materials.

[0075] All edges and corners of the trapezoidal protrusion 6 and the bottom of the groove of the protrusion key are rounded, and the radius of the rounded arc is... It is 3-8mm.

[0076] In this embodiment, as Figure 3 As shown, the trapezoidal protrusions 6 are arranged on the base plate 5 in a parallel stripe or grid pattern.

[0077] In this embodiment, the trapezoidal protrusion 6 is divided into a standard trapezoidal protrusion 6 and an enhanced trapezoidal protrusion 6, such as... Figure 2 As shown, the height of the standard trapezoidal protrusion 6 is... It is 15-20mm;

[0078] The side wall inclination angle of the standard trapezoidal protrusion 6 The angle is 20°-30°.

[0079] The top width of the standard trapezoidal protrusion 6 is greater than the bottom width; and the top width 40-45mm; bottom width It is 25-30mm.

[0080] The height of the enhanced trapezoidal protrusion 6 It is 20-25mm;

[0081] The sidewall inclination angle of the enhanced trapezoidal protrusion 6 The angle is 25°-35°.

[0082] The top width of the enhanced trapezoidal protrusion 6 is greater than the bottom width; and the top width 40-45mm; bottom width It is 15-20mm.

[0083] Furthermore, the center distance between two adjacent trapezoidal protrusions 6 is twice the width of the top of the trapezoidal protrusion 6.

[0084] S2) Transport the pre-installed interlocking components 4 to the construction site; clean the base layer 1, and mark the installation outline and control points of each pre-installed interlocking component 4 on the base layer 1 using a total station and a 3D laser scanner;

[0085] S3) Use lifting equipment to hoist the coded pre-installed interlocking component 4 to the corresponding installation position; use a laser level, level and jack to adjust the three-dimensional posture of the pre-installed interlocking component 4 to ensure that its top surface flatness and elevation fully meet the design requirements.

[0086] S4) A structural adhesive layer 3 is uniformly applied to the bottom of the pre-installed interlocking component 4 and the surface of the treated base layer 1 after adjustment; wherein the structural adhesive layer 3 is an epoxy resin layer or a polymer mortar layer; then the pre-installed interlocking component 4 is accurately positioned on the base layer 1 coated with the structural adhesive layer 3, and the anchor bolt 7 is installed through the preset mounting holes; during the tightening of the anchor bolt 7, the adhesive is squeezed and forms a uniform, non-void thin layer at the interface, thus completing both chemical bonding and mechanical anchoring.

[0087] S5) Install the connecting bolts, prestressing tendons or fitting tenons of adjacent pre-installed interlocking components 4 to connect all pre-installed interlocking components 4 into a whole.

[0088] S6) Pour the asphalt mixture or cement mixture onto the pre-installed interlocking component 4, and then compact it after leveling. During the compaction process, the raised array area is subjected to overlapping, slow, and multiple passes of focused rolling.

[0089] S7) Inspect the construction by using a handheld 3D laser scanner to scan the area of ​​the pre-installed interlocking component 4, compare the point cloud data with the design model, and accept the positional deviation, flatness and geometric integrity of the pre-installed interlocking component 4.

[0090] High-frequency ground-penetrating radar was used to scan the interface area, and the signals were analyzed to determine the filling density of the surface layer 2 material in the gap of the protrusion and to identify voids.

[0091] In key areas, the pre-installed interlocking components 4 are scanned using a tapping method, an impact echo method, or an ultrasonic detector to check for area-specific void defects and ensure the quality of interface bonding.

[0092] When the installation accuracy, interface density, and interface bonding quality all meet the preset standards, the construction quality of the prefabricated three-dimensional interlocking interface is deemed qualified.

[0093] The embodiments and descriptions above are merely illustrative of the principles and preferred embodiments of the present invention. Various changes and modifications may be made to the present invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed.

Claims

1. A prefabricated airport pavement three-dimensional interlocking interface structure system, characterized in that, It includes a base layer (1), a surface layer (2), a structural adhesive layer (3), and a pre-installed interlocking component (4); the pre-installed interlocking component (4) and the base layer (1) are provided with a structural adhesive layer (3), and the base layer (1), the structural adhesive layer (3), and the pre-installed interlocking component (4) are connected by anchor bolts (7). The pre-installed interlocking component (4) includes a base plate (5) and a plurality of regularly arranged trapezoidal protrusions (6) disposed on the base plate (5); the surface of the trapezoidal protrusions (6) is also provided with a micro-interlocking structure; the surface roughness of the micron-level surface texture The size is 2-12μm, formed by sandblasting; The micro-interlocking structure is a micron-level surface texture set on the surface of the trapezoidal protrusion (6); the surface layer (2) is filled on the pre-installed interlocking component (4) with the micro-interlocking structure in the form of casting.

2. The prefabricated airport pavement three-dimensional interlocking interface structure system according to claim 1, characterized in that: The pre-installed interlocking component (4) is made of fiber-reinforced concrete, polymer concrete or high-performance composite material.

3. The prefabricated airport pavement three-dimensional interlocking interface structure system according to claim 2, characterized in that: The two adjacent pre-installed interlocking components (4) are connected by a mortise and tenon structure set on their edges; Furthermore, the base plate (5) of the pre-installed interlocking component (4) is provided with multiple mounting holes, and the anchor bolt (7) is connected to the base layer (1), the structural adhesive layer (3), and the pre-installed interlocking component (4) through the mounting holes.

4. The prefabricated airport pavement three-dimensional interlocking interface structure system according to claim 1, characterized in that: All edges and corners of the trapezoidal protrusion (6) and the bottom of the groove of the protrusion key are rounded, and the radius of the rounded arc is... It is 3-8mm.

5. The prefabricated airport pavement three-dimensional interlocking interface structure system according to claim 4, characterized in that: The trapezoidal protrusion (6) is divided into a standard trapezoidal protrusion (6) and an enhanced trapezoidal protrusion (6).

6. The prefabricated airport pavement three-dimensional interlocking interface structure system according to claim 5, characterized in that: The height of the standard trapezoidal protrusion (6) It is 15-20mm; The sidewall inclination angle of the standard trapezoidal protrusion (6) The angle is 20°-30°. The top width of the standard trapezoidal protrusion (6) is greater than the bottom width; and the top width 40-45mm; bottom width It is 25-30mm.

7. The prefabricated airport pavement three-dimensional interlocking interface structure system according to claim 5, characterized in that: The height of the enhanced trapezoidal protrusion (6) It is 20-25mm; The sidewall inclination angle of the enhanced trapezoidal protrusion (6) The angle is 25°-35°. The top width of the enhanced trapezoidal protrusion (6) is greater than the bottom width; and the top width 40-45mm; bottom width It is 15-20mm.

8. The prefabricated airport pavement three-dimensional interlocking interface structure system according to claim 5, characterized in that: The trapezoidal protrusions (6) are arranged on the base plate (5) in a parallel stripe pattern or grid pattern; Furthermore, the center distance between two adjacent trapezoidal protrusions (6) is twice the width of the top of the trapezoidal protrusion (6).

9. The prefabricated airport pavement three-dimensional interlocking interface structure system according to claim 2, characterized in that, The structural adhesive layer (3) is an epoxy resin layer or a polymer mortar layer; The bottom of the base plate (5) is also provided with a striped structure or a groove structure to increase the interlocking area with the structural adhesive layer (3).

10. A rapid construction method for a prefabricated airport pavement three-dimensional interlocking interface structure system, characterized in that, Includes the following steps: S1) The pre-set interlocking component (4) is pre-set according to its type and geometric parameters, and a micron-level surface texture is prepared on the trapezoidal protrusion (6) of the pre-set interlocking component (4) by sandblasting, and its surface roughness is... 2-12μm; S2) Clean the base layer (1) and mark the installation outline and control points of each pre-installed interlocking component (4) on the base layer (1) using a total station and a three-dimensional laser scanner; S3) Use lifting equipment to hoist the coded pre-installed interlocking component (4) to the corresponding installation position; use a laser level, level and jack to adjust the three-dimensional posture of the pre-installed interlocking component (4) in place; S4) Apply a layer of structural adhesive (3) evenly to the bottom of the pre-installed interlocking component (4) and the surface of the treated base layer (1) after the adjustment has been completed; then accurately place the pre-installed interlocking component (4) on the base layer (1) coated with structural adhesive (3) and install the anchor bolt (7) through the pre-installed mounting hole. S5) Install connecting bolts, prestressing tendons or fitting tenons of adjacent pre-installed interlocking components (4) to connect all pre-installed interlocking components (4) into a whole; S6) Pour the asphalt mixture or cement mixture onto the pre-installed interlocking component (4), and compact it after leveling. During the compaction process, the raised array area is subjected to overlapping, slow, and multiple key rolling. S7) Inspect the construction. When the installation accuracy, interface density, and interface bonding quality all meet the preset standards, the construction quality of the prefabricated three-dimensional interlocking interface is deemed qualified.

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