CN108643132B - Rolled concrete structure with composite slurry injected into stone slag material and construction method thereof - Google Patents
Rolled concrete structure with composite slurry injected into stone slag material and construction method thereof Download PDFInfo
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02B—HYDRAULIC ENGINEERING
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- E02B7/02—Fixed barrages
- E02B7/04—Dams across valleys
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Abstract
The invention discloses a roller compacted concrete structure which is formed by injecting composite slurry into stone slag. The concrete is composed of a plurality of layers of composite slurry material roller compacted concrete layers, wherein the composite slurry material roller compacted concrete layers are formed by vibrating and rolling stone slag materials and composite slurry poured on the surfaces of the stone slag materials, and the stone slag materials are excavation materials with the particle size of more than or equal to 5 mm; the slabstone material is piled up on the dam foundation layer by layer, the composite grout is poured on the slabstone material piled up layer by layer to fill the slabstone material at random, and when the liquid level of the composite grout is close to the top surface of the slabstone material, a grouting and rolling concrete structure with uniform and stable structure is formed by vibrating and rolling the bin surface. The invention has the advantages of local materials, uniform and stable structure, excellent performance, high construction speed and engineering cost saving. The invention also discloses a construction method of the roller compacted concrete structure by injecting the composite slurry into the ballast material.
Description
Technical Field
The invention relates to the technical field of materials, structures and construction of hydraulic and hydroelectric engineering, in particular to a roller compacted concrete structure with composite slurry injected into stone slag. The invention also discloses a construction method of the roller compacted concrete structure by injecting the composite slurry into the ballast material.
Background
The concrete panel rock-fill dam is one of the dam types which are the most competitive and have the most development prospect in the dam construction at present, and the dam type has the advantages of low manufacturing cost, high safety, strong adaptability and the like, so that the dam type is generally regarded by the dam construction boundary, has excellent application prospect and is the preferred dam type of a plurality of projects; at present, more than 150 face rockfill dams are built and built in China, wherein 37 face rockfill dams with the height of more than 100m are built; the modern concrete rockfill dam has the development trend that the dam is built higher and the engineering scale is larger and larger, and the dam building technology is relatively mature through the construction practices of the projects of the level one of the natural bridges (the maximum dam height 178m), the water buffet (the maximum dam height 233m) and the like in China, so that a certain technical foundation is laid for the development of the 300 m-level ultrahigh-panel rockfill dam.
With the acceleration of the development progress of hydropower in southwest of China, in areas with inconvenient traffic and poor economy, such as Jinsha river, lanchong river, anger river, Yashu river, big river and yellow river upstream, Yalu Tibet Bujiang of Tibet, and the like, a plurality of river valley topographic and geological conditions suitable for building high-face rockfill dams are provided, such as hydroelectric stations of ancient water, Maji and the like, the dam height is about 250-300 m, and because the engineering characteristics, the key technology and the operation characteristics of the 300 m-level high-face rockfill dam cannot be mastered, the face rockfill dam scheme cannot be directly selected, and a concrete dam scheme with large external transportation volume and high manufacturing cost or a concrete dam scheme with large volume, large occupied cultivated land and easy adverse influence on environment and soil conservation is selected, and some projects even have no available impermeable earth materials in a near dam area; the competitiveness of economic indexes of the hydropower station is reduced, and all the technical breakthroughs of the 300 m-level high-concrete face rockfill dam construction are urgently expected by all the engineering construction parties.
However, in the face of the construction target of the ultra-high face rockfill dam of 300m level or even higher, there still exist a plurality of key technical problems, such as reasonable zoning of the ultra-high rockfill dam, influence of the characteristics of the damming material on the deformation characteristics of the dam, deformation characteristics and safety of the ultra-high rockfill dam, anti-seismic safety, engineering measures and the like, especially, the dam construction on the basis of a deep covering layer is difficult to break through the limitation of the dam height, and these become the technical bottleneck for developing the ultra-high face rockfill dam; the existing concrete technology applied to the lower base of the ultra-high rock-fill dam generally has requirements on gradation and particle size of blocky stones or pebbles, and in the construction method, concrete needs to be produced by a mixing plant, so that consumed materials are time-consuming.
Therefore, a roller compacted concrete structure which is fast in construction speed, saves engineering cost, is applied to a 300 m-grade ultrahigh-face rockfill dam, is uniform and stable in structure and good in mechanical property and a construction method thereof are needed.
Disclosure of Invention
The invention aims to provide a rolled concrete structure which is formed by injecting composite slurry into stone ballast materials, and has the advantages of local materials, uniform and stable structure, excellent performance, high construction speed and engineering cost saving; the composite pulp material rolled concrete structure is suitable for the lower base of the ultra-high rockfill dam structure of the hydraulic and hydroelectric engineering, solves the problem of dam construction on the basis of a deep covering layer from the aspects of materials, structure, construction mode and the like, breaks through the limitation of the height of a dam body, realizes the construction target of the ultra-high concrete faced rockfill dam, and can be applied to the ultra-high concrete faced rockfill dam with the grade of 300m and even higher; the structure is also suitable for other rolled concrete structure parts with larger volume.
The second purpose of the invention is to provide a construction method of a rolled concrete structure by injecting composite slurry into stone slag, the method directly lays a layer of excavated stone slag (the grain diameter is 5-500 mm, special screening is basically not needed), then pours the composite slurry (no aggregate, the composite slurry can be stirred on site), and finally rolls, so that the construction is more convenient, the construction speed is high, and the engineering cost is saved.
In order to achieve the first object of the present invention, the technical solution of the present invention is: the rolling concrete structure with the composite slurry injected into the stone slag material is characterized in that: the concrete is composed of a plurality of layers of composite slurry material roller compacted concrete layers, wherein the composite slurry material roller compacted concrete layers are formed by vibrating and rolling stone slag materials and composite slurry poured on the surfaces of the stone slag materials, and the stone slag materials are excavation materials with the particle size of more than or equal to 5 mm; the slabstone material is piled up on the dam foundation layer by layer, the composite grout is poured on the slabstone material piled up layer by layer to fill the slabstone material at random, and when the liquid level of the composite grout is close to the top surface of the slabstone material, a grouting and rolling concrete structure with uniform and stable structure is formed by vibrating and rolling the bin surface.
In the technical scheme, the height of each layer of the composite pulp material roller compacted concrete layer is 0.5-0.8 m; the stone slag is a cutting material with the particle size of 5 mm-500 mm.
In the technical scheme, the composite slurry comprises clean cement slurry and a cementing material, and the flowability of the composite slurry is 200-240 mm; the water-to-gel ratio of the cement paste is 0.4-0.5; the proportion of the admixture in the cementing material is 50-70%, and the admixture is fly ash and stone powder.
In order to achieve the second object of the present invention, the technical solution of the present invention is: the construction method of the roller compacted concrete structure by injecting the composite slurry into the ballast material is characterized by comprising the following steps of: the method comprises the following steps:
step 1: the dam foundation and the bank slope of the rock-fill dam are processed according to the related technical requirements in the early-stage work of construction;
step 2: after the step 1 is finished, stacking the treated dam foundation by adopting the slag materials with the particle size of more than 5mm in a layering way, wherein the thickness of each layer of the slag material is 0.5-0.8 m, and leveling the dam foundation mechanically or manually;
and step 3: after the step 2 is finished, grouting is started, composite slurry is uniformly poured on the surface of the stone slag material layer during grouting, and the total grouting amount of the composite slurry is the slurry pouring liquid level until the composite slurry is close to the top surface of the rockfill material or is 10-20 mm away from the top surface of the rockfill material;
and 4, step 4: after the step 3 is finished, adopting a rolling vibration machine to vibrate the rolling bin surface to form a composite pulp rolling concrete layer, and finishing the specified rolling times; when the pouring amount of the composite slurry does not meet the requirement, slurry supplement is carried out in the rolling process; after rolling, performing necessary early maintenance on the surface of the composite pulp material roller compacted concrete layer;
and 5: and (5) repeating the steps 2 to 4 until the layered construction of the grouting and rolling concrete structure is completed.
In the technical scheme, in the step 4, the rolling times are 6-8 times; the rolling times of the last layer of composite pulp material rolled concrete layer are the most; in the step 2, the paving thickness of each layer of the stone slag layer is the sum of the compacted thickness and the pre-compression amount of 5-10%.
The invention has the following advantages:
(1) the materials are used locally, the stone slag materials in the invention are excavation materials with clean surfaces in the construction process of local hydraulic and hydroelectric engineering, the requirement on the particle size is low, the excavation materials can be fully utilized, no waste materials are basically produced, namely, more than 5mm of aggregate can be utilized, and the invention is energy-saving and environment-friendly; the composite slurry material roller compacted concrete layer is formed by pouring composite slurry on the excavated ballast material (basically without screening) with the thickness of 5-500 mm and performing vibration roller compaction on the composite slurry poured on the surface, and the composite slurry material roller compacted concrete layer is of a structure formed by downward seepage of the slurry due to roller compaction, so that the material is easier to obtain, and the structure is simpler;
(2) the composite slurry material roller compacted concrete has the advantages of moderate mechanical property, small hydration temperature rise, good volume stability and strong interlayer shearing resistance; the rolled block stone concrete and the construction method thereof break through the limitation of the dam height of the face rockfill dam and eliminate the technical development bottleneck of the 300 m-level ultrahigh face rockfill dam;
(3) the construction speed is high, the construction method of the composite paste roller compacted concrete is simple and convenient, the working procedure is simple, the temperature control measure can be omitted, the working efficiency is improved, and the construction period is shortened; the construction method comprises the steps of directly laying a layer of excavating stone slag material (5-500 mm, special screening is basically not needed), pouring composite slurry (without aggregate and capable of being stirred on site), and finally rolling, so that construction is more convenient;
(4) the engineering cost is saved, the excavated materials are fully utilized, and a material yard for sand and stone waste materials is not required to be arranged; the stone slag particles do not need to be screened, so that the construction and operation cost of a related screening system is saved; the composite slurry has the advantages of small cement consumption, high local mineral admixture mixing amount and obvious raw material cost saving;
(5) compared with the existing technologies such as rock-fill concrete, riprap type rock-fill concrete and the like, the invention has the advantages of low cost, good overall performance, capability of reducing rock-fill body deformation and overall settlement, suitability for engineering construction of ultrahigh rock-fill dams or other applicable building structure parts, capability of being applied to ultrahigh concrete-fill dams with the grade of 300m or even higher, and popularization and application in large-scale engineering.
Drawings
Fig. 1 is a schematic view of a rock-fill dam structure of a composite crushed concrete structure for a rock-fill dam foundation according to the present invention.
FIG. 2 is a schematic structural diagram of the stone ballast without grouting after layered stacking.
Fig. 3 is a schematic structural diagram of the roller compacted concrete of the invention after rolling.
In the figure, 1-ballast material, 2-composite slurry, 3-composite slurry roller compacted concrete base, 31-composite slurry roller compacted concrete layer, 4-concrete impermeable panel and 5-rock-fill dam body.
Detailed Description
The embodiments of the present invention will be described in detail with reference to the accompanying drawings, which are not intended to limit the present invention, but are merely exemplary. While the advantages of the invention will be clear and readily understood by the description.
With reference to the accompanying drawings: the rolling concrete structure with the composite slurry injected into the stone slag material is characterized in that: the concrete is composed of a plurality of layers of composite slurry material roller compacted concrete layers 31, wherein the composite slurry material roller compacted concrete layers are formed by vibrating and rolling stone slag materials 1 and composite slurry 2 poured on the surfaces of the stone slag materials 1, and the stone slag materials 1 are excavation materials with the particle size of more than or equal to 5 mm; the slabstone material 1 is layered and stacked on the dam foundation, the composite slurry 2 is poured on the layered and stacked slabstone material to be randomly filled with the slabstone material, and when the liquid level of the composite slurry 2 is close to the top surface of the slabstone material, the bin surface is rolled by vibration to form a grouting and rolling concrete structure with a uniform and stable structure (as shown in fig. 1, 2 and 3).
In fig. 1, the total height of the face plate rock-fill dam is 300m, the face plate rock-fill dam comprises a composite pulp material roller compacted concrete base 3 with the height of 100m, a concrete anti-seepage face plate 4 and a rock-fill dam body 5, and the rock-fill dam body 5 is positioned on the composite pulp material roller compacted concrete base 3.
The composite pulp material roller compacted concrete base 3 is composed of a plurality of layers of composite pulp material roller compacted concrete layers 31, and the height of each layer of composite pulp material roller compacted concrete layer 31 is 0.5-0.8 m; the slag charge 1 is a cutting charge with the grain diameter of 5 mm-500 mm.
The composite slurry 2 comprises clean cement slurry and a cementing material, and the fluidity of the composite slurry 2 is 200-240 mm; the water-to-gel ratio of the cement paste is 0.4-0.5; the proportion of the admixture in the cementing material is 50-70%, and the admixture is fly ash and stone powder.
With reference to the accompanying drawings: the construction method of the roller compacted concrete structure by injecting the composite slurry into the ballast material is characterized by comprising the following steps of: the method comprises the following steps:
step 1: the dam foundation and the bank slope of the rock-fill dam are processed according to the related technical requirements in the early-stage work of construction;
step 2: after the step 1 is finished, stacking the treated dam foundation by adopting the slag charge 1 with the particle size of more than 5mm in a layering way, wherein the thickness of each layer of the slag charge is 0.5-0.8 m, and leveling the dam foundation mechanically or manually;
and step 3: after the step 2 is finished, grouting is started, composite slurry is uniformly poured on the surface of the stone slag material layer during grouting, the total grouting amount of the composite slurry is the slurry pouring liquid level until the composite slurry is close to the top surface of the rockfill material or is 10-20 mm away from the top surface of the rockfill material, and a uniform composite slurry roller compacted concrete layer with strong integrity is formed;
and 4, step 4: after the step 3 is finished, a rolling vibration machine is adopted to vibrate the rolling bin surface to form a composite pulp rolling concrete layer, and the specified rolling times are finished (as shown in figures 1, 2 and 3); when the pouring amount of the composite slurry 2 does not meet the requirement, slurry supplement is carried out in the rolling process; after rolling, performing necessary early maintenance on the surface of the composite pulp material roller compacted concrete layer;
and 5: and (5) repeating the steps 2 to 4 until the layered construction of the grouting and rolling concrete structure is completed.
In the step 4, rolling for 6-8 times; the rolling times of the last layer of composite pulp material rolled concrete layer are the most; in the step 2, the paving thickness of each layer of the stone slag material layer is the compacted thickness plus 5-10% pre-compression amount, so that the smooth surface of an excavated stone slag material bin is ensured, the overall performance of the dam foundation is good, the deformation of a rock-fill body is reduced, and the overall settlement is reduced; the service life of the dam body is prolonged.
Verification test
In order to verify the application of the invention in hydraulic and hydroelectric engineering, the invention is verified by the field application test of the invention in a certain 300 m-level high-concrete face rockfill dam hydroelectric engineering construction site, and the specific test steps are as follows:
the excavation slabstone 1 directly adopts engineering excavation materials with the grain diameter of more than 5 mm; the cement is ordinary silicate 42.5 cement (P.042.5), and the admixture is F class I-grade fly ash; according to actual conditions on site, three groups of composite slurry with different mixing ratios are tested, and the mixing ratio parameters of the three groups of composite slurry are shown in table 1;
TABLE 1 composite slurry mix proportion parameters
Step 1: test preparation and site planning: the whole test strip is 44m long and is divided into 11 areas (a transition area is arranged in the middle), the length, the width and the height of each area are 4m multiplied by 1.5m, and the periphery of the strip is provided with a vertical mold;
step 2: stacking stone slag materials in a layered mode: in the planning area, the excavated stone slag materials are stacked in layers, each layer is 0.5-0.75 m thick, the stone slag materials are stacked in two to three layers, the total layer is 1.5m thick, and the flat surface of a rock-fill body bin is ensured as much as possible through mechanical or manual leveling; the stone slag material is a hydropower station tail water hole digging material, the particle size is 5 mm-500 mm, and the stone slag material is transported to a test site by a dump truck; paving the excavated stone slag materials by adopting an occupation method, wherein the thickness of the paved excavated stone slag materials is the thickness after compaction plus the pre-compression amount, and the pre-compression amount is considered to be 5-10% of the paving thickness; after the stone residue materials are paved and excavated, selecting partial areas to measure the porosity of the rockfill, wherein the porosity of the rockfill is 26-30%;
and step 3: pouring composite slurry: after the composite slurry is stirred on site, pouring the composite slurry to a corresponding test area; when grouting, composite slurry is required to be uniformly poured on the surface of the laid excavated stone slag material, and the total grouting amount is about 10-20 mm from the top surface of the rockfill material according to the liquid level of the poured slurry; wherein the grouting amount of each layer of the excavated stone slag material in the thick area of 0.5m is 1.8-2 m3About, the grouting amount of each layer of the excavated stone slag material in the thick area of 0.75m is 2.5m3Left and right;
and 4, step 4: layering and rolling: after grouting of each layer of excavated stone slag, performing vibration rolling by adopting a rolling vibration machine, and rolling by adopting a Longworker LG520D single steel wheel road roller according to the actual situation on site; wherein the first and second layers are laminated 6 times and the third layer is laminated 8 times.
After the field test block is subjected to safety flood fighting, the roller compacted concrete performance of the hardened test block is detected on the field by adopting the core drilling method, the ultrasonic wave, the geological radar and other technologies, the uniform compactness and the mechanical property of the composite slurry roller compacted concrete of the hardened test block are evaluated by detecting indexes such as the compressive strength (data) and the volume weight (data) of the concrete, and the detection result shows that the composite slurry roller compacted concrete of the test block is uniform and stable, and the mechanical property of the composite slurry roller compacted concrete of the test block is shown in the following table 2.
TABLE 2 compressive strength of concrete core samples
From the above table 2, it can be seen that the mechanical properties of the composite slurry roller compacted concrete of the test block of the invention are good, and the application of the composite slurry roller compacted concrete structure of the invention to a 300 m-grade high concrete faced rock-fill dam is technically feasible.
Other parts not described belong to the prior art.
Claims (4)
1. Be applied to rolling concrete structure of 300m level super high-rise face rockfill dam, its characterized in that: the mortar is composed of a plurality of layers of composite mortar rolled concrete layers, wherein the composite mortar rolled concrete layers are formed by stone slag materials (1) and composite grout (2) poured on the surfaces through vibration rolling; the stone slag materials (1) are stacked on the dam foundation layer by layer, the composite slurry (2) is poured on the stone slag materials stacked layer by layer to be randomly filled with the stone slag materials, and when the liquid level of the composite slurry (2) is close to the top surface of the stone slag materials, a grouting and rolling concrete structure with a uniform and stable structure is formed by vibrating and rolling the bin surface;
the height of each layer of composite pulp material roller compacted concrete layer (3) is 0.5 m-0.8 m; the stone slag material (1) is a cutting material with the particle size of 5 mm-500 mm.
2. The roller compacted concrete structure applied to a 300 m-grade ultra-high-face rockfill dam according to claim 1, wherein: the composite slurry (2) comprises cement paste, fly ash and stone powder, and the flowability of the composite slurry (2) is 200-240 mm; the water-to-gel ratio of the cement paste is 0.4-0.5.
3. The method of constructing a roller compacted concrete structure applied to a 300 m-grade ultra-high-face rock-fill dam according to any one of claims 1 to 2, wherein: the method comprises the following steps:
step 1: the dam foundation and the bank slope of the rock-fill dam are processed according to the related technical requirements in the early-stage work of construction;
step 2: after the step 1 is finished, adopting stone slag materials (1) with the particle size of 5 mm-500 mm to stack on the treated dam foundation layer by layer, wherein the thickness of each layer of the stone slag material layer is 0.5 m-0.8 m, and leveling the dam foundation layer mechanically or manually;
and step 3: after the step 2 is finished, grouting is started, composite slurry is uniformly poured on the surface of the stone slag material layer during grouting, and the total grouting amount of the composite slurry is the pouring slurry liquid level until the composite slurry is close to the top surface of the rockfill material;
and 4, step 4: after the step 3 is finished, adopting a rolling vibration machine to vibrate the rolling bin surface to form a composite pulp rolling concrete layer, and finishing the specified rolling times; when the pouring amount of the composite slurry (2) does not meet the requirement, slurry supplement is carried out in the rolling process; after rolling, performing necessary early maintenance on the surface of the composite pulp material roller compacted concrete layer;
and 5: and (5) repeating the steps 2 to 4 until the layered construction of the grouting and rolling concrete structure is completed.
4. The method of constructing a roller compacted concrete structure applied to a 300 m-grade ultra-high-face rock-fill dam as claimed in claim 3, wherein: in the step 4, rolling for 6-8 times; the rolling times of the last layer of composite pulp material rolled concrete layer are the most; in the step 2, the paving thickness of each layer of the stone slag layer is the sum of the compacted thickness and the pre-compression amount of 5-10%.
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