CN110185004B - 混凝土面板堆石坝脱空处理方法 - Google Patents
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Abstract
本发明公开了一种混凝土面板堆石坝脱空处理方法，具体步骤为：1）对面板堆石坝进行脱空情况无损检测；2）对存在脱空的区域钻注浆孔，孔径为2‑5cm，相邻注浆孔的距离为20‑50cm；3）通过注浆孔向脱空处注射高聚物材料，4）利用红外热成像、地质雷达、声波反射法中的至少一种方法测评混凝土面板堆石坝处理位置的性能，确定注浆效果，如满足要求，则停止注浆；如不满足要求，则需进行补注至达到要求，完成脱空处理。采用该方法能够实现面板堆石坝脱空区快速无损处理，而且脱空区可以为挤压边墙脱空区、面板堆石坝施工期面板脱空区、面板堆石坝运行期面板脱空区、坝顶防浪墙底部脱空区及坝顶混凝土路面底部脱空区，适用范围广。
Description
技术领域
本发明属于水利水电工程技术领域，涉及混凝土面板堆石坝脱空处理方法及脱空处理用的高聚物。
背景技术
混凝土面板堆石坝(简称“面板堆石坝”)是以碾压堆石体为支撑结构，以上游面混凝土面板为防渗体的挡水大坝，具有结构简单、施工方便、经济性突出等优点，是水利水电工程建设广泛采用的一种坝型。目前，面板堆石坝的坝高已发展到200m级，正往更高坝高发展。
混凝土面板坝脱空区主要为挤压边墙脱空区、面板堆石坝施工期面板脱空区、面板堆石坝运行期面板脱空区，坝顶防浪墙底部脱空区及坝顶混凝土路面底部脱空区。
其中挤压边墙脱空区的产生是由于混凝土面板坝上游坡面的施工是一个控制坝体填筑进度和影响坝体质量的关键环节，为保证上游垫层坡面施工质量，简化施工工序，采用挤压边墙施工技术，挤压边墙是在垫层区上游侧由挤压机连续挤压形成的低标号混凝土边墙，简化了坡面施工程序、节省填筑材料和碾压的工作量。由于垫层料是一种人工填筑的细料，是一种松散体，虽然经过反复辗压，但在大坝面板施工之前仍有较大沉降，而挤压边墙相对垫层料而言为刚性体，强度较大，其在重力作用下，却只会发生较小的变形沉降，不能与坝体的变形相协调，因此挤压边墙与垫层料之间的难免会有脱空情况。如果挤压边墙与垫层料之间的脱空在蓄水之前未被发现和处理，面板挡水后可能在水压力的作用下发生开裂。在以往面板堆石坝挤压边墙的脱空处理中，传统的处理方法是开挖回填处理，该方法费时、费力、造价高，且质量也得不到保障，对面板的运行安全仍然存在隐患。
面板堆石坝施工期面板脱空区的形成主要是由于度汛、工期、提前发电效益需求等原因，一般都采取分期施工面板，前期面板施工完成后，在前期坝体自重和继续填筑的后续坝体的作用下，坝体会发生沉降变形，由于面板混凝土材料的模量远大于堆石料的模量，面板难以与堆石坝体的变形相协调，致使前期面板上部离开坝体而形成脱空。
面板堆石坝运行期面板脱空区是面板堆石坝在运行期间常见的一种病害，尽管在施工过程中坝体堆石料经振动碾反复碾压，但在大坝运行期间，由于堆石料的流变性，坝体仍会产生沉陷，如天生桥一级水电站面板堆石坝在运行过程中出现了面板与垫层料间脱空、面板挤压破坏等问题。此外，当遭遇地震作用，面板堆石坝会产生较大的地震永久变形，也会导致面板出现脱空，如2008年5.12汶川大地震中，紫坪铺面板堆石坝左岸845.0m高程以上面板出现了大面积脱空，约有23块，右岸面板顶部(870.0m高程以上)全部脱空。库水压力作用于脱空位置的面板，可能会造成面板开裂和挤压破坏，对大坝安全带来严重影响。
同样，在面板堆石坝运行过程中或遭遇地震的时候，坝顶防浪墙和坝顶混凝土路面与坝体也会产生脱空。
在以往面板坝的脱空处理中，多采用水泥和粉煤灰混合料组成的水泥粉煤灰稳定浆液进行充填灌浆处理，存在压浆孔大、破坏面板整体性、灌浆压力不易控制、浆液流动性差、需要一定养护时间、浆液凝固收缩等缺点，当脱空部位较大，采用水泥粉煤灰灌浆，灌浆处理部位后期仍可能产生较大变形。
发明内容
本发明提供一种混凝土面板堆石坝脱空处理方法，能够实现快速无损处理。
本发明采取的技术方案是，一种混凝土面板堆石坝脱空处理方法，包括下列步骤：
1)采用地质雷达、红外热成像、声波反射法中的至少一种方法对面板堆石坝进行脱空情况无损检测；
2)对存在脱空的区域钻注浆孔，孔径为2-5cm，相邻注浆孔的距离为20-50cm；
3)通过注浆孔向脱空处注射高聚物材料，高聚物材料在脱空处体积膨胀，填满脱空区并固化胶结在一起形成高聚物注浆复合体；
4)利用红外热成像、地质雷达、声波反射法中的至少一种方法测评混凝土面板堆石坝处理位置的性能，确定注浆效果，如满足要求，则停止注浆；如不满足要求，则需进行补注至达到要求，完成脱空处理。
上述脱空处理方法可用于处理混凝土面板坝挤压边墙脱空区、面板堆石坝施工期面板脱空区、面板堆石坝运行期面板脱空区、坝顶防浪墙底部脱空区及坝顶混凝土路面底部脱空区。
进一步地，在注射高聚物材料的过程中，从注浆孔的底部向上逐渐提升注浆管，浆液自下而上填满脱空区，形成高聚物注浆复合体。
进一步地，所述步骤3)中的高聚物材料的固化时间在20min以内。
进一步地，所述步骤3)中的高聚物材料采用A组分和B组分按重量比1-1.5:1配制而成，其中A组分包含聚醚多元醇100份、三乙醇胺2-8份、环氧树脂20-30份、邻苯二甲酸二辛酯5-10份、短切聚丙烯纤维2-5份、扩链剂1-3份、引发剂0.5-2份、交联剂1-3份和催化剂辛酸亚锡0.1-0.5份；其中B组分为异氰酸酯。
进一步地，所述聚醚多元醇的羟值在350～400mgKOH/g，分子量为800-2000。
进一步地，所述扩链剂为二元醇，引发剂为偶氮二异丁腈，交联剂为N,N二甲基苄胺。
进一步地，所述异氰酸酯为甲苯二异氰酸酯、异佛尔酮二异氰酸酯及六亚甲基二异氰酸酯中的一种或几种。
进一步地，所述短切聚丙烯纤维的长度为1cm以下。
进一步地，所述高聚物材料注射前，先将A组分中的聚醚多元醇和短切聚丙烯纤维混合，然后加入其它物料，在100-115℃，真空条件下脱水并搅拌混合均匀得到A组分，使用前将A组分和B组分按配比混合3-5min得到高聚物材料。
进一步地，所述短切聚丙烯纤维与聚醚多元醇混合前，采用甲苯浸渍处理0.5-1min，或者喷洒甲苯至其表面。
目前常用的面板堆石坝脱空无损探测方法有地质雷达、声波垂直反射法、地震波垂直反射法及红外热成像等，各种方法都有其一定的局限性，受周围环境及测试条件的影响较大。采用单一方法对于探测的准确性无法保证，容易出现误判或漏判，很难满足大坝面板脱空无损探测的准确率要求。采用多组探测方法组合，能够大幅提升判断的准确性。
高聚物注浆是近年来被广泛关注的技术，高聚物浆液通过化学反应形成固体.同时体积迅速膨胀，高聚物注浆材料自身体积膨胀可达20倍，因此，它不完全依赖压浆压力来填充脱空区，其膨胀性能保障了其对填充区域的压实作用。高聚物渗透扩散填充到脱空区域，依靠自身体积的膨胀达到填充脱空区域的目的，并通过体积的快速膨胀与周围区域填充密实，达到脱空处理的效果。
本发明提供的高聚物中，三乙醇胺具有交联和催化的双重作用，通过三乙醇胺、交联剂N,N二甲基苄胺和催化剂辛酸亚锡的共同作用，促进聚醚多元醇中的-OH与异氰酸酯中的-NCO反应生成交联结构，而且N,N二甲基苄胺能够促进网状结构的形成，提高材料的韧性。环氧树脂的使用可以根据需要调整用量来控制高聚物固化时间；邻苯二甲酸二辛酯作为增塑剂使用；
本发明的高聚物为非水反应类、双组份发泡体、水不敏感型高聚物注浆材料，采用聚醚多元醇和异氰酸酯反应产生聚氨酯，通过添加短切聚丙烯纤维能够提高材料的抗压强度和抗折强度，同时加入短切聚丙烯纤维后聚醚多元醇和异氰酸酯反应体积增加，能够增加材料的韧性和抗渗性，由此能提高高聚物硬化后的抗疲劳强度、抗碎裂能力和抗冲刷能力，从而达到更好的面板堆石坝脱空处理效果。在聚丙烯纤维加入前，采用甲苯对其进行预处理，一方面可以对短切聚丙烯纤维进行软化，增加材料的流动性，防止注浆时发生堵塞，另外，在甲苯处理后的短切聚丙烯纤维更容易与聚醚多元醇及其他原料混合，进一步增加材料的防渗性能。
本发明采用高聚物进行填充，高聚物材料用量较少，只有水泥注浆体积的25％，工时较短，只需要几个小时；压浆孔径小，不易对面板或边墙造成损伤，另外高聚物材料轻质，重量仅相当于同体积水泥、水泥混凝土的5％，注浆时材料不发生弱交叉结合，强大的结合力避免了处理后的材料因浸水导致的坍塌。这些特点相对于传统的开挖维修或者水泥压浆方法具有明显的优越性。不仅可以节省大量经费和工期，而且有利于保护环境和节约资源。
本发明具有以下有益效果：
1、耐久性好。注射的高聚物材料寿命至少50年以上，不会发生收缩和变质，满足遇水不收缩，防水性能优良，基本无收缩(10年内体积收缩1～3％)，并具有较好的弹性。而传统水泥压浆会产生干缩，固结后为脆性材料，抗折强度低，因此耐久性较差。
2、早强。材料注射后15分钟内即形成90％的强度，而传统水泥压浆由于养生要求，对工期影响较大。
3、针对性强，可控性好。高聚物材料在膨胀过程中可自行填充、加固松散区或软弱区，对周围介质压力主要取决于注浆量的大小，而不象传统压浆方法主要取决于注浆压力。注浆量的控制与调整显然比注浆压力的控制与调整更为方便。
4、高膨胀。高聚物材料的自由膨胀率比达20倍以上，可以迅速填充裂隙和封堵渗漏，同时进一步压密周围介质，具备反压注浆的特性。
5、轻质：材料膨胀固化后，其自重一般不到同体积水泥浆的10％，极大地减少了自重对结构的附加荷载。
6、防水：形成的泡沫状固体为闭孔材料，防水性能优良。
7、环保：对环境无污染。
具体实施方式
下面结合实施例，进一步阐明本发明。
实施例：
混凝土面板堆石坝挤压边墙脱空处理方法，包括以下步骤：
1)采用地质雷达对某面板堆石坝挤压边墙脱空情况进行无损检测；地质雷达在面板堆石坝挤压边墙脱空检测中效果明显，可以实现无损、快速、可视等优点，脱空深度可精确至2-3cm；通过检测，发现多处缺陷，缺陷的长度在1-3m，横向宽度较小；
2)对存在脱空的挤压边墙上钻注浆孔，孔径为2cm，相邻注浆孔的距离为20-50cm；
3)通过注浆孔向挤压边墙脱空处注射高聚物材料，在注射过程中，从注浆孔的底部向上逐渐提升注浆管，浆液自下而上填满脱空区，并通过体积膨胀与周围坝体固化胶结在一起形成高聚物注浆复合体；
4)利用红外热成像、地质雷达扫描和声波反射法测评价挤压边墙性能，确定注浆效果，如满足要求，则停止注浆；如不满足要求，则需进行补注至达到要求，完成脱空处理。
实施例2：
混凝土面板堆石坝施工期面板脱空处理方法，包括以下步骤：
1)面板坝施工完成之后，在大坝蓄水之前，以红外热成像和地质雷达扫描普查，其中红外热成像是测面普查，地质雷达扫描是测线普查，地质雷达检测和超声横波反射法对缺陷位置详查的面板无损脱空识别；
2)对存在脱空的混凝土面板钻注浆孔，孔径为2cm，相邻注浆孔的距离为20-50cm；
3)通过注浆孔向脱空处注射高聚物材料，灌浆压力以不抬动面板为准，在注射过程中，从注浆孔的底部向上逐渐提升注浆管，浆液自下而上填满脱空区，并通过体积膨胀与周围坝体固化胶结在一起形成高聚物注浆复合体；
4)利用红外热成像、地质雷达扫描检和声波反射法测评价面板性能，确定注浆效果，如满足要求，则停止注浆；如不满足要求，则需进行补注至达到要求，完成脱空处理。
实施例3：
混凝土面板堆石坝运行期面板脱空处理方法，包括以下步骤：
1)以红外热成像和地质雷达扫描普查，其中红外热成像是测面普查，地质雷达扫描是测线普查，地质雷达检测和超声横波反射法对缺陷位置详查的面板无损脱空识别；
2)对存在脱空的混凝土面板钻注浆孔，孔径为3cm，相邻注浆孔的距离为20-50cm；
3)通过注浆孔向脱空处注射高聚物材料，灌浆压力以不抬动面板为准，在注射过程中，从注浆孔的底部向上逐渐提升注浆管，浆液自下而上填满脱空区，并通过体积膨胀与周围坝体固化胶结在一起形成高聚物注浆复合体；
4)利用红外热成像、地质雷达扫描检和声波反射法测评价面板性能，确定注浆效果，如满足要求，则停止注浆；如不满足要求，则需进行补注至达到要求，完成脱空处理。
实施例4：
高聚物材料采用A组分和B组分按重量比1:1配制而成，其中A组分包含聚醚多元醇100份(其采用至少两种聚醚多元醇组合而成，官能度在2-3，羟值在350～400mgKOH/g，分子量为800-2000)、三乙醇胺6份、环氧树脂20份、邻苯二甲酸二辛酯5份、短切聚丙烯纤维3份(长度在1cm以下)、扩链剂乙二醇1份、引发剂偶氮二异丁腈0.5份、交联剂N,N二甲基苄胺1份和催化剂辛酸亚锡0.1份；其中B组分为甲苯二异氰酸酯。
制备时先将A组分中的聚醚多元醇和短切聚丙烯纤维混合，然后加入其它物料，在100-115℃，真空条件下脱水并搅拌混合均匀得到A组分，使用前将A组分和B组分按配比混合3-5min得到高聚物材料。
实施例5：
高聚物材料采用A组分和B组分按重量比1.2:1配制而成，其余同组方1。其中A组分包含聚醚多元醇303 100份、三乙醇胺3份、环氧树脂25份、邻苯二甲酸二辛酯8份、短切聚丙烯纤维3份、扩链剂乙二醇2份、引发剂偶氮二异丁腈1份、交联剂N,N二甲基苄胺2份和催化剂辛酸亚锡0.3份；其中B组分为甲苯二异氰酸酯。
制备时先将A组分中的聚醚多元醇和短切聚丙烯纤维混合，然后加入其它物料，在100-115℃，真空条件下脱水并搅拌混合均匀得到A组分，使用前将A组分和B组分按配比混合3-5min得到高聚物材料。
实施例6：
高聚物材料采用A组分和B组分按重量比1.5:1配制而成，其中A组分包含聚醚多元醇303 100份、三乙醇胺8份、环氧树脂30份、邻苯二甲酸二辛酯10份、长度为1cm以下短切聚丙烯纤维3份、扩链剂乙二醇3份、引发剂偶氮二异丁腈2份、交联剂N,N二甲基苄胺3份和催化剂辛酸亚锡0.5份；其中B组分为甲苯二异氰酸酯。
制备时先将A组分中的聚醚多元醇和短切聚丙烯纤维混合，然后加入其它物料，在100-115℃，真空条件下脱水并搅拌混合均匀得到A组分，使用前将A组分和B组分按配比混合3-5min得到高聚物材料。
实施例7：
配方同案例1，制备时先将短切聚丙烯纤维采用甲苯浸渍处理0.5min，取出后与聚醚多元醇，然后加入其它物料，在100-115℃，真空条件下脱水并搅拌混合均匀得到A组分，使用前将A组分和B组分按配比混合3-5min得到高聚物材料。
对实施例4-7中得到的高聚物材料利用注浆机械将其注入砂浆三联试模中成型标准试件，用于高聚物复合注浆材料的性能测试，其结果如下表1所示。
表1
Claims (6)
1.一种混凝土面板堆石坝脱空处理方法，其特征在于，包括下列步骤：
1）采用地质雷达、红外热成像、声波反射法中的至少一种方法对面板堆石坝进行脱空情况无损检测；
2）对存在脱空的区域钻注浆孔，孔径为2-5cm，相邻注浆孔的距离为20-50cm；
3）通过注浆孔向脱空处注射高聚物材料，高聚物材料在脱空处体积膨胀，填满脱空区并固化胶结在一起形成高聚物注浆复合体；高聚物材料采用A组分和B组分按重量比1-1.5:1配制而成，其中A组分包含聚醚多元醇100份、三乙醇胺2-8份、环氧树脂20-30份、邻苯二甲酸二辛酯5-10份、短切聚丙烯纤维2-5份、扩链剂1-3份、引发剂0.5-2份、交联剂1-3份和催化剂辛酸亚锡0.1-0.5份；其中B组分为异氰酸酯；高聚物材料注射前，先将A组分中的聚醚多元醇和短切聚丙烯纤维混合，然后加入其它物料，在100-115℃，真空条件下脱水并搅拌混合均匀得到A组分，使用前将A组分和B组分按配比混合3-5min得到高聚物材料；所述短切聚丙烯纤维的长度为1cm以下；短切聚丙烯纤维与聚醚多元醇混合前，采用甲苯浸渍处理0.5-1min，或者喷洒甲苯至其表面；
4）利用红外热成像、地质雷达、声波反射法中的至少一种方法测评混凝土面板堆石坝处理位置的性能，确定注浆效果，如满足要求，则停止注浆；如不满足要求，则需进行补注至达到要求，完成脱空处理。
2.根据权利要求1所述的方法，其特征在于：在注射高聚物材料的过程中，从注浆孔的底部向上逐渐提升注浆管，浆液自下而上填满脱空区，形成高聚物注浆复合体。
3.根据权利要求1所述的方法，其特征在于：所述步骤3）中的高聚物材料的固化时间在20min以内。
4.根据权利要求1所述的方法，其特征在于：所述聚醚多元醇的羟值在350～400mgKOH/g，分子量为800-2000。
5.根据权利要求1所述的方法，其特征在于：所述扩链剂为二元醇，引发剂为偶氮二异丁腈，交联剂为N,N二甲基苄胺。
6.根据权利要求1所述的方法，其特征在于：所述异氰酸酯为甲苯二异氰酸酯、异佛尔酮二异氰酸酯及六亚甲基二异氰酸酯中的一种或几种。
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