CN110640866A - Interlocking plate prefabricating process - Google Patents

Interlocking plate prefabricating process Download PDF

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Publication number
CN110640866A
CN110640866A CN201910711621.3A CN201910711621A CN110640866A CN 110640866 A CN110640866 A CN 110640866A CN 201910711621 A CN201910711621 A CN 201910711621A CN 110640866 A CN110640866 A CN 110640866A
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China
Prior art keywords
interlocking
curing
concrete
pouring
lower die
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CN201910711621.3A
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Chinese (zh)
Inventor
李平
张汇
宋涛
杜冰群
余浩波
李杏波
章俊
周吉
江山
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CHANGJIANG WUHAN WATERWAY ENGINEERING BUREAU
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CHANGJIANG WUHAN WATERWAY ENGINEERING BUREAU
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Priority to CN201910711621.3A priority Critical patent/CN110640866A/en
Publication of CN110640866A publication Critical patent/CN110640866A/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/08—Producing shaped prefabricated articles from the material by vibrating or jolting
    • B28B1/087—Producing shaped prefabricated articles from the material by vibrating or jolting by means acting on the mould ; Fixation thereof to the mould
    • B28B1/0873—Producing shaped prefabricated articles from the material by vibrating or jolting by means acting on the mould ; Fixation thereof to the mould the mould being placed on vibrating or jolting supports, e.g. moulding tables
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
    • B28B11/245—Curing concrete articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
    • B28B13/02—Feeding the unshaped material to moulds or apparatus for producing shaped articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/38—Treating surfaces of moulds, cores, or mandrels to prevent sticking
    • B28B7/382—Devices for treating, e.g. sanding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/38—Treating surfaces of moulds, cores, or mandrels to prevent sticking
    • B28B7/384—Treating agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/38—Treating surfaces of moulds, cores, or mandrels to prevent sticking
    • B28B7/388—Treating surfaces of moulds, cores, or mandrels to prevent sticking with liquid material, e.g. lubricating

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Structural Engineering (AREA)
  • On-Site Construction Work That Accompanies The Preparation And Application Of Concrete (AREA)

Abstract

The invention relates to a process for prefabricating an interlocking plate, which comprises the following steps: preparing concrete for pouring according to the formula proportion; cleaning the upper die and the lower die, and brushing a release agent; firstly fixing a lower die, then laying a cord in the lower die, and then installing an upper die; quantitatively pouring the prepared concrete into a mold, vibrating after pouring, and forming a product in the mold; maintaining the molded interlocking piece; the interlocking pieces are demolded and placed in a storage area for later use. The invention solves the defects in the prior art, adopts standardized processing operation, realizes the smooth surface and uniform compactness of the finished product, avoids the phenomena of edge damage and the like of the finished product in the demoulding process, has high quality of the finished product and reduces the defective rate.

Description

Interlocking plate prefabricating process
Technical Field
The invention relates to the technical field of construction material processing, in particular to a process for prefabricating an interlocking plate.
Background
The interlocking piece pavement structure is a flexible pavement structure developed in the last decade and is widely used in dam engineering and channel engineering at present, the interlocking piece is formed by closely arranging high-strength cement concrete prefabricated blocks according to a specific method, and under the action of an external load, the blocks are not stressed independently, but are mutually interlocked and diffused. Has the following advantages: the cost is low, the paving is convenient, the sliding resistance and the temperature deformation resistance are realized, the technical requirements on constructors are low, and the construction is convenient; the adaptability to foundation settlement is strong, the method can adapt to uneven settlement of the foundation, and the vertical and horizontal resistance is high; the adaptability is strong, the block can be opened and used immediately after construction is finished, the service life is long, the block can be repeatedly used, the residual value is higher than that of other pavement types, and the maintenance and the transformation are convenient; the blocks are produced in batches, the cost is low, the product quality is ensured, high-energy-consumption products such as asphalt do not need to be used, and the requirements of environmental protection, low carbon, energy conservation and emission reduction in the modern society are met.
At present, the interlocking piece is produced in a prefabricating field in a prefabricating mode, and the following problems exist: the finished product has the defects of easy occurrence of holes on the surface, uneven surface, non-ideal quality of the finished product, uneven compactness, poor demoulding effect and easy occurrence of edge damage or grinding of the finished product after demoulding.
Chinese patent CN103171025B discloses a method for prefabricating interlocking plates, which comprises the following steps: presetting an interlocking piece connecting rope in a lower die of an interlocking piece extruding device; starting a conveying device, and conveying the hard concrete prepared in advance on the feeding platform into a storage chamber and a feeding channel; opening the switch door, and horizontally pushing the dry and hard concrete in the feeding channel into a lower die of the interlocking piece extrusion device; after the detection system detects that the injection modulus of the dry and hard concrete meets the requirement, the horizontal pushing is reset, the switch door is closed, and the dry and hard concrete in the storage chamber enters the feeding channel to wait; closing the interlocking piece extrusion device, extruding the lower die by the upper die to enable the lower die to retract along with the pressure, and pressing and forming the interlocking piece; resetting an upper die of the interlocking piece extrusion device; and (4) feeding the formed interlocking pieces into a hoisting transfer platform. The above-mentioned patent adopts the hard concrete, extrudees through last mould and lower mould, and one-time molding omits concrete mixing and maintenance process, nevertheless because of adopting hard concrete, the damaged phenomenon appears in the course of working very easily, and final product quality hardly guarantees.
Therefore, how to provide a interlocking plate prefabricating process to realize finished product surface flatness and uniform compactness, avoid edge damage in the demolding process and improve the quality of finished products is a technical problem to be solved urgently by technical personnel in the field at present.
Disclosure of Invention
In view of this, the present application aims to provide an interlocking sheet prefabrication process to realize finished product surface smoothness, compactness is even, avoid edge damage in the demolding process, improve finished product quality.
In order to achieve the above object, the present application provides the following technical solutions.
An interlocking plate prefabricating process comprises the following steps:
101. preparing concrete for pouring according to the formula proportion;
102. cleaning the upper die and the lower die, and brushing a release agent;
103. after step 102, fixing a lower die, laying a cord in the lower die, and then installing an upper die;
104. pouring the concrete prepared in the step 101 into a mold quantitatively, vibrating after pouring, and forming a product in the mold;
105. after step 104, maintaining the molded interlocking pieces;
106. after step 105, the interlocking pieces are demolded and placed in a storage area for later use.
Preferably, the concrete in step 101 comprises the following components in parts by weight: 300 to 400kg/m3600-700 kg/m of cement31100-1200 kg/m of sand3Crushed stone of 200-250 kg/m34-5 kg/m of mixing water3A composite early strength agent.
Wherein the cement strength grade is P.O.42.5 (ordinary portland cement); the sand is medium sand with fineness modulus of 2.3-3.0%, and the mud content is less than 3%; the crushed stone particle composition is 5-20 mm, and the mud content is less than 1%; the pH value of the blending water is more than 4, the chloride (calculated by C1 < - >) is less than 3000mg/L, and the sulfate (calculated by SO2 < -4 >) is less than 2200 mg/L; the composite early strength agent has initial setting time of-60 to +90min, final setting time of-60 to +90min, compression strength ratio of 1d to 140%, 3d to 135%, 7d to 120%, 28d to 100%.
Preferably, the volume weight of the concrete is 2300-2400 kg/m3The slump is 100-120 mm, and the strength is not lower than 20 MP.
Preferably, in the step 102, the residual concrete slag on the surfaces of the upper die and the lower die, the end faces, the clamp, the sleeve positioning pin and the positioning screw is removed by using an iron shovel, so that the interiors of the upper die and the lower die are clean and have no impurities.
Preferably, the release agent in the step 102 is an aqueous release agent, and the painting thickness of the release agent is less than 0.5mm, and preferably 0.2-0.4 mm.
Preferably, the cord in step 103 is a polypropylene cord, and the cord is laid in a manner that one side of the mold is of a single cord structure and the other side of the mold is of a serpentine structure.
Preferably, the diameter of the polypropylene rope is 10-15 mm.
Preferably, in the step 104, the pouring is a mode of synchronous, uniform and continuous pouring on the mold, the frequency of the vibration is 3-4 times, and the vibration time is 5-15 s.
Preferably, the vibration mode comprises vibration of a vibration table and a flat plate vibrator.
Preferably, the curing in the step 105 is carried out by atomizing water vapor to solidify the concrete, the curing temperature is 50-60 ℃, and the curing time is 4-6 hours.
Preferably, the curing in the step 105 comprises a first curing and a second curing, wherein the first curing is dry steaming, the curing temperature is 50-60 ℃, and the curing time is 1-2 hours;
and the second curing is spraying high-temperature steam, wherein the curing temperature is 50-60 ℃, and the curing time is 4-6 h.
The beneficial technical effects obtained by the invention are as follows:
1) the invention solves the problems of the prior interlocking piece prefabrication production, adopts standardized processing operation, realizes the smooth surface and uniform compactness of a finished product, avoids the phenomenon of edge damage of the finished product in the demoulding process and has high quality of the finished product;
2) in the invention, the precast block is maintained by adopting a method of atomizing water vapor, so that the surface of the interlocking block is moisturized, cracks are avoided, the maintenance temperature and time are accurately controlled, and the maintenance quality is ensured;
3) the invention adopts the material distributing machine to distribute the material quantitatively, thus improving the accuracy and the uniformity of the material distribution and being beneficial to controlling the quality of finished products; vibration treatment is carried out after the cloth is distributed, the vibration frequency and the vibration time are accurately controlled, the compactness of a finished product is controlled, and meanwhile, the flatness of the surface of the finished product is guaranteed.
The foregoing description is only an overview of the technical solutions of the present application, so that the technical means of the present application can be more clearly understood and the present application can be implemented according to the content of the description, and in order to make the above and other objects, features and advantages of the present application more clearly understood, the following detailed description is made with reference to the preferred embodiments of the present application and the accompanying drawings.
The above and other objects, advantages and features of the present application will become more apparent to those skilled in the art from the following detailed description of specific embodiments thereof, taken in conjunction with the accompanying drawings.
Drawings
In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings needed to be used in the description of the embodiments or the prior art will be briefly introduced below, and it is obvious that the drawings in the following description are some embodiments of the present application, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without creative efforts. Throughout the drawings, like elements or portions are generally identified by like reference numerals. In the drawings, elements or portions are not necessarily drawn to scale.
Fig. 1 is a process flow diagram of an interlocking piece prefabrication process of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application, and it is obvious that the described embodiments are some embodiments of the present application, but not all embodiments. In the following description, specific details such as specific configurations and components are provided only to help the embodiments of the present application be fully understood. Accordingly, it will be apparent to those skilled in the art that various changes and modifications may be made to the embodiments described herein without departing from the scope and spirit of the present application. In addition, descriptions of well-known functions and constructions are omitted in the embodiments for clarity and conciseness.
Further, the present application may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.
The term "and/or" herein is merely an association describing an associated object, meaning that three relationships may exist, e.g., a and/or B, may mean: a exists alone, B exists alone, and A and B exist at the same time, and the term "/and" is used herein to describe another association object relationship, which means that two relationships may exist, for example, A/and B, may mean: a alone, and both a and B alone, and further, the character "/" in this document generally means that the former and latter associated objects are in an "or" relationship.
It is further noted that, herein, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion.
Example 1
As shown in the attached figure 1, the interlocking plate prefabricating process comprises the following steps:
101. and preparing concrete for pouring according to the formula proportion.
Wherein, the concrete comprises the following components by weight: 300kg/m3600kg/m of cement3Sand, 1100kg/m3Crushed stone of 200kg/m3Mixing water, 4kg/m3A composite early strength agent. The concrete stirred at the stirring station is transferred to the distributing machine through the stirring truck, and the concrete in the stirring truck is transferred to a distributing box on the distributing machine through the hoisting and conveying device.
Wherein the cement strength grade is P.O.42.5 (ordinary portland cement); the sand is medium sand with fineness modulus of 2.3-3.0%, and the mud content is less than 3%; the crushed stone particle composition is 5-20 mm, and the mud content is less than 1%; the pH value of the blending water is more than 4, the chloride (calculated by C1 < - >) is less than 3000mg/L, and the sulfate (calculated by SO2 < -4 >) is less than 2200 mg/L; the composite early strength agent has initial setting time of-60 to +90min, final setting time of-60 to +90min, compression strength ratio of 1d to 140%, 3d to 135%, 7d to 120%, 28d to 100%.
Concrete mixing must meet 3 basic requirements: accurate measurement, thorough stirring and stable slump. Otherwise, the cement mortar distribution is not uniform in concrete mixture, which brings congenital deficiency to concrete pouring, and color difference is left on the concrete surface, or non-uniformity phenomena such as easy segregation and bleeding of concrete vibration occur.
The volume weight of the concrete prepared after stirring is 2350kg/m3The slump is 100mm, and the strength is not lower than 20 MP.
102. Cleaning the upper die and the lower die, and brushing a release agent.
Wherein, upper and lower mould adopts portable steel mould, uses shaped steel and stamping workpiece section bar welding to form, and the die height ratio with last mould is 3: 1, the sizes of the upper die and the lower die are 5 multiplied by 4m, the interlocking blocks are distributed by 10 multiplied by 8, and the total number of the interlocking blocks is 80.
The cleaning adopts a shovel to shovel off the residual concrete slag on the surfaces of the upper die and the lower die, the end faces, the clamp, the sleeve positioning pin and the positioning screw, so that the interiors of the upper die and the lower die are clean and have no sundries.
The release agent is a water-based release agent, has no influence on the quality of products, and is pollution-free and environment-friendly; and spraying a release agent by using an automatic spraying machine, wherein the coating thickness of the release agent is 0.2 mm.
103. After step 102, fixing the lower die, laying a cord in the lower die, and installing the upper die.
The lower die is fixed firstly, then the cord is laid, the upper die is moved to the upper side of the lower die through the crane, then the side sections of the upper die and the lower die are aligned, the clamp is fixed through the bolts, the rubber pad is arranged in the clamp, the installation is firm, and the abutted seam is tight.
The wire rope is a polypropylene fiber rope, the diameter of the polypropylene fiber rope is 10mm, and the wire rope is distributed in a mode that the 5m long side of the mold is of a single-rope structure and is used for connecting adjacent interlocking blocks on one row; the 4m long edge is of a snake-shaped structure and is used for connecting adjacent interlocking blocks on an adjacent row, and meanwhile, the interlocking blocks on the adjacent row are connected on the edge, so that the tightly arranged reticular interlocking pieces are formed.
104. And (4) pouring the concrete prepared in the step (101) into a mold quantitatively, vibrating after pouring, and forming a product in the mold.
The pouring is a mode of synchronously, uniformly and continuously pouring the mould, the embedded part and the connecting part are ensured not to deform or move during concrete pouring, and measures are taken to correct in time if deviation exists; after pouring, the mould is vibrated by adopting vibration of a vibration table, the vibration frequency is 3 times, excessive vibration and leakage vibration are strictly forbidden, and the vibration time is 5 s.
The concrete tap is characterized in that: the concrete had not significantly subsided, the surface was flat, and the concrete had not bubbled and began to flood.
105. And (104) curing the molded interlocking piece.
The mode of maintenance is atomizing steam, makes the concrete solidify, shifts the mould to the maintenance room in, and the temperature is 50 ℃ in the maintenance room, adopts high-temperature steam circulation to carry out the heating of maintenance room, and the principle of similar radiator sprays a small amount of high-temperature steam simultaneously, because of the lower quick fog steam of liquefaction zone uniform temperature of room temperature, moisturizes the interlock piece surface to avoid the interlock piece surface to appear the crack, the maintenance time is 6 h.
In the curing process, the phenomenon that the temperature rises too fast and too high is avoided, the moisture on the surface of the concrete is easily and rapidly taken away, and a drying shrinkage crack is formed.
106. After step 105, the interlocking pieces are demolded and placed in a storage area for later use.
The upper die and the lower die are sequentially dismounted by adopting a crane, the interlocking pieces are separated from the lower die in a hoisting mode when the lower die is dismounted, the hoisting strength is not lower than 75% of the design strength, the hoisting is stable, and a special multi-point hoisting frame is adopted for hoisting.
Example 2
As shown in the attached figure 1, the interlocking plate prefabricating process comprises the following steps:
101. and preparing concrete for pouring according to the formula proportion.
Wherein, the concrete comprises the following components by weight: 355kg/m3652kg/m of cement3Sand, 1161kg/m3Crushed stone, 220kg/m3Mixing water, 4.5kg/m3A composite early strength agent. The concrete stirred at the stirring station is transferred to the distributing machine through the stirring truck, and the concrete in the stirring truck is transferred to a distributing box on the distributing machine through the hoisting and conveying device.
Wherein the cement strength grade is P.O.42.5 (ordinary portland cement); the sand is medium sand with fineness modulus of 2.3-3.0%, and the mud content is less than 3%; the crushed stone particle composition is 5-20 mm, and the mud content is less than 1%; the pH value of the blending water is more than 4, the chloride (calculated by C1 < - >) is less than 3000mg/L, and the sulfate (calculated by SO2 < -4 >) is less than 2200 mg/L; the composite early strength agent has initial setting time of-60 to +90min, final setting time of-60 to +90min, compression strength ratio of 1d to 140%, 3d to 135%, 7d to 120%, 28d to 100%.
Concrete mixing must meet 3 basic requirements: accurate measurement, thorough stirring and stable slump. Otherwise, the cement mortar distribution is not uniform in concrete mixture, which brings congenital deficiency to concrete pouring, and color difference is left on the concrete surface, or non-uniformity phenomena such as easy segregation and bleeding of concrete vibration occur.
The volume weight of the concrete prepared after stirring is 2380kg/m3The slump is 110mm, and the strength is not lower than 20 MP.
102. Cleaning the upper die and the lower die, and brushing a release agent.
Wherein, upper and lower mould adopts portable steel mould, uses shaped steel and stamping workpiece section bar welding to form, and the die height ratio with last mould is 3: 1, the sizes of the upper die and the lower die are 5 multiplied by 4m, the interlocking blocks are distributed by 10 multiplied by 8, and the total number of the interlocking blocks is 80.
The cleaning adopts a shovel to shovel off the residual concrete slag on the surfaces of the upper die and the lower die, the end faces, the clamp, the sleeve positioning pin and the positioning screw, so that the interiors of the upper die and the lower die are clean and have no sundries.
The release agent is a water-based release agent, has no influence on the quality of products, and is pollution-free and environment-friendly; and spraying a release agent by using an automatic spraying machine, wherein the coating thickness of the release agent is 0.3 mm.
103. After step 102, fixing the lower die, laying a cord in the lower die, and installing the upper die.
The lower die is fixed firstly, then the cord is laid, the upper die is moved to the upper side of the lower die through the crane, then the side sections of the upper die and the lower die are aligned, the clamp is fixed through the bolts, the rubber pad is arranged in the clamp, the installation is firm, and the abutted seam is tight.
The wire rope is a polypropylene fiber rope, the diameter of the polypropylene fiber rope is 12mm, and the wire rope is distributed in a mode that the 5m long side of the mold is of a single-rope structure and is used for connecting adjacent interlocking blocks on one row; the 4m long edge is of a snake-shaped structure and is used for connecting adjacent interlocking blocks on an adjacent row, and meanwhile, the interlocking blocks on the adjacent row are connected on the edge, so that the tightly arranged reticular interlocking pieces are formed.
104. And (4) pouring the concrete prepared in the step (101) into a mold quantitatively, vibrating after pouring, and forming a product in the mold.
The pouring is a mode of synchronously, uniformly and continuously pouring the mould, the embedded part and the connecting part are ensured not to deform or move during concrete pouring, and measures are taken to correct in time if deviation exists; after pouring, the mould is vibrated by a flat vibrator, the vibration frequency is 3.5 times, excessive vibration and leakage vibration are strictly forbidden, and the vibration time is 10 s.
The concrete tap is characterized in that: the concrete had not significantly subsided, the surface was flat, and the concrete had not bubbled and began to flood.
105. And (104) curing the molded interlocking piece.
The mode of maintenance is atomizing steam, makes the concrete solidify, shifts the mould to the maintenance room in, and the temperature is 55 ℃ in the maintenance room, adopts high temperature vapor circulation to carry out the heating of maintenance room, and similar radiator's principle sprays a small amount of high temperature steam simultaneously, because of the lower quick vaporific steam of liquefaction zone uniform temperature of room temperature, moisturizes the processing to interlocking piece surface to avoid interlocking piece surface crack to appear, the maintenance time is 5 h.
In the curing process, the phenomenon that the temperature rises too fast and too high is avoided, the moisture on the surface of the concrete is easily and rapidly taken away, and a drying shrinkage crack is formed.
106. After step 105, the interlocking pieces are demolded and placed in a storage area for later use.
The upper die and the lower die are sequentially dismounted by adopting a crane, the interlocking pieces are separated from the lower die in a hoisting mode when the lower die is dismounted, the hoisting strength is not lower than 75% of the design strength, the hoisting is stable, and a special multi-point hoisting frame is adopted for hoisting.
Example 3
As shown in the attached figure 1, the interlocking plate prefabricating process comprises the following steps:
101. and preparing concrete for pouring according to the formula proportion.
Wherein, the concrete comprises the following components by weight: 400kg/m3700kg/m of cement3Sand, 1200kg/m3Crushed stone, 250kg/m3Mixing water, 5kg/m3A composite early strength agent. The concrete stirred at the stirring station is transferred to the distributing machine through the stirring truck, and the concrete in the stirring truck is transferred to a distributing box on the distributing machine through the hoisting and conveying device.
Wherein the cement strength grade is P.O.42.5 (ordinary portland cement); the sand is medium sand with fineness modulus of 2.3-3.0%, and the mud content is less than 3%; the crushed stone particle composition is 5-20 mm, and the mud content is less than 1%; the pH value of the blending water is more than 4, the chloride (calculated by C1 < - >) is less than 3000mg/L, and the sulfate (calculated by SO2 < -4 >) is less than 2200 mg/L; the composite early strength agent has initial setting time of-60 to +90min, final setting time of-60 to +90min, compression strength ratio of 1d to 140%, 3d to 135%, 7d to 120%, 28d to 100%.
Concrete mixing must meet 3 basic requirements: accurate measurement, thorough stirring and stable slump. Otherwise, the cement mortar distribution is not uniform in concrete mixture, which brings congenital deficiency to concrete pouring, and color difference is left on the concrete surface, or non-uniformity phenomena such as easy segregation and bleeding of concrete vibration occur.
The volume weight of the concrete prepared after stirring is 2400kg/m3The slump is 120mm, and the strength is not lower than 20 MP.
102. Cleaning the upper die and the lower die, and brushing a release agent.
Wherein, upper and lower mould adopts portable steel mould, uses shaped steel and stamping workpiece section bar welding to form, and the die height ratio with last mould is 3: 1, the sizes of the upper die and the lower die are 5 multiplied by 4m, the interlocking blocks are distributed by 10 multiplied by 8, and the total number of the interlocking blocks is 80.
The cleaning adopts a shovel to shovel off the residual concrete slag on the surfaces of the upper die and the lower die, the end faces, the clamp, the sleeve positioning pin and the positioning screw, so that the interiors of the upper die and the lower die are clean and have no sundries.
The release agent is a water-based release agent, has no influence on the quality of products, and is pollution-free and environment-friendly; and spraying a release agent by using an automatic spraying machine, wherein the coating thickness of the release agent is 0.4 mm.
103. After step 102, fixing the lower die, laying a cord in the lower die, and installing the upper die.
The lower die is fixed firstly, then the cord is laid, the upper die is moved to the upper side of the lower die through the crane, then the side sections of the upper die and the lower die are aligned, the clamp is fixed through the bolts, the rubber pad is arranged in the clamp, the installation is firm, and the abutted seam is tight.
The cotton rope is a polypropylene rope, the diameter of the polypropylene rope is 15mm, and the cotton rope is laid in a mode that the side of the mold with the length of 5m is of a single-rope structure and is used for connecting adjacent interlocking blocks on one row; the 4m long edge is of a snake-shaped structure and is used for connecting adjacent interlocking blocks on an adjacent row, and meanwhile, the interlocking blocks on the adjacent row are connected on the edge, so that the tightly arranged reticular interlocking pieces are formed.
104. And (4) pouring the concrete prepared in the step (101) into a mold quantitatively, vibrating after pouring, and forming a product in the mold.
The pouring is a mode of synchronously, uniformly and continuously pouring the mould, the embedded part and the connecting part are ensured not to deform or move during concrete pouring, and measures are taken to correct in time if deviation exists; after pouring, the mould is vibrated by adopting a flat vibrator, the vibration frequency is 4 times, excessive vibration and leakage vibration are strictly forbidden, and the vibration time is 15 s.
The concrete tap is characterized in that: the concrete had not significantly subsided, the surface was flat, and the concrete had not bubbled and began to flood.
105. And (104) curing the molded interlocking piece.
The curing comprises first curing and second curing, wherein the first curing is dry steaming, the mold is transferred into a curing chamber, the temperature in the curing chamber is 60 ℃, and the curing time is 1 h;
the second maintenance is to spray high temperature vapor, sprays a small amount of high temperature vapor, and the fog steam of certain temperature is taken because of the lower quick liquefaction of room temperature, moisturizes the interlock piece surface to avoid interlocking piece surface crack to appear, the indoor temperature is 60 ℃, and the maintenance time is 4 h.
In the curing process, the phenomenon that the temperature rises too fast and too high is avoided, the moisture on the surface of the concrete is easily and rapidly taken away, and a drying shrinkage crack is formed.
Alternatively, the first curing is dry steaming, the curing temperature is 50-60 ℃, and the curing time is 1-2 hours; and the second curing is spraying high-temperature steam, the curing temperature is 50-60 ℃, and the curing time is 4-6 hours.
106. After step 105, the interlocking pieces are demolded and placed in a storage area for later use.
The upper die and the lower die are sequentially dismounted by adopting a crane, the interlocking pieces are separated from the lower die in a hoisting mode when the lower die is dismounted, the hoisting strength is not lower than 75% of the design strength, the hoisting is stable, and a special multi-point hoisting frame is adopted for hoisting.
The interlocking piece manufactured by the embodiment has the advantages of smooth surface, uniform compactness, high strength, no damage phenomenon on the edge, high finished product quality, high production efficiency and low defective rate.
The method is characterized in that the allowable deviation requirement of the prefabricated soft ballast row block of No. 2.1.6.28 is checked according to the inspection standard of water transportation engineering quality (JTS 257-2008), the actual measurement is carried out on the length, the width, the thickness, the plane diagonal difference, the flatness and the position of the axis of the connecting rope, and all the interlocking pieces prepared by the embodiment meet the standard requirement.
The above description is only a preferred embodiment of the present invention, and it is not intended to limit the scope of the present invention, and various modifications and changes may be made by those skilled in the art. Variations, modifications, substitutions, integrations and parameter changes of the embodiments may be made without departing from the principle and spirit of the invention, which may be within the spirit and principle of the invention, by conventional substitution or may realize the same function.

Claims (10)

1. The interlocking plate prefabricating process is characterized by comprising the following steps of:
101. preparing concrete for pouring according to the formula proportion;
102. cleaning the upper die and the lower die, and brushing a release agent;
103. after step 102, fixing a lower die, laying a cord in the lower die, and then installing an upper die;
104. pouring the concrete prepared in the step 101 into a mold quantitatively, vibrating after pouring, and forming a product in the mold;
105. after step 104, maintaining the molded interlocking pieces;
106. after step 105, the interlocking pieces are demolded and placed in a storage area for later use.
2. An interlocking segment prefabrication process as claimed in claim 1 wherein the concrete in step 101 includes the following ingredients in amounts: 300 to 400kg/m3600-700 kg/m of cement31100-1200 kg/m of sand3Crushed stone of 200-250 kg/m34-5 kg/m of mixing water3A composite early strength agent.
3. A prefabrication process for interlocking pieces as claimed in claim 2, wherein in step 102, the cleaning is carried out by using a shovel to remove residual concrete slag on the surfaces of the upper and lower dies, the end faces, the clamps, the sleeve positioning pins and the positioning screws, so that the interiors of the upper and lower dies are clean and free of impurities.
4. An interlocking plate preparation process as claimed in any one of claims 1 to 3, wherein said release agent in step 102 is an aqueous release agent, said release agent being applied at a thickness of less than 0.5 mm.
5. A process of prefabricating interlocking pieces as claimed in any one of claims 1 to 3, wherein the step 103 of laying the cords is a polypropylene cord in such a manner that the mould has a single cord structure on one side and a serpentine structure on the other side.
6. An interlocking piece prefabrication process as claimed in claim 5, wherein the polypropylene rope is 10-15 mm in diameter.
7. The interlocking piece prefabrication process of any one of claims 1 to 3, wherein in the step 104, the pouring is a mode of synchronous uniform continuous pouring on a mold, the frequency of the vibration is 3-4 times, and the vibration time is 5-15 s.
8. An interlocking segment prefabrication process as claimed in claim 7 wherein said manner of vibration includes vibration table vibration, plate vibrator.
9. The interlocking piece prefabrication process of any one of claims 1 to 3, wherein the curing in step 105 is carried out by atomizing water vapor to solidify the concrete, and the curing temperature is 50-60 ℃ and the curing time is 4-6 hours.
10. An interlocking piece prefabrication process according to any one of claims 1 to 3, wherein the curing in step 105 comprises a first curing and a second curing, the first curing is dry steaming, the curing temperature is 50-60 ℃, and the curing time is 1-2 hours;
and the second curing is spraying high-temperature steam, the curing temperature is 50-60 ℃, and the curing time is 4-6 hours.
CN201910711621.3A 2019-08-02 2019-08-02 Interlocking plate prefabricating process Pending CN110640866A (en)

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