CN111844412A - Production process of ultrahigh-performance concrete-based large-hollow-rate wallboard - Google Patents

Production process of ultrahigh-performance concrete-based large-hollow-rate wallboard Download PDF

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Publication number
CN111844412A
CN111844412A CN202010582474.7A CN202010582474A CN111844412A CN 111844412 A CN111844412 A CN 111844412A CN 202010582474 A CN202010582474 A CN 202010582474A CN 111844412 A CN111844412 A CN 111844412A
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China
Prior art keywords
performance concrete
wallboard
grouting
hollow
ultrahigh
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CN202010582474.7A
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Chinese (zh)
Inventor
高育欣
程宝军
涂玉林
麻鹏飞
王军
杨文�
康升荣
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Building Materials Science Research Institute Co Ltd of China West Construction Group Co Ltd
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Building Materials Science Research Institute Co Ltd of China West Construction Group Co Ltd
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Priority to CN202010582474.7A priority Critical patent/CN111844412A/en
Publication of CN111844412A publication Critical patent/CN111844412A/en
Pending legal-status Critical Current

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B15/00General arrangement or layout of plant ; Industrial outlines or plant installations
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00Producing shaped prefabricated articles from the material
    • B28B1/26Producing shaped prefabricated articles from the material by slip-casting, i.e. by casting a suspension or dispersion of the material in a liquid-absorbent or porous mould, the liquid being allowed to soak into or pass through the walls of the mould; Moulds therefor ; specially for manufacturing articles starting from a ceramic slip; Moulds therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00Producing shaped prefabricated articles from the material
    • B28B1/26Producing shaped prefabricated articles from the material by slip-casting, i.e. by casting a suspension or dispersion of the material in a liquid-absorbent or porous mould, the liquid being allowed to soak into or pass through the walls of the mould; Moulds therefor ; specially for manufacturing articles starting from a ceramic slip; Moulds therefor
    • B28B1/261Moulds therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00Producing shaped prefabricated articles from the material
    • B28B1/52Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
    • B28B1/525Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement containing organic fibres, e.g. wood fibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00Moulds; Cores; Mandrels
    • B28B7/28Cores; Mandrels
    • B28B7/285Core puller
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28CPREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28C5/00Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
    • B28C5/40Mixing specially adapted for preparing mixtures containing fibres
    • B28C5/402Methods
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Structural Engineering (AREA)
  • Dispersion Chemistry (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Abstract

The invention discloses a production process of an ultrahigh-performance concrete-based large-hollow-rate wallboard, which comprises the following steps: the surface density range is less than or equal to 65kg/m2The volume hollow rate is more than or equal to 75 percent, and the bending load is more than or equal to 15 times of the self weight of the wallboard; the production process of the ultra-high performance concrete-based large-hollow-rate wallboard comprises a storage system, a high-precision feeding metering system, a stirring system, a grouting system, a forming host machine, an automatic pipe loading and pulling system, an automatic board discharging system and a transferring systemThe method comprises the following steps: 1) preparing ultra-high performance concrete slurry; 2) cleaning and assembling a molding host; 3) grouting and forming; 4) pre-curing; 5) tube drawing; 6) maintaining with a mold, taking out the plate and stacking; 7) and (5) maintaining a finished product. The invention has the advantages of reasonable production process steps, light weight, high strength, ultrahigh toughness, ultrahigh durability and other excellent performances.

Description

Production process of ultrahigh-performance concrete-based large-hollow-rate wallboard
Technical Field
The invention relates to a production process of an ultrahigh-performance concrete-based large-hollow-rate wallboard, belonging to the field of wallboard production.
Background
With the gradual acceleration of the building industrialization process, the wallboard will gradually replace the traditional wall body, become the main building structure of structural fence and wall. At present, the types of wall boards are many, such as gypsum boards, ash boards, ECP boards, light aggregate concrete wall boards and the like, and the product quality of the wall boards has some problems: the problems of size deviation and appearance quality are more; secondly, the surface density is not controlled well; and the detection results of mechanical properties such as impact resistance, bending resistance and earthquake resistance are generally lower.
The ultra-high performance concrete is a novel ultra-high strength and ultra-high durability cement-based material, and the wallboard produced by using the ultra-high performance concrete has excellent shock resistance, bending resistance and earthquake resistance. Under the condition of meeting the mechanical property requirement of a building structure, the wall panel structure can be designed into a large-hollow-rate wall panel, so that the ultra-high-performance concrete wall panel has the excellent properties of light weight, high strength, ultra-high toughness, ultra-high durability and the like. However, the large-cavity thin-wall structural member adopts the pouring forming process to have the following problems: firstly, a large amount of air is easily wrapped in the casting process from the upper part of the mould, so that the thin-wall component has defects and the performance of the large-cavity thin-wall component is seriously influenced; secondly, the ultra-high performance concrete slurry contains fiber, and meanwhile, the slurry has relatively high viscosity, so that certain difficulty exists in filling narrow space. The prior production process of the wallboard is not suitable for the production of the ultrahigh-performance concrete-based large-hollow-rate wallboard, and the large-scale production and application of the wallboard are limited.
Aiming at the problems, the invention develops a production process suitable for the ultrahigh-performance concrete-based large-hollow-rate wallboard.
Disclosure of Invention
The invention mainly overcomes the defects in the prior art and provides a production process of an ultrahigh-performance concrete-based large-hollow-rate wallboard.
The technical scheme provided by the invention for solving the technical problems is as follows: a production process of an ultrahigh-performance concrete-based large-hollow-rate wallboard comprises the following steps:
step S1, preparing the ultra-high performance concrete slurry: according to the proportioning scheme, preparing ultra-high performance concrete slurry through a storage system, a high-precision feeding metering system and a stirring system and through stirring equipment;
step S2, cleaning and assembling the forming host machine: cleaning a forming host machine, simultaneously coating a release agent to ensure the flatness of the surface, and then assembling all the parts;
step S3, performing injectability and pressure bleeding detection on the ultra-high performance concrete slurry prepared in the step S1, and after the detection is passed, injecting the fresh slurry into a forming host machine through a grouting system and compacting the slurry by means of pressure; if the detection fails, the injectability and pressure bleeding parameters of the water purifier are adjusted by adding the additive until the water purifier passes through the water purifier; plugging a grouting hole and an exhaust hole of the forming host after grouting;
step S4, moving the forming host machine into a pre-curing kiln through a transfer system for pre-curing;
s5, removing the sealing cover plate, drawing the pipe through an automatic pipe installing and drawing system, automatically cleaning the core pipe, and coating a release agent;
Step S6, maintaining the wall boards with the moulds, and stacking a plurality of wall boards in the forming host machine through an automatic board discharging system;
and step S7, curing the finished wallboard for 28 days to obtain the qualified ultrahigh-performance concrete-based large-hollow-rate wallboard.
The further technical scheme is that the specific process of the step S1 is as follows:
step S11, weighing the cementing material, the mineral admixture and 200-mesh quartz powder according to the mass percentage of the raw materials, adding the materials into a stirrer, and stirring for 2-3 minutes until the materials are uniform;
s12, weighing a water reducing agent, a defoaming agent and water in proportion, dissolving the water reducing agent and the defoaming agent in the water, pouring the water reducing agent and the defoaming agent into a stirrer, and stirring for 2-3 minutes to form uniform cement paste;
and step S13, weighing PVA fibers, adding the PVA fibers into the cement slurry through a fiber dispersing device, and stirring for 3-4 minutes until the PVA fibers are uniformly dispersed in the slurry to obtain the ultra-high performance concrete slurry.
The further technical scheme is that the proportioning scheme in the step S1 is as follows: 29-54 parts of a cementing material, 11-18 parts of a mineral admixture, 18-26 parts of water, 10-15 parts of 200-mesh quartz powder, 0.3-1.1 part of a water reducing agent, 0.05-0.1 part of a defoaming agent and 1-2 parts of PVA fibers.
The further technical scheme is that the grouting pressure of the grouting system in the step S3 is more than or equal to 12MPa, and the grouting pressure in each cavity of the molding host machine is more than or equal to 2 MPa.
The further technical scheme is that the tube drawing mode in the step S5 is dislocation tube drawing, and the tube drawing speed range is 100 mm/S-200 mm/S.
The further technical scheme is that the transmission mode in the step S5 is hydraulic transmission.
The invention has the beneficial effects that: the periphery and two ends of the forming host are respectively sealed by the rubber hose and the sealing cover plate, so that the slurry leakage phenomenon under the action of the grouting pressure can be effectively avoided; secondly, a high-precision feeding metering system is adopted to ensure the design requirement of the mix proportion; the automatic pipe loading and pulling system, the automatic plate discharging system and the transferring system ensure the high-efficiency output of the ultrahigh concrete wallboard, thereby realizing large-scale production; the product has the excellent performances of light weight, high strength, ultrahigh toughness, ultrahigh durability and the like.
Drawings
FIG. 1 is a flow chart of the process steps of the present invention;
FIG. 2 is a cross-sectional dimension view of the wall panel of the embodiment;
FIG. 3 is a flow diagram of the stirring process of the present invention;
FIG. 4 is a schematic structural diagram of a molding machine according to an embodiment;
FIG. 5 is a schematic view showing the structure of a core tube in the example;
FIG. 6 is a schematic diagram of a sealing cover structure in an embodiment;
FIG. 7 is a schematic structural view of an end face of an upper mold in the embodiment;
FIG. 8 is a schematic structural view of an end face of a lower die in the embodiment;
FIG. 9 is a schematic structural view of a hole plugging device for a grouting hole of a lower mold in the embodiment;
FIG. 10 is a schematic view of an end mold structure in an embodiment;
FIG. 11 is a left side view of the end mold in the embodiment.
Detailed Description
The present invention will be further described with reference to the following examples and the accompanying drawings.
As shown in fig. 1 to 11, a production process of an ultra-high performance concrete based large hollow wallboard, wherein the relevant parameters of the ultra-high performance concrete based large hollow wallboard are as follows: the wallboard has the size of 100mm multiplied by 596mm multiplied by 3000mm and the surface density of 63kg/m2The volume hollow rate is 75 percent, and the bending load is 15.4 times of the self weight of the wallboard; the production process of the ultra-high performance concrete-based large-hollow-rate wallboard comprises a storage system, a high-precision feeding metering system, a stirring system, a grouting system, a forming host machine, an automatic pipe installing and pulling system, an automatic board discharging system and a transferring system, and specifically comprises the following steps:
s1, preparing the ultra-high performance concrete slurry: the composition comprises the following components in parts by weight: 29-54 parts of a cementing material, 11-18 parts of a mineral admixture, 18-26 parts of water, 10-15 parts of 200-mesh quartz powder, 0.3-1.1 part of a water reducing agent, 0.05-0.1 part of a defoaming agent and 1-2 parts of PVA fiber, and the ultra-high performance concrete slurry is prepared through a material storage system, a high-precision feeding metering system and a stirring system, feeding and high-precision metering and through stirring equipment;
Specifically, the method comprises the following steps: s11, weighing the cementing material, the mineral admixture and 200-mesh quartz powder according to the mass percentage of the raw materials, adding the materials into a stirrer, and stirring for 2-3 minutes until the materials are uniform;
s12, weighing a water reducing agent, a defoaming agent and water in proportion, dissolving the water reducing agent and the defoaming agent in the water, pouring the water reducing agent and the defoaming agent into a stirrer, and stirring for 2-3 minutes to form uniform cement paste;
s13, weighing PVA fibers, adding the PVA fibers into the cement paste through a fiber dispersing device, and stirring for 3-4 minutes until the PVA fibers are uniformly dispersed in the paste to obtain the ultra-high performance concrete paste;
s2, cleaning and assembling the forming host: cleaning a forming host machine, simultaneously coating a release agent to ensure the flatness of the surface, and then assembling all the parts;
s3, detecting the injectability and pressure bleeding of the freshly mixed ultra-high performance concrete slurry in the S1, after the detection is passed, injecting the freshly mixed slurry into the forming host machine through a grouting system, compacting the slurry by means of pressure, and after the grouting is finished, plugging grouting holes and exhaust holes of the forming host machine;
s4, moving the forming main machine into a pre-curing kiln through a transfer system, and performing pre-curing for 1.5 hours at the curing temperature of 30-40 ℃;
s5, removing the sealing cover plate, drawing the pipe through an automatic pipe installing and drawing system, automatically cleaning the core pipe, and coating a release agent;
S6, maintaining the wallboard for 6 hours with a mold, wherein the maintaining temperature is 40-50 ℃, and then stacking a plurality of wallboards in the forming host machine through an automatic board discharging system;
and S7, curing the finished wallboard for 28 days to obtain the qualified ultrahigh-performance concrete-based large-hollow-rate wallboard.
The forming main machine comprises a left side die 1, a right side die 1, an upper side die 2-1, a lower side die 2-2, a front end die 3, a rear end die 3, 54 core tubes 4 and a sealing cover plate 5, the number of die cavities is 6, sealing structures are arranged on the peripheries of the upper side die 2-1, the lower side die 2-2 and the sealing cover plate 5, a silica gel strip 6 is used for sealing, the upper side die 2-1 and the lower side die 2-2 are of combined structures and mainly comprise light aluminum alloy forming structures 2-1-1 and 2-2-1 and bending stress resisting structures 2-1-2 and 2-2-2, the core tubes 4 and the front end die 3 are positioned between the left side die 1, the right side die 1, the upper side die 2-1 and the lower side die 2-2-2, an auxiliary tube drawing structure 4-1 is arranged at the tube drawing end of the core tubes 4, and the, the core tube 4 is a rectangular hollow tube, and the core tube 4 vertically penetrates through the rectangular through holes of the front end die and the rear end die 3, so that two ends of the core tube 4 are flush with the outer surface of the end die 3; the upper side die 2-1 is provided with four exhaust holes and corresponding hole plugging devices which are evenly distributed, and the lower side die 2-2 is provided with grouting holes and corresponding hole plugging devices 2-2-3 which are positioned at one quarter of the lower side die 2-2.
The automatic pipe loading and drawing system has the functions of pipe drawing, pipe loading, cleaning and mold release agent brushing, the transmission mode is hydraulic transmission, the pipe drawing mode is staggered pipe drawing, and the pipe drawing speed range is 100-200 mm/s.
The grouting pressure of the grouting system is more than or equal to 12MPa, the grouting pressure in each mold cavity of the molding host is more than or equal to 2MPa, and the structures of the left side mold, the right side mold, the upper side mold, the lower side mold, the front end mold and the rear end mold of the molding host are thickened and ribbed.
The metering error range of the high-precision feeding metering system is as follows: less than or equal to 0.5 percent of powder, less than or equal to 0.5 percent of water, less than or equal to 1 percent of additive and less than or equal to 1 percent of fiber.
The automatic plate discharging system has the functions of hoisting an upper side die, opening and closing a left side die and a right side die by hydraulic pressure, drawing out a wallboard by connecting a lower die and stacking the wallboard.
The transfer system comprises a conveying track and an electric control system and is used for transferring the forming host.
Although the present invention has been described with reference to the above embodiments, it should be understood that the present invention is not limited to the above embodiments, and those skilled in the art can make various changes and modifications without departing from the scope of the present invention.

Claims (6)

1. A production process of an ultrahigh-performance concrete-based large-hollow-rate wallboard is characterized by comprising the following steps of:
step S1, preparing the ultra-high performance concrete slurry: according to the proportioning scheme, preparing ultra-high performance concrete slurry through a storage system, a high-precision feeding metering system and a stirring system and through stirring equipment;
step S2, cleaning and assembling the forming host machine: cleaning a forming host machine, simultaneously coating a release agent to ensure the flatness of the surface, and then assembling all the parts;
step S3, performing injectability and pressure bleeding detection on the ultra-high performance concrete slurry prepared in the step S1, and after the detection is passed, injecting the fresh slurry into a forming host machine through a grouting system and compacting the slurry by means of pressure; if the detection fails, the injectability and pressure bleeding parameters of the water purifier are adjusted by adding the additive until the water purifier passes through the water purifier; plugging a grouting hole and an exhaust hole of the forming host after grouting;
step S4, moving the forming host machine into a pre-curing kiln through a transfer system for pre-curing;
s5, removing the sealing cover plate, drawing the pipe through an automatic pipe installing and drawing system, automatically cleaning the core pipe, and coating a release agent;
Step S6, maintaining the wall boards with the moulds, and stacking a plurality of wall boards in the forming host machine through an automatic board discharging system;
and step S7, curing the finished wallboard for 28 days to obtain the qualified ultrahigh-performance concrete-based large-hollow-rate wallboard.
2. The process of claim 1, wherein the step S1 is as follows:
step S11, weighing the cementing material, the mineral admixture and 200-mesh quartz powder according to the mass percentage of the raw materials, adding the materials into a stirrer, and stirring for 2-3 minutes until the materials are uniform;
s12, weighing a water reducing agent, a defoaming agent and water in proportion, dissolving the water reducing agent and the defoaming agent in the water, pouring the water reducing agent and the defoaming agent into a stirrer, and stirring for 2-3 minutes to form uniform cement paste;
and step S13, weighing PVA fibers, adding the PVA fibers into the cement slurry through a fiber dispersing device, and stirring for 3-4 minutes until the PVA fibers are uniformly dispersed in the slurry to obtain the ultra-high performance concrete slurry.
3. The production process of the ultrahigh-performance concrete-based large hollow wallboard as claimed in claim 2, wherein the proportioning scheme in the step S1 is as follows: 29-54 parts of a cementing material, 11-18 parts of a mineral admixture, 18-26 parts of water, 10-15 parts of 200-mesh quartz powder, 0.3-1.1 part of a water reducing agent, 0.05-0.1 part of a defoaming agent and 1-2 parts of PVA fibers.
4. The process for producing an ultra-high performance concrete-based large hollow ratio wallboard as claimed in claim 1, wherein the grouting pressure of the grouting system in step S3 is more than or equal to 12MPa, and the grouting pressure in each cavity of the forming main machine is more than or equal to 2 MPa.
5. The process of claim 1, wherein the tube drawing in step S5 is performed by staggered tube drawing at a speed ranging from 100mm/S to 200 mm/S.
6. The process of claim 5, wherein the driving manner in step S5 is hydraulic driving.
CN202010582474.7A 2020-06-23 2020-06-23 Production process of ultrahigh-performance concrete-based large-hollow-rate wallboard Pending CN111844412A (en)

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113374100A (en) * 2021-07-19 2021-09-10 中建西部建设建材科学研究院有限公司 Active noise reduction and sound insulation large-hollow-rate wallboard and preparation method thereof
CN114505953A (en) * 2022-01-19 2022-05-17 中交公路长大桥建设国家工程研究中心有限公司 Method for industrially producing ultra-high performance concrete

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GB0123118D0 (en) * 2001-09-25 2001-11-14 Wright David Hollow-core floor slabs
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CN108582457A (en) * 2018-05-08 2018-09-28 成都上筑建材有限公司 Wallboard automated production equipment and method
CN110776334A (en) * 2019-10-31 2020-02-11 中建材料技术研究成都有限公司 Cement-based wallboard with large hollow rate and ultrahigh toughness and preparation method thereof
CN110821032A (en) * 2019-10-31 2020-02-21 中建材料技术研究成都有限公司 Light heat-preservation high-toughness cement-based composite wallboard and preparation process thereof

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Publication number Priority date Publication date Assignee Title
GB0123118D0 (en) * 2001-09-25 2001-11-14 Wright David Hollow-core floor slabs
CA2523936A1 (en) * 2005-10-20 2007-04-20 Groupe Grb Inc. System for filling molds with cementitious concrete-like material and for unmolding resulting products
CN102581948A (en) * 2012-03-07 2012-07-18 蚌埠远程置业有限公司 Automatic production line of light partition board
CN103802210A (en) * 2014-03-05 2014-05-21 天津市得全轻质板制造有限公司 Multi-functional tubeinserting and drawing equipment for lightweight wall plate formwork uprighting machine
CN104723448A (en) * 2015-04-01 2015-06-24 泉州市三联机械制造有限公司 Automatic wallboard demolding, stacking and separating equipment
CN106166794A (en) * 2016-08-26 2016-11-30 中民筑友科技投资有限公司 A kind of preform production line
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CN108582457A (en) * 2018-05-08 2018-09-28 成都上筑建材有限公司 Wallboard automated production equipment and method
CN110776334A (en) * 2019-10-31 2020-02-11 中建材料技术研究成都有限公司 Cement-based wallboard with large hollow rate and ultrahigh toughness and preparation method thereof
CN110821032A (en) * 2019-10-31 2020-02-21 中建材料技术研究成都有限公司 Light heat-preservation high-toughness cement-based composite wallboard and preparation process thereof

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113374100A (en) * 2021-07-19 2021-09-10 中建西部建设建材科学研究院有限公司 Active noise reduction and sound insulation large-hollow-rate wallboard and preparation method thereof
CN114505953A (en) * 2022-01-19 2022-05-17 中交公路长大桥建设国家工程研究中心有限公司 Method for industrially producing ultra-high performance concrete

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Application publication date: 20201030