CN114213096A - 一种双氧水作发泡剂的粉煤灰蒸压加气砼砌块的制备方法 - Google Patents
一种双氧水作发泡剂的粉煤灰蒸压加气砼砌块的制备方法 Download PDFInfo
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- MHAJPDPJQMAIIY-UHFFFAOYSA-N Hydrogen peroxide Chemical compound OO MHAJPDPJQMAIIY-UHFFFAOYSA-N 0.000 title claims abstract description 96
- 239000010881 fly ash Substances 0.000 title claims abstract description 35
- 239000004567 concrete Substances 0.000 title claims abstract description 22
- 239000004088 foaming agent Substances 0.000 title claims abstract description 13
- 238000002360 preparation method Methods 0.000 title claims description 11
- ODINCKMPIJJUCX-UHFFFAOYSA-N Calcium oxide Chemical compound [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 claims abstract description 33
- 238000003756 stirring Methods 0.000 claims abstract description 31
- NUJOXMJBOLGQSY-UHFFFAOYSA-N manganese dioxide Chemical compound O=[Mn]=O NUJOXMJBOLGQSY-UHFFFAOYSA-N 0.000 claims abstract description 24
- 239000000292 calcium oxide Substances 0.000 claims abstract description 18
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 18
- 235000012255 calcium oxide Nutrition 0.000 claims abstract description 17
- 239000004568 cement Substances 0.000 claims abstract description 17
- 239000006260 foam Substances 0.000 claims abstract description 14
- 229910052602 gypsum Inorganic materials 0.000 claims abstract description 14
- 239000010440 gypsum Substances 0.000 claims abstract description 14
- 239000012286 potassium permanganate Substances 0.000 claims abstract description 14
- 239000003381 stabilizer Substances 0.000 claims abstract description 14
- CJZGTCYPCWQAJB-UHFFFAOYSA-L calcium stearate Chemical compound [Ca+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CJZGTCYPCWQAJB-UHFFFAOYSA-L 0.000 claims abstract description 10
- 239000008116 calcium stearate Substances 0.000 claims abstract description 10
- 235000013539 calcium stearate Nutrition 0.000 claims abstract description 10
- 238000005520 cutting process Methods 0.000 claims abstract description 6
- 238000002156 mixing Methods 0.000 claims abstract description 5
- 239000000203 mixture Substances 0.000 claims description 12
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 7
- 230000029087 digestion Effects 0.000 claims description 6
- GSEJCLTVZPLZKY-UHFFFAOYSA-N Triethanolamine Chemical compound OCCN(CCO)CCO GSEJCLTVZPLZKY-UHFFFAOYSA-N 0.000 claims description 4
- GVGUFUZHNYFZLC-UHFFFAOYSA-N dodecyl benzenesulfonate;sodium Chemical compound [Na].CCCCCCCCCCCCOS(=O)(=O)C1=CC=CC=C1 GVGUFUZHNYFZLC-UHFFFAOYSA-N 0.000 claims description 4
- 239000000377 silicon dioxide Substances 0.000 claims description 4
- 229940080264 sodium dodecylbenzenesulfonate Drugs 0.000 claims description 4
- 230000003068 static effect Effects 0.000 claims description 4
- 238000001035 drying Methods 0.000 claims description 3
- 235000012239 silicon dioxide Nutrition 0.000 claims description 3
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 claims description 2
- PASHVRUKOFIRIK-UHFFFAOYSA-L calcium sulfate dihydrate Chemical compound O.O.[Ca+2].[O-]S([O-])(=O)=O PASHVRUKOFIRIK-UHFFFAOYSA-L 0.000 claims description 2
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 2
- 238000003860 storage Methods 0.000 claims description 2
- 238000006243 chemical reaction Methods 0.000 abstract description 11
- 238000004519 manufacturing process Methods 0.000 abstract description 6
- 239000003054 catalyst Substances 0.000 abstract description 2
- 238000010025 steaming Methods 0.000 abstract description 2
- 239000002002 slurry Substances 0.000 description 21
- 239000007789 gas Substances 0.000 description 15
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 13
- 238000000034 method Methods 0.000 description 12
- 230000008569 process Effects 0.000 description 11
- 239000000463 material Substances 0.000 description 8
- 238000005187 foaming Methods 0.000 description 6
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 4
- 239000011381 foam concrete Substances 0.000 description 4
- 239000002910 solid waste Substances 0.000 description 4
- 239000004570 mortar (masonry) Substances 0.000 description 3
- 239000000047 product Substances 0.000 description 3
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- 239000004927 clay Substances 0.000 description 2
- 229910052681 coesite Inorganic materials 0.000 description 2
- 229910052593 corundum Inorganic materials 0.000 description 2
- 229910052906 cristobalite Inorganic materials 0.000 description 2
- 239000010408 film Substances 0.000 description 2
- 239000001257 hydrogen Substances 0.000 description 2
- 229910052739 hydrogen Inorganic materials 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 230000000284 resting effect Effects 0.000 description 2
- 239000002689 soil Substances 0.000 description 2
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- 229910052682 stishovite Inorganic materials 0.000 description 2
- 229910052905 tridymite Inorganic materials 0.000 description 2
- 229910001845 yogo sapphire Inorganic materials 0.000 description 2
- 241000282414 Homo sapiens Species 0.000 description 1
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- 238000009825 accumulation Methods 0.000 description 1
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- 239000000654 additive Substances 0.000 description 1
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- 230000009286 beneficial effect Effects 0.000 description 1
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- 230000007547 defect Effects 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
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- 230000007613 environmental effect Effects 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 230000036541 health Effects 0.000 description 1
- 229910001385 heavy metal Inorganic materials 0.000 description 1
- XLYOFNOQVPJJNP-ZSJDYOACSA-N heavy water Substances [2H]O[2H] XLYOFNOQVPJJNP-ZSJDYOACSA-N 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
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- 238000004886 process control Methods 0.000 description 1
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- 239000010959 steel Substances 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
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- 231100000331 toxic Toxicity 0.000 description 1
- 230000002588 toxic effect Effects 0.000 description 1
- 239000011573 trace mineral Substances 0.000 description 1
- 235000013619 trace mineral Nutrition 0.000 description 1
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- C—CHEMISTRY; METALLURGY
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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
- C04B28/142—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements containing synthetic or waste calcium sulfate cements
- C04B28/144—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements containing synthetic or waste calcium sulfate cements the synthetic calcium sulfate being a flue gas desulfurization product
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- C04B22/08—Acids or salts thereof
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Abstract
本发明涉及加气砼砌块生产领域。一种双氧水作发泡剂的粉煤灰蒸压加气砼砌块的制备方法,将粉煤灰与水混合后在搅拌机中搅拌,搅拌均匀后加入脱硫石膏、稳泡剂继续搅拌均匀,然后加入生石灰、水泥、硬脂酸钙继续搅拌均匀,然后加入高锰酸钾、二氧化锰继续搅拌均匀,然后加入双氧水搅拌均匀,浇注入模,薄膜覆盖,最后通过静养、脱模切割、蒸养后自然条件下存放。配方中引入二氧化锰和高锰酸剂作为催化剂,加大了双氧水在常温下的反应程度,使双氧水反应更加彻底。
Description
技术领域
本发明涉及加气砼砌块生产领域。
背景技术
随着社会科技的飞速发展,社会生产力的提高加快了现代化的进程,与此同时,也带来了生态环境问题。尤其是工业领域中天然资源的大量开采和冶炼,不仅造成了不可再生资源的减少,还造成大量固体废弃物的堆积,占用有限的土地资源,甚至造成二次污染。因此,根据固体废弃物的特性对其进行合理利用具有重要的现实意义。
粉煤灰主要主要成分是SiO2和Al2O3,还有少量的Fe2O3、CaO、MgO及其它微量元素。以粉煤灰为主要原料,添加胶凝材料和发气材料制备蒸压加气砼砌块,对解决粉煤灰高效利用具有重大意义,一方面拓宽了燃煤产生固体废弃物粉煤灰的使用渠道,另一方面轻型砌块在建筑行业的推广应用,大大提高了建筑装配率。
当下加气砼行业中铝粉是普遍使用的发气材料,使用铝粉发气反应速度可控,发气时间和料浆的硬化时间比较容易匹配,且材料易得;但铝粉发气率低,反应产生的氢气易燃,生产过程中具有一定的危险性;铝粉在空气中容易氧化成氧化铝,不易保存,为了使铝粉与水接触反应,需要加入较多的胶结料使溶液具备一定的碱性,从而将铝粉表面的氧化铝溶解;铝粉不溶于水,使用过程中加入料浆后分散性差,造成发气不均匀;同时电解铝为粗放型行业,生产过程中消耗大量能量,且铝粉价格不稳定,随矿石价格波动较大。
鉴于上述不足,本发明创作者经过长期的研究和实践,利用粉煤灰为主要基体材料,复掺生石灰和水泥作为胶凝材料,添加石膏作为缓凝剂,使用双氧水作为发气剂,另加少量激发剂和稳泡剂,制备蒸压加气砼砌块。
双氧水易溶于水溶液,在浆料中能均匀分散,添加极少量的外加剂即可激发反应的进行,实现双氧水发气速率可控,且静养室的高温和粉煤灰料浆天然的碱性环境都能促进双氧水的反应进程;以双氧水为发气材料制备的粉煤灰砌块轻质、高强,内部孔隙更加均匀。但是当双氧水发气速率快时,发气时间短,容易造成料浆坍塌;当双氧水发气速率慢时,料浆容易过早硬化,反应产生的气泡无法有效封闭在料浆中,双氧水发泡过程和料浆的硬化过程很难相匹配。
发明内容
本发明所要解决的技术问题是:如何使双氧水发泡过程和料浆的硬化过程相匹配,同时匹配大掺量粉煤灰制备加气砼砌块。
本发明所采用的技术方案是:一种双氧水作发泡剂的粉煤灰蒸压加气砼砌块的制备方法,将粉煤灰与水混合后在搅拌机中搅拌,搅拌均匀后加入脱硫石膏、稳泡剂继续搅拌均匀,然后加入生石灰、水泥、硬脂酸钙继续搅拌均匀,然后加入高锰酸钾、二氧化锰继续搅拌均匀,然后加入双氧水搅拌均匀,浇注入模,薄膜覆盖,最后通过静养、脱模切割、蒸养后自然条件下存放。
所用的粉煤灰为65-72质量份、生石灰为8-14质量份、水泥为5-11质量份、脱硫石膏为4-5质量份、双氧水为2-6质量份、硬脂酸钙为0.5-0.8质量份、高锰酸钾为0.05-0.07质量份、二氧化锰为0.5-0.9质量份、稳泡剂为0.6-0.8质量份、水100-200份。
脱硫石膏、稳泡剂加入前搅拌时间不限制,搅拌均匀即可,脱硫石膏、稳泡剂加入后搅拌500-700s,加入生石灰、水泥、硬脂酸钙,搅拌60-120s,然后加入高锰酸钾、二氧化锰,搅拌30-60s,加入双氧水搅拌8-20s,浇注入模。
粉煤灰要求二氧化硅和氧化铝的和的质量百分比大于85%,0.045mm方孔筛筛余39%;生石灰要求氧化钙的质量百分比大于50%,消解速度3.5-5-4.5min,消化温度65-70℃;水泥采用42.5的硫铝酸盐水泥;脱硫石膏中二水硫酸钙质量百分比大于95%,自由水质量含量为8-12%, 0.08mm方孔筛筛余量为8%;双氧水质量百分比含量为30%,高锰酸钾浓度为4-6g/100mL,。
稳泡剂中十二烷基苯磺酸钠质量百分比为1%,三乙醇胺百分比为1%,水质量百分比为98%。
静养是指放置在干燥箱,60℃养护3-4小时。
蒸养是指置于蒸养釜中蒸压养护,其中,抽真空,0-0.06MPa保持0.5小时;升温升压,在1.5小时内,缓慢将压强升高到1.2MPa,温度升高到60℃;恒温恒压,在压强1.15±0.05MPa,温度60℃,保持0.5小时6.0-7.0小时;降温降压,在2-3小时内,缓慢将压强降低到大气压,温度降低到20-30℃;自然条件下存放是指在常温常压下自然存放3-10天。
本发明的有益效果是:粉煤灰巨大的堆存量给环境带来了安全隐患,占用了宝贵的土地资源,经过风化及雨淋的作用,粉煤灰堆场中的有毒有害重金属离子会渗到土壤中,污染土壤及地下水,危害人类的生命健康,处理不当便会产生扬尘,污染大气,所以开发大掺量的粉煤灰利用方式是缓解当下粉煤灰堆存所造成环境压力的有效途径。
传统的砌砖抹灰作业方式使建筑产业成为劳动密集型产业,工人劳动强度大,施工效率低,建筑物自重大,整体性差,且生产烧结砖消耗大量的黏土资源和天然水,加之砌筑过程中大量抹灰砂浆的配制,造成水资源和黏土资源的大量消耗,急需一种新型的定制化的砌筑方式减少能源消耗,提高砌筑效率,降低劳动强度。
现行蒸压加气砼行业主要使用铝粉作为发气剂,该材料发气率低,在空气中容易氧化,不易保存;铝粉不溶于水,使用过程中加入料浆后分散性差,造成发气不均匀,且反应产生的氢气在生产过程存在较大的安全隐患;同时电解铝为粗放型行业,生产过程中消耗大量能量,且铝粉价格不稳定,随矿石价格波动较大。
目前在发泡混凝土中有人做过双氧水作为发泡剂的试验性研究,发泡混凝土现场拌制,常温硬化,一方面对双氧水发泡时间无有效控制手段,双氧水反应快速,短时间内冒泡完毕,气泡大量无效散发,且气孔不均匀,大小不一,导致其使用量大,混凝土强度不高;而将双氧水作为发泡剂工业化应用在蒸压加气混凝土中还少见研究,难点就在双氧水反应快,过程控制难度大。
蒸压加气混凝土料浆向模具车中浇注完毕后,进入静养室进行静压养护。如不对双氧水的发泡时间进行有效控制,磨具车在运行还未进入静养室过程中双氧水即反应完毕,气泡很难保存在料浆中;同时养护过程中,双氧水反应过快,气泡短时间散发,容易造成料浆坍塌,双氧水反应过慢,料浆已经硬化,反应产生的气泡无法有效封闭在料浆中。所以需要双氧水发泡过程和料浆的硬化过程相匹配。
配方中引入二氧化锰和高锰酸剂作为催化剂,加大了双氧水在常温下的反应程度,使双氧水反应更加彻底,通过双氧水加入料浆中顺序的安排和浓度的控制,有效调节其反应时间;三乙醇胺作为粉煤灰料浆的缓凝调节剂,可有效调节料浆的凝结硬化时间;硬脂酸钙、十二烷基苯磺酸钠作为表面活性剂,可增强料浆中气泡的机械强度,使气泡更加均匀圆润,将气泡有效包覆在料浆中,从而使蒸压加气砼质量更轻,内部气孔结构更加均匀,相同容重下具有更高的物理强度。
具体实施方式
基础原料(以质量计)
粉煤灰(活性成份SiO2+ Al2O3 ≥45%,0.045mm方孔筛筛余35~45%);生石灰(有效含量CaO+MgO ≥65%,消解速度5~15min,消化温度60~90℃);水泥(硫铝酸盐水泥,42.5);脱硫石膏(CaSO4·2H2O≥95%,自由水含量≤15%,细度0.08mm方孔筛筛余量≤10%);双氧水(工业,浓度30%);二氧化锰(工业,85);高锰酸钾(工业,KMnO4≥99.1%);硬脂酸钙(工业,99%);十二烷基苯磺酸钠(工业一级);三乙醇胺(工业级)。其次,配置稳泡剂(A + B)、高锰酸钾溶液备用。
基础配比(以质量计)
粉煤灰(65~72%),生石灰(8~14%),水泥(5~11%),脱硫石膏(4~5%),双氧水(2~6%),硬脂酸钙(0.5~0.8%),高锰酸钾(0.05~0.07%),二氧化锰(0. 5~0.9%),稳泡剂(0. 6~0.8%)。
原料配制和浇注
先将粉煤灰与适量水混合放入砂浆搅拌机,加入脱硫石膏、稳泡剂,加入二氧化锰,慢速搅拌600s,加入生石灰和水泥,快速搅拌140s,加入双氧水,快速搅拌10s,浇注入模,薄膜覆盖。
先将粉煤灰与适量水混合放入砂浆搅拌机,加入脱硫石膏、稳泡剂,慢速搅拌600s,加入生石灰和水泥,快速搅拌100s,加入高锰酸钾,快速搅拌40s,加入双氧水,快速搅拌10s,浇注入模,薄膜覆盖。
静养
将模具放入干燥箱,60℃养护2~4h。
脱模、切割
坯体具备一定强度后取出,用切割钢丝将溢模的坯体切除,拆模,取出坯体。
蒸养
将坯体置于蒸养釜中蒸压养护,其中
抽真空(排冷空气) 0~-0.06MPa 0.5小时
升温升压 0.06~1.2MPa 1.5 小时
恒温恒压 1.15±0.05MPa 6.0~7.0小时
降温降压 1.2~0 MPa 2~3 小时
成品取出,自然条件下存放5天以上,测量性能指标。
通过测量成品的力学性能、干密度、含水率和干湿循环等,综合分析其性能。
Claims (7)
1.一种双氧水作发泡剂的粉煤灰蒸压加气砼砌块的制备方法,其特征在于:将粉煤灰与水混合后在搅拌机中搅拌,搅拌均匀后加入脱硫石膏、稳泡剂继续搅拌均匀,然后加入生石灰、水泥、硬脂酸钙继续搅拌均匀,然后加入高锰酸钾、二氧化锰继续搅拌均匀,然后加入双氧水搅拌均匀,浇注入模,薄膜覆盖,最后通过静养、脱模切割、蒸养后自然条件下存放。
2.根据权利要求1所述的一种双氧水作发泡剂的粉煤灰蒸压加气砼砌块的制备方法,其特征在于:所用的粉煤灰为65-72质量份、生石灰为8-14质量份、水泥为5-11质量份、脱硫石膏为4-5质量份、双氧水为2-6质量份、硬脂酸钙为0.5-0.8质量份、高锰酸钾为0.05-0.07质量份、二氧化锰为0.5-0.9质量份、稳泡剂为0.6-0.8质量份、水100-200份。
3.根据权利要求1所述的一种双氧水作发泡剂的粉煤灰蒸压加气砼砌块的制备方法,其特征在于:脱硫石膏、稳泡剂加入前搅拌时间不限制,搅拌均匀即可,脱硫石膏、稳泡剂加入后搅拌500-700s,加入生石灰、水泥、硬脂酸钙,搅拌60-120s,然后加入高锰酸钾、二氧化锰,搅拌30-60s,加入双氧水搅拌8-20s,浇注入模。
4.根据权利要求1所述的一种双氧水作发泡剂的粉煤灰蒸压加气砼砌块的制备方法,其特征在于:粉煤灰要求二氧化硅和氧化铝的和的质量百分比大于85%,0.045mm方孔筛筛余39%;生石灰要求氧化钙的质量百分比大于50%,消解速度3.5-5-4.5min,消化温度65-70℃;水泥采用42.5的硫铝酸盐水泥;脱硫石膏中二水硫酸钙质量百分比大于95%,自由水质量含量为8-12%, 0.08mm方孔筛筛余量为8%;双氧水质量百分比含量为30%,高锰酸钾浓度为4-6g/100mL,。
5.根据权利要求1所述的一种双氧水作发泡剂的粉煤灰蒸压加气砼砌块的制备方法,其特征在于:稳泡剂中十二烷基苯磺酸钠质量百分比为1%,三乙醇胺百分比为1%,水质量百分比为98%。
6.根据权利要求1所述的一种双氧水作发泡剂的粉煤灰蒸压加气砼砌块的制备方法,其特征在于:静养是指放置在干燥箱,60℃养护3-4小时。
7.根据权利要求1所述的一种双氧水作发泡剂的粉煤灰蒸压加气砼砌块的制备方法,其特征在于:蒸养是指置于蒸养釜中蒸压养护,其中,抽真空,0-0.06MPa保持0.5小时;升温升压,在1.5小时内,缓慢将压强升高到1.2MPa,温度升高到60℃;恒温恒压,在压强1.15±0.05MPa,温度60℃,保持0.5小时6.0-7.0小时;降温降压,在2-3小时内,缓慢将压强降低到大气压,温度降低到20-30℃;自然条件下存放是指在常温常压下自然存放3-10天。
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