CN114215183B - Construction method for realizing pouring of space special-shaped structure by using UHPC material - Google Patents
Construction method for realizing pouring of space special-shaped structure by using UHPC material Download PDFInfo
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Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/34—Extraordinary structures, e.g. with suspended or cantilever parts supported by masts or tower-like structures enclosing elevators or stairs; Features relating to the elastic stability
-
- 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
- B28B1/14—Producing shaped prefabricated articles from the material by simple casting, the material being neither forcibly fed nor positively compacted
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G21/00—Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G21/00—Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
- E04G21/14—Conveying or assembling building elements
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- Engineering & Computer Science (AREA)
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- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Manufacturing & Machinery (AREA)
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Abstract
The invention provides a construction method for realizing pouring of a space special-shaped structure by using UHPC materials, wherein the space special-shaped structure is a space floating strip-shaped structure, and the construction method comprises the following steps: erecting a die carrier support: according to design requirements, a vertical support body and a foundation support are respectively arranged, the vertical support body comprises a plurality of vertical boards with gradually rising or gradually falling heights, the foundation support is designed in size according to horizontal projection of a space special-shaped structure, the vertical boards are arranged on the foundation support, a curved-surface template system is arranged along the upper surface of the vertical support body, and the template system forms a transverse pouring cavity which changes along with the height change of the vertical boards; casting to form a prefabricated part: casting to form a prefabricated member with a UHPC floating structure by a mode that UHPC mixture naturally flows in the transverse casting cavity; splicing between prefabricated parts: and welding and fixing the prefabricated members with the rising or falling heights through the embedded parts.
Description
Technical Field
The invention relates to the technical field of construction of space special-shaped structures with floating structures, in particular to a construction method for pouring space special-shaped structures by using UHPC materials.
Background
In the prior art, many building structures formed by pouring are formed by directly pouring by taking the existing building or the ground as a supporting point. However, for a landscape building with a floating structure, the construction is difficult due to the specificity of floating, and particularly when a curve structure and a floating structure are combined at the same time, the construction pouring difficulty is further increased.
Specifically, when the physical space structure of the constructed building structure is complex, the curvature is small, the gradient is large, and the bearing requirement exists, the tensile resistance or the bending resistance of the conventional concrete material cannot meet the requirement, and the construction is difficult to realize.
Disclosure of Invention
The invention aims to provide a construction method for realizing pouring of a space special-shaped structure by using UHPC materials, which realizes combined forming of a floating space special-shaped structure by formwork support erection, in-plant prefabrication casting and construction site splicing, and can better ensure the form and landscape effect of a structure when the constructed building structure simultaneously floats above relative to the ground or a base surface and integrally presents a curve and the like.
In order to achieve the technical effects, the invention is realized by the following technical scheme.
The construction method for realizing pouring of the space special-shaped structure by using the UHPC material, wherein the space special-shaped structure is a space floating strip-shaped structure, and comprises the following steps of:
dividing a space special-shaped structure: dividing the space special-shaped structure into a plurality of prefabricated sections according to stress distribution conditions and transportation weight limit;
erecting a die carrier support: according to design requirements, a vertical support body and a foundation support are respectively arranged, the vertical support body comprises a plurality of vertical boards with gradually rising or gradually falling heights, the foundation support is designed in size according to horizontal projection of a space special-shaped structure, the vertical boards are arranged on the foundation support, a curved-surface template system is arranged along the upper surface of the vertical support body, and the template system forms a transverse pouring cavity which changes along with the height change of the vertical boards;
casting to form a prefabricated part: casting to form a prefabricated member with a UHPC floating structure by a mode that UHPC mixture naturally flows in the transverse casting cavity;
splicing between prefabricated parts: and welding and fixing the prefabricated members with the rising or falling heights through embedded parts to form the space floating strip-shaped structure.
Firstly, among the prior art, steel pipe or shaped steel support are adopted to the die carrier support, however, in this technical scheme, owing to adopt UHPC mix to pour, and then the building structure after pouring, under the prerequisite that satisfies the atress requirement, dead weight greatly reduced, it is feasible to adopt the plank support that with low costs, light in weight this moment, more importantly, because the space of structure is linear complicated, adopts the plank to support, not only more nimble, and the alignment is smoother moreover.
Secondly, in this technical scheme, adopt the plank to set up the die carrier and support, compare with preceding support, plank shape, size all can the custom cutting for the die carrier in this technical scheme supports, can directly form the space dysmorphism structure that needs to float and pour the chamber, through pouring this structure, directly forms the floating structure, has realized one shot forming's effect, and is more efficient in technology.
Thirdly, in the technical scheme, when the formwork support is erected, the wood board is cut through combining the design requirements, so that the formwork directly forms a structure with radian and curve, and compared with the process of straight line splicing and the like, the formwork directly pours the formed curve, thereby meeting the design requirements more and forming the desired building effect more easily.
Finally, in the technical scheme, when the integral molding of the space special-shaped structure is needed to be spliced by the existing prefabricated members, the two prefabricated members can be aligned and then fixedly connected by the embedded member, and at the moment, the structure can be suitable for various situations, for example, a longer landscape structure is divided into a plurality of prefabricated members and then spliced by the prefabricated members; or the prefabricated members with floating structures are arranged, so that new landscape structures are formed in a modified mode, and the novel landscape structures can be formed by splicing the prefabricated members.
As a further improvement of the present invention, the division of the spatially shaped structure is specifically: and (3) establishing a stress calculation model of the space special-shaped structure, and dividing the segments in the stress non-concentrated section, wherein the segment division is required to meet the weight and length limiting requirements in the transportation process.
In the technical scheme, the special-shaped structures with longer length, more various structural changes and more abundant functions can be divided according to space curves and the like, so that a plurality of divided prefabricated members are poured simultaneously, and the efficiency is improved.
Specifically, the prefabricated part is divided into a plurality of sections according to the demand of the prefabricated part, and the length of each section is 2-5m.
As a further improvement of the invention, in the step of erecting the formwork support, the method further comprises the connection of transition parts of a curved surface and/or inclined surface formwork system, wherein the connection of the transition parts is specifically as follows: and coating and paving a glass fiber reinforced cement layer at the transition part.
In the technical scheme, when the curvature is too small or the gradient of the inclined plane is too steep, the glass fiber reinforced cement layer can be smeared at the transition part, so that the arc or gradient of the joint part is smoother, the occurrence of folded angles and the like is avoided, and the attractiveness is influenced.
As a further improvement of the invention, after the step of erecting the formwork support and before the step of pouring to form the prefabricated member, the invention further comprises the steps of clamping and fixing the formwork system, specifically: and the top and the bottom of the template system are respectively clamped and fixed by utilizing steel pipes.
Furthermore, the top steel pipe can apply pre-pressure to the template besides the function of fixing the template, so that the pouring quality of the prefabricated part is improved.
According to the technical scheme, through the addition of steel pipe clamping and fixing, the running die or the expanding die can be prevented, the pre-pressure applied can be eliminated, the generation of holes and free water in pouring can be eliminated, the poured particles are more compact, and the bending strength and the toughness of the prefabricated part are improved.
As a further improvement of the present invention, in the step of erecting the formwork support, the method further includes reserving pouring holes, specifically: the top of vertical plank is equipped with the recess, set up die block board and side form board in the template system in the recess, form horizontal pouring chamber, the highest point department in horizontal pouring chamber forms the reservation and pours the hole.
In the technical scheme, the casting holes are reserved, and then later casting is achieved through the reserved holes, in the technical scheme, the reserved holes are arranged at high positions, and casting liquid flows naturally from high to low along the bottom template by utilizing gravity in casting. Specifically, in the technical scheme, a reserved pouring hole is formed at the highest point of the transverse pouring cavity by using a construction mode without a sealing plate.
As a further improvement of the invention, before the step of casting to form the prefabricated member, the method further comprises the preparation of casting liquid, specifically: after stirring the UHPC premix for T1 time, adding water and an additive, continuing stirring for T2 time, and finally adding stainless steel fiber, and stirring for T3 time to form the pouring liquid, wherein T2 is more than T3 and more than T1.
In the technical scheme, because components such as UHPC cement, aggregate, steel fiber and the like are easy to agglomerate in the mixing process, the homogeneity and the material characteristics of the UHPC cement, aggregate and steel fiber are influenced, and the agglomeration is avoided by adjusting the stirring time, the feeding sequence and the like of each material, so that the UHPC cement, aggregate and steel fiber composite material form a relatively uniform and compact internal structure, and the stability of indexes such as flexural strength, compressive strength and the like is facilitated.
As a further improvement of the invention, in the preparation of the casting solution, the UHPC premix: water: additive: the mass ratio of the stainless steel fiber is 1000:76.9:10.6:45.
according to the technical scheme, the UHPC pouring liquid capable of meeting expected requirements on mechanical properties such as strength, toughness and the like is obtained by adjusting the mass ratio of raw materials.
As a further improvement of the invention, the UHPC premix comprises powder with the particle size smaller than 1mm, the additive is a water reducing agent, and the length of the stainless steel fiber is 13-14mm.
In the technical scheme, in order to realize that the compressive strength of the material is higher than 130MPa, the bending strength is higher than 20MPa and the tensile strength is higher than 7MPa, stainless steel fibers are added into the pouring liquid, so that the pouring liquid shows certain directionality and connectivity during pouring, the expansion of microcracks in the material is slowed down, and the corresponding mechanical property requirements can be met. In the embodiment, the length of the stainless steel fiber is less than or equal to 14mm, and the purpose is to select the stainless steel fiber with the length, so that the mixing can be well realized, the coupling force between materials is realized, and the mixing effect of the mixing materials is ensured.
As a further improvement of the invention, the splicing step between the prefabricated parts further comprises filling, wherein the filling is as follows: and the openings of the two embedded parts and the butt joint of the prefabricated parts are filled with UHPC mixture.
In the technical scheme, the filling after the connection of the prefabricated parts is specifically to set up a die carrier support at the connection part of the components, pour UHPC pouring liquid, and repair the surface after the completion of coagulation and hardening. By re-filling the UHPC pouring liquid, the joint has better strength and mechanical property.
As a further development of the invention, the connection of the preform to the existing structure is also included when the preform is in contact with the existing structure, in particular: the H-shaped steel base is embedded in the existing structure, the high-strength bolts are embedded in the bottoms of the prefabricated parts, and the bolts are connected with the steel base in a nested mode through the bolts.
In the technical scheme, when the prefabricated member contacts with the existing structures such as the ground, the steel base can be embedded in the ground to realize stable connection.
Drawings
FIG. 1 is a process flow diagram of a construction method for realizing pouring of a space special-shaped structure by using UHPC materials;
fig. 2 is a schematic structural diagram of a spatially irregular structure in embodiment 4 provided by the present invention;
FIG. 3 is a schematic view of a structure of a mold frame support according to the present invention;
fig. 4 is a schematic structural diagram of a pre-buried steel base in embodiment 4 provided by the present invention;
fig. 5 is a schematic connection diagram of a pre-buried steel base in embodiment 4 provided by the present invention;
fig. 6 is a schematic structural diagram of an embedded steel plate in embodiment 4 provided by the present invention;
FIG. 7 is a front view of the two-section preform of example 4 provided by the present invention after assembly;
fig. 8 is an assembly view of two-segment preforms in example 4 provided by the present invention.
In the figure:
1. a lower steel plate; 2. an H-shaped support; 3. an upper steel plate; 4. embedding bolts; 5. embedding a steel plate; 6. a preform; 7. welding and connecting the steel plates; 8. a preformed hole; 9. UHPC mixture;
100. a spatially profiled structure; 200. a vertical support; 300. a foundation support; 400. a template system.
Detailed Description
The present invention will be described in detail below with reference to the embodiments shown in the drawings, but it should be understood that the embodiments are not limited to the present invention, and functional, method, or structural equivalents and alternatives according to the embodiments are within the scope of protection of the present invention by those skilled in the art.
In the description of the present embodiment, it should be understood that the terms "center", "longitudinal", "lateral", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. indicate orientations or positional relationships based on the drawings, are merely for convenience in describing the present invention and simplify the description, and do not indicate or imply that the devices or elements referred to must have a specific orientation, be configured and operated in a specific orientation, and thus should not be construed as limiting the present invention.
The terms "mounted," "connected," and "relatively fixed" are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communication between two elements. The specific meaning of the above terms in the creation of the present invention can be understood by those of ordinary skill in the art in a specific case.
Example 1
Referring to fig. 1 and 3, in this embodiment, a construction method for implementing pouring of a space special-shaped structure by using a UHPC material, where the space special-shaped structure is a space floating strip structure, includes the following steps:
division of the spatially profiled structure 100: dividing the space special-shaped structure into a plurality of prefabricated sections according to stress distribution conditions and transportation weight limit;
erecting a die carrier support: according to design requirements, a vertical supporting body 200 and a foundation support 300 are respectively arranged, the vertical supporting body 200 comprises a plurality of vertical boards with gradually rising or gradually falling heights, the foundation support 300 is designed in size according to the horizontal projection of the space special-shaped structure 100, the vertical boards are arranged on the foundation support 300, a curved-surface template system 400 is arranged along the upper surface of the vertical supporting body 200, and the template system 400 forms a transverse pouring cavity which changes along with the height change of the vertical boards;
casting to form a prefabricated part: casting to form a prefabricated member with a UHPC floating structure by a mode that UHPC mixture naturally flows in the transverse casting cavity;
splicing between prefabricated parts: and welding and fixing the prefabricated members with the rising or falling heights through embedded parts to form the space floating strip-shaped structure.
Firstly, in the prior art, steel pipes or section steel supports are adopted for supporting the die carrier, however, in the embodiment, because UHPC mixture is adopted for pouring, and then the self weight of the poured building structure is greatly reduced on the premise of meeting the stress requirement, at the moment, the adoption of the wood board supports with low cost and light weight is feasible, and more importantly, because the structural space is complicated in linear shape, the adoption of the wood board supports not only is more flexible, but also the linear shape is smoother.
Secondly, in this embodiment, adopting the plank to set up the die carrier and support, compare with preceding support, plank shape, size all can the custom cutting for the die carrier in this technical scheme supports, can directly form the space dysmorphism structure that needs to float and pours the chamber, through pouring this structure, directly forms the floating structure, has realized one shot forming's effect, and is more efficient in technology.
In this embodiment, when setting up the die carrier and supporting, cut the plank through combining the design requirement for the die carrier directly forms the structure that has radian and curve, compares in through processes such as sharp concatenation, directly pours fashioned curve, accords with the design requirement more, forms wanted building effect more easily.
Finally, in this embodiment, when the integral molding of the space special-shaped structure needs to be formed by splicing existing prefabricated members, the two prefabricated members can be aligned and then fixedly connected through the embedded member, and at this time, the method can be applicable to various situations, for example, a longer landscape structure is divided into a plurality of prefabricated members, and then the prefabricated members are spliced to form the space special-shaped structure; or the prefabricated members with floating structures are arranged, so that new landscape structures are formed in a modified mode, and the novel landscape structures can be formed by splicing the prefabricated members.
According to the invention, through the addition of the UHPC material and the height change of the vertical wood plate, compared with other materials, the UHPC material can form a compact UHPC floating structure in the transverse pouring cavity.
Example 2
In this embodiment, description is mainly directed to setting up a formwork support and pouring.
Specifically, the division of the space special-shaped structure is specifically as follows: and (3) establishing a stress calculation model of the space special-shaped structure, and dividing the segments in the stress non-concentrated section, wherein the segment division is required to meet the weight and length limiting requirements in the transportation process.
In this embodiment, to the special-shaped structure that length is longer, structural variation is more various, the function is more abundant, can carry out the division of corresponding prefabrication according to space curve etc for a plurality of prefabrication after dividing pour simultaneously, raise the efficiency.
Specifically, the prefabricated part is divided into a plurality of sections according to the demand of the prefabricated part, and the length of each section is 2-5m.
Specifically, in the step of erecting the formwork support, the method further comprises the transition part connection of the curved surface and/or inclined surface formwork system, wherein the transition part connection specifically comprises the following steps: and coating and paving a glass fiber reinforced cement layer at the transition part.
In this embodiment, when the curvature is too small, or the slope of the inclined plane is too steep, the glass fiber reinforced cement layer can be coated at the transition part, so that the arc or the slope of the connection part is smoother, and the occurrence of folded angles and the like is avoided, thereby affecting the beauty.
Specifically, after the step of erecting the die carrier support and before the step of pouring to form the prefabricated member, the method further comprises the step of clamping and fixing the template system, specifically: and the top and the bottom of the template system are respectively clamped and fixed by utilizing steel pipes.
Furthermore, the top steel pipe can apply pre-pressure to the template besides the function of fixing the template, so that the pouring quality of the prefabricated part is improved.
In the embodiment, through adding steel pipe clamping and fixing, not only can prevent running or expanding the die, but also the pre-pressure applied can eliminate the generation of holes and free water in pouring, so that the poured particles are more compact, and further the bending strength and toughness of the prefabricated member are improved.
Specifically, in the step of erecting the formwork support, the method further comprises reserving pouring holes, specifically: the top of vertical plank is equipped with the recess, set up die block board and side form board in the template system in the recess, form horizontal pouring chamber, the highest point department in horizontal pouring chamber forms the reservation and pours the hole. Specifically, a sealing plate is not arranged at the highest point of the transverse pouring cavity, and a reserved pouring hole is formed.
In this embodiment, the casting hole is reserved, and then later casting is achieved through the reserved hole, but in this embodiment, the reserved hole is arranged at a high position, and casting liquid naturally flows from high to low along the bottom template by utilizing gravity in casting. Further, a reserved pouring hole is formed at the highest point of the transverse pouring cavity by using a construction mode without a sealing plate.
Specifically, the method also comprises monitoring in pouring, wherein the monitoring in pouring specifically comprises the following steps: and arranging observation holes at intervals of 40-60cm along the length direction of the pouring cavity, and monitoring pouring through the observation holes.
Example 3
In this embodiment, preparation of casting solution and the like are mainly described.
Further, before the step of pouring to form the prefabricated member, the method further comprises the preparation of pouring liquid, specifically: after stirring the UHPC premix for T1 time, adding water and an additive, continuing stirring for T2 time, and finally adding stainless steel fiber, and stirring for T3 time to form the pouring liquid, wherein T2 is more than T3 and more than T1.
In this embodiment, because components such as cement, aggregate, steel fiber and the like of the UHPC are easy to agglomerate in the mixing process, and the homogeneity and material characteristics of the components are affected, the agglomeration is avoided by adjusting the stirring time, the feeding sequence and the like of each material, so that the components form a relatively uniform and compact internal structure, and the stability of indexes such as flexural strength, compressive strength and the like is facilitated.
Specifically, in the preparation of the casting solution, the UHPC premix: water: additive: the mass ratio of the stainless steel fiber is 1000:76.9:10.6:45.
in the embodiment, the aim is to obtain UHPC casting liquid capable of meeting expected requirements of mechanical properties such as strength, toughness and the like by adjusting the mass ratio of raw materials.
Further, the UHPC premix comprises powder with particle size smaller than 1mm, the additive is a water reducing agent, and the length of the stainless steel fiber is 13-14mm.
In the embodiment, in order to realize that the compressive strength of the material is higher than 130MPa, the bending strength is higher than 20MPa and the tensile strength is higher than 7MPa, stainless steel fibers are added into the pouring liquid, so that the pouring liquid shows certain directionality and connectivity during pouring, the expansion of microcracks in the material is slowed down, and the corresponding mechanical property requirements can be met. In the embodiment, the length of the stainless steel fiber is less than or equal to 14mm, and the purpose is to select the stainless steel fiber with the length, so that the mixing can be well realized, the coupling force between materials is realized, and the mixing effect of the mixing materials is ensured.
Further, the splicing step between the prefabricated members further comprises filling, wherein the filling is as follows: and the openings of the two embedded parts and the butt joint of the prefabricated parts are filled with UHPC mixture.
In this embodiment, the filling after the connection of the prefabricated members is specifically to set up a mold frame support at the connection position of the members, pour UHPC casting liquid, and repair the surface after the completion of the coagulation and hardening. By re-filling the UHPC pouring liquid, the joint has better strength and mechanical property.
Specifically, when the preform is in contact with an existing structure, it also includes the connection of the preform to the existing structure, specifically: the H-shaped steel base is embedded in the existing structure, the high-strength bolts are embedded in the bottoms of the prefabricated parts, and the bolts are connected with the steel base in a nested mode through the bolts.
In this embodiment, when the prefabricated member contacts with an existing structure such as the ground, the steel base can be embedded in the ground to realize stable connection.
Example 4
In this embodiment, the description is mainly made of actual scene construction.
Referring to fig. 2-8, in this embodiment, the space special-shaped structure 100 to be constructed is a ribbon-shaped suspension seat, and the model is novel and unique. The space curve is continuously changed to form different structural or functional areas, such as a seat, a slide, a swing and the like, so that the space curve is used for adult rest and children to play.
In terms of structural characteristics, the total building area of the ribbon-shaped suspended landscape seat is 133 square meters, and the maximum height is 2.35 meters. The outer ring consists of 7 pi-shaped and 2 curved members, the outer diameter is 5.6 meters, the outer ring section width is 0.6 meter, and the member height is 1.85 meters. The inner ring consists of 3 pi-shaped and 2 curved members, the outer diameter is 2.15 meters, the inner ring section width is 0.3 meter, and the member height is 0.45 meter.
The suspension seat has a plurality of functional partitions, such as a seat, a slide, a swing and the like, and the structural stress requirement is high. The engineering adopts finite element software SOFISTIK 2020 to establish a calculation model, the permanent load DL=24 kN/m2, the live load LL=3 kN/m2 and the wind load WL=1 kN/m2, and structural thickness design and checking calculation under the bearing capacity limit state and the normal use limit state are respectively carried out, and the result shows that: the material consumption is about 8 tons, and the structure thickness is in the range of 30-80 mm; the maximum tensile stress is 13.5MPa in the bearing capacity state; the maximum deflection is 12.7mm under the normal use state. For this reason, the compressive strength of the material is higher than 130MPa, the bending strength is higher than 20MPa, and the tensile strength is higher than 7MPa.
In this embodiment, in performing related construction, the main steps are as follows:
the first step: preparation of casting solution formed by UHPC material
In order to ensure that the mechanical property of the structure meets the design requirement, the engineering strictly controls the selection of UHPC materials, and finally adopts Lafuji Haorei (Ductal) UHPC raw materials, specifically comprising Lafuji Haorei B3 type UHPC premixed powder and F4 type additive. Wherein, the premixed powder already contains superfine powder, and the sufficient stirring can effectively reduce the gaps of aggregate and improve the compactness of the material. The main component of the admixture is a water reducing agent, so that the unit mixing water consumption of concrete is greatly reduced.
1) Material mixing ratio
According to the material description and the on-site trial-and-test effect of Lafaji haorel, the material compounding ratio is shown in table 1, namely, each 1000g of Lafaji haorel B3 type UHPC premixed powder needs to be mixed with 76.9g of water, 10.6g of F4 type additive and 45g of stainless steel fiber (with the length of 14 mm) to achieve the mechanical property.
TABLE 1 Lafaji Haorei UHPC Material mix ratio
2) Mixing process
Adding UHPC raw materials into a stirrer according to the mixing ratio for stirring. 1000g of the premix was first stirred for 2 minutes, and the fine aggregate and the ultrafine powder in the premix were uniformly mixed. Then 76.9g of water and 10.6g of additive are added and stirred for 5 minutes, 45g of stainless steel fiber is added and stirred for 4 minutes, and finally UHPC mixture is prepared for standby.
In this embodiment, the reason for selecting UHPC is as follows:
ultra-high performance concrete (UHPC) is a cement-based composite material with high strength (compressive strength is more than or equal to 130 MPa), high toughness (flexural strength is more than or equal to 20 MPa), long durability and high environmental protection. It contains no coarse aggregate, and its main components include silica fume with grain size less than or equal to 1mm, cement, fine aggregate, steel fiber, etc. The method adopts the theory of maximum bulk density, namely, finer particles are continuously filled in gaps among coarse particles, so that the pore size and the porosity are sufficiently reduced, wherein the silica fume generates calcium silicate hydrate (C-S-H) through chemical reaction, and other components are sufficiently gelled to form a compact structure, so that higher strength and excellent durability are obtained. Organic fiber or steel fiber is often added into UHPC to slow down the expansion of micro-cracks inside the material, and stronger toughness and ductility are obtained. Due to the excellent performance of UHPC, the cross section size and the dead weight of the structure can be obviously reduced under the condition of meeting the same function, so that the natural resource consumption and the pollutant emission of waste gas, dust and the like are reduced, and the UHPC is more energy-saving and environment-friendly.
Currently, UHPC materials are mainly applied in the field of bridge engineering, including girder, arch ring, bridge deck, bridge joint, old bridge reinforcement and the like. The method can effectively solve a series of problems that the large-span girder bridge is excessively bent and cracked, a steel bridge pavement layer is easy to damage, a bridge deck plate is fatigued and cracked, the self weight of the large-span steel-concrete combined bridge is excessively large, a hogging moment concrete bridge deck plate is easy to crack and the like. UHPC materials have also been tried in the field of landscape architecture, and are mainly used for landscape structures with unique modeling and complex stress.
The components such as UHPC cement, aggregate, steel fiber and the like are easy to agglomerate in the mixing process, so that the homogeneity and the material characteristics of the UHPC are affected, and the mixing and curing technology of the UHPC cement, aggregate, steel fiber and the like is partially researched by students at home and abroad. Researches show that the indexes such as the material mixing proportion, the material feeding time, the material feeding sequence and the stirring method can have great influence on the flexural strength, the compressive strength and the like of the material. It has also been shown that high temperature, pressurized curing accelerates the pozzolanic reaction of silica fume, promotes the formation of crystalline hydrate and the dehydration of hardened slurry, and facilitates the formation of a dense internal structure.
Second, the segmentation and preparation of the prefabrication stage:
in order to reduce the occupied space and the construction period, the project performs all prefabrication of UHPC structural members in a factory, wherein the content comprises segment division, formwork design, segment prefabrication, connection nodes and the like.
1) Segment division
In this embodiment, the floating seat is divided into 4 parts according to the functional division: the wind-load-bearing device can be used for a man-climbing part, a stair pavement, a ground anchoring part and a wind load main action area. When dividing the prefabricated sections, the single section is required to have at least 1 ground anchoring force point, and on the basis, the single pouring square quantity is comprehensively considered to divide the whole structure into 14 prefabricated sections, and the lengths of the sections are 2-5 meters.
2) Die carrier design
The suspension seat has unique shape, and a conventional mould frame system is difficult to be applied; meanwhile, because the construction period is short and a customized steel template cannot be selected, the engineering proposes a formwork system combining a wood template, PVC and GRC, as shown in figure 7. Firstly, the cross section and longitudinal section sizes of the formwork systems of each segment are calculated by using Rhinoceros software. Then, nine clamping plates 9mm thick were cut as a stent foundation (pitch 10 cm) according to the shape and size of the horizontal projection of each segment. Finally, cutting the nine clamping plates with the height of the vertical section and the shape of the lower arc to manufacture a bottom die and a side die, and ensuring that the bottom die plate is firmly connected with the support foundation. If the basic height of the bracket exceeds 60cm, a diaphragm plate can be added at a proper position to ensure the stability of the bracket system. Specifically, vertical supports 200 and base supports 300 are included.
Referring to fig. 3, a double-layer template system 400 is formed by paving 4mm thick PVC coiled materials on the bottom die and the side die, the bottom template and the PVC coiled materials are required to be glued comprehensively, and the bracket foundation and the bottom template are fixed by adopting a nail shooting mode. If the curvature of the local structure is too small or the gradient is too large, glass fiber reinforced cement (GRC) is adopted to smoothly transition at the moment, so that the smooth and non-angle-folding of the structural curve is ensured. Meanwhile, when the gradient of the component is steeper, a single-layer PVC coiled material with the thickness of 4mm is additionally arranged as a top-layer template.
In addition, a plurality of pairs of square steel pipes with the wall thickness of 1.2mm and 40mm are arranged on the upper side of the top die and the lower side of the bottom die, and 18# iron wires are used for binding the steel pipes on the top and bottom layers so as to prevent the die from running or expanding. In addition, the extrusion die plate of the top and bottom steel pipes can also be used as the pre-pressure applied during UHPC condensation, which is beneficial to eliminating pores and free water, ensuring that particles are more compact and improving the bending strength and toughness of the component.
Third, pouring and maintaining
And after the die carrier system is finished, pouring the UHPC mixture. Considering the size of the component comprehensively, reserving 1 pouring hole at the height of each section, and arranging 1 observation hole at intervals of 50cm in the extending direction of the component. During pouring, the UHPC mixture is poured from the pouring hole, naturally flows along the bottom die from high to low, and the pouring position is mastered in real time by observing the overflow condition of the hole. It is particularly noted that the UHPC mixture is not required to be vibrated when being poured. The stainless steel fiber shows certain directionality and connectivity in the flowing process, and can greatly slow down the expansion of microcracks in the material, so that the material shows ultrahigh toughness and ductility. Finally, under the normal temperature condition, the prefabricated part can be lifted and carried after being sprayed and maintained for 28 days with a die, and at the moment, the compressive strength of the prefabricated part is higher than 130MPa, the bending strength is higher than 20MPa, and the tensile strength is higher than 7MPa.
Fourth, field assembly
The suspension seat accumulates 14 prefabricated sections, and when in on-site assembly, the prefabricated sections are connected with a concrete foundation, and then the prefabricated sections are connected.
1) The prefabricated section is connected with the concrete foundation
The prefabricated section is connected with the concrete foundation by adopting a pre-buried steel plate and a high-strength bolt. As shown in figures 4-5, a steel base is required to be embedded in a concrete foundation, and the concrete foundation consists of a lower steel plate 1, an H-shaped support 2 and an upper steel plate 3, and is subjected to rust prevention treatment by adopting Q355B steel.
Taking the outer ring of the suspension seat as an example, the lower steel plate of the section is 600 multiplied by 20mm, the upper steel plate is 400 multiplied by 20mm, the H-shaped support is H=200mm, B=200mm and t=20mm, and the height is changed within the range of 39-264 mm according to the height and the inclination angle of the bottom of the section. 4M 20 high-strength embedded bolts 4 are needed to be embedded in the UHPC prefabricated section, and the strength grade is 8.8. The on-site installation is only needed to nest and connect the high-strength bolts of the prefabricated sections with the reserved bolt holes of the upper steel plate, and screw nuts.
2) The prefabricated part is connected with the prefabricated part
The prefabricated sections are connected by adopting a pre-buried steel plate and field grouting. Taking the suspension seat outer ring as an example, the section width is 0.6m, the size of the embedded steel plate is 250 multiplied by 350 multiplied by 15mm, and the size of the welded connection steel plate is 300 multiplied by 150 multiplied by 10mm. The pre-buried plate and the connecting plate are all required to be provided with pre-reserved holes. As shown in fig. 6-8, 2 pre-buried steel plates 5 with the thickness of 250 multiplied by 350 multiplied by 15mm are respectively poured at the connecting ends of adjacent sections of UHPC, after two prefabricated parts 6 are aligned on site, the pre-buried steel plates are clamped through two welding connection steel plates 7, the upper pre-reserved holes 8 and the lower pre-reserved holes are aligned and communicated, then the pre-buried steel plates 5 and the welding connection steel plates 7 are welded and fixed (fillet welds are applied along the overlapped parts), finally UHPC mixture 9 is poured at the connecting parts of the components, and surface repair is carried out after the condensation hardening is finished.
The building entity has complex space structure, small curvature, large gradient and bearing requirement, and the tensile resistance or the bending resistance of the conventional concrete material can not meet the requirement, so that the UHPC material is adopted, and meanwhile, the UHPC material introduction and the common field or the professional are attached. In the invention, the addition of UHPC material has the following significance:
1) The UHPC mixture is used as casting material, the formed casting body is light in volume and low in cost, meets the acceptance requirement of a suspension structure, and greatly reduces the dead weight;
2) The embodiment is supported by the wood board, so that the device is more suitable for a complex space structure with small curvature and large gradient, and can meet the special environment of the embodiment;
3) In this embodiment, adopt the plank to support, not only with low costs, light in weight, plank concatenation is more nimble moreover, and the linear structure of formation is smoother, is more suitable for special-shaped structure.
The above list of detailed descriptions is only specific to practical embodiments of the present invention, and they are not intended to limit the scope of the present invention, and all equivalent embodiments or modifications that do not depart from the spirit of the present invention should be included in the scope of the present invention.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.
Furthermore, it should be understood that although the present disclosure describes embodiments, not every embodiment is provided with a separate embodiment, and that this description is provided for clarity only, and that the disclosure is not limited to the embodiments described in detail below, and that the embodiments described in the examples may be combined as appropriate to form other embodiments that will be apparent to those skilled in the art.
Claims (9)
1. The construction method for realizing pouring of the space special-shaped structure by using the UHPC material is characterized by comprising the following steps:
dividing a space special-shaped structure: dividing the space special-shaped structure into a plurality of prefabricated sections according to stress distribution conditions and transportation weight limit;
erecting a die carrier support: according to design requirements, a vertical support body and a foundation support are respectively arranged, the vertical support body comprises a plurality of vertical boards with gradually rising or gradually falling heights, the foundation support is designed in size according to horizontal projection of a space special-shaped structure, the vertical boards are arranged on the foundation support, a curved-surface template system is arranged along the upper surface of the vertical support body, and the template system forms a transverse pouring cavity which changes along with the height change of the vertical boards;
casting to form a prefabricated part: casting to form a prefabricated member with a UHPC floating structure by a mode that UHPC mixture naturally flows in the transverse casting cavity;
splicing between prefabricated parts: welding and fixing the prefabricated members with the rising or falling heights through embedded parts to form the space floating strip-shaped structure;
the space floating strip-shaped structure is a floating seat, the floating seat is provided with a plurality of functional areas, the floating seat comprises an inner ring and an outer ring, and the inner ring and the outer ring comprise n-shaped and curved members;
in the step of erecting the formwork support, the method further comprises reserving pouring holes, specifically: the top of vertical plank is equipped with the recess, set up die block board and side form board in the template system in the recess, form horizontal pouring chamber, the highest point department in horizontal pouring chamber forms the reservation and pours the hole.
2. The construction method for realizing casting of space special-shaped structures by using UHPC materials according to claim 1, wherein the division of the space special-shaped structures is specifically as follows: and (3) establishing a stress calculation model of the space special-shaped structure, and dividing the segments in the stress non-concentrated section, wherein the segment division is required to meet the weight and length limiting requirements in the transportation process.
3. The construction method for realizing casting of space special-shaped structures by using UHPC materials according to claim 1, wherein in the step of erecting a formwork support, the construction method further comprises the step of connecting transition parts of a curved surface and/or inclined surface formwork system, wherein the transition part connection is specifically as follows: and coating and paving a glass fiber reinforced cement layer at the transition part.
4. The construction method for realizing casting of space special-shaped structures by using UHPC materials according to claim 3, wherein after the step of erecting the formwork support and before the step of casting to form prefabricated members, the construction method further comprises the steps of clamping and fixing a template system, and is characterized in that: and the top and the bottom of the template system are respectively clamped and fixed by utilizing steel pipes.
5. The construction method for realizing casting of space special-shaped structures by using UHPC materials according to claim 1, wherein the casting step before forming prefabricated parts further comprises the preparation of UHPC mixture casting liquid, specifically: after stirring the UHPC premix for T1 time, adding water and an additive, continuing stirring for T2 time, and finally adding stainless steel fiber, and stirring for T3 time to form the pouring liquid, wherein T2 is more than T3 and more than T1.
6. The construction method for realizing casting of spatially special-shaped structures by using UHPC materials according to claim 5, wherein in the preparation of the casting solution, the UHPC premix is as follows: water: additive: the mass ratio of the stainless steel fiber is 1000:76.9:10.6:45.
7. the construction method for realizing casting of space special-shaped structures by using UHPC materials according to claim 6, wherein the UHPC premix comprises powder with particle size smaller than 1mm, the additive is a water reducing agent, and the length of the stainless steel fiber is 13-14mm.
8. The construction method for realizing casting of space special-shaped structures by using UHPC materials according to claim 1, wherein the splicing step between the prefabricated members further comprises filling, and the filling is as follows: and the openings of the two embedded parts and the butt joint of the prefabricated parts are filled with UHPC mixture.
9. The construction method for realizing casting of space special-shaped structures by using UHPC materials according to claim 1, wherein when the prefabricated member is contacted with the existing structure, the construction method further comprises the steps of connecting the prefabricated member with the existing structure, specifically: the H-shaped steel base is embedded in the existing structure, the high-strength bolts are embedded in the bottoms of the prefabricated parts, and the bolts are connected with the steel base in a nested mode through the bolts.
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