CN117550870B - 一种海上风电吸力桶用低密度灌浆料及其制备方法 - Google Patents
一种海上风电吸力桶用低密度灌浆料及其制备方法 Download PDFInfo
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Abstract
本发明涉及水泥基建筑材料领域，尤其是涉及一种海上风电吸力桶用低密度灌浆料及其制备方法，以解决现有的流态淤泥不适用用作低密度灌浆料的技术问题。由以下重量份原料组成：粉煤灰15‑25份，矿粉4‑15份，激发剂1‑5份，水泥2‑5份，抗分散剂1‑2份，淤泥30‑50份，轻质骨料10‑40份，水20‑30份，激发剂为硅酸钠、碳酸钠、氯化铁以重量比8‑10:2‑5:1‑2的混合物，抗分散剂为淀粉、引发剂和聚丙烯酰胺进行接枝反应后经洗涤、干燥得到的改性聚丙烯酰胺与聚醚多元醇按质量比1‑3:1的混合物。本发明可用作低密度灌浆料，具有更好的耐水性，综合成本更低。
Description
技术领域
本发明涉及水泥基建筑材料技术领域，尤其是涉及一种海上风电吸力桶用低密度灌浆料及其制备方法。
背景技术
传统海上风电的基础的形式有钢桩式和漂浮式，钢桩式是将打钢桩插入到海床基础上，漂浮式是使基础漂浮在海上，吸力桶基础是一种新型的海上风电基础形式，吸力桶就位时，将桶内海水抽出形成负压，迫使吸力桶贯入至淤泥、砂砾等软土地基中，当吸力桶壁的摩擦阻力足够大时，即可承担上部风机运转的荷载。吸力桶基础形式具有施工方便、可重复利用、造价低等优势因此受到了越来越多的重视。在吸力桶贯入深度达到要求时，需要对上部空腔进行回填，为了不对原有淤泥产生扰动，要求材料具有较低的容重，否则会扰动基础表层的淤泥而造成灌注量大的问题，而目前传统的灌浆材料容重普遍大于2200kg/m3，并且，相比于传统的水泥基灌浆料、普通灌浆料、风电用灌浆料，吸力桶用低密度灌浆料需要的强度很低，0.5个兆帕即可满足承载力要求。此外，由于吸力桶的直径较大，也对材料的流动性能提出较高的要求，并具有良好的抗分散性，避免出现离析分散。
目前，CN114890738提出采用普通硅酸盐水泥、活性填料I级粉煤灰、轻质填料膨胀珍珠岩等原材料制备了一种海上风机吸力筒填充专用水下轻质灌浆料。CN112759320提出采用水泥、粉煤灰、矿粉、发泡剂、减水剂、抗分散剂制备了一种海上风电吸力桩基础用灌浆料，也具有高流动度、低泌水、低密度、低强度的特点。然而，现有技术均采用水泥作为最主要的胶结材，而超高的加水量导致水泥水化胶结能力大大削弱，综合材料成本仍较高。发明人在前期进行过水下抗分散流态淤泥固化剂的研究并申请专利CN115974503A，然而直接利用其固化淤泥后制备的流态淤泥不适用用作低密度灌浆料。
发明内容
为克服现有技术中存在的问题，本发明提供一种海上风电吸力桶用低密度灌浆料，采用粉煤灰、矿粉、激发剂作为主要胶凝材料，辅以水泥并加入淤泥作为填料，并添加轻骨料降低灌浆料密度，采用抗分散剂保证灌浆料在吸力桶基础中的灌注性能。
具体的，本发明海上风电吸力桶用低密度灌浆料，由以下重量份原料组成：
粉煤灰15-25份，
矿粉4-15份，
激发剂1-5份，
水泥2-5份，
抗分散剂1-2份，
淤泥30-50份，
轻质骨料10-40份，
水20-30份。
现有技术中主要采用水泥+矿物掺合料+外加剂作为胶凝材料的技术路线制备低密度、低强度、大流态的吸力桶低密度灌浆料，本发明考虑到港口淤泥更容易获得，便于就地取材，且原料体系更贴近于海底环境的因素，设计采用淤泥作为成分进行配置。发明人研究发现，若采用现有技术水泥+矿物掺合料+外加剂作为胶凝材料，加入淤泥进行替代后几乎无法形成固结体，究其原因是因为体系内水泥添加量低，矿物掺合料本身活性也不高，然而低密度灌浆料用水量高，加之轻质骨料的影响，无法形成连续骨架结构，然而，本发明采用粉煤灰、矿粉、激发剂作为主要胶凝材料则可解决上述问题，淤泥由于同样属于硅铝质粘土矿物，在碱激发理论下同样可以在一定程度上参与水化反应，实现良好的强度效果。
优选的，所述激发剂为硅酸钠、碳酸钠、氯化铁以重量比8-10:2-5:1-2的混合物。激发剂用于对粉煤灰和矿粉进行碱激发，本发明因添加大量淤泥作为填料，并添加轻质骨料，因此对浆料的流动性和力学性能提出更高要求，经大量实验，本发明采用硅酸钠、碳酸钠、氯化铁以重量比8-10:2-5:1-2的混合物作为激发剂，克服大掺量淤泥和轻质骨料在大水胶比下对低密度灌浆料匀质性的影响，辅以少量水泥提供一定的水化和碱性液相促进粉煤灰、矿粉水化功能，可实现低密度灌浆料具有大流动度和超长流动度保持能力，并在超高加水量下仍可产生较高的力学性能，而不会出现无法胶结硬化的情况。
优选的，所述抗分散剂为淀粉、引发剂和聚丙烯酰胺进行接枝反应后经洗涤、干燥得到的改性聚丙烯酰胺与聚醚多元醇按质量比1-3:1的混合物。为保持水下施工时低密度灌浆料的抗分散性，本发明特采用淀粉接枝聚丙烯酰胺和聚醚多元醇作为抗分散剂，其对添加轻质骨料的低密度灌浆料具有良好的增稠效果，避免轻质骨料的上浮，对添加淤泥的浆料有良好的匀质性保持效果，无离析泌水情况，同时具有流动性保持能力。更优选的，所述引发剂为过硫酸盐，洗涤剂为无水乙醇，接枝反应温度为65-85℃，反应时间为3-5h。
优选的，所述粉煤灰为Ⅰ级粉煤灰、Ⅱ级粉煤灰的至少一种。
优选的，所述矿粉为S95级矿粉、S105级矿粉的至少一种。
优选的，所述水泥为硅酸盐水泥、普通硅酸盐水泥、矿渣硅酸盐水泥、火山灰硅酸盐水泥的至少一种。
优选的，所述轻质骨料为陶粒、玻化微珠、膨胀珍珠岩的至少一种。
优选的，所述轻质骨料为2-5mm连续级配。
优选的，所述水为自来水。
本发明还涉及上述海上风电吸力桶用低密度灌浆料的制备方法，具体的，包括如下制备步骤：
1）按重量份称取各原料，
2）将粉煤灰、矿粉、激发剂、水泥、抗分散剂、淤泥、水投入搅拌机拌合均匀，得灌浆料母料，
3）将轻质骨料投入灌浆料母料，拌合均匀后静停，继续搅拌。
优选的，所述静停时间为3-5min。
本发明具有以下技术优势：
1.本发明采用粉煤灰、矿粉和激发剂作为主要胶凝材料，碱激发反应实现与水泥相近的水化硬化强度，同时相比于水泥具有更好的耐水性，可采用更高的加水量，另一方面相比于水泥的综合成本更低，具有利废减碳的优势。
2.本发明添加淤泥作为填料，可实现就地取材，并贡献部分水化活性，降低施工成本。
3.采用轻质骨料降低灌浆料密度至1100-1600kg/m3，可避免底部淤泥翻起。
4.采用特定组成激发剂，配合抗分散剂实现低密度灌浆料流动性大、流动性保持性好，避免轻骨料离析、浆体分散，实现低密度灌浆料水下灌注自流平、自密实，满足空腔灌浆方量大的需求，无需添加减水剂等其他外加剂。
具体实施方式
为表征本发明技术效果，配制低密度灌浆料并进行浆液密度、流动度、泌水率和抗压强度检测，流动度检测在10cm深的水下进行。其中，粉煤灰采用Ⅱ级粉煤灰，矿粉采用S95级矿粉，水泥采用PO42.5普通硅酸盐水泥，激发剂采用硅酸钠、碳酸钠、氯化铁以重量比10:3: 2的混合物，抗分散剂为聚醚多元醇接枝聚丙烯酰胺与聚醚多元醇质量比2:1的混合物，轻质骨料为2-5mm连续级配。
实施例1
低密度灌浆料，由以下重量份原料组成：粉煤灰17份，矿粉6份，激发剂2.5份，水泥3.5份，抗分散剂1.2份，淤泥46份，陶粒18份，水22份。
经检测，低密度灌浆料匀质性良好，浆液密度1580kg/m3，初始流动度293mm，60min流动度保持值288mm，120min流动度保持值258mm，480min流动度保持值245mm，泌水率0%，7d抗压强度1.1MPa，28d抗压强度3.4MPa。
实施例2
低密度灌浆料，由以下重量份原料组成：粉煤灰21份，矿粉5份，激发剂4.5份，水泥2份，抗分散剂2份，淤泥31份，膨胀珍珠岩35份，水23份。
经检测，低密度灌浆料匀质性良好，浆液密度1150kg/m3，初始流动度305mm，60min流动度保持值276mm，120min流动度保持值235mm，480min流动度保持值208mm，泌水率0%，7d抗压强度0.4MPa，28d抗压强度0.8MPa。
对比例1
灌浆料，由以下重量份原料组成：粉煤灰2份，矿粉5份，激发剂0.5份，水泥25份，抗分散剂2份，淤泥31份，膨胀珍珠岩35份，水23份。
经检测，灌浆料离析，膨胀珍珠岩上浮，浆液密度1360kg/m3，无法进行水下流动度测试和力学性能测试。
对比例2
灌浆料，由以下重量份原料组成：粉煤灰21份，矿粉5份，激发剂4.5份，水泥2份，抗分散剂2份，石英砂31份，膨胀珍珠岩35份，水23份。
经检测，灌浆料泌浆，浆液密度1760kg/m3，无法进行水下流动度测试，7d抗压强度5.2MPa，28d抗压强度7.6MPa。
对比例3
灌浆料，由以下重量份原料组成：粉煤灰21份，矿粉5份，硅酸钠2.5份，碳酸钠2份，水泥2份，抗分散剂2份，淤泥31份，膨胀珍珠岩35份，水23份。
经检测，灌浆料轻微泌水，浆液密度1230kg/m3，初始流动度285mm，60min流动度保持值250mm，120min无流动性，7d抗压强度0.25MPa，28d抗压强度0.6MPa。
对比例4
灌浆料，由以下重量份原料组成：粉煤灰21份，矿粉5份，激发剂4.5份，水泥2份，淀粉接枝聚丙烯酰胺2份，淤泥31份，膨胀珍珠岩35份，水23份。
经检测，灌浆料膨胀珍珠岩上浮，性能无法进行检测。
最后应说明的是：以上各实施方式仅用以说明本发明的技术方案，而非对其限制；尽管参照前述各实施方式对本发明进行了详细的说明，本领域的普通技术人员应当理解：其依然可以对前述各实施方式所记载的技术方案进行修改，或者对其中部分或者全部技术特征进行等同替换；而这些修改或者替换，并不使相应技术方案的本质脱离本发明各实施方式技术方案的范围。
Claims (9)
1.一种海上风电吸力桶用低密度灌浆料，其特征在于，由以下重量份原料组成：
粉煤灰15-25份，
矿粉4-15份，
激发剂1-5份，
水泥2-5份，
抗分散剂1-2份，
淤泥30-50份，
轻质骨料10-40份，
水20-30份，
所述激发剂为硅酸钠、碳酸钠、氯化铁以重量比8-10:2-5:1-2的混合物，
所述抗分散剂为淀粉、引发剂和聚丙烯酰胺进行接枝反应后经洗涤、干燥得到的改性聚丙烯酰胺与聚醚多元醇按质量比1-3:1的混合物；
所述引发剂为过硫酸盐，洗涤剂为无水乙醇，接枝反应温度为65-85℃，反应时间为35h。
2.根据权利要求1所述海上风电吸力桶用低密度灌浆料，其特征在于，所述粉煤灰为Ⅰ级粉煤灰、Ⅱ级粉煤灰的至少一种。
3.根据权利要求1所述海上风电吸力桶用低密度灌浆料，其特征在于，所述矿粉为S95级矿粉、S105级矿粉的至少一种。
4.根据权利要求1所述海上风电吸力桶用低密度灌浆料，其特征在于，所述水泥为硅酸盐水泥、普通硅酸盐水泥、矿渣硅酸盐水泥、火山灰硅酸盐水泥的至少一种。
5.根据权利要求1所述海上风电吸力桶用低密度灌浆料，其特征在于，所述轻质骨料为陶粒、玻化微珠、膨胀珍珠岩的至少一种。
6.根据权利要求5所述海上风电吸力桶用低密度灌浆料，其特征在于，所述轻质骨料为2-5mm连续级配。
7.根据权利要求1所述海上风电吸力桶用低密度灌浆料，其特征在于，所述水为自来水。
8.根据权利要求1-7任一所述海上风电吸力桶用低密度灌浆料的制备方法，其特征在于，包括如下制备步骤：
1）按重量份称取各原料，
2）将粉煤灰、矿粉、激发剂、水泥、抗分散剂、淤泥、水投入搅拌机拌合均匀，得灌浆料母料，
3）将轻质骨料投入灌浆料母料，拌合均匀后静停，继续搅拌。
9.根据权利要求8所述海上风电吸力桶用低密度灌浆料的制备方法，其特征在于，所述静停时间为3-5min。
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