RU2599300C2 - Method of producing unsupported tape material for road surface and method of construction of joints and connections of unsupported tape material - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: group of inventions relates to a method of manufacturing the tape road-construction material based on the polymer-bitumen bonding materials and can be used for provision of sealing of joints and connections during arrangement of road surfaces, bridges and aerodromes. Method of producing unsupported tape material involves formation of a layer within one step from the polymer-bitumen bonding materials with a temperature of 100-110 °C by supplying of the bonding material into moving anti-adhesive film. Wherein the layer thickness is profiled using microprocessor. Ready tape material is cooled with water. Cooling degree is controlled automatically. After drying the material is rolled up. Method for construction of joints and connections includes laying, manual and mechanical fixation by the asphalt mixture with a temperature of 140-160 °C simultaneously with sealing of the tape material on the edge of joints of road surface or adjacent element. Manual fixation advances the mechanical one.

EFFECT: automation of technological process of unsupported tape material within one step and improvement of tightness when constructing joints and connections using obtained unsupported tape material.

4 cl, 3 dwg, 1 tbl, 3 ex

Description

The group of inventions relates to a method of manufacturing a tape road-building material based on polymer-bitumen binders and can be used to provide sealing joints and joints when installing asphalt concrete coatings on roads, bridges and airfields.

It is known that asphalt concrete pavements are arranged from separate strips with a width equal to the width of the paver grab, and the required coating width is achieved by joining the hot newly laid strips to the previously cold laid ones. The joints formed in this case, due to the excessive porosity of asphalt concrete, are subject to intense cracking, which violates the integrity of the coating and opens up access to atmospheric moisture in the lower layers of the pavement. In turn, cyclic freezing and thawing of water in the autumn-spring period leads to premature destruction of the coating and the need for repair or replacement. Similar defects occur at the junction of the asphalt concrete pavement to cement concrete and metal surfaces, such as curbs, drainage trays, manholes and gratings of storm sewers, tram rails.

These problems can be solved by manufacturing baseless tape material for paving based on a polymer-bitumen binder with predetermined physical and mechanical characteristics. Such material can be used to prevent the above defects.

It is known that polymer-bitumen binders (PBB) used in road and airfield construction are produced, stored, transported and used in the form of a melt at temperatures of 140-160 ° C. It is impossible to use them in solid form (to make molded products from them), because due to insufficient heat resistance, in the entire range of permissible application temperatures (from 0 to 45 ° C) they have a fluidity that does not allow to maintain the physical shape of the body.

Therefore, in order to achieve the possibility of manufacturing, transporting, storing and using molded products, for example, docking tapes for paving, the binder must have heat resistance, ensuring the physical shape of the product’s body in the entire operating temperature range.

Since the absolute temperature maximum recorded on the territory of the Russian Federation is 45 ° C, then for the safety of molded products from a polymer-bitumen binder, its heat resistance should exceed this value. The heat resistance of the PBB is estimated by the softening temperature according to the method of the ring and ball and the depth of penetration of the needle at 25 ° C.

It was experimentally established that to ensure heat resistance of more than 45 ° C, the softening temperature should be at least 85 ° C and the penetration depth of the needle at 25 ° C not more than 60 ° C penetration degrees. Since PBB is used in the construction of asphalt concrete pavements, it should maintain frost resistance at the level of oil bitumen. Frost resistance of bitumen is characterized by the value of the fragility index according to Fraas minimum acceptable value, which is minus 20 ° C.

A known method of manufacturing a baseless roll material based on a bitumen-rubber composition by mixing the necessary components, supplying the finished mixture to leafing and profiling according to the specified thickness parameters, connecting the resulting sheet with anticorrosive material and winding the finished baseless tape material into a roll (RF patent No. 20111664, IPC D06N 5/00, 1994).

The disadvantages of this method include the discontinuity of the process and the inability to control the thickness of the formed sheet in automatic mode.

The closest technical solution to the claimed method according to the set of essential features is a method of manufacturing a baseless tape material based on a polymer-bitumen binder, including the formation of a layer made of a polymer-bitumen binder based on a temperature of 100-110 ° C by feeding a binder to a moving release film, profiling the layer according to the specified parameters of thickness and width and winding the finished baseless tape material into a roll (RF patent No. 2409470, IPC 32 V 11/00, 2011 - prot type).

The disadvantages of the prototype method are that the formation of tape material of the required geometric dimensions is carried out in several stages, and the production process is periodic and non-automated. Obtaining tape material of a given thickness is carried out by heat-gluing at least three tapes of smaller thickness, which is due to the impossibility of forming a layer of the desired thickness in one pass due to the draining of the binder from the substrate due to its fluidity in the molten state.

In addition, the composition of bitumen mastic used for the manufacture of this material does not have the ability to stably maintain its overall dimensions under storage conditions in warehouses at a temperature of + 45 ° C.

The closest technical solution to the claimed method of the device joints and joints is a method of devices joints and joints of baseless tape material made on the basis of a polymer-bitumen binder, including laying, manual and mechanical fixing of the tape material at the edge of the joints of the road surface or on the side surface of the adjacent element presented in the description of the utility model of the Russian Federation No. 143147, IPC E01C 7/22, 2014 - prototype.

The disadvantage of the prototype is that the mechanical fixation of the tape material is carried out either by rolling motor vehicles at the junction of the strips, or by rolling the roller at the junction of asphalt and concrete structure. In both cases, an expansion joint of insufficient quality is formed, namely with insufficient tightness.

At the same time, it is known that asphalt concrete is subject to temperature compression at lower temperatures, as a result of which the linear dimensions of joints, cracks, joints and joints increase by an average of 100%. At the same time, to ensure tightness, the sealing material must have reliable adhesion to the surface, which is not provided by the prototype.

In addition, the prototype method does not provide reliable tightness at the joints of asphalt concrete with asphalt concrete when the coating device.

The task of the claimed group of inventions is to automate a method of manufacturing a baseless tape material of a rectangular shape in cross section, capable of maintaining its physical shape at temperatures up to + 45 ° C and ensuring tightness of joints and joints of asphalt concrete pavements when implementing the method of connecting joints and joints before starting to use it in road construction. from this material over the entire range of operating temperatures.

The problem is solved due to the fact that in the method of manufacturing a baseless tape material based on a polymer-bitumen binder, including the formation of a layer prepared from a polymer-bitumen binder with a temperature of 100-110 ° C by feeding a binder to a moving release film, profiling the layer by the specified parameters of thickness and width and winding the finished tape baseless material into a roll, the formation of the layer is carried out in one step, the binder is fed to a moving along a U-shaped weight To the tray, the release film stretched from the unwinding machine using a conveyor belt and a pressure roller, the thickness profiling of the layer is controlled by a microprocessor, before being rolled into a roll, the fabricated material is cooled in a container with water, while the degree of cooling is automatically controlled by means of a circulation pump and a heat exchanger interacting with water, then drained, and winding into a roll and cutting of the finished material is carried out automatically by a programmable winding-cutting device, synchronized with the conveyor belt drive.

The problem is also solved due to the fact that in the method of arranging joints and joints from baseless tape material made on the basis of a polymer-bitumen binder, including laying, manual and mechanical fixing of tape material at the edge of the joints of the pavement strips or on the side surface of an adjacent element, after manual fixation, the release film is removed from the tape material, mechanical fixation is carried out with an asphalt-concrete mixture with a temperature of 140-160 ° С simultaneously with its compacted it using the paver, wherein the manual fixing is carried out with an advancing movement of the paver 150-200 m at an air temperature below 25 ° C and 50-100 m at an air temperature over 25 ° C.

It is advisable to mechanically fix the tape material to a level with a pavement.

It is advisable to connect adjacent bands of tape material to carry out end-to-end.

The technical result is achieved due to automatic control of the flow rate necessary for the formation of a tape of a given thickness, due to the implementation of the feedback principle of the dependence of the speed of release of the release film on the mass of the supplied binder. In this case, the analog signal from the load cells, corresponding to the mass of the binder supplied by the pump, was converted to digital and processed by a microprocessor, which, in turn, controlled the rotational speed of the conveyor belt through the frequency controller. In the case of a decrease in the mass of the supplied binder, for example, as a result of a decrease in pump performance during cooling of the binder, the broaching speed was proportionally reduced. In the case of an increase in the mass of the supplied binder, for example, as a result of an increase in the pump performance during heating of the binder, the broaching speed was proportionally increased. The formation of a layer of molten binder of a given thickness is carried out in one pass due to the use of a U-shaped weighing tray, which prevents the binder from draining from the substrate until it cools and yields. The rectangular profile of the tape material is attached in a heated profiling device, which is a metal frame with a given size.

The technical result is also achieved due to the fact that when arranging joints and joints of asphalt concrete pavements, mechanical fixation is carried out by a hot asphalt mixture at the same time as it is compacted by the paver.

As a result of melting of the baseless tape material under the influence of high temperature (140-160 ° C) of the asphalt concrete mixture, the adhesive bond of the tape material with contacting surfaces increases and, accordingly, high tightness of joints and joints is ensured.

The technological scheme for manufacturing baseless tape material is presented in FIG. 1, where 1 is the first mixer for the preparation of the polymer-bitumen binder, 2 is the second mixer, 3 is the binder feed pump, 4 is the U-shaped weighing tray, 5 is the load cell, 6 is the release film, 7 is the unwinding machine, 8 is the tape conveyor, 9 - belt conveyor electric motor, 10 - pressure roller, 11 - profiling device, 12 - microprocessor, 13 - water cooling bath, 14 - guide rollers, 15 - circulation water pump, 16 - cooling heat exchanger, 17 - air cooling fan , 18 - made be basic web material (docking tape) 19 - Coiler edging device 20 - Inverter.

Preferably, as a polymer-bitumen binder used binder containing 81.0-87.0 wt. % of oil road bitumen, 4.0-7.0 wt. % block copolymer of butadiene and styrene type SBS in the form of granules or 3.0-6.0 wt.% triple block copolymer of styrene-ethylene-butylene-styrene type SEBS / SEBS in the form of a powder, or 2.0-5.0 wt. % block copolymer of styrene and butadiene type SBS in the form of granules with 1.5-3.5 wt. % copolymer of ethylene and vinyl acetate type EVA (trade name "Sevilen", brand 11104-030) TU 6-05-1636-57 in the form of granules, 8.0-10 wt. % plasticizer, 1.0-2.0 wt. % amide wax.

It is preferable that BND - 60/90 grade bitumen (GOST 22245-90) be used as oil road bitumen.

It is preferable that the brand DST-30P-01 (TU 2294-019-00148889-2013) be used as a block copolymer of butadiene and styrene of the SBS type.

Examples of the manufacture of baseless tape material based on a polymer-bitumen binder.

Example 1

In mixers 1 and 2 with a capacity of 0.3 m ^{3, they were} successively loaded: 81.0 kg of liquid bitumen of oil road viscous grade BND - 60/90 (GOST 22245-90), 7.0 kg of block copolymer of butadiene and styrene SBS grade DST - 30R-01 (TU 2294-019-00148889-2013), 10 kg of liquid plasticizer of polyalkylbenzene (TU 2414-025-05766480-2006) and 2.0 kg of amide wax (TU 38-401190-92). This mixture was heated to a temperature of 160 ° C. with constant stirring for 2 hours until a homogeneous consistency is obtained.

The resulting binder was cooled in a cooking vessel to a temperature of 100 ° C, and pump 3 was applied to a release film 6 of a width of 40 mm, moving along a U-shaped load-measuring tray 4, mounted on load cells 5, to form a layer on it. The release of the release film from the unwinding machine 7 was carried out using a conveyor belt 8 and a pressure roller 10.

The speed of the drive was controlled by changing the speed of rotation of the drive of the conveyor belt 9 by the microprocessor 12 through the frequency controller 20.

The formed layer entered the heated profiling device 11, in which it acquired a rectangular profile of a given thickness - 4 mm. The calibrated tape material was cooled at a temperature of 8 ° C in a water cooling bath 13 connected to a heat exchanger 16 and a circulation water pump 15.

Maintaining a constant temperature in the bath was carried out automatically by changing the performance of the circulation pump and the capacity of the heat exchanger. To increase the cooling efficiency, the tape material was pulled through the guide rollers 14 mounted in a zigzag fashion.

At the outlet of the bath, the material was dried with an air cooling fan 17.

The winding and trimming of the finished material 18 was carried out by an automatically programmable winding-trimming device 19, synchronized with the belt conveyor electric motor and providing winding of the tape material of the required length into a roll.

The manufactured tape material had a thickness of 4.0 mm, a width of 40 mm, a length of 15,000 mm.

Example 2

The manufacture of the material was carried out analogously to example 1, but the binder had a composition, kg:

Bitumen 85.0 Triple block copolymer styrene-ethylene-butylene-styrene (type SEBS / SEBS) 6.0 Polyalkylbenzene 8.0 Amide wax 1,0

The mixture was heated to a temperature of 150 ° C, and the finished binder was cooled to a temperature of 105 ° C.

The tape material had a thickness of 6.0 mm, a width of 45 mm, a length of 1000 mm.

Example 3

The manufacture of the material was carried out analogously to example 1, but the binder had a composition, kg:

Bitumen 85.0 Block copolymer of styrene and butadiene (type SBS) 3,5 Ethylene Vinyl Acetate Copolymer (EVA Type) 2.0 Polyalkylbenzene 8.0 Amide wax 1,5

The mixture was heated to a temperature of 140 ° C, and the finished binder was cooled to a temperature of 110 ° C.

The tape material had a thickness of 10 mm, a width of 50 mm and a length of 7000 mm.

All of the polymer additives indicated in the examples extend the plasticity range (increase the softening temperature and lower the brittle temperature) and increase the elasticity of bitumen.

The initial properties of the polymer-bitumen binder for the manufacture of tape material are presented in the table.

If the components are taken above the upper limits, then the viscosity of the binder increases so that the receipt of molded products becomes impossible.

If the components are taken below the lower limits, then obtaining molded products becomes impossible due to the insufficient heat resistance of the binder.

An example implementation of the device joints and interfaces.

The pavement interface device is shown in FIG. 2, where 21 is the edge of the previously laid strip of asphalt concrete coating, 22 is the base. In FIG. 3 shows an adjacency device for an asphalt concrete pavement, where 23 is a cement concrete or metal surface or structure.

The finished tape material was delivered in rolls to the place of work in the factory packaging (in cardboard drums) in an amount not exceeding the shift output. The rolls were freed from the factory packaging and placed along the edge of the mating surfaces with an interval of 25-40 m.

Then the rolls of the docking tape 18 were unwound, laid with their unprotected side on the cold edge of the previously laid strip of pavement 21 in a level with a coating. Then, the tape was manually fixed by pressing and the release film was removed. In this case, the ends of adjacent tapes were joined end-to-end.

Laying and fixing the mite was carried out by two people with a productivity of 5-7 m per minute.

The tape was mechanically fixed using a hot asphalt mixture with a temperature of 150 ° С simultaneously with compaction of the hot mixture using an asphalt paver, i.e. simultaneously with the formation of a new pavement strip. This fixation was carried out at an air temperature of 30 ° C ahead of the movement of the paver by 75 m.

As a result, a strip of bitumen-polymer binder 0.4 mm thick and 12 mm wide was formed along the junction of the pavement strips.

Thus, the technical result from the implementation of the claimed group of inventions related to a single inventive concept is expressed in the fact that the method of manufacturing baseless tape material is automated, which helped to increase the productivity of the process and reduce its complexity, and the method of making joints and joints in asphalt concrete pavement using received baseless tape material increases their tightness and allows you to extend their life and create comfort s and a safe environment for vehicular traffic.

Claims (4)

1. A method of manufacturing a baseless tape material for a road surface based on a polymer-bitumen binder, comprising forming a layer of a polymer-bitumen binder with a temperature of 100-110 ° C by feeding a binder onto a moving release film, profiling the layer according to predetermined thickness and width parameters and reeling finished material in a roll, characterized in that the formation of the layer is carried out in one step, the binder is fed to a release film moving along a U-shaped weighing tray, stretched and From the unwinding machine using a conveyor belt and a pressure roller, the thickness profiling of the layer is controlled by a microprocessor that controls the speed of the adhesive film by changing the rotation speed of the belt conveyor drive, before being rolled into a roll, the fabricated material is cooled in a container with water, while the degree of cooling is automatically controlled with using a circulation pump and a heat exchanger interacting with water, then dried, and winding into a roll and cutting the finished material is carried out t automatically programmable Coiler edging device is synchronized with the drive of the conveyor belt. 2. A method of arranging joints and mates from a baseless tape material made on the basis of a polymer-bitumen binder, including laying, manual and mechanical fixing of the tape material at the edge of the joints of the pavement strips or on the side surface of an adjacent element, characterized in that after manual fixing with tape material remove the release film, mechanical fixation is carried out with an asphalt mixture with a temperature of 140-160 ° C simultaneously with its compaction using asphalt adchika, wherein the manual fixing is carried out with an advancing movement of the paver 150-200 m at an air temperature below 25 ° C and 50-100 m at an air temperature over 25 ° C. 3. The method according to claim 2, characterized in that the mechanical fixing of the tape material is carried out in a level with a road surface. 4. The method according to claim 2, characterized in that the connection of adjacent bands of tape material is carried out end-to-end.

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