WO2021212750A1 - 一种tre可拼装永久性圆柱模板及其制作方法 - Google Patents

一种tre可拼装永久性圆柱模板及其制作方法 Download PDF

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Publication number
WO2021212750A1
WO2021212750A1 PCT/CN2020/118604 CN2020118604W WO2021212750A1 WO 2021212750 A1 WO2021212750 A1 WO 2021212750A1 CN 2020118604 W CN2020118604 W CN 2020118604W WO 2021212750 A1 WO2021212750 A1 WO 2021212750A1
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WIPO (PCT)
Prior art keywords
panel
bolt
fiber
mold
tre
Prior art date
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PCT/CN2020/118604
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English (en)
French (fr)
Inventor
尹世平
彭张涛
李修贤
华云涛
任旭东
赵瑛德
龙浩风
丛昊楠
Original Assignee
Yin Shiping
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Publication date
Application filed by Yin Shiping filed Critical Yin Shiping
Priority to US17/435,029 priority Critical patent/US20220325542A1/en
Publication of WO2021212750A1 publication Critical patent/WO2021212750A1/zh

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    • 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
    • E04G13/00—Falsework, forms, or shutterings for particular parts of buildings, e.g. stairs, steps, cornices, balconies foundations, sills
    • E04G13/02—Falsework, forms, or shutterings for particular parts of buildings, e.g. stairs, steps, cornices, balconies foundations, sills for columns or like pillars; Special tying or clamping means therefor
    • 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
    • E04G13/00—Falsework, forms, or shutterings for particular parts of buildings, e.g. stairs, steps, cornices, balconies foundations, sills
    • E04G13/02—Falsework, forms, or shutterings for particular parts of buildings, e.g. stairs, steps, cornices, balconies foundations, sills for columns or like pillars; Special tying or clamping means therefor
    • E04G13/021—Falsework, forms, or shutterings for particular parts of buildings, e.g. stairs, steps, cornices, balconies foundations, sills for columns or like pillars; Special tying or clamping means therefor for circular columns
    • 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
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/34—Moulds, cores, or mandrels of special material, e.g. destructible materials
    • B28B7/346—Manufacture of moulds
    • 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
    • B28B1/04—Producing shaped prefabricated articles from the material by tamping or ramming
    • B28B1/045—Producing shaped prefabricated articles from the material by tamping or ramming combined with vibrating or jolting
    • 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
    • B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
    • 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
    • B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
    • B28B1/525—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement containing organic fibres, e.g. wood fibres
    • 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
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
    • B28B11/245—Curing concrete articles
    • 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
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/0006—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects the reinforcement consisting of aligned, non-metal reinforcing elements
    • 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
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
    • 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
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/0002—Auxiliary parts or elements of the mould
    • 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
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/36—Linings or coatings, e.g. removable, absorbent linings, permanent anti-stick coatings; Linings becoming a non-permanent layer of the moulded article
    • B28B7/364—Linings or coatings, e.g. removable, absorbent linings, permanent anti-stick coatings; Linings becoming a non-permanent layer of the moulded article of plastic material or rubber
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A30/00—Adapting or protecting infrastructure or their operation
    • Y02A30/30—Adapting or protecting infrastructure or their operation in transportation, e.g. on roads, waterways or railways

Definitions

  • the invention relates to a TRE permanent cylindrical template and a manufacturing method thereof.
  • the template is suitable for industrial and civil building structures, marine structures, hydraulic structures and other building structures, and belongs to the technical field of reinforced concrete building construction.
  • Formwork is an indispensable model for newly poured concrete. According to the material, it can be divided into steel formwork, wood formwork, bamboo plywood, and plastic board. This type of formwork generally has less repeated use, high cost of use, large impact on the environment, and disassembly. Inconvenience and other issues. Therefore, the permanent formwork that can be assembled with environmental protection and durability is becoming a new direction of research and development.
  • TRC Temporal Reinforced Concrete, fiber woven mesh reinforced concrete
  • the new type TRC permanent formwork can improve the above-mentioned problems of traditional wooden formwork and steel formwork.
  • TRC Texttile Reinforced Concrete, fiber woven mesh reinforced concrete
  • the TRC permanent formwork is light in weight and convenient for construction, and can be used as a part of the component to bear the load after being cast. But its matrix has low ductility and single assembly form.
  • TRE Textile Reinforced Ecc
  • ECC Engineered Cementitions Composites
  • Reinforced cement-based composite materials have significant strain hardening characteristics and excellent crack control capabilities. Using it in combination with TRC can effectively improve the ductility of the TRC permanent template.
  • the column is one of the frame columns in the current domestic frame structure, which is formed by using a column formwork.
  • a staggered lap support mold is required during installation.
  • the joint of the cylindrical formwork without staggered lap joint is a full circle joint, and the cylindrical formwork is integral and stable. The performance is poor, and the phenomenon of mold running is prone to occur after pouring.
  • the cylindrical template connected by bolts in the prior art has problems such as difficult to determine the position of the bolt holes and the complicated assembly process.
  • the purpose of the present invention is to solve the above-mentioned problems and provide a TRE assemblable permanent cylindrical template that is easy to assemble and firmly spliced, and a manufacturing method thereof, so as to make up for the deficiencies of the prior art.
  • the present invention discloses a TRE assemblable permanent cylindrical template, which includes a first panel, a second panel, circumferential bolts, longitudinal bolts, nuts and gaskets.
  • the first panel is used for assembling the cylindrical templates at both ends of the column.
  • the second panel is used for assembling the cylindrical formwork in the middle section.
  • Bolt holes are reserved at the assembling place of the panels, and the hole positions between the panels correspond to each other.
  • the first panel and the second panel have a curvature.
  • the upper end of the panel is a fan ring plane, the lower end has a convex block, the left end has a convex block extending in the circumferential direction, the right end has a groove matching the convex block, and the upper and lower ends of the second panel have convex blocks at the lower end of the first panel A matching groove, the left end of the second panel has a convex block extending in the circumferential direction, and the right end has a groove matching the convex block; the ring bolts and the longitudinal bolts each include two bolt heads and a bolt rod.
  • the bolt shank of the ring bolt has a radian
  • the bolt shank of the longitudinal bolt is a straight rod
  • the shape of the bolt head is a solid body formed by two semi-elliptical surfaces at an angle to each other and a curved surface between the two semi-elliptical surfaces.
  • the ellipse major axes of the two semi-elliptical surfaces are different
  • the bolt head has external threads at both ends
  • the middle position on the semi-elliptical surface with the shorter major axis of the bolt head has internal threads.
  • the bolt rod and the bolt head are connected by threads, so
  • the shape of the bolt hole is a groove adapted to the bolt head;
  • the first panel and the second panel are made of engineering cement-based composite material ECC and fiber woven mesh.
  • the woven fiber mesh is located in the middle of the panel.
  • the fiber woven mesh has an arc corresponding to the panel and has the same distance from the inner diameter and outer diameter of the cylindrical template.
  • a cylinder includes 8 first panels and 4N second panels, where N is a natural number greater than or equal to 1.
  • the bolts, nuts and washers are all made of FRP material.
  • the material FRP of the bolt can be any one of AFRP, BFRP, CFRP and GFRP.
  • FRP fluorescence adsorption potential
  • a method for making TRE assembleable permanent cylindrical formwork panels includes the following steps:
  • Step 1 Determine the size of the TRE panel according to the size of the column to be poured to facilitate transportation;
  • Step two select the glulam template as the panel forming mold, and support the wooden mold according to the panel size and shape.
  • the wooden mold shape is divided into two types for making two types of panels.
  • the wooden mold needs to be provided with lateral support to prevent lateral deformation during ECC pouring;
  • Step 3 Cut the rigid plastic foam board according to the size of the side mold of the wooden mold, and paste it on the inner side of the side mold. Drill holes in the corresponding cylindrical template to reserve the bolt holes to install the prefabricated PVC plastic hole model.
  • prefabricated hoop PVC plastic hole-forming models and prefabricated longitudinal PVC plastic hole-forming models, which are used to reserve hoop and longitudinal bolt holes required for the panel respectively;
  • Step 4 Apply a release agent to the inside of the mold to facilitate the release of the permanent template
  • Step 5 Cut the fiber woven net according to the size and shape of the mold; the fiber woven net is woven from several of carbon fiber, aramid fiber, alkali-resistant glass fiber, basalt fiber, polyethylene fiber and polyvinyl alcohol fiber; The weft and warp directions of the woven mesh are mixed with different fibers;
  • Step 6 Cut the steel mesh according to the size and shape of the required fiber woven mesh, and attach the fiber woven mesh to the steel mesh, and then use a brush to evenly apply the epoxy resin coating solution on the fiber woven mesh, and do not miss the brush when brushing , In order to make the connection between the fiber woven net fibers closer, and prevent deformation when pouring ECC;
  • Step 7 sandblasting the fiber woven net before the epoxy resin coating solution is cured, and the used sand is silica sand;
  • Step 8 Put the fiber woven net to dry in a dry and ventilated environment
  • Step 9 install the fiber woven net in the middle of the mold
  • Step 10 Turn the upper part of the mold over and close the hinged mold opening and closing, and the panel adopts a horizontal pouring method, leaving only one cut for pouring to ensure continuous production without deformation and sealing and no leakage;
  • Step eleven pouring ECC, the workability and fluidity of ECC are good.
  • the mold can be vibrated once to eliminate the bubbles inside the ECC and enhance the compactness of the ECC. Repeat the above process several times until ECC fills the entire mold, opens the flip hinge to open and close the mold, and carry out the smoothing process;
  • Step 12 After pouring is completed, put it into proper humidity and proper temperature conditions for curing for 28 days; finally, demolish the mold and enter the stacking stage.
  • step 6 the method for preparing the epoxy resin coating solution is to fully stir the epoxy resin, curing agent, and diluent in a closed environment at a ratio of 2:2:1 until they are uniformly mixed to obtain a ring. Oxygen resin coating liquid.
  • step eleven the ECC manufacturing method is
  • Step 1 Prepare the following materials: P.O42.5 Portland cement 442kg/m 3 , Grade I fly ash 821kg/m 3 , 140-280 mesh quartz sand 455kg/m 3 , Sika with a water reduction rate of 30% Polycarboxylic acid high-performance water reducing agent 9.7kg/m 3 , thickening agent 0.63kg/m 3 , tap water 354kg/m 3 and chopped fiber with a volume content of 2%;
  • Step 2 Pour cement, quartz sand, fly ash, and thickener into the mixer and stir for 2-3 minutes. After the materials are evenly mixed, pour the tap water with Sika polycarboxylic acid high-performance water reducing agent into the mixer and stir for 6 -8min, continue to add chopped fibers uniformly, after all the fibers are added to the mixer, continue to stir for 3-5min to complete the preparation of ECC.
  • step twelve suitable curing conditions: temperature (20 ⁇ 1)° C., humidity ⁇ 95%.
  • the chopped fiber includes one or more of non-metal fibers with different properties, such as basalt fiber, polypropylene fiber, polyvinyl alcohol fiber, polyethylene fiber, carbon fiber, glass fiber, and the like.
  • the present invention discloses a TRE assemblable permanent cylindrical template and a manufacturing method thereof.
  • the panels required for assembling can be obtained through the above-mentioned manufacturing process.
  • the panels have the advantages of easy assembling, firm assembling, convenient transportation, and low production cost. , Has great development prospects.
  • the present invention has the following beneficial effects:
  • the FRP is a fiber-reinforced composite material, which has the characteristics of light weight, high tensile strength, and good corrosion resistance.
  • the corrosion resistance is mainly reflected in the good corrosion resistance of chloride salts. Due to the lack of river sand resources and the construction needs of offshore islands and reefs, seawater and sea sand concrete is gradually replacing the existing concrete. Therefore, the use of FRP bolts meets the needs of development.
  • the cylindrical formwork has novel assembly technology, simple operation, firm assembly, easy stacking management, and wide practicability.
  • Figure 1 is an overall schematic diagram of the assembling structure of the TRE assemblable permanent cylindrical formwork of the present invention
  • Figure 2 is a top view of the assembling of the permanent cylindrical formwork that can be assembled with the TRE of the present invention
  • Figure 3 is a perspective view of the first panel structure of the TRE of the present invention.
  • Figure 4 is an isometric view of the TRE second panel structure of the present invention.
  • Figure 5 is a partial enlarged view of A in Figure 1;
  • Figure 6(a) is an axonometric view of the prefabricated circumferential PVC plastic hole-forming model
  • Figure 6(b) is an axonometric view of the prefabricated longitudinal PVC plastic hole-forming model
  • Fig. 7(a) is a plan view of a ring bolt
  • Fig. 7(b) is a plan view of a longitudinal bolt.
  • the present invention discloses a TRE assembleable permanent cylindrical template, which includes a first panel 1, a second panel 2, an annular bolt 4, a longitudinal bolt 5, a nut and a gasket.
  • Figure 2 is a top view of it , The first panel 1 is used for assembling the cylindrical formwork at both ends of the cylinder, the second panel 2 is used for assembling the cylindrical formwork at the middle section, the bolt holes 3 are reserved at the panel assembly, and the holes between the panels are one by one.
  • first panel 1 and the second panel 2 both have an arc
  • the upper end of the first panel 1 is a fan ring plane
  • the lower end has a convex block
  • the left end has a convex block extending in the circumferential direction
  • the right end has a convex block
  • Compatible grooves are shown in Figure 3;
  • the upper and lower ends of the second panel 2 have grooves that match the protrusions on the lower end of the first panel 1, and the left end of the second panel 1 has protrusions extending in the circumferential direction.
  • the right end has a groove adapted to the bump, as shown in Figure 4; the ring bolt 4 and the longitudinal bolt 5 each include two bolt heads and bolt rods, as shown in Figure 5, the ring bolt 4
  • the bolt rod of the longitudinal bolt 5 is a straight rod, and the shape of the bolt head is a solid body formed by two semi-elliptical surfaces at an angle and a curved surface between the two semi-elliptical surfaces.
  • the major axis of the ellipse of the semi-ellipse is different; both ends of the bolt head have external threads.
  • the circular bolt rod and the longitudinal bolt rod and the corresponding nuts are shown in Figure 7(a) and Figure 7(b). The long axis of the bolt head is shorter.
  • the middle position on the semi-ellipse has an internal thread, the bolt rod and the bolt head are connected by threads, and the shape of the bolt hole is a groove adapted to the bolt head.
  • the first panel 1 and the second panel 2 are made of engineering cement-based composite material ECC and fiber woven mesh 6.
  • the fiber woven mesh 6 is located in the middle of the panel, has an arc corresponding to the panel and is at a distance from the inner diameter and outer diameter of the cylindrical template same.
  • a cylinder includes 8 first panels and 4N second panels, where N is a natural number greater than or equal to 1.
  • the bolts, nuts and washers are all made of FRP.
  • the material FRP of the bolt can be any of AFRP, BFRP, CFRP and GFRP.
  • the use of FRP for the bolt can effectively resist chloride corrosion and enhance the corrosion resistance of the permanent template.
  • a method for making TRE assembleable permanent cylindrical formwork panels includes the following steps:
  • Step 1 Determine the size of the TRE panel according to the size of the column to be poured to facilitate transportation;
  • Step two select the glulam template as the panel forming mold, and support the wooden mold according to the panel size and shape.
  • the wooden mold shape is divided into two types for making two types of panels.
  • the wooden mold needs to be provided with lateral support to prevent lateral deformation during ECC pouring;
  • Step 3 Cut the rigid plastic foam board according to the size of the side mold of the wooden mold, and paste it on the inner side of the side mold. Drill holes in the corresponding cylindrical template to reserve the bolt holes to install the prefabricated PVC plastic hole model.
  • Step 4 Apply a release agent to the inside of the mold to facilitate the release of the permanent template
  • Step 5 Cut the fiber woven net according to the size and shape of the mold; the fiber woven net is woven from several of carbon fiber, aramid fiber, alkali-resistant glass fiber, basalt fiber, polyethylene fiber and polyvinyl alcohol fiber; The weft and warp directions of the woven mesh are mixed with different fibers;
  • Step 6 Cut the steel mesh according to the size and shape of the required fiber woven mesh, and attach the fiber woven mesh to the steel mesh, and then use a brush to evenly apply the epoxy resin coating solution on the fiber woven mesh, and do not miss the brush when brushing ,
  • the preparation method of epoxy resin coating liquid is, in a closed environment, epoxy resin: curing agent: diluent according to 2:2: The ratio of 1 is fully stirred until the mixture is uniform to prepare an epoxy resin coating solution.
  • Step 7 sandblasting the fiber woven net before the epoxy resin coating solution is cured, and the used sand is silica sand;
  • Step 8 Put the fiber woven net to dry in a dry and ventilated environment
  • Step 9 install the fiber woven net in the middle of the mold
  • Step 10 Turn the upper part of the mold over and close the hinged mold opening and closing, and the panel adopts a horizontal pouring method, leaving only one cut for pouring to ensure continuous production without deformation and sealing and bonding without leakage. ;
  • Step eleven pouring ECC (engineered cement-based composite material).
  • the ECC has good workability and fluidity.
  • the mold can be vibrated once when the pouring is completed about 1/4 to eliminate the bubbles inside the ECC and enhance the compactness of the ECC. Repeat the above process several times until the ECC fills the entire mold, open the flip hinge to open and close the mold, and carry out the smoothing process;
  • Step 12 After pouring is completed, put it in suitable humidity and temperature for curing for 28 days; finally dismantle the mold and enter the stacking stage.
  • suitable curing conditions temperature (20 ⁇ 1)°C, humidity ⁇ 95 %.
  • step 11 the ECC production method is
  • Step 1 Prepare the following materials: P.O42.5 Portland cement 442kg/m 3 , Grade I fly ash 821kg/m 3 , 140-280 mesh quartz sand 455kg/m 3 , Sika with a water reduction rate of 30% Polycarboxylic acid high-performance water reducing agent 9.7kg/m 3 , thickening agent 0.63kg/m 3 , tap water 354kg/m 3 and chopped fiber with a volume content of 2%.
  • Step 2 Pour cement, quartz sand, fly ash, and thickener into the mixer and stir for 2-3 minutes. After the materials are evenly mixed, pour the tap water with Sika polycarboxylic acid high-performance water reducing agent into the mixer and stir for 6 -8min, continue to add the chopped fiber evenly. After all the fibers are added to the mixer, continue to stir for 3-5 minutes to complete the preparation of ECC.
  • the chopped fiber includes basalt fiber, polypropylene fiber, polyvinyl alcohol fiber, polyethylene fiber, Carbon fiber, glass fiber and other non-metal fibers with different properties are mixed with one or more

Abstract

一种TRE可拼装永久性圆柱模板及其制作方法，包括第一面板（1）、第二面板（2）、环向螺栓（4）、纵向螺栓（5）、螺母和垫片，第一、二面板（1, 2）拼装处均留有螺栓孔（3），第一面板（1）下端和左端具有凸块，右端具有与凸块相适配的凹槽，第二面板（2）的上端及下端具有与第一面板（1）下端凸块相适配的凹槽，第二面板（1）的左端具有延圆周方向的凸块，右端具有与凸块相适配的凹槽；环向螺栓（4）、纵向螺栓（5）均包括首尾两个螺栓头和螺栓杆。第一面板（1）和第二面板（2）选用工程水泥基复合材料ECC和纤维编织网（6）制作。制作方法主要包括制作模具、预留螺栓孔（3）、裁剪纤维编织网（6）、浇筑ECC等步骤。该模板拼装方便、易于堆放。

Description

一种TRE可拼装永久性圆柱模板及其制作方法 技术领域
本发明涉及一种TRE永久性圆柱模板及其制作方法，该模板适用于工业与民用建筑结构、海工结构、水工结构等建筑结构，属于钢筋混凝土建筑施工技术领域。
背景技术
模板是新浇混凝土成型的必备模型，按材料可分为钢模板、木模板、竹胶板、塑胶板，该类模板普遍存在重复使用次数少、使用成本高、对环境影响大且拆装不便等问题。因此，具有环保和耐久性的可拼装永久性模板正成为研究和发展的新方向。
新型TRC永久性模板可改善传统木模板、钢模板上述问题。TRC(Textile Reinforced Concrete，纤维编织网增强混凝土)是由多轴纤维编织网和精细混凝土结合而成，具有良好的承载、限裂、抗渗及耐腐蚀能力，并具有多缝开裂及其微缝自愈能力。TRC永久性模板自重轻便于施工，且浇筑成型后可作为构件的一部分承受荷载。但其基体延性较低，拼装形式单一。
TRE(Textile Reinforced Ecc，纤维编织网增强Ecc)为TRC与ECC(Engineered Cementitions Composites，工程水泥基复合材料)相结合的新型材料，ECC是基于微观力学和断裂力学的原理在近代提出的一种纤维增强水泥基复合材料，具有显著的应变硬化特性和优异的裂缝控制能力。利用其与TRC结合，可以有效改善TRC永久性模板的延性。
圆柱是目前国内框架结构中框架柱的形式之一，其利用圆柱模板浇筑成型。圆柱模板施工时，为了保证竖直方向整体在一条直线上，安装时需进行错位搭接支模，不进行错位搭接的圆柱模板接缝为一道整圆的接缝，圆柱模板整体性和稳定性较差，浇筑后易出现跑模现象。
现有技术中采用螺栓连接的圆柱模板存在螺栓孔位置不易确定，拼装过程繁琐等问题。
发明内容
发明目的：本发明的目的是为了解决上述问题，提供一种易于拼装且拼接牢固的TRE可拼装永久性圆柱模板及其制作方法，以弥补现有技术的不足。
技术方案：
本发明公开了一种TRE可拼装永久性圆柱模板，包括第一面板、第二面板、环向螺栓、纵向螺栓、螺母和垫片，所述第一面板用于圆柱两端圆柱模板拼装，所述第二面板用于中间段圆柱模板拼装，所述面板拼装处均留有螺栓孔，面板之间的孔位一一对应，所述第一面板和第二面板均具有弧度，所述第一面板的上端为扇环平面，下端具有一个凸块，左端具有延圆周方向的凸块，右端具有与凸块相适配的凹槽，第二面板的上端及下端具有与第一面板下端凸块相适配的凹槽，第二面板的左端具有延圆周方向的凸块，右端具有与凸块相适配的凹槽；所述环向螺栓、纵向螺栓均包括首尾两个螺栓头和螺栓杆，环向螺栓的螺栓杆具有弧度，纵向螺栓的螺栓杆为直杆，所述螺栓头的形状为互成角度的两个半椭圆面及两个半椭圆面圆周之间的曲面形成的实心体，两个半椭圆面的椭圆长轴不同，螺栓头两端具有外螺纹，螺栓头长轴较短的半椭圆面上的中间位置具有内螺纹，所述螺栓杆与螺栓头通过螺纹连接，所述螺栓孔的形状为与螺栓头相适配的凹槽；，所述第一面板和第二面板选用工程水泥基复合材料ECC和纤维编织网制作。纤维编织网位于面板中部。
进一步地，所述纤维编织网具有与面板相对应的弧度且距离圆柱模板内径和外径的距离相同。
进一步地，一个圆柱包括8个第一面板，4N个第二面板，其中，N为大于等于1的自然数。
进一步地，所述螺栓、螺母和垫片均为FRP材质。
进一步地，螺栓的材料FRP可以为AFRP、BFRP、CFRP和GFRP中的任意一种，螺栓采用FRP材质可以有效的耐氯盐腐蚀，增强永久性模板的耐腐蚀性。
一种制作TRE可拼装永久性圆柱模板面板的方法，包括以下步骤：
步骤一，根据需浇筑圆柱的尺寸，确定TRE面板的尺寸，以方便运输尺寸为宜；
步骤二，选用胶合木模板作为面板成型的模具，并根据面板尺寸、形状支木模，木模形状分为两种，用于制作两种类型面板，模具上部采用翻转铰接式开合模，在木模同时需设置侧向支撑，防止在进行ECC浇筑时产生侧向变形；
步骤三，根据木模侧模尺寸裁剪硬质塑料泡沫板，将其粘贴于侧模内侧，在对应圆柱模板需预留螺栓孔位置钻孔，用以安装预制PVC塑料成孔模型，成孔模型分为预制环向PVC塑料成孔模型和预制纵向PVC塑料成孔模型两种，分别用以预留面板所需环向和纵向螺栓孔；
步骤四，在模具内部涂脱模剂，方便永久性模板脱模；
步骤五，根据模具尺寸、形状裁剪纤维编织网；所述纤维编织网采用碳纤维、芳纶纤维、耐碱玻璃纤维、玄武岩纤维、聚乙烯纤维和聚乙烯醇纤维中的几种编织而成；纤维编织网的纬向和经向采用不同的纤维混编而成；
步骤六，根据所需纤维编织网尺寸、形状裁剪钢丝网，并将纤维编织网依附在钢丝网上，然后用刷子将环氧树脂涂液均匀涂抹在纤维编织网上，刷时均匀涂抹且勿漏刷，以使纤维编织网纤维之间联结更加紧密，防止在浇筑ECC时发生变形；
步骤七，在环氧树脂涂液未固化前对所述纤维编织网进行喷砂处理，所采用砂石为硅砂；
步骤八，将纤维编织网放在干燥通风环境中晾干；
步骤九，将纤维编织网安装在模具中部；
步骤十，将模具上部翻转铰接式开合模关闭，面板采用水平浇筑的方式，仅留有一道切口用于浇筑，保证连续生产不变形、密封贴合不漏浆；
步骤十一，浇筑ECC，ECC和易性和流动性较好，在浇筑完成大约1/4时可进行一次模具振捣，以排除ECC内部气泡，增强ECC密实性，重复几次上述过程，直至ECC充满整个模具，打开翻转铰接开合模，进行光面工序；
步骤十二，浇筑完成后，将其放入适宜的湿度以及适宜的温度条件下养护28天；最后进行拆模，进入堆放阶段。
进一步地，步骤六中，所述环氧树脂涂液的制作方法为，在密闭环境，将环氧树脂、固化剂、稀释剂按照2：2：1的比例充分搅拌至混合均匀即制得环氧树脂涂液。
进一步地，步骤十一中，ECC制作方法为
步骤一，准备以下材料：P.O42.5硅酸盐水泥442kg/m 3、Ⅰ级粉煤灰821kg/m 3、140-280目石英砂455kg/m 3、减水率为30％的Sika聚羧酸高性能减水剂9.7kg/m 3、增稠剂0.63kg/m 3、自来水354kg/m 3和体积掺量为2％的短切纤维；
步骤二，将水泥、石英砂、粉煤灰、增稠剂倒入搅拌机中搅拌2-3min，在材料均匀混合后将溶有Sika聚羧酸高性能减水剂的自来水倒入搅拌机，搅拌6-8min，继续均匀加入短切纤维，待纤维全部加入到搅拌机后，继续搅拌3-5min，即完成ECC的制备。
进一步地，步骤十二中，适宜的养护条件：温度(20±1)℃、湿度≥95％。
进一步地，所述短切纤维包括玄武岩纤维、聚丙烯纤维、聚乙烯醇纤维、聚乙烯纤维、碳纤维、玻璃纤维等性能各异的非金属纤维中的一种或多种混合而成。
有益效果：本发明公开了一种TRE可拼装永久性圆柱模板及其制作方法，通过上述 制作工艺可得拼装所需面板，所述面板具有易于拼装、拼装牢固、运输方便、制作成本低等优点，具有很大的发展前景。与现有技术相比，本发明具有如下有益效果：
(1)利用永久性模板代替传统木模板、钢模板，一方面，使用永久性模板简化了施工的程序、节约了人力、大大缩短了施工工期；另一方面，使用永久性模板降低了材料损耗、减少了人工成本、提高了建筑物耐久性，可使项目总成本降低。
(2)提高了结构的预制化程度。拼装所需面板均采用施工前预制的方法，拼装使用方便，可操作性强。
(3)利用新型预制面板替代传统错位拼装。对于高度高于3米的柱，不再需要错位搭接支模来保证模板竖直方向在同一条直线上，有效的简化的拼装过程。
(4)螺栓、螺母、垫片均为FRP材质。所述FRP为纤维增强复合材料，具有质量轻、拉伸强度高、耐腐蚀性能好等特点。其中耐腐蚀性能主要体现在耐氯盐腐蚀性能良好。基于河沙资源匮乏和远洋岛礁建设需求，海水海砂混凝土正逐步替代现有混凝土，因此，使用FRP螺栓符合发展的需要。
(5)利用ECC替代精细混凝土，即利用TRE代替TRC。TRE相比于TRC基体延性更强，可以有效控制圆柱在使用过程中产生的裂缝宽度，增强结构使用性能。
(6)该圆柱模板拼装技术新颖，操作简单，拼装牢固，易于堆放管理，具有广泛的实用性。
附图说明
图1为本发明的TRE可拼装永久性圆柱模板拼装结构整体示意图；
图2为本发明的TRE可拼装永久性圆柱模板拼装俯视图；
图3为本发明的TRE第一面板结构轴侧图；
图4为本发明的TRE第二面板结构轴测图；
图5为图1中A处的局部放大图；
图6(a)为预制环向PVC塑料成孔模型轴测图，图6(b)为预制纵向PVC塑料成孔模型轴测图；
图7(a)为环向螺栓平面视图，图7(b)纵向螺栓平面视图。
具体实施方式
下面结合附图对本发明作进一步说明：
如图1所示，本发明公开了一种TRE可拼装永久性圆柱模板，包括第一面板1、第二面板2、环向螺栓4、纵向螺栓5、螺母和垫片，图2为其俯视图，所述第一面板1用 于圆柱两端圆柱模板拼装，所述第二面板2用于中间段圆柱模板拼装，所述面板拼装处均留有螺栓孔3，面板之间的孔位一一对应，所述第一面板1和第二面板2均具有弧度，所述第一面板1的上端为扇环平面，下端具有一个凸块，左端具有延圆周方向的凸块，右端具有与凸块相适配的凹槽，如图3所示；第二面板2的上端及下端具有与第一面板1下端凸块相适配的凹槽，第二面板1的左端具有延圆周方向的凸块，右端具有与凸块相适配的凹槽，如图4所示；所述环向螺栓4、纵向螺栓5均包括首尾两个螺栓头和螺栓杆，如图5所示，环向螺栓4的螺栓杆具有弧度，纵向螺栓5的螺栓杆为直杆，所述螺栓头的形状为互成角度的两个半椭圆面及两个半椭圆面圆周之间的曲面形成的实心体，两个半椭圆面的椭圆长轴不同；螺栓头两端具有外螺纹，环向螺栓杆和纵向螺栓杆及对应螺母如图7(a)、图7(b)所示，螺栓头长轴较短的半椭圆面上的中间位置具有内螺纹，所述螺栓杆与螺栓头通过螺纹连接，所述螺栓孔的形状为与螺栓头相适配的凹槽。所述第一面板1和第二面板2选用工程水泥基复合材料ECC和纤维编织网6制作，纤维编织网6位于面板中部，具有与面板相对应的弧度且距离圆柱模板内径和外径的距离相同。
一个圆柱包括8个第一面板，4N个第二面板，其中，N为大于等于1的自然数。所述螺栓、螺母和垫片均为FRP材质。螺栓的材料FRP可以为AFRP、BFRP、CFRP和GFRP中的任意一种，螺栓采用FRP材质可以有效的耐氯盐腐蚀，增强永久性模板的耐腐蚀性。
一种制作TRE可拼装永久性圆柱模板面板的方法，包括以下步骤：
步骤一，根据需浇筑圆柱的尺寸，确定TRE面板的尺寸，以方便运输尺寸为宜；
步骤二，选用胶合木模板作为面板成型的模具，并根据面板尺寸、形状支木模，木模形状分为两种，用于制作两种类型面板，模具上部采用翻转铰接式开合模，在木模同时需设置侧向支撑，防止在进行ECC浇筑时产生侧向变形；
步骤三，根据木模侧模尺寸裁剪硬质塑料泡沫板，将其粘贴于侧模内侧，在对应圆柱模板需预留螺栓孔位置钻孔，用以安装预制PVC塑料成孔模型，成孔模型分为预制环向PVC塑料成孔模型7和预制纵向PVC塑料成孔模型8两种，如图6(a)、图6(b)所示，分别用以预留面板所需环向和纵向螺栓孔；
步骤四，在模具内部涂脱模剂，方便永久性模板脱模；
步骤五，根据模具尺寸、形状裁剪纤维编织网；所述纤维编织网采用碳纤维、芳纶纤维、耐碱玻璃纤维、玄武岩纤维、聚乙烯纤维和聚乙烯醇纤维中的几种编织而成；纤 维编织网的纬向和经向采用不同的纤维混编而成；
步骤六，根据所需纤维编织网尺寸、形状裁剪钢丝网，并将纤维编织网依附在钢丝网上，然后用刷子将环氧树脂涂液均匀涂抹在纤维编织网上，刷时均匀涂抹且勿漏刷，以使纤维编织网纤维之间联结更加紧密，防止在浇筑ECC时发生变形；环氧树脂涂液的制作方法为，在密闭环境，将环氧树脂：固化剂：稀释剂按照2：2：1的比例充分搅拌至混合均匀即制得环氧树脂涂液。
步骤七，在环氧树脂涂液未固化前对所述纤维编织网进行喷砂处理，所采用砂石为硅砂；
步骤八，将纤维编织网放在干燥通风环境中晾干；
步骤九，将纤维编织网安装在模具中部；
步骤十，将模具上部翻转铰接式开合模关闭，面板采用水平浇筑的方式，仅留有一道切口用于浇筑，保证连续生产不变形、密封贴合不漏浆。；
步骤十一，浇筑ECC(工程水泥基复合材料)，所述ECC和易性和流动性较好，在浇筑完成大约1/4时可进行一次模具振捣，以排除ECC内部气泡，增强ECC密实性，重复几次上述过程，直至ECC充满整个模具，打开翻转铰接开合模，进行光面工序；
步骤十二，浇筑完成后，将其放入适宜的湿度以及适宜的温度条件下养护28天；最后进行拆模，进入堆放阶段，适宜的养护条件：温度(20±1)℃、湿度≥95％。
步骤十一中，ECC制作方法为
步骤一，准备以下材料：P.O42.5硅酸盐水泥442kg/m 3、Ⅰ级粉煤灰821kg/m 3、140-280目石英砂455kg/m 3、减水率为30％的Sika聚羧酸高性能减水剂9.7kg/m 3、增稠剂0.63kg/m 3、自来水354kg/m 3和体积掺量为2％的短切纤维。
步骤二，将水泥、石英砂、粉煤灰、增稠剂倒入搅拌机中搅拌2-3min，在材料均匀混合后将溶有Sika聚羧酸高性能减水剂的自来水倒入搅拌机，搅拌6-8min，继续均匀加入短切纤维，待纤维全部加入到搅拌机后，继续搅拌3-5min，即完成ECC的制备，短切纤维包括玄武岩纤维、聚丙烯纤维、聚乙烯醇纤维、聚乙烯纤维、碳纤维、玻璃纤维等性能各异的非金属纤维中的一种或多种混合而成
以上所述仅是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以做出若干改进和润饰，这些改进和润饰也应视为本发明的保护范围。

Claims (10)

  1. 一种TRE可拼装永久性圆柱模板，其特征在于，包括第一面板(1)、第二面板(2)、环向螺栓(4)、纵向螺栓(5)、螺母和垫片，所述第一面板(1)用于圆柱两端圆柱模板拼装，所述第二面板(2)用于中间段圆柱模板拼装，所述面板拼装处均留有螺栓孔(3)，面板之间的孔位一一对应，所述第一面板(1)和第二面板(2)均具有弧度，所述第一面板(1)的上端为扇环平面，下端具有一个凸块，左端具有延圆周方向的凸块，右端具有与凸块相适配的凹槽，第二面板(2)的上端及下端具有与第一面板(1)下端凸块相适配的凹槽，第二面板(1)的左端具有延圆周方向的凸块，右端具有与凸块相适配的凹槽；所述环向螺栓(4)、纵向螺栓(5)均包括首尾两个螺栓头和螺栓杆，环向螺栓(4)的螺栓杆具有弧度，纵向螺栓(5)的螺栓杆为直杆，所述螺栓头的形状为互成角度的两个半椭圆面及两个半椭圆面圆周之间的曲面形成的实心体，两个半椭圆面的椭圆长轴不同，螺栓头两端具有外螺纹，螺栓头长轴较短的半椭圆面上的中间位置具有内螺纹，所述螺栓杆与螺栓头通过螺纹连接，所述螺栓孔的形状为与螺栓头相适配的凹槽；所述第一面板(1)和第二面板(2)选用工程水泥基复合材料ECC和纤维编织网(6)制作，纤维编织网(6)位于面板中部。
  2. 根据权利要求1所述的TRE可拼装永久性圆柱模板，其特征在于，所述纤维编织网(6)具有与面板相对应的弧度且距离圆柱模板内径和外径的距离相同。
  3. 根据权利要求2所述的TRE可拼装永久性圆柱模板，其特征在于，一个圆柱包括8个第一面板，4N个第二面板，其中，N为大于等于1的自然数。
  4. 根据权利要求1所述的TRE可拼装永久性圆柱模板，其特征在于，所述螺栓、螺母和垫片均为FRP材质。
  5. 根据权利要求4所述的TRE可拼装永久性圆柱模板，其特征在于，螺栓的材料FRP可以为AFRP、BFRP、CFRP和GFRP中的任意一种。
  6. 一种制作TRE可拼装永久性圆柱模板面板的方法，其特征在于，包括以下步骤：
    步骤一，根据需浇筑圆柱的尺寸，确定TRE面板的尺寸；
    步骤二，选用胶合木模板作为面板成型的模具，并根据面板尺寸、形状支木模，木模形状分为两种，用于制作两种类型面板，模具上部采用翻转铰接式开合模，在木模同时需设置侧向支撑；
    步骤三，根据木模侧模尺寸裁剪硬质塑料泡沫板，将其粘贴于侧模内侧，在对应圆柱模板需预留螺栓孔位置钻孔，用以安装预制PVC塑料成孔模型，成孔模型分为预制环向 PVC塑料成孔模型(7)和预制纵向PVC塑料成孔模型(8)两种，分别用以预留面板所需环向和纵向螺栓孔；
    步骤四，在模具内部涂脱模剂；
    步骤五，根据模具尺寸、形状裁剪纤维编织网；所述纤维编织网采用碳纤维、芳纶纤维、耐碱玻璃纤维、玄武岩纤维、聚乙烯纤维和聚乙烯醇纤维中的几种编织而成；纤维编织网的纬向和经向采用不同的纤维混编而成；
    步骤六，根据所需纤维编织网尺寸、形状裁剪钢丝网，并将纤维编织网依附在钢丝网上，然后用刷子将环氧树脂涂液均匀涂抹在纤维编织网上，刷时均匀涂抹且勿漏刷，以使纤维编织网纤维之间联结更加紧密，防止在浇筑ECC时发生变形；
    步骤七，在环氧树脂涂液未固化前对所述纤维编织网进行喷砂处理，所采用砂石为硅砂；
    步骤八，将纤维编织网放在干燥通风环境中晾干；
    步骤九，将纤维编织网安装在模具中部；
    步骤十，将模具上部翻转铰接式开合模关闭，面板采用水平浇筑的方式，仅留有一道切口用于浇筑；
    步骤十一，浇筑ECC(工程水泥基复合材料)，在浇筑完成大约1/4时可进行一次模具振捣，以排除ECC内部气泡，增强ECC密实性，重复几次上述过程，直至ECC充满整个模具，打开翻转铰接开合模，进行光面工序；
    步骤十二，浇筑完成后，将其放入适宜的湿度以及适宜的温度条件下养护28天；最后进行拆模，进入堆放阶段。
  7. 根据权利要求6所述的一种制作TRE可拼装永久性圆柱模板面板的方法，其特征在于，步骤六中，所述环氧树脂涂液的制作方法为，在密闭环境，将环氧树脂：固化剂：稀释剂按照2：2：1的比例充分搅拌至混合均匀即制得环氧树脂涂液。
  8. 根据权利要求6所述的一种制作TRE可拼装永久性圆柱模板面板的方法，其特征在于，步骤十一中，ECC制作方法为
    步骤一，准备以下材料：P.O42.5硅酸盐水泥442kg/m 3、Ⅰ级粉煤灰821kg/m 3、140-280目石英砂455kg/m 3、减水率为30％的Sika聚羧酸高性能减水剂9.7kg/m 3、增稠剂0.63kg/m 3、自来水354kg/m 3和体积掺量为2％的短切纤维；
    步骤二，将水泥、石英砂、粉煤灰、增稠剂倒入搅拌机中搅拌2-3min，在材料均匀混合后将溶有Sika聚羧酸高性能减水剂的自来水倒入搅拌机，搅拌6-8min，继续均匀加入短切纤维，待纤维全部加入到搅拌机后，继续搅拌3-5min，即完成ECC的制备。
  9. 根据权利要求6所述的一种制作TRE可拼装永久性圆柱模板面板的方法，其特征在于，步骤十二中，适宜的养护条件：温度(20±1)℃、湿度≥95％。
  10. 根据权利要求8所述的一种制作TRE可拼装永久性圆柱模板面板的方法，其特征在于，所述短切纤维包括玄武岩纤维、聚丙烯纤维、聚乙烯醇纤维、聚乙烯纤维、碳纤维、玻璃纤维等性能各异的非金属纤维中的一种或多种混合而成。
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