WO2022151677A1 - 一种民航不停航施工破损道面板快速整体换板施工工艺 - Google Patents

一种民航不停航施工破损道面板快速整体换板施工工艺 Download PDF

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WO2022151677A1
WO2022151677A1 PCT/CN2021/105043 CN2021105043W WO2022151677A1 WO 2022151677 A1 WO2022151677 A1 WO 2022151677A1 CN 2021105043 W CN2021105043 W CN 2021105043W WO 2022151677 A1 WO2022151677 A1 WO 2022151677A1
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grouting
concrete
construction
plate
slab
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PCT/CN2021/105043
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English (en)
French (fr)
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汪建国
刘庭荣
金敏
蒋正
白高岭
王岩
张文秀
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中铁北京工程局集团有限公司
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Priority to US17/506,702 priority Critical patent/US20220228323A1/en
Publication of WO2022151677A1 publication Critical patent/WO2022151677A1/zh

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    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
    • E01C7/00—Coherent pavings made in situ
    • E01C7/08—Coherent pavings made in situ made of road-metal and binders
    • E01C7/10—Coherent pavings made in situ made of road-metal and binders of road-metal and cement or like binders
    • E01C7/14—Concrete paving
    • E01C7/147—Repairing concrete pavings, e.g. joining cracked road sections by dowels, applying a new concrete covering
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
    • E01C3/00—Foundations for pavings

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  • the invention relates to the technical field of airport runway construction, in particular to a construction technology for rapid integral panel replacement of damaged road panels in non-stop construction of civil aviation.
  • the runway is the main place for aircraft to take off and land. Due to the slow growth of the strength of ordinary cement concrete, the use of ordinary cement concrete to suspend service for the runway requires waiting for the cement concrete strength to increase to the design strength (usually 28 days) before it can be opened to traffic. Airport operations are greatly affected. Therefore, the repair of damaged road panels at runway airports is mostly carried out by non-stop construction, that is, the flight area is temporarily closed for a few hours in the early morning at night, and the damaged area is quickly repaired with fast-setting high-strength repair materials. After the repair is completed, a short period of time Maintenance will be able to achieve open traffic conditions.
  • the non-stop construction has extremely high requirements on the performance of pavement repair materials and construction technology.
  • the disposal method of damaged pavement panels was mainly to use epoxy resin mortar to locally repair the damaged pavement panels.
  • This repair method has certain limitations: 1. Only the damaged surface is repaired, and the base layer below the damaged surface is not treated, so that the symptoms are not cured. 2. The shrinkage is large, which can easily lead to the formation of joints and misalignment between the repaired area and the plate. 3. Due to the difference in strength between the repaired area and the adjacent plate, the damage of the repaired area and the adjacent plate will be accelerated. 4.
  • the room temperature epoxy resin curing agent generally has certain toxicity, which has a great impact on the construction personnel and the environment. 5.
  • the epoxy resin mortar When the temperature is low, the epoxy resin mortar will harden, and it needs to be heated with a flame gun during the construction process, which is cumbersome and dangerous. 6.
  • the durability is poor, and it is easy to age and peel off after being exposed to sunlight and rain, which affects the safety of airport operations.
  • the embodiments of the present invention provide a construction technology for rapid and integral plate replacement of damaged road panels during non-stop construction of civil aviation, which well solves the limitations of the traditional road panel repair process in engineering practice.
  • the present invention adopts the following technical solutions.
  • a construction process for rapid and integral panel replacement of damaged road panels in non-stop construction of civil aviation comprising the following steps:
  • the first stage Reinforcing the foundation of the damaged road panel by grouting
  • the second stage use early-strength and quick-drying concrete to carry out the overall replacement of the damaged panel.
  • the first stage includes the following steps:
  • Grouting plate positioning positioning and marking the damaged plate and its adjacent plates
  • Drilling and blowing Drilling must penetrate the base layer and go deep into the soil foundation. After the drilling is completed, the dust in the hole should be blown clean, and the grouting can be carried out after the blowing is completed;
  • the second stage includes the following steps:
  • Material preparation and calibration of the concrete integrated truck Use a concrete integrated truck that integrates concrete mixing, transportation and pouring. Before entering the construction site, the materials required for construction are placed in the corresponding silos of the concrete integrated truck and weighed and prepared. After completion, the metering equipment of the concrete integrated vehicle should be calibrated, and a small amount of concrete should be mixed at the same time, and the construction mix ratio of the day should be determined according to the concrete state;
  • Break the slab with a breaking hammer Start breaking from the middle of the damaged slab with a breaking hammer. After the middle of the slab is broken, the broken concrete block is pulled out, and then broken to the edge of the slab in turn, and the edge of the slab is reserved for manual breaking;
  • the first layer of concrete is poured in place by the concrete integrated truck
  • Fine leveling and surface closing After the double-steel-tube vibrating beam is leveled and grouted, the concrete surface is scraped and rubbed with an aluminum alloy scraper. The parts with concrete are filled with concrete aggregates, and the parts with more materials are shoveled away with a shovel. After the scraping is completed, the surface is collected;
  • the drill bit of the drilling rig is not larger than 60mm for drilling the pavement; the drilled hole penetrates the base layer and penetrates into the soil foundation for 10 cm; after the drilled hole is drilled to the designed depth, the air compressor is used to blow the hole.
  • the blowing time shall not be less than 10s.
  • the technical indicators controlled in the grouting process include: 1. Grouting pressure: the grouting pressure is not greater than 1.0 MPa during grouting on the airport pavement. During grouting, when the grouting pressure is maintained at a certain value, When the grouting amount no longer increases, stop grouting; 2. Lifting amount of slab surface: During the grouting process, the allowable lifting amount of the track panel is not more than 5mm, and the final allowable lifting amount of the track panel after stabilization is not more than 3mm. When the lift of the panel is greater than 5mm, the grouting should be stopped; 3. The situation of the overflow of the plate around the plate: when the overflow occurs around the panel during grouting, the grouting should be stopped and the overflow should be cleaned up.
  • an electric pick should be manually used to cut out a protective layer with a width of not less than 15cm and a depth of not less than 10cm along the crack of the broken plate before the plate is broken, to prevent large-scale mechanical crushing of the plate. Damage to adjacent slabs.
  • the pouring thickness of the first layer is 15cm
  • the pouring thickness of the second layer is 25cm
  • the second layer of concrete needs to be poured before the initial setting of the first layer of concrete to prevent cold joints.
  • a "half-height formwork" is set up in the middle of the joint between the two adjacent slabs. ”, that is, the height of the half-height formwork is 1/2 of the plate thickness; then two adjacent plates are poured in layers respectively, and the pouring sequence is: support the “half-height formwork” ⁇ the first layer of the first plate ⁇ pour the first plate The second layer of a board ⁇ remove the "half-height formwork” ⁇ pour the first layer of the second board ⁇ pour the second layer of the second board.
  • the water spray curing is as follows: when the concrete surface cannot press fingerprints and starts to heat up, the sprayer can be used for water spray curing. In the initial stage of curing, the sprinkler head should be directed upward, so that the water mist naturally falls on the concrete surface. Ensure that the concrete surface is moist, and the curing time should not be less than 3 hours.
  • the present invention adopts two-stage construction.
  • the pavement foundation is reinforced by the grouting method.
  • This process is simple in technology, convenient for entering and leaving the site without large mechanical equipment, and the construction speed is fast. It does not affect the flight safety of the pavement. It can effectively solve the void problem at the bottom of the track panel, and improve the foundation density, strength and track base reaction modulus.
  • a quick-drying and early-strength concrete is used to quickly replace the damaged slab as a whole.
  • the application of a new equipment such as a concrete intelligent integrated vehicle and the improvement of the traditional pavement concrete construction process greatly shorten the construction time and reduce the cost of investment in equipment and personnel. This process is very suitable for projects with limited space or other reasons that are not suitable for investing a lot of machinery, high engineering quality requirements, and tight construction schedules, especially for non-stop construction at airports;
  • Fig. 1 is a kind of non-stop construction of damaged road panels in civil aviation provided by the embodiment of the present invention.
  • FIG. 2 is a schematic diagram of a process (first stage) of reinforcing the foundation of a damaged road panel by grouting according to an embodiment of the present invention
  • FIG. 3 is a schematic diagram of the arrangement of grouting holes according to an embodiment of the present invention.
  • FIG. 4 is a schematic diagram of the overall panel replacement construction process (second stage) using early-strength and quick-drying concrete provided by an embodiment of the present invention.
  • An embodiment of the present invention provides a construction process for rapid integral panel replacement of damaged road panels during non-stop construction of civil aviation, as shown in FIG. 1 , including the following steps:
  • the foundation of the damaged road panel is reinforced by grouting construction: first measure the line, release the grouting hole position, and then carry out drilling construction. After completing the above operations, start grouting construction, and stop grouting when the grouting pressure or plate lift reaches the critical thickness; after stopping grouting, pull out the grouting pipe after the grouting pressure dissipates, and then use the quick-drying
  • the hole is sealed with mortar; after the grouting liquid reaches the design time, the HWD deflection test is performed on the grouting area to check the grouting effect. If the bearing capacity of the foundation meets the requirements of the specification, the next stage of plate replacement construction can be carried out.
  • the second stage uses early-strength and quick-drying concrete to carry out the overall plate replacement construction of the damaged panel: the positioning of the plate is removed, the adjacent plates are laid with geotextiles, the lamps are removed, the edges are cut with a manual electric pick, the breaker is in place and the concrete is removed from the middle of the plate.
  • Block shipment, manual electric pick and clearance, base level acceptance, geotextile laying, base level watering and moistening, concrete mixing truck is in place, and the concrete pouring construction is started in two layers.
  • the second layer of concrete pouring construction followed by double steel tube vibrating beam leveling and slurry lifting, surface closing, maintenance, slitting, grooved and other procedures.
  • the expansion joints and the restoration of the marking lines need to be carried out when the construction is carried out the next day.
  • the two-stage construction process is as follows:
  • the plate foundation in the plate replacement area needs to be grouted for reinforcement, but also the plates adjacent to the plate replacement area need to be grouted for the foundation.
  • the plate that needs grouting shall be positioned and marked;
  • the layout of the grouting holes should focus on the following two important factors: one is the effective diffusion radius of the slurry. For the foundation with larger voids, the effective diffusion radius of the slurry is generally 1.5 m; The second is the shape and size of the concrete slab slab, and it should be ensured that each part of each slab slab is subjected to even force as much as possible. According to the shape and size of the slab slab, the arrangement of the grouting holes is shown in Figure 3;
  • the pavement drilling should select a suitable drilling rig, and use a drill bit no larger than 60mm to drill the pavement; the drilling depth should be able to penetrate the base layer and penetrate 10cm into the soil foundation.
  • the air compressor should be used to blow the hole, and the blowing time should not be less than 10s, and the dust in the hole should be blown clean.
  • the grouting can be carried out after the blow hole is completed;
  • the preparation of mortar should be carried out as soon as possible while positioning the holes in the field. In strict accordance with the design requirements, the construction mix ratio is measured, and the addition and feeding work are carried out according to the procedures to ensure the timely preparation and supply of the slurry.
  • the specific gravity of the cement slurry should be checked at any time with a mortar specific gravity detection recorder;
  • Grouting pressure When grouting on the airport road surface, the grouting pressure is not easy to be greater than 1.0MPa, and 0.3Mpa-0.5Mpa is appropriate. During grouting, when the grouting pressure remains at a certain value and the grouting volume no longer increases, the grouting can be stopped. 2.
  • the lifting amount of the board surface During the grouting process, the allowable lifting amount of the general road board is not more than 5mm. After stabilization, the allowable lifting amount of the final panel is not more than 3mm. When the lift of the track slab is greater than 5mm, the grouting should be stopped (referring to the lift of the non-settling slab). 3. Grout overflow around the plate: When a large amount of overflow occurs around the panel during grouting, the grouting should be stopped and the overflow should be cleaned up in time;
  • the grouting pipe cannot be pulled out immediately to prevent the leakage of the grout. Let it stand for 5-10 minutes or install a pressure relief valve on the grouting pipe, and then pull out the grouting pipe after the grouting pressure dissipates. After pulling out the grouting pipe, seal the hole with quick-drying cement mortar;
  • the HWD deflection test will be carried out on the grouting reinforcement area.
  • the judging index of the voids at the edge and corner of the board is the ratio of the deflection of "edge/board” and "board corner/board”.
  • the standard adopts the technical standards recommended in "Technical Specifications for Pavement Evaluation Management of Civil Airports". That is, "the deflection at the edge of the plate / deflection in the plate ⁇ 2" and “the deflection at the corner of the plate / deflection in the plate ⁇ 3" indicate that the foundation is in good condition, and the next plate replacement construction can be carried out. If the above requirements cannot be met, the above steps (1) to (6) need to be continued until the test results meet the requirements.
  • the invention is mainly aimed at the panel replacement construction of damaged roads in non-stop construction. Short construction time and high quality requirements are the biggest features of non-stop construction. Therefore, before entering the construction site, it is necessary to change the plate materials for careful screening, and carry out trial mixing in the laboratory and on-site construction of the selected materials to detect and familiarize themselves with their construction performance. To ensure that the formal construction can be carried out smoothly when entering the site;
  • the concrete integrated truck used in this project is a new type of equipment integrating concrete mixing, transportation and pouring.
  • the equipment can effectively solve the problem that the quick-drying concrete used in this project has a short setting time and is not suitable for long-distance transportation.
  • the quick-drying cement, gravel, water and other materials required for the construction are installed in the corresponding silos of the concrete integrated truck.
  • weighing is carried out to ensure that the concrete mixing amount can be met on the day, and the material preparation amount should exceed 20% of the design demand for the day to prevent the shortage of materials caused by factors such as loss.
  • the silos of the integrated car should be closed and covered to prevent spillage.
  • the metering equipment of the concrete integrated vehicle should be calibrated. At the same time, try mixing a small amount of concrete and determine the construction mix ratio of the day according to the concrete state;
  • the navigation aids on the plate should be removed first, and geotextiles should be laid on the adjacent plates to prevent the broken concrete blocks from falling and smashing the adjacent plates.
  • a protective layer with a width of not less than 15cm and a depth of not less than 10cm should be manually cut out along the seam of the damaged plate with an electric pick to prevent damage to the adjacent plates when the plate is broken by large-scale machinery;
  • the concrete block is transported with an excavator, and the broken pieces at the bottom of the warehouse are manually cleaned until a dense and flat base is cleared;
  • the concrete pouring construction adopts two layers of layered pouring.
  • the pouring thickness of the first layer should be 15cm
  • the pouring thickness of the second layer is 25cm
  • the thickness of the second layer is 25cm.
  • the concrete is required to be poured before the initial setting of the first layer of concrete to prevent cold joints.
  • two high-frequency plug-in vibrators are used to follow the discharge port while pouring and vibrating;
  • the second-layer concrete pouring work is started immediately.
  • the pouring sequence is to pour from one side of the slab to the other side.
  • the concrete surface is leveled and grouted by the double steel tube vibration beam;
  • a cold joint is formed between the two layers.
  • a "half-height formwork" is set up in the middle of the seam between two adjacent boards, that is, the height of the formwork is 1/2 of the board thickness. Then two adjacent slabs are poured in layers respectively.
  • the pouring sequence is: support the "half-height formwork" ⁇ the first layer of the first slab ⁇ pour the second layer of the first slab ⁇ remove the "half-height formwork" ⁇ pouring The first layer of the second board ⁇ pour the second layer of the second board;
  • the curing method is to use a sprayer for watering curing. In the initial stage of maintenance, do not aim the sprayer nozzle directly at the concrete surface. When curing, ensure that the concrete surface is wet, and the curing time should not be less than 3 hours;
  • the grooving construction can be carried out 1.5 hours after the pouring is completed;
  • the embodiments of the present invention provide a construction process for rapid and integral panel replacement of damaged track panels during non-stop construction of civil aviation, which solves the limitations of traditional track panel repair technologies.
  • the invention firstly reinforces the foundation of the damaged track slab through grouting construction, so as to solve the problems of emptying of the slab bottom, foundation settlement and insufficient bearing capacity of the base layer;
  • the whole board replacement construction is carried out.
  • the invention effectively solves the contradiction between the construction period and the construction quality, has the advantages of significantly shortening the construction period, improving the construction quality, reducing equipment and labor input, etc., and can achieve good economic and social benefits.

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Abstract

一种民航不停航施工破损道面板快速整体换板施工工艺，包括以下步骤：第一阶段：通过注浆施工对破损道面板基础进行加固；第二阶段：利用早强快干混凝土对破损面板进行整体换板施工；第一阶段对破损道面板基础进行加固，解决板底脱空、基础沉降、基层承载力不足的问题；第二阶段对破损道面板进行整体换板施工，有效解决施工工期与施工质量之间的矛盾，具有显著的缩短施工工期、提高施工质量、降低设备和人工投入等优点。

Description

一种民航不停航施工破损道面板快速整体换板施工工艺 技术领域
本发明涉及机场跑道施工技术领域，尤其涉及一种民航不停航施工破损道面板快速整体换板施工工艺。
背景技术
随着国内航空产业的迅猛发展和机型的更新换代，交通量和客流量的大幅增加，枢纽机场运营压力逐渐增大，很多未到设计使用年限的机场跑道出现了不同程度的破坏。另外，近年来，相当一部分的机场跑道已经接近了设计使用年限，混凝土道面板脱空，受力模式改变。这些隐患不仅影响了正常的交通运输，甚至直接威胁到飞行安全。所以，在未来一段时间内对于机场跑道道面进行维护和修补已经成为了机场场务工作中的重要任务。
跑道为飞机起降的主要场地，由于普通水泥混凝土强度增长慢，运用普通水泥混凝土对跑道进行停航维修，需要等到水泥混凝强度增长至设计强度后(一般为28天)才能开放交通，这对机场运营影响较大。因此跑道机场破损道面板修补较多的采用不停航施工进行，即在夜间凌晨几个小时的时间内飞行区临时关闭，利用速凝高强修补材料对破损区域进行快速修复，修复完成后经过短暂的养护就能够达到开放交通条件。
不停航施工对道面修补材料性能、施工工艺等要求极高，以往损坏道面板处置方式主要是利用环氧树脂砂浆对损坏道面板进行局部修补。此种修补方法存在一定局限性：1、仅对破损面层进行修补，未对损坏面层下面基层进行处理，治标不治本。2、收缩大，易导致修补区域与板块之间形成接缝、错台等病害。3、由于修补区域与相邻板块强度存在差异，会加速修补区域与相邻板块的破坏。4、常温环氧树脂固化剂一般都有一定毒性，对施工人员及环境影响较大。5、温度较低时环氧树脂砂浆会硬化，施工过程中需要用喷火枪加热，施工繁琐且存在一定危险性。6、耐久性差，经过日晒雨淋易老化剥落从而影响机场运营安全。
发明内容
本发明的实施例提供了一种民航不停航施工破损道面板快速整体换板施工工艺，在工程实践中很好地解决了传统道面板修补工艺存在的局限性。
为了实现上述目的，本发明采取了如下技术方案。
一种民航不停航施工破损道面板快速整体换板施工工艺，包括以下步骤：
第一阶段：通过注浆施工对破损道面板基础进行加固；
第二阶段：利用早强快干混凝土对破损面板进行整体换板施工。
优选地，所述第一阶段包括以下步骤：
(1)注浆板块定位：对破损板块及其相邻板块进行定位标记；
(2)注浆孔定位：根据浆液的有效扩散半径、道面板块的形状和尺寸布置注浆孔；
(3)钻孔、吹孔：钻孔须穿过基层深入土基中，钻孔完成后将孔内灰尘吹干净，吹孔完成后方可进行注浆；
(4)浆液制备：在进场布孔定位的同时进行灰浆制备工作；
(5)注浆：将灰浆从注浆孔注入；
(6)泄压、封孔：注浆完成后，待注浆压力消散之后方可拔出注浆管，拔出注浆管后用快干水泥砂浆进行封孔；
(7)注浆效果检测：注浆完成28天后开始对注浆加固区域进行HWD弯沉测试，“板边弯沉/板中弯沉”＜2及“板角弯沉/板中弯沉＜3”则表明基础状况良好，可以进行下一步换板施工，若不能满足上述要求则需要继续执行上述步骤(1)至(6)直至检测结果满足要求。
优选地，所述第二阶段包括以下步骤：
(1)快干混凝土选型及性能测试：在进场施工前对换板材料进行筛选并对选定材料进行是试验室试拌及现场开展试验段施工以检测和熟悉其施工性能；
(2)混凝土一体车备料和标定：使用集混凝土搅拌、运输、浇筑为一体的混凝土一体车，在进场施工前将施工所需材料装在混凝土一体车的相应料仓里并进行过磅，备料完后要对混凝土一体车的计量设备进行标定，同时试拌少量混凝土并根据混凝土状态确定当天的施工配合比；
(3)进场及换板定位：按照设计要求找出需快速置换板块的位置；
(4)板块破除前施工装备：板块破除前，将破损板块上的助航灯具拆除，在相邻板块上铺设土工布，人工用电镐沿破损板块的板缝位置抠边；
(5)用破碎锤破除板块：用破碎锤从破损板块中间位置开始破除，板中部破除完成后将破碎混凝土块抠出，然后依次向板边破除，板边预留位置，进行人工破除；
(6)混凝土块装运及人工清仓：破损板块破除完成之后，进行混凝土块装运，人工清理仓底碎块，直至清理出密实平整的基层；
(7)铺设土工布、仓底洒水湿润：清仓完成之后开始铺设土工布，并洒水湿润仓底；
(8)混凝土一体车就位浇筑第一层混凝土；
(9)铺设钢筋网片：待第一层混凝土浇筑完成后安装钢筋网片补强；
(10)浇筑第二层混凝土：补强钢筋网片安装完成之后，立刻开始第二层混凝土浇筑工作，浇筑顺序为从板的一边依次向另一边浇筑，浇筑的同时利用双钢管振动梁对混凝土面进行找平提浆；
(11)精平、收面：双钢管振动梁找平提浆完成之后，利用铝合金刮杠对混凝土面进行刮搓，刮搓前将邻板板边的水泥浆清理干净，刮搓时缺料的部位用混凝土骨料进行填补，多料的部位用铁锹铲走，刮搓完成之后开始进行收面；
(12)养护：进行喷水养护；
(13)切缝、刻槽：根据所用的快干混凝土性能进行切缝刻槽施工；
(14)灌缝、标志线恢复。
优选地，在钻孔、吹孔步骤中，道面钻孔采用钻机的钻头不大于60mm；钻孔穿过基层深入土基中10cm；钻孔钻至设计深度后，采用空压机进行吹孔，吹孔时间不得少于10s。
优选地，在注浆过程中控制的技术指标包括:1、注浆压力:在机场道面注浆时灌浆压力不大于1.0MPa，在注浆时，当注浆压力保持在一定的数值上，且注浆量不再增加时，停止灌浆；2、板面抬升量:注浆过程中，道面板允许抬高量要求不大于5mm，稳定后最终道面板允许抬高量要求不大于3mm，当道面板抬升量大于5mm时，应停止灌浆；3、板块周边溢浆情况：注浆时道面板周边出现溢浆时应停止灌浆，并清理溢浆。
优选地，在板块破除前施工装备步骤中，板块破碎前应人工用电镐沿破损板块板缝位置抠出一条宽不小于15cm深度不小于10cm的保护层，用于防止大型机械破碎板块时对相邻板块造成损伤。
优选地，在用破碎锤破除板块步骤中，破损板块板边位置留出15cm，进行人工破除。
优选地，当混凝土板厚为40cm时，第一层浇筑厚度为15cm，第二层浇筑厚度为25cm，第二层混凝土要求在第一层混凝土初凝前浇筑完成，防止出现冷缝。
优选地，当进行相邻两块板块同时浇筑施工时，为防止两块板同时进行分层浇筑时两层中间形成冷缝，在相邻两块板板缝中间位置支设一块“半高模板”，即半高模板高度为板厚的1/2；然后再进行相邻两块板分别分层浇筑，浇筑顺序为：支设“半高模板”→第一块板第一层→浇筑第一块板第二层→拆除“半高模板”→浇筑第二块板第一层→浇筑第二块板第二层。
优选地，所述进行喷水养护具体为：待混凝土表面不能按出手印且开始发热时，即可用喷雾器进行喷水养护，养护初期喷头应朝上，让水雾自然落到混凝土面上，养护时保证混凝土面湿润，养护时间不应小于3小时。
由上述本发明的实施例提供的技术方案可以看出，本发明实施例提供的一种民航不停航施工破损道面板快速整体换板施工工艺，具有以下优点：
(1)工艺适用范围：本发明采用两阶段施工。第一阶段通过注浆法对道面基础进行加固处理，该工艺技术简单，无大型机械设备进出场方便，施工速度快，不影响道面飞行安全，既不破坏道面现有结构层，又能有效解决道面板底脱空问题，提高基础密实度、强度和道基反应模量。第二阶段利用一种快干早强混凝土对破损板块进行快速整体换板，通过混凝土智能一体车这种新设备的应用和对传统道面混凝土施工工艺进的改良大大缩短了施工时间并减少了设备和人员的投入。本工艺非常适合场地有限或其它原因不适合投入大量机械、工程质量要求高、工期紧的工程，尤其适合机场不停航施工；
(2)设备效率方面：该工艺人员和设备分工明确，施工工序安排紧凑，尤其进行多块板块进行基础加固或者换板施工时，各种施工设备形成一个良性的循环状态，有效减少设备闲置率，提高利用率；
(3)施工质量方面：通过注浆法对道面基础加固能有效改善道面基础承载力，从而提高了道面板的耐久性。通过对普通道面混凝土施工工艺的优化和改良保证了混凝土的施工质量，同时对快干早强混凝土的采用又能够在极短的时间内达到开放交通的强度要求；
(4)施工进度方面：该工艺可以有效解决施工工期与施工质量之间的矛盾，加快了工程的进度；
(5)工程成本方面：该工艺通过混凝土智能一体车的利用，仅用2人就能完成混凝土的搅拌工作，不仅提高了搅拌质量，还大大减少了人工和运输机械设备投入，有效得节约了成本。
本发明附加的方面和优点将在下面的描述中部分给出，这些将从下面的描述中变得明显，或通过本发明的实践了解到。
附图说明
为了更清楚地说明本发明实施例的技术方案，下面将对实施例描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1为本发明实施例提供的一种民航不停航施工破损道面板快速整体换板施工工艺流程示意图；
图2为本发明实施例提供的通过注浆施工对破损道面板基础进行加固的流程(第一阶段)示意图；
图3为本发明实施例提供的注浆孔布置示意图；
图4为本发明实施例提供的利用早强快干混凝土对破损面板进行整体换板施工流程(第二阶段)示意图。
具体实施方式
下面详细描述本发明的实施方式，所述实施方式的示例在附图中示出，其中自始至终相同或类似的标号表示相同或类似的元件或具有相同或类似功能的元件。下面通过参考附图描述的实施方式是示例性的，仅用于解释本发明，而不能解释为对本发明的限制。
本技术领域技术人员可以理解，除非特意声明，这里使用的单数形式“一”、“一个”、“所述”和“该”也可包括复数形式。应该进一步理解的是，本发明的说明书中使用的措辞“包括”是指存在所述特征、整数、步骤、操作、元件和/或组件，但是并不排除存在或添加一个或多个其他特征、整数、步骤、操作、元件、组件和/或它们的组。应该理解，当我们称元件被“连接”或“耦接”到另一元件时，它可以直接连接或耦接到其他元件，或者也可以存在中间元件。此外，这里使用的“连接”或“耦接”可以包括无线连接或耦接。这里使用的措辞“和/或”包括一个或更多个相关联的列出项的任一单元和全部组合。
本技术领域技术人员可以理解，除非另外定义，这里使用的所有术语(包括技术术语和科学术语)具有与本发明所属领域中的普通技术人员的一般理解相同的意义。还应该理解的是，诸如通用字典中定义的那些术语应该被理解为具有与现有技术的上下文中的意义一致的意义，并且除非像这里一样定义，不会用理想化或过于正式的含义来解释。
为便于对本发明实施例的理解，下面将结合附图以几个具体实施例为例做进一步的解释说明，且各个实施例并不构成对本发明实施例的限定。
本发明实施例提供的一种民航不停航施工破损道面板快速整体换板施工工艺，如图1所示，包括以下步骤：
第一阶段通过注浆施工对破损道面板基础进行加固：先进行测量放线，放出注浆孔位，然后进行钻孔施工，钻孔深度要求能够深入到土基，钻孔的同时制备注浆液；完成以上操作之后即开始进行注浆施工，当注浆压力或板块抬升量达到临界值厚即可停止注浆；停止注浆后，待注浆压力消散后拔出注浆管然后利用快干砂浆进行封孔；待注浆液达到设计时间之后，对注浆区域进行HWD弯沉测试以检验注浆效果。若基础承载力满足规范要求，则可以进行下一阶段换板施工。
第二阶段利用早强快干混凝土对破损面板进行整体换板施工：破除板块定位，相邻板块铺设土工布，灯具拆除，人工电镐抠边，破碎锤就位开始从板中间部位破除，混凝土块装运，人工电镐清边及清仓，基层验收，铺设土工布，基层洒水湿润，混凝土搅拌一体车就 位开始分两层进行混凝土浇筑施工，第一层混凝土浇筑完成后铺设钢筋网片补强，然后进行第二层混凝土浇筑施工，依次进行双钢管振捣梁找平提浆，收面，养护，切缝，刻槽等工序操作。扩缝灌缝和标志线恢复需要次日进场施工时再进行施工。
两阶段施工工序具体如下：
如图2所示，第一阶段换板区域基础注浆加固
(1)注浆板块定位
为保证换板施工质量，不仅换板区域板块基础需要注浆加固，与换板区域相邻的板块也需要进行基础注浆加固施工。在开始注浆施工前应对需要注浆的板块进行定位标记；
(2)注浆孔定位
在保证处理效果及其均匀性的前提下，注浆孔的布置应着重考虑以下两个重要因素：一是浆液的有效扩散半径，对于较大空隙的基础而言，浆液有效扩散半径一般为1.5m；二是混凝土道面板块的形状和尺寸，应尽可能保证每块道面板各部位受力均匀。根据道面板块的形状和尺寸，注浆孔的布置如图3所示；
(3)钻孔、吹孔
道面钻孔应选用合适的钻机，用不大于60mm的钻头对道面钻孔；钻孔深度要求能够穿过基层深入土基中10cm。以重庆江北机场二跑道为例：钻孔深度＝40cm道面板+36cm水泥稳定碎石+10cm土基＝86cm。钻孔钻至设计深度后，应采用空压机进行吹孔，吹孔时间不得少于10s，要求能够将将孔内灰尘吹干净。吹孔完成后方可进行注浆；
(4)浆液制备
在进场布孔定位的同时应抓紧进行灰浆制备工作。严格按照设计要求进行施工配合比的计量，按程序进行添加、上料工作，保证浆液的及时制备和供应。水泥浆的比重应采用灰浆比重检测记录仪进行随时检测；
(5)注浆
将注浆枪插入已完成的道面板注浆孔内的适当深度，旋紧注浆枪的封堵胶圈，启动注浆泵进行灰浆的注入。注浆量采用注浆自动记录仪进行认真记录。为保证注浆质量和道面平整度。在注浆过程中主要控制的技术指标有三个:1、注浆压力:在机场道面注浆时灌浆压力不易大于1.0MPa，0.3Mpa-0.5Mpa为宜。在注浆时，当注浆压力保持在一定的数值上，且注浆量不再增加时，可以停止灌浆。2、板面抬升量:注浆过程中，一般道面板允许抬高量要求不大于5mm。稳定后最终道面板允许抬高量要求不大于3mm。当道面板抬升量大于5mm时，应停止灌浆(指非沉降板抬升)。3、板块周边溢浆情况：注浆时道面板周边出现大量的溢浆时 应停止灌浆，并及时清理溢浆；
(6)泄压、封孔
注浆完成后，不能立刻拔出注浆管以防止浆液外泄。静置5-10分钟或者在注浆管上安装泄压阀，待注浆压力消散之后方可拔出注浆管。拔出注浆管后用快干水泥砂浆进行封孔；
(7)注浆效果检测
注浆完成28天后开始对注浆加固区域进行HWD弯沉测试，板边、板角脱空情况的判定指标采用“板边/板中”和“板角/板中”弯沉的比值，判定标准采用《民用机场道面评价管理技术规范》中推荐的技术标准。即“板边弯沉/板中弯沉＜2”及“板角弯沉/板中弯沉＜3”则表明基础状况良好，可以进行下一步换板施工。若不能满足上述要求则需要继续执行上述步骤(1)至(6)直至检测结果满足要求。
如图4所示，第二阶段破损板块快速换板施工：
(1)快干混凝土选型及性能测试
本发明主要针对于在不停航施工中破损道面板换板施工。施工时间短、质量要求高为不停航施工最大特点。因此在进场施工前需要换板材料进行仔细筛选和并对选定材料进行是试验室试拌及现场开展试验段施工以检测和熟悉其施工性能。确保在进场正式施工时能够顺利进行；
(2)混凝土一体车备料和标定
本工程使用的混凝土一体车是一种集混凝土搅拌、运输、浇筑为一体的新型设备。该设备能有效解决本工程使用的快干混凝土凝结时间短不宜长距离运输的问题，同时具有现用现拌、现拌现浇、方便快捷、计量准确、出料快等优点。在进场施工前将施工所需的快干水泥、碎石、水等材料装在混凝土一体车的相应料仓里。同时进行过磅，确保能够满足当天混凝土拌合量，备料量要超出当天设计需求量的20％，以防止损耗等因素造成备料不足。备料完成后要对一体车各料仓进行封闭覆盖处理，防止洒落。备料完后要对混凝土一体车的计量设备进行标定。同时试拌少量混凝土并根据混凝土状态确定当天的施工配合比；
(3)进场及换板定位
按照设计要求找出需快速置换板块的位置；
(4)板块破除前施工装备
板块破除前应先将该板块上的助航灯具拆除，同时在相邻板块上铺设土工布，以防止破碎混凝土块掉落砸伤相邻板块。板块破碎前应人工用电镐沿破损板块板缝位置抠出一条宽不小于15cm深度不小于10cm的保护层，防止在用大型机械破碎板块时对相邻板块造成损伤；
(5)用破碎锤破除板块
用破碎锤从板块中间位置开始破除，板中部破除完成后将破碎混凝土块抠出以便于释放板中的应力，防止破碎板块挤压损伤相邻板块，然后依次向板边破除。破损板块板边位置留出15cm，进行人工破除；
(6)混凝土块装运及人工清仓
板块破除完成之后用挖掘机进行混凝土块装运，人工清理仓底碎块，直至清理出密实平整的基层；
(7)铺设土工布、仓底洒水湿润
清仓完成之后开始铺设土工布，并洒水湿润仓底；
(8)混凝土一体车就位浇筑第一层混凝土
由于本工艺使用的快干混凝土的施工性能，混凝土浇筑施工采用两层分层浇筑，当混凝土板厚为40cm时，第一层浇筑厚度宜为15cm，第二层浇筑厚度为25cm，第二层混凝土要求在第一层混凝土初凝前浇筑完成，防止出现冷缝。浇筑过程中用两个高频插入式振捣棒跟随着出料口边浇筑边振捣；
(9)铺设钢筋网片
待第一层15cm厚混凝土浇筑完成后安装钢筋网片补强；
(10)浇筑第二层混凝土
补强钢筋网片安装完成之后，立刻开始第二层混凝土浇筑工作，浇筑顺序为从板的一边依次向另一边浇筑，浇筑的同时利用双钢管振动梁对混凝土面进行找平提浆；
当进行相邻两块板块同时浇筑施工时，为防止两块板同时进行分层浇筑时两层中间形成冷缝。在相邻两块板板缝中间位置支设一块“半高模板”，即模板高度为板厚的1/2。然后再进行相邻两块板分别分层浇筑，浇筑顺序为：支设“半高模板”→第一块板第一层→浇筑第一块板第二层→拆除“半高模板”→浇筑第二块板第一层→浇筑第二块板第二层；
(11)精平、收面
双钢管振动梁找平提浆完成之后，利用铝合金刮杠对混凝土面进行刮搓，刮搓前一定将邻板板边的水泥浆清理干净。刮搓时缺料的部位用混凝土骨料进行填补，多料的部位用铁锹铲走。刮搓完成之后开始进行收面，塑料抹两遍，铁抹子两遍；
(12)养护
待混凝土表面不能按出手印且开始发热时，即可进行洒水养护，养护的方法是用喷雾器进行喷水养护。养护初期切忌将喷雾器喷头直接对准混凝土面，喷头应朝上，让水雾自然落到混凝土面上。养护时保证混凝土面湿润，养护时间不应小于3小时；
(13)切缝、刻槽
根据本工程所用的快干混凝土性能，浇筑完成1.5小时后即可进行切缝刻槽施工；
(14)灌缝、标志线恢复
由于混凝土养护及切缝刻槽为湿作业无法进行灌缝、标志线恢复施工，因此灌缝、标志线恢复施工宜安排在次日进行。
综上所述，本发明实施例提供了一种民航不停航施工破损道面板快速整体换板施工工艺，解决了传统道面板修补工艺存在的局限性。本发明首先通过注浆施工对破损道面板基础进行加固，解决板底脱空、基础沉降、基层承载力不足的问题；继而利用一种适用于跑道快速整体换板的早强速凝混凝土对破损道面板进行整体换板施工。本发明有效解决施工工期与施工质量之间的矛盾，具有显著的缩短施工工期、提高施工质量、降低设备和人工投入等优点，可以取得良好的经济效益和社会效益。
本领域普通技术人员可以理解：附图只是一个实施例的示意图，附图中的模块或流程并不一定是实施本发明所必须的。
以上所述，仅为本发明较佳的具体实施方式，但本发明的保护范围并不局限于此，任何熟悉本技术领域的技术人员在本发明揭露的技术范围内，可轻易想到的变化或替换，都应涵盖在本发明的保护范围之内。因此，本发明的保护范围应该以权利要求的保护范围为准。

Claims (10)

  1. 一种民航不停航施工破损道面板快速整体换板施工工艺，其特征在于，包括以下步骤：
    第一阶段：通过注浆施工对破损道面板基础进行加固；
    第二阶段：利用早强快干混凝土对破损面板进行整体换板施工。
  2. 根据权利要求1所述的工艺，其特征在于，所述第一阶段包括以下步骤：
    (1)注浆板块定位：对破损板块及其相邻板块进行定位标记；
    (2)注浆孔定位：根据浆液的有效扩散半径、道面板块的形状和尺寸布置注浆孔；
    (3)钻孔、吹孔：钻孔须穿过基层深入土基中，钻孔完成后将孔内灰尘吹干净，吹孔完成后方可进行注浆；
    (4)浆液制备：在进场布孔定位的同时进行灰浆制备工作；
    (5)注浆：将灰浆从注浆孔注入；
    (6)泄压、封孔：注浆完成后，待注浆压力消散之后方可拔出注浆管，拔出注浆管后用快干水泥砂浆进行封孔；
    (7)注浆效果检测：注浆完成28天后开始对注浆加固区域进行HWD弯沉测试，“板边弯沉/板中弯沉”＜2及“板角弯沉/板中弯沉＜3”则表明基础状况良好，可以进行下一步换板施工，若不能满足上述要求则需要继续执行上述步骤(1)至(6)直至检测结果满足要求。
  3. 根据权利要求1所述的工艺，其特征在于，所述第二阶段包括以下步骤：
    (1)快干混凝土选型及性能测试：在进场施工前对换板材料进行筛选并对选定材料进行是试验室试拌及现场开展试验段施工以检测和熟悉其施工性能；
    (2)混凝土一体车备料和标定：使用集混凝土搅拌、运输、浇筑为一体的混凝土一体车，在进场施工前将施工所需材料装在混凝土一体车的相应料仓里并进行过磅，备料完后要对混凝土一体车的计量设备进行标定，同时试拌少量混凝土并根据混凝土状态确定当天的施工配合比；
    (3)进场及换板定位：按照设计要求找出需快速置换板块的位置；
    (4)板块破除前施工装备：板块破除前，将破损板块上的助航灯具拆除，在相邻板块上铺设土工布，人工用电镐沿破损板块的板缝位置抠边；
    (5)用破碎锤破除板块：用破碎锤从破损板块中间位置开始破除，板中部破除完成后将破碎混凝土块抠出，然后依次向板边破除，板边预留位置，进行人工破除；
    (6)混凝土块装运及人工清仓：破损板块破除完成之后，进行混凝土块装运，人工清理仓底碎块，直至清理出密实平整的基层；
    (7)铺设土工布、仓底洒水湿润：清仓完成之后开始铺设土工布，并洒水湿润仓底；
    (8)混凝土一体车就位浇筑第一层混凝土；
    (9)铺设钢筋网片：待第一层混凝土浇筑完成后安装钢筋网片补强；
    (10)浇筑第二层混凝土：补强钢筋网片安装完成之后，立刻开始第二层混凝土浇筑工作，浇筑顺序为从板的一边依次向另一边浇筑，浇筑的同时利用双钢管振动梁对混凝土面进行找平提浆；
    (11)精平、收面：双钢管振动梁找平提浆完成之后，利用铝合金刮杠对混凝土面进行刮搓，刮搓前将邻板板边的水泥浆清理干净，刮搓时缺料的部位用混凝土骨料进行填补，多料的部位用铁锹铲走，刮搓完成之后开始进行收面；
    (12)养护：进行喷水养护；
    (13)切缝、刻槽：根据所用的快干混凝土性能进行切缝刻槽施工；
    (14)灌缝、标志线恢复。
  4. 根据权利要求2所述的工艺，其特征在于，在钻孔、吹孔步骤中，道面钻孔采用钻机的钻头不大于60mm；钻孔穿过基层深入土基中10cm；钻孔钻至设计深度后，采用空压机进行吹孔，吹孔时间不得少于10s。
  5. 根据权利要求2所述的工艺，其特征在于，在注浆过程中控制的技术指标包括:1、注浆压力:在机场道面注浆时灌浆压力不大于1.0MPa，在注浆时，当注浆压力保持在一定的数值上，且注浆量不再增加时，停止灌浆；2、板面抬升量:注浆过程中，道面板允许抬高量要求不大于5mm，稳定后最终道面板允许抬高量要求不大于3mm，当道面板抬升量大于5mm时，应停止灌浆；3、板块周边溢浆情况：注浆时道面板周边出现溢浆时应停止灌浆，并清理溢浆。
  6. 根据权利要求3所述的工艺，其特征在于，在板块破除前施工装备步骤中，板块破碎前应人工用电镐沿破损板块板缝位置抠出一条宽不小于15cm，深度不小于10cm的保护层，用于防止大型机械破碎板块时对相邻板块造成损伤。
  7. 根据权利要求3所述的工艺，其特征在于，在用破碎锤破除板块步骤中，破损板块板边位置留出15cm，进行人工破除。
  8. 根据权利要求3所述的工艺，其特征在于，当混凝土板厚为40cm时，第一层浇筑厚度为15cm，第二层浇筑厚度为25cm，第二层混凝土要求在第一层混凝土初凝前浇筑完成，防止出现冷缝。
  9. 根据权利要求3所述的工艺，其特征在于，当进行相邻两块板块同时浇筑施工时，为防止两块板同时进行分层浇筑时两层中间形成冷缝，在相邻两块板板缝中间位置支设一块“半 高模板”，即半高模板高度为板厚的1/2；然后再进行相邻两块板分别分层浇筑，浇筑顺序为：支设“半高模板”→第一块板第一层→浇筑第一块板第二层→拆除“半高模板”→浇筑第二块板第一层→浇筑第二块板第二层。
  10. 根据权利要求3所述的工艺，其特征在于，所述进行喷水养护具体为：待混凝土表面不能按出手印且开始发热时，即可用喷雾器进行喷水养护，养护初期喷头应朝上，让水雾自然落到混凝土面上，养护时保证混凝土面湿润，养护时间不应小于3小时。
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