WO2024088361A1 - 复材裹层钢筋及其制造方法、现场弯折方法与应用 - Google Patents

复材裹层钢筋及其制造方法、现场弯折方法与应用 Download PDF

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WO2024088361A1
WO2024088361A1 PCT/CN2023/126946 CN2023126946W WO2024088361A1 WO 2024088361 A1 WO2024088361 A1 WO 2024088361A1 CN 2023126946 W CN2023126946 W CN 2023126946W WO 2024088361 A1 WO2024088361 A1 WO 2024088361A1
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WIPO (PCT)
Prior art keywords
steel bar
composite
wrapped
bars
winding
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PCT/CN2023/126946
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English (en)
French (fr)
Inventor
滕锦光
向宇
张译文
王汉珽
余涛
徐菲
Original Assignee
香港理工大学
菲普国际有限公司
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Application filed by 香港理工大学, 菲普国际有限公司 filed Critical 香港理工大学
Publication of WO2024088361A1 publication Critical patent/WO2024088361A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/14—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to metal, e.g. car bodies
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E04C5/01—Reinforcing elements of metal, e.g. with non-structural coatings
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E04C5/01—Reinforcing elements of metal, e.g. with non-structural coatings
    • E04C5/02—Reinforcing elements of metal, e.g. with non-structural coatings of low bending resistance

Definitions

  • the present application belongs to the field of engineering material technology, and more specifically, relates to a composite wrapped steel bar and its manufacturing method, on-site bending method and application.
  • the composite wrapped steel bar has the characteristics of corrosion resistance, impact resistance, peeling resistance, good bonding performance with concrete, high cost performance, etc., and is suitable for reinforcing concrete structures in corrosive environments.
  • Reinforced concrete structures are reliable and inexpensive, and are widely used in civil engineering. With the continuous advancement of global urbanization, the development of reinforced concrete structures has been rapid. Engineers have built bridges with a span of more than 400 meters (Beipanjiang Bridge on the Shanghai-Kunming High-speed Railway in China, with a main span of 445 meters and a top-bearing reinforced concrete arch bridge) and houses with a height of more than 800 meters (Dubai Tower in the United Arab Emirates, with a total height of 828 meters, of which the section from 30 meters underground to 601 meters above ground is a reinforced concrete structure) through a reasonable combination of steel bars and concrete. In sharp contrast to the rapid changes in quantity and form is the structural durability problem caused by steel corrosion.
  • Reinforced concrete structures especially those serving in corrosive environments (such as marine environments), such as cross-sea bridges, seaports, docks, etc., generally have steel corrosion problems. Steel corrosion will cause the durability of the structure to decrease and endanger the safety of the structure, and the maintenance of reinforced concrete structures requires a lot of financial, human and material resources.
  • steel bars From the perspective of steel bars: it is suggested to use epoxy resin as a steel bar coating to block the contact between the steel bar surface and oxygen and water; it is suggested to spray short fiber reinforced resin-based materials, wrap wet-laid resin-impregnated fiber cloth or outer fiber reinforced resin-based composite material pipe (abbreviated as: outer composite pipe) to form composite force-bearing bars; it is also suggested to use corrosion-resistant stainless steel bars or composite bars to strengthen concrete structures, completely abandon ordinary steel bars, and fundamentally avoid corrosion problems, etc.
  • epoxy resin as a steel bar coating to block the contact between the steel bar surface and oxygen and water
  • spray short fiber reinforced resin-based materials wrap wet-laid resin-impregnated fiber cloth or outer fiber reinforced resin-based composite material pipe (abbreviated as: outer composite pipe) to form composite force-bearing bars
  • corrosion-resistant stainless steel bars or composite bars to strengthen concrete structures, completely abandon ordinary steel bars, and fundamentally avoid corrosion problems, etc.
  • the method of improving the durability of reinforced concrete structures by changing the physical and chemical properties of concrete has considerable limitations.
  • the use of high-strength or ultra-high-strength concrete to meet durability requirements requires changes in the structural design; rust inhibitors are difficult to disperse evenly in concrete; the interaction mechanism between mineral admixtures and cement is not yet clear, and the predicted chlorine fixation efficiency is not reliable.
  • the durability improvement methods surrounding steel bars also have considerable limitations.
  • the coating of epoxy-coated steel bars is prone to "leakage points", easy to peel off, and has poor impact resistance; spraying short fiber reinforced resins and outsourcing wet-laid resin-impregnated fibers are not suitable for this purpose.
  • the covering method of fiberglass cloth or outer composite tube has a great influence on the rib height and rib spacing of the steel bars, which will weaken its bonding performance with concrete, and the interface bonding between the outer protective layer and the steel bars is not tight enough; although the corrosion resistance of stainless steel bars is stronger than that of ordinary steel bars, they still have local corrosion problems such as pitting corrosion in chloride environments such as the ocean, and their prices are significantly higher than ordinary steel bars; using composite bars to replace steel bars can certainly completely solve the corrosion problem, but their ductility is poor, and their prices are also significantly higher than ordinary steel bars at this stage.
  • an object of the present application is to provide a composite-wrapped steel bar to solve the technical problem of steel bar corrosion in existing reinforced concrete structures.
  • Another object of the present application is to provide a method for manufacturing the composite-wrapped steel bars.
  • Another object of the present application is to provide an on-site bending method for the composite wrapped steel bars.
  • Another object of the present application is to provide application of the composite wrapped steel bar.
  • a composite wrapped steel bar comprises a core steel bar and a composite protective layer wrapped around the surface of the steel bar.
  • the composite material of the present application is a fiber-reinforced resin-based composite material.
  • the steel bar is a plain round steel bar; or, the steel bar is a commercial standardized deformed steel bar, including any one of herringbone, crescent, cross, bamboo, and spiral ribs; or, the steel bar is a non-standard deformed steel bar customized by hot rolling, cutting or additive manufacturing methods according to application requirements; or, the steel bar is a corrosion-resistant steel bar, including any one of epoxy coated steel bars, hot-dip galvanized steel bars, and stainless steel bars.
  • the composite protective layer is formed by continuous winding of fiber material and resin material.
  • the fiber material includes at least one of glass fiber, basalt fiber, and aramid fiber.
  • the resin material includes at least one of epoxy resin, vinyl resin, unsaturated polyester fiber, and phenolic resin; and/or,
  • the viscosity of the resin material should be between 200mPa ⁇ s and 1500mPa ⁇ s.
  • End sealing spray waterproof material on the cut end of the semi-finished product or wrap the composite material to protect it, so as to obtain composite-wrapped steel bars.
  • the method of wrapping the composite material used for end sealing includes at least one of wet laying and continuous winding.
  • the composite wrapped steel bar is a linear composite wrapped steel bar or a non-linear composite wrapped steel bar; and/or,
  • Types of non-linear steel bars include any one of U-shaped bars, stirrups, and bent bars.
  • the above method is not only applicable to the manufacture of linear composite wrapped steel bars, but also applicable to the manufacture of non-linear composite wrapped steel bars, that is, the composite wrapped steel bars are linear composite wrapped steel bars or non-linear composite wrapped steel bars.
  • the winding angle is any angle between ⁇ 10° and ⁇ 90°; and/or,
  • the combination of the number of winding layers and the winding angle includes at least one of single-layer single-angle, single-layer multiple-angle, single-layer variable-angle, multi-layer single-angle, multi-layer multiple-angle, and multi-layer variable-angle.
  • a method for bending the composite wrapped steel bar on site which is used to bend the composite wrapped steel bar on site to meet the requirements of the construction site for the shape of the composite wrapped steel bar, and the method for bending the composite wrapped steel bar on site comprises the following steps:
  • the composite wrapped steel bars shall be bent at least once.
  • the method for protecting the area affected by the bending of the steel bars in the composite wrapping layer is to wrap the composite material.
  • the method of wrapping the composite material comprises at least one of wet laying and continuous winding of the composite material.
  • the composite material is used as the protective layer of the steel bar, which has the characteristics of good durability and low permeability, and can protect the core steel bar from the erosion of water, oxygen, and chloride ions for a long time.
  • the composite wrapped steel bar provided by the present application is used as the reinforcement bar of the concrete structure, which will significantly improve the durability of the reinforced concrete structure, thereby extending the life of the structure;
  • the composite protective layer formed by the continuous winding process with a certain tension can make the composite protective layer more closely bonded to the steel bar surface and retain the original rib shape of the steel bar to a greater extent, thereby ensuring the durability of the composite wrapped steel bar and reliable bonding with concrete;
  • the mechanical properties, durability and adhesion of the composite wrapped steel bar to concrete can be improved by optimizing the design of the winding layer (such as winding angle, number of layers), fiber material tension and material type, curing temperature and pressure, and steel bar surface shape. Active regulation of the interfacial bonding properties of concrete to meet a variety of structural application requirements;
  • the composite wrapped steel bars provided in this application are particularly suitable for infrastructure construction in corrosive environments (such as marine environments), and can even be used in concrete structures that are directly mixed with seawater and sea sand, to assist in the construction of offshore islands and reefs with national defense and economic value.
  • FIG1 is a schematic diagram of the structure of a composite wrapped steel bar provided in the present application.
  • FIG2 is a flow chart of a method for manufacturing a composite-wrapped steel bar provided in the present application.
  • FIG3 is a flow chart of an on-site bending method of a composite wrapped steel bar provided in the present application.
  • FIG4 is a schematic diagram of a glass fiber composite wrapped crescent-shaped ribbed steel bar provided in Example 1 of the present application;
  • FIG5 is a schematic diagram of a glass fiber composite wrapped spiral ribbed steel bar provided in Example 2 of the present application.
  • FIG6 is a schematic diagram of multi-layer and multi-angle glass fiber composite wrapped steel bars provided in Example 3 of the present application.
  • the present application embodiment provides a composite wrapped steel bar 1, the structure of which is shown in FIG1.
  • the wrapped steel bar 1 comprises a core steel bar 10 and a composite material protective layer 20 wrapped around the surface of the steel bar 10 .
  • the composite wrapped steel bar 1 provided in the embodiment of the present application is intended to be a substitute for the traditional steel bars used in concrete structures in a corrosive environment. Therefore, common steel bar types on the market are suitable for use as the core steel bar 10, including at least one of plain round steel bars, commercial standardized deformed steel bars, non-standard deformed steel bars, and corrosion-resistant steel bars.
  • the steel bar 10 is a plain round steel bar; or, the steel bar 10 is a commercial standardized deformed steel bar, including any one of herringbone, crescent, cross, bamboo, and spiral ribs; or, the steel bar 10 is a non-standard deformed steel bar customized by hot rolling, cutting or additive manufacturing methods according to application requirements; or, the steel bar 10 is a corrosion-resistant steel bar, including any one of epoxy coated steel bars, hot-dip galvanized steel bars, and stainless steel bars.
  • the composite material of the embodiment of the present application is a fiber-reinforced resin-based composite material.
  • the composite protective layer is formed by continuously winding fiber material and resin material, so that the fiber material and resin material are continuously wound and coated on the surface of the steel bar 10 to form the composite protective layer 20 .
  • the composite material has the characteristics of good durability and low permeability, it can protect the steel bar 10 from the corrosion of water, oxygen and chloride ions from the external corrosive environment for a long time; (2) Due to the continuous winding composite forming process, the bonding tightness between the composite protective layer 20 and the steel bar 10 is enhanced.
  • the composite protective layer 20 has better impact resistance, peeling resistance and permeation resistance; (3) Due to the small amount of composite material used and the low price of the core steel bar 10, the composite wrapped steel bar 1 has a lower price than stainless steel bars; (4) Since the core steel bar 10 itself has ductility, and the composite wrapping will not affect the ductility of the steel bar, the composite wrapped steel bar 1 has not only a lower price than the composite bar, but also has good ductility.
  • the fiber material includes at least one of glass fiber, basalt fiber, and aramid fiber.
  • These fiber materials have the advantages of good durability and high strength, and can provide the composite protective layer 20 with necessary strength, rigidity and durability, maintain the integrity of the protective layer under the action of external forces, and give the protective layer necessary impact resistance and peeling resistance.
  • the resin material includes at least one of epoxy resin, vinyl resin, unsaturated polyester resin, and phenolic resin.
  • These resin materials have the characteristics of good durability, good anti-permeability, and good compatibility with fiber materials. They can be used as the matrix of the composite material to provide the necessary anti-permeability, rigidity, and durability for the composite material protective layer 20, and isolate water, oxygen, and chloride ions from the external corrosive environment, thereby reducing the corrosion risk of the core steel bar 10.
  • the viscosity of the resin material is 200mPa ⁇ s to 1500mPa ⁇ s.
  • Resins with a viscosity higher than 1500mPa ⁇ s will result in insufficient impregnation of the fiber material, resulting in uneven distribution of the thickness of the protective layer, affecting the corrosion resistance of the composite wrapped steel bars and the bonding performance with concrete.
  • Resins with a viscosity lower than 200mPa ⁇ s have excessive fluidity and are easily lost during the winding process, affecting the ratio of the protective layer resin to the fiber, and thus affecting the anti-corrosion effect.
  • the present application embodiment provides a method for manufacturing the composite wrapped steel bar 1, as shown in FIG2, comprising the following steps:
  • the pretreatment can remove rust, grease, dirt and debris on the surface of the steel bar 10 , and improve the bonding performance between the steel bar 10 and the composite protective layer 20 .
  • the method of pre-treating the surface of the steel bar 10 includes at least one of sandblasting, pickling, laser, and mechanical grinding.
  • the steel bar 10 is fixed on a rotatable support of the winding device to serve as a core mold for fixed-length continuous winding.
  • the fiber material is introduced from a creel into a resin impregnation tank filled with resin, so that the fiber material is fully impregnated to obtain the fiber material impregnated with resin.
  • the winding angle in the embodiment of the present application refers to the angle between the fiber material and the length direction of the steel bar 10, and the winding angle is any angle between ⁇ 10° and ⁇ 90°.
  • the number of winding layers is one layer when the fiber is wound along the length direction of the steel bar 10 at a predetermined fixed winding angle or a winding angle variation until the surface of the core steel bar 10 is completely covered.
  • the winding method of the composite material can be, for example, full winding at +86° or half winding at +86° and +60°.
  • the number of winding layers may be one or more layers.
  • the surface of the ribbed steel bar has raised ribs, and there is a certain gap between adjacent ribs, which makes the bond between the steel bar 10 and the concrete stronger. If the number of composite winding layers is too many and the thickness of the composite protective layer 20 is too large, it will affect the relative height of the ribs on the surface of the steel bar 10 (that is, the ratio of the rib height to the nominal diameter of the steel bar, reflecting the degree of protrusion of the rib) and the rib spacing, and weaken the bonding performance between the composite wrapped steel bar 1 and the concrete. Therefore, in practical applications, it is necessary to comprehensively consider the impact of the number of winding layers on the impact resistance, peeling resistance, penetration resistance, corrosion resistance and bonding performance of the composite wrapped steel bar 1 and concrete, and select the appropriate number of winding layers according to needs.
  • the combination of the number of winding layers and the winding angle of the fiber material includes at least one of single-layer single angle, single-layer multiple angles, single-layer variable angles, multiple layers single angles, multiple layers multiple angles, and multiple layers variable angles.
  • the fiber material is wound at an angle of +86° from one end of the steel bar 10 to the other end of the steel bar 10, and the entire process is wound until the surface of the steel bar 10 is completely covered to form a single-layer single-angle composite protective layer 20; or the fiber The material is firstly wound at an angle of +86° from one end of the steel bar 10, and then changed to a winding angle of +60° at half the length of the steel bar 10 and continued to be wound to the other end of the steel bar 10, forming a single-layer multi-angle composite protective layer 20 with +86° and +60° at each half; or the fiber material is wound at an angle of +10° from one end of the steel bar 10, and the winding angle is linearly increased with the increase of the winding distance and is continuously wound, and the
  • the fiber material is firstly wound at a winding angle of +86° to completely cover the surface of the steel bar 10 to form a first layer, and then reversely wound at a winding angle of -86° to completely cover the surface of the steel bar 10 again to form a second layer, and finally a multi-layer multi-angle composite protective layer 20 of +86° and -86° is formed; or the fiber material is firstly wound at a winding angle of +86° to completely cover the surface of the steel bar 10 to form a first layer, and then the winding angle is linearly reduced with the increase of the winding distance in the reverse direction and continuously wound, and the winding angle reaches -80° at the starting end of the winding, forming a multi-layer variable angle composite protective layer 20;
  • the steel bar 10 when the steel bar 10 is a herringbone rib deformed steel bar with a nominal diameter of 10 mm and a maximum rib height of about 1 mm, the number of winding layers of the fiber material is 1-2 layers, and the combination of the number of winding layers and the winding angle is a multi-layer multi-angle method.
  • the composite protective layer 20 can have a certain thickness to provide the steel bar 10 with sufficient impact resistance, peeling resistance, penetration resistance, and corrosion resistance, and can also retain the rib height and rib spacing of the steel bar 10 to the maximum extent, so that the bonding performance between the steel bar 10 and the concrete can still meet the requirements of engineering applications.
  • the intermediate product is placed in a predetermined environment for curing to obtain a primary product.
  • the composite protective layer 20 forms a certain strength and rigidity, thereby providing necessary protection for the steel bar 10.
  • the predetermined environment includes temperature and pressure environment.
  • the curing temperature and pressure environment include any one of normal temperature and pressure, normal temperature and high pressure, high temperature and high pressure, and high temperature and normal pressure.
  • normal temperature refers to room temperature (about 25°C)
  • normal pressure refers to 1 standard atmosphere.
  • the curing environment is selected by factors such as the type of resin material and the durability requirements of the composite wrapped steel bar 1.
  • the initial product after solidification is cut to a fixed length to obtain a semi-finished product of a predetermined length.
  • End sealing spray waterproof material or wrap composite material on the ends of the semi-finished products after the fixed-length cutting process to protect them, so as to obtain the finished composite-wrapped steel bars 1.
  • the method of wrapping the composite material includes at least one of wet laying and continuous winding.
  • the manufacturing method of the composite wrapped steel bar 1 provided in the embodiment of the present application is not only applicable to the manufacturing of linear composite wrapped steel bars, but also applicable to the manufacturing of non-linear composite wrapped steel bars.
  • the non-linear composite wrapped steel bars include but are not limited to U-shaped bars, stirrups, bent bars, etc.
  • the manufacturing method of the composite wrapped steel bar 1 provided in the embodiment of the present application is simple to operate and suitable for industrial promotion and large-scale application.
  • the embodiment of the present application also provides an on-site bending method for the composite wrapped steel bar 1, as shown in FIG3, comprising the following steps:
  • the composite wrapped steel bar 1 is bent once or multiple times to meet the requirements of the composite wrapped steel bar shape due to the processes of steel bar anchoring, lap jointing, etc. at the construction site.
  • the field bending method wraps the composite material again on the outer surface of the bending affected area of the composite wrapped steel bars to ensure that the impact resistance, peeling resistance, penetration resistance and corrosion resistance of the bending affected area are not lower than those of the non-affected area.
  • the method for protecting the area affected by the bending of the steel bars in the composite wrapping layer is to wrap the composite material.
  • the method of wrapping the composite material in the bending-affected area of the composite-wrapped steel bar 1 comprises at least one of wet laying and continuous winding.
  • This embodiment shows a continuously wound glass fiber reinforced resin-based composite wrapped crescent rib steel bar (referred to as: glass fiber composite wrapped crescent rib steel bar) and its manufacturing method, as shown in Figure 4.
  • the glass fiber composite wrapped crescent rib steel bar 1 consists of a core crescent rib steel bar 10 and a glass fiber composite protective layer 20 wrapped on the surface of the steel bar.
  • the steel bar 10 is a HRB500 grade commercial standardized deformed steel bar with a total length of 1250 mm, a nominal diameter of 10 mm, a yield strength of 567 MPa, a tensile strength of 636 MPa, and a crescent-shaped rib;
  • the fiber material is a silane-type impregnating agent treated glass fiber with a linear density of 1200 Tex; and
  • the resin material is an epoxy resin with a viscosity of 500 mPa ⁇ s, a tensile strength of not less than 79 MPa, and a glass transition temperature of not less than 120°C.
  • This embodiment shows the manufacturing method of the above-mentioned glass fiber composite wrapped crescent-shaped rib steel bar, comprising the following steps:
  • the surface of the steel bar 10 is pretreated by sandblasting to remove rust, grease and dirt, thereby obtaining pretreated steel bars.
  • the steel bar is fixed on a rotatable clamp of the winding device as a core mold for fixed-length continuous winding.
  • the glass fiber material is introduced from the yarn frame into a resin impregnation tank containing epoxy resin to fully impregnate the glass fiber material to obtain a resin-impregnated glass fiber material.
  • the intermediate product is obtained by winding one layer on the steel bar surface at a winding angle of -86° and -86°, with a total of two layers.
  • the composite wrapped steel bar is placed in a 105° C. normal pressure environment for high temperature and normal pressure curing for 15 minutes to obtain a primary product.
  • a quick-drying epoxy resin-based waterproof coating is sprayed on both ends of the cut primary product with a total length of 1200 mm for protection, thereby obtaining a finished glass fiber composite wrapped crescent-shaped ribbed steel bar 1.
  • the selected crescent-shaped rib deformed steel bar is the most widely used steel bar in reinforced concrete structures in the field of civil engineering. Therefore, this embodiment has a relatively general representative significance.
  • the glass fiber composite outer protective layer used in this embodiment has excellent durability and can well block oxygen, water, and chloride ions from contacting the steel bars, thereby achieving the purpose of corrosion protection;
  • the viscosity of the epoxy resin used is relatively low (500mPa ⁇ s), and its purpose is to maintain the original rib shape of the steel bar as much as possible, so as not to affect the bonding performance between the composite wrapped steel bar and the concrete;
  • the curing conditions used are 105°C high temperature and normal pressure curing, which can effectively shorten the production time and improve the durability of the glass fiber resin-based composite protective layer.
  • This embodiment shows a continuously wound glass fiber reinforced resin-based composite wrapped spiral ribbed steel bar (referred to as: glass fiber composite wrapped spiral ribbed steel bar) and its manufacturing method, as shown in Figure 5.
  • the glass fiber composite wrapped spiral ribbed steel bar 1 consists of a spiral ribbed steel bar 10 at the core and a glass fiber composite protective layer 20 wrapped on the surface of the steel bar.
  • steel bar 10 is a commercial standard PSB930 grade fine rolled threaded steel bar with a total length of 1250mm, a nominal diameter of 15mm, a yield strength of not less than 980MPa, a tensile strength of not less than 1120MPa, an ultimate elongation of 10%, and a spiral rib;
  • the fiber material is a silane-type impregnated glass fiber with a linear density of 1200Tex;
  • the resin material is a viscosity of 500mPa ⁇ s, a tensile strength of not less than 79MPa, and a glass transition temperature of not less than Epoxy resin below 120°C.
  • This embodiment shows the manufacturing method of the above-mentioned glass fiber composite wrapped crescent-shaped rib steel bar, comprising the following steps:
  • the surface of the steel bar 10 is pretreated by pickling process to remove rust, grease and dirt to obtain pretreated steel bars.
  • the steel bar is fixed on a rotatable clamp of the winding device as a core mold for fixed-length continuous winding.
  • the glass fiber material is introduced from the yarn frame into a resin impregnation tank containing epoxy resin to fully impregnate the glass fiber material to obtain a resin-impregnated glass fiber material.
  • step S03 Pull the impregnated glass fiber material in step S03 out of the dipping tank, and wrap it on the surface of the steel bar in a tensioned state at a winding angle of +86° and -86°, one layer each, for a total of two layers, to obtain an intermediate product.
  • the composite wrapped steel bar is placed in a 105° C. normal pressure environment for high temperature and normal pressure curing for 15 minutes to obtain a primary product.
  • a quick-drying epoxy resin-based waterproof coating is sprayed on both ends of the cut primary product with a total length of 1200 mm for protection, thereby obtaining a finished glass fiber composite wrapped spiral ribbed steel bar 1.
  • the selected spiral rib deformed steel bar is commonly used in the field of civil engineering for anchor rods of prestressed structures and underground structures.
  • the spiral rib deformed steel bar will be subjected to a higher constant load stress amplitude for a long time, and its working environment will further make it more susceptible to corrosion. Therefore, this example uses two layers of glass fiber composite winding, and uses a higher curing temperature and a longer curing time to achieve a better anti-corrosion effect.
  • This embodiment shows a multi-layer multi-angle continuously wound glass fiber reinforced resin-based composite wrapped steel bar (abbreviated as: multi-layer multi-angle glass fiber composite wrapped steel bar) and its manufacturing method, as shown in Figure 6.
  • the multi-layer multi-angle glass fiber composite wrapped steel bar 1 consists of a core steel bar 10 and a glass fiber composite protective layer 20 wrapped on the surface of the steel bar.
  • steel bar 10 is a non-standard spiral rib deformed steel bar customized by cutting process with a total length of 1250 mm, a nominal diameter of 12 mm, a yield strength of about 550 MPa, a tensile strength of about 650 MPa; (2) the fiber material is a silane-type impregnating agent treated glass fiber with a linear density of 1200 Tex; (3) the resin material is an epoxy resin with a viscosity of 500 mPa ⁇ s, a tensile strength of not less than 79 MPa, and a glass transition temperature of not less than 120°C.
  • This embodiment shows the manufacturing method of the above-mentioned glass fiber composite wrapped crescent-shaped rib steel bar, comprising the following steps:
  • the surface of the steel bar 1 is pretreated by sandblasting to remove rust, grease and dirt, thereby obtaining pretreated steel bars.
  • the steel bar is fixed on a rotatable clamp of the winding device as a core mold for fixed-length continuous winding.
  • the glass fiber material is introduced from the yarn frame into a resin impregnation tank containing epoxy resin to fully impregnate the glass fiber material to obtain a resin-impregnated glass fiber material.
  • step S03 Pull the soaked glass fiber material in step S03 out of the dipping tank, keep it in a tensioned state, and wind it one layer at +30° and one layer at -30° respectively; change the winding angle, and wind it one layer at +86° and one layer at -86° respectively, so that the total number of layers reaches 4, and obtain an intermediate product.
  • the intermediate product is placed in a 105°C normal pressure environment for high temperature and normal pressure curing for 15 minutes to obtain a primary product.
  • the primary product is cut to remove the clamped areas at both ends of the primary product, with 25 mm removed at each end, to obtain a semi-finished product.
  • the composite material is wrapped at both ends of the cut primary product with a total length of 1200 mm to protect it, thereby obtaining a finished multi-layer and multi-angle glass fiber composite wrapped steel bar 1.
  • This embodiment is intended to demonstrate a composite wrapped steel bar and its manufacturing method having stronger corrosion resistance and impact resistance than embodiments one and two.
  • the composite protective layer of the composite wrapped steel bar is successively wound with 1 layer at angles of +30°, -30°, +86°, and -86°, so that the total number of layers of the composite protective layer reaches 4 layers.
  • ⁇ 30° indicates that the fiber direction is relatively close to the parallel length direction of the steel bar
  • ⁇ 86° indicates that the fiber direction is close to perpendicular to the length direction of the steel bar.
  • the combination of the two can strengthen the resin matrix in two nearly orthogonal directions, so that the composite protective layer has stronger mechanical properties, thereby providing better protection for the steel bars in the core.
  • the selected spiral rib deformed steel bar is a customized non-standard deformed steel, and its rib shape has higher ribs and a larger relative rib area than standard steel bars with similar nominal diameters, which can ensure the bonding performance with concrete in the case of multi-layer composite wrapping.

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Abstract

本申请提供了复材裹层钢筋及其制造方法、现场弯折方法与应用。所述复材裹层钢筋包括芯部的钢筋和包裹于钢筋表面的复材保护层。本申请的复材裹层钢筋，具有耐腐蚀、耐冲击、抗剥离、与混凝土粘结性能好、性价比高等特点。采用本申请提供的复材裹层钢筋增强混凝土结构，可以显著提高结构耐久性、延长结构寿命；本申请提供的复材裹层钢筋适用于腐蚀环境中的基础设施建设，适用于采用海水、海砂直接拌合的混凝土结构，也适用于具有国防、经济价值的海上岛礁建设。

Description

复材裹层钢筋及其制造方法、现场弯折方法与应用
本申请要求于2022年10月28日在中国专利局提交的、申请号为202211337337.2、发明名称为“复材裹层钢筋及其制造方法、现场弯折方法与应用”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本申请属于工程材料技术领域，更具体地说，是涉及一种复材裹层钢筋及其制造方法、现场弯折方法与应用。复材裹层钢筋具有耐腐蚀、耐冲击、抗剥离、与混凝土粘结性能好、性价比高等特点，适用于增强腐蚀环境下的混凝土结构。
背景技术
钢筋混凝土结构性能可靠、造价低廉，是土木工程中广泛应用的一种结构形式。随着全球城镇化的不断推进，钢筋混凝土结构的发展可谓是突飞猛进。工程师们通过钢筋、混凝土的合理组合，建成了跨径超过400米的桥梁(中国沪昆高铁北盘江特大桥，主跨跨径445米，上承式钢筋混凝土拱桥)、高度超过800米的房屋(阿联酋迪拜大厦，总高度828米，其中地下30米至地上601米区段为钢筋混凝土结构)。与数量、形式上的日新月异形成鲜明反差的是钢筋锈蚀带来的结构耐久性问题。钢筋混凝土结构，尤其是在腐蚀环境(如海洋环境)中服役的钢筋混凝土结构，如跨海桥梁、海港、码头等，普遍存在钢筋锈蚀问题。钢筋锈蚀会造成结构耐久性下降，危害结构安全，而维护钢筋混凝土结构则需要投入大量的财力、人力和物力。
根据美国腐蚀工程师协会(NACE)等几个组织的联合调查结果，美国在1999至2001年间由于因腐蚀而产生的直接经济损失为国民经济总产值(GDP) 的3.1％，平均每年约2760亿美元。其中，交通公共设施和建筑业分别占34.9％和18％，两项合计达52％。根据中国工程院“我国腐蚀状况及控制战略研究”项目结论，我国2014年腐蚀成本约为2.1万亿元，相当于当年国民经济总产值的3.34％，其中基础设施和交通行业占30.6％。美国学者Sitter曾用“五倍定律”来形象地描述钢筋混凝土设施维护的重要性：“在设计、建造及混凝土养护阶段多投入1美元，等同于在发现钢筋锈蚀再采取补救措施阶段节省5美元，等同于在发现混凝土表面开裂再采取补救措施阶段节省25美元，等同于在结构严重损伤再采取补救措施阶段节省125美元。”
在设计、建造及混凝土养护阶段提升钢筋混凝土结构耐久性的方法已有很多。从混凝土的角度：有建议采用高强、超高强混凝土，以提升混凝土密实度和抗渗性；有建议采用具有阻锈功能的外加剂，在钢筋表面形成钝化膜；也有建议采用矿物掺合料，提高水泥基胶凝材料的固氯能力，等。从钢筋的角度：有建议采用环氧树脂作为钢筋涂层，阻断钢筋表面与氧气、水的接触；有建议喷涂短纤维增强树脂基材料，外包湿铺树脂浸渍纤维布或外套纤维增强树脂基复合材料管(简称：外套复材管)，形成复合受力筋；也有建议采用耐腐蚀的不锈钢筋或复材筋增强混凝土结构，彻底摈弃普通钢筋，从根本上避免腐蚀问题，等。
这些措施中，通过改变混凝土的物理、化学性质，提高钢筋混凝土结构耐久性的方法，具有相当的局限性。例如，为满足耐久性要求而改用高强或超高强混凝土，需要改变结构设计方案；阻锈剂在混凝土中难以均匀分散；矿物掺合料与水泥的相互作用机理尚不明确，所预测的固氯效率并不可靠。而围绕钢筋的耐久性提升方法同样具有相当的局限性，例如，环氧涂层钢筋的涂层易“漏点”、易剥离、抗冲击性能较差；喷涂短纤维增强树脂、外包湿铺树脂浸渍纤 维布或外套复材管包覆方式对钢筋的肋高、肋间距影响较大，会减弱其与混凝土的粘结性能，且外包保护层和与钢筋之间的界面粘结不够紧密；不锈钢筋的耐腐蚀性虽然强于普通钢筋，但其在海洋等氯盐环境中依然存在点蚀等局部腐蚀问题，且价格明显高于普通钢筋；采用复材筋替代钢筋固然可以彻底解决腐蚀问题，但其延性较差，且现阶段价格也明显高于普通钢筋。
因此，现有技术仍有待改进和发展。
技术问题
鉴于上述现有技术的不足，本申请的一个目的是提供一种复材裹层钢筋，以解决现有钢筋混凝土结构中钢筋锈蚀的技术问题。
技术解决方案
本申请的又一目的是提供上述复材裹层钢筋的制造方法。
本申请的又一目的是提供上述复材裹层钢筋的现场弯折方法。
本申请的再一目的是提供上述复材裹层钢筋的应用。
为实现上述目的，本申请采用的技术方案是：
一种复材裹层钢筋，包括芯部的钢筋和包裹于钢筋表面的复材保护层。
可选地，本申请的复材是纤维增强树脂基复合材料。
可选地，钢筋为光圆钢筋；或者，钢筋为商业标准化变形钢筋，包括带人字形、月牙形、十字形、竹节形、螺旋形肋中的任意一种；或者，钢筋为根据应用需求采用热轧、切削或增材制造方法定制的非标准变形钢筋；或者，钢筋为耐腐蚀钢筋，包括环氧涂层钢筋、热浸锌钢筋、不锈钢筋中的任意一种。
可选地，复材保护层采用纤维材料和树脂材料，经连续缠绕成形。
可选地，纤维材料包括玻璃纤维、玄武岩纤维、芳纶纤维中的至少一种。
可选地，树脂材料包括环氧树脂、乙烯基树脂、不饱和聚酯纤维、酚醛树脂中的至少一种；和/或，
树脂材料的粘度应介于200mPa·s至1500mPa·s之间。
以及，一种复材裹层钢筋的制造方法，包括以下步骤：
(1)对钢筋的表面进行预处理，得到预处理后的钢筋；
(2)将钢筋进行夹持；
(3)将纤维材料浸渍于树脂材料中，得到浸润树脂材料后的纤维材料；
(4)将浸润树脂材料后的纤维材料拉出，以张紧状态沿钢筋的长度方向按预定的一个固定缠绕角度或缠绕角度变化连续缠绕在钢筋表面至预定缠绕层数，得到中间产品；
(5)将中间产品置于预定环境中进行固化,得到初产品；
(6)根据需求对初产品进行切割，得到半成品；
(7)端部密封，对半成品的切割端喷涂防水材料予或包裹复材予以保护，得到复材裹层钢筋。
可选地，端部密封所采用的包裹复材的方法包括湿铺、连续缠绕中的至少一种。
可选地，复材裹层钢筋为直线型复材裹层钢筋或非直线型复材裹层钢筋；和/或，
非直线型钢筋的种类包括U型筋、箍筋、弯起筋中的任意一种。
以上所述方法不仅适用于制造直线型复材裹层钢筋，也适用于制造非直线型复材裹层钢筋，即复材裹层钢筋为直线型复材裹层钢筋或非直线型复材裹层钢筋。
可选地，缠绕角度为±10°至±90°之间的任意角度；和/或，
缠绕层数与缠绕角度的组合包括单层单角度、单层多角度、单层变角度、多层单角度、多层多角度、多层变角度中的至少一种。
以及，一种复材裹层钢筋的现场弯折方法，用于现场弯折上述复材裹层钢筋，以满足施工现场对复材裹层钢筋形状的要求，现场弯折方法包括以下步骤：
(1)根据现场对钢筋形状、尺寸的需求，对复材裹层钢筋进行至少一次弯折。
(2)对复材裹层钢筋弯折影响区域采取适当方法予以保护，以保证弯折影响区域的耐冲击、耐剥离、耐渗透、防腐蚀性能不低于非影响区域。
可选地，对复材裹层钢筋弯折影响区域的保护方法为包裹复材。
可选地，包裹复材的方法包括湿铺、连续缠绕复材中的至少一种。
以及，上述任一项所述的复材裹层钢筋在腐蚀环境中的基础设施建设、采用海水和海砂直接拌合的混凝土结构以及海上岛礁建设中的应用。
有益效果
与现有技术相比，本申请的有益效果包括：
(1)采用复材作为钢筋的保护层，具有耐久性好、渗透速率低等特点，可以长时间保护芯部的钢筋免受水、氧气、氯离子的侵蚀，相较于现有的环氧树脂涂层、短纤维增强树脂涂层具有更好的耐冲击、耐剥离、耐渗透性能；相较于不锈钢筋具有更低的价格；相较于复材筋，则具有更低的价格和更好的延性；因而，采用本申请提供的复材裹层钢筋作为混凝土结构增强筋，将可以显著提高钢筋混凝土结构的耐久性，从而延长结构寿命；
(2)采用具有一定张力的连续缠绕工艺成形的复材保护层，相较于喷涂法、湿铺法可以使复材保护层与钢筋表面结合更加紧密，更大程度地保留钢筋的原有肋外形，从而保证复材裹层钢筋的耐久性及与混凝土的可靠粘结；可以通过优化缠绕铺层的设计(如缠绕角度、层数)、纤维材料张力及材料种类、固化温度及压强、钢筋表面形状，实现复材裹层钢筋力学性能、耐久性及与混 凝土的界面粘结性能的主动调控，从而满足多种结构应用需求；
(3)允许在施工现场对钢筋进行弯折，对钢筋的形状、尺寸进行灵活调整，从而适应工程中经常遇到的锚固、搭接等应用需求，并且保证弯折后的钢筋具有足够的耐久性；
(4)本申请提供的复材裹层钢筋特别适合应用于腐蚀环境(如海洋环境)中的基础设施建设，甚至可以用于采用海水、海砂直接拌合的混凝土结构中，助力具有国防、经济价值的海上岛礁建设。
附图说明
下面结合附图及实施例对本发明作进一步说明，附图中：
图1为本申请提供的复材裹层钢筋的结构示意图；
图2为本申请提供的复材裹层钢筋的制造方法的流程图；
图3为本申请提供的复材裹层钢筋的现场弯折方法的流程图；
图4为本申请的实施例1提供的玻纤复材裹层月牙形肋钢筋示意图；
图5为本申请的实施例2提供的玻纤复材裹层螺旋形肋钢筋示意图；
图6为本申请的实施例3提供的多层多角度玻纤复材裹层钢筋示意图。
附图标记说明：
1、复材裹层钢筋；
10、钢筋；
20、复材保护层。
本发明的实施方式
为了使本申请所要解决的技术问题、技术方案及有益效果更加清楚明白，以下结合附图及实施例，对本申请进行进一步详细说明。应当理解，此处所描述的具体实施例仅仅用以解释本申请，并不用于限定本申请。
本申请实施例提供了一种复材裹层钢筋1，其结构如附图1所示。该复材 裹层钢筋1包括芯部的钢筋10和包裹于钢筋10表面的复材保护层20。
本申请实施例提供的复材裹层钢筋1意在作为腐蚀性环境下混凝土结构所使用的传统钢筋的替代品。所以，市面常见的钢筋品类均适合用作芯部的钢筋10，包括光圆钢筋、商业标准化变形钢筋、非标准变形钢筋以及耐腐蚀钢筋中的至少一种。
具体地，钢筋10为光圆钢筋；或者，钢筋10为商业标准化变形钢筋，包括带人字形、月牙形、十字形、竹节形、螺旋形肋中的任意一种；或者，钢筋10为根据应用需求采用热轧、切削或增材制造方法定制的非标准变形钢筋；或者，钢筋10为耐腐蚀钢筋，包括环氧涂层钢筋、热浸锌钢筋、不锈钢筋中的任意一种。
本申请实施例的复材是纤维增强树脂基复合材料。
可选地，复材保护层采用纤维材料和树脂材料，经连续缠绕成形，如此，纤维材料和树脂材料经连续缠绕包覆于钢筋10的表面，形成复材保护层20。
与现有技术相比：(1)由于复材具有耐久性好、渗透速率低等特点，可以长时间保护钢筋10免受来自外部腐蚀性环境的水、氧气、氯离子的侵蚀；(2)由于采用了连续缠绕的复材成形工艺，增强了复材保护层20与钢筋10的结合紧密性，与现有的环氧树脂涂层、短纤维增强树脂涂层相比，复材保护层20具有更好的耐冲击、耐剥离、耐渗透性能；(3)由于复材用量少，且芯部的钢筋10价格低廉，复材裹层钢筋1与不锈钢筋相比，具有更低的价格；(4)由于芯部的钢筋10本身具有延性，而复材包裹不会对钢筋的延性造成影响，复材裹层钢筋1与复材筋相比，不仅具有更低的价格，而且具有很好的延性。
可选地，纤维材料包括玻璃纤维、玄武岩纤维、芳纶纤维中的至少一种。 这些纤维材料具有耐久性好、强度高等优点，可以为复材保护层20提供必要的强度、刚度和耐久性，维持保护层在外力作用下的完整性、赋予保护层必要的抗冲击、抗剥离性能。
可选地，树脂材料包括环氧树脂、乙烯基树脂、不饱和聚酯树脂、酚醛树脂中的至少一种。这些树脂材料自身具有耐久性好、抗渗透性能好、与纤维材料相容性好等特点，可作为复材的基体，为复材保护层20提供必要的抗渗性、刚度和耐久性，隔绝外部腐蚀性环境的水、氧气、氯离子，从而降低芯部钢筋10的腐蚀风险，
可选地，树脂材料的粘度为200mPa·s至1500mPa·s。粘度高于1500mPa·s的树脂会导致纤维材料浸渍不充分，进而使保护层厚度分布不均，影响复材裹层钢筋的耐腐蚀性能以及与混凝土的粘结性能。粘度小于200mPa·s的树脂流动性过大，在缠绕过程中易流失，影响保护层树脂与纤维的比例，进而影响防腐效果。
本申请实施例提供了上述复材裹层钢筋1的制造方法，如附图2所示，包括以下步骤：
(1)对钢筋的表面进行预处理，得到预处理后的钢筋。
预处理可去除钢筋10表面的锈斑、油脂、污垢及杂物，提升钢筋10与复材保护层20之间的粘结性能。
可选地，对钢筋10的表面进行预处理的方法包括喷砂、酸洗、激光、机械打磨中的至少一种。
(2)对钢筋进行夹持。
将钢筋10固定于缠绕装置的可旋转支座上，作为定长连续缠绕的芯模。
(3)将纤维材料浸渍于树脂材料中，得到浸润树脂材料后的纤维材料。
具体地，将纤维材料由纱架导入盛有树脂的浸胶槽，使纤维材料充分浸润，得到树脂浸润后的纤维材料。
(4)将树脂材料浸润后的纤维材料拉出，以张紧状态按预定的一个固定缠绕角度或缠绕角度变化连续缠绕在钢筋10表面至预定的缠绕层数，得到中间产品。
其中，本申请实施例的缠绕角度指纤维材料与钢筋10长度方向的夹角，缠绕角度取±10°至±90°之间的任意角度。缠绕层数以纤维按预先设定的一个固定缠绕角度或缠绕角度变化沿钢筋10的长度方向缠绕至完全覆盖芯部钢筋10表面为一层。复合材料的缠绕方式例如可以为+86°全程缠绕或+86°、+60°各半程缠绕。
可选地，缠绕层数可以为一层或多层。
可以理解地，缠绕层数越多，复材保护层20的厚度就越大，相应的耐冲击、耐剥离、耐渗透、防腐蚀性能就越好。但带肋钢筋的表面具有凸起的肋，相邻肋之间有一定的间隙，令钢筋10与混凝土的粘结更加牢固。若复材缠绕层数过多、复材保护层20的厚度过大，将会影响钢筋10表面肋的相对高度(即肋高与钢筋公称直径之比，反映了肋的凸起程度)以及肋间距，削弱复材裹层钢筋1与混凝土的粘结性能。因此，在实际应用中，需综合考虑缠绕层数对复材裹层钢筋1的耐冲击、耐剥离、耐渗透、防腐蚀性能及其与混凝土的粘结性能的影响，根据需求选择适合的缠绕层数。
可选地，纤维材料的缠绕层数与缠绕角度的组合包括单层单角度、单层多角度、单层变角度、多层单角度、多层多角度、多层变角度中的至少一种。例如，纤维材料以+86°的缠绕角度从钢筋10的一端起，至钢筋10的另一端止，全程缠绕至完全覆盖钢筋10表面形成单层单角度的复材保护层20；或者纤维 材料先以+86°的缠绕角度从钢筋10的一端起，至钢筋10的一半长度处改为+60°的缠绕角度继续缠绕至钢筋10的另一端止，形成+86°、+60°各半程的单层多角度复材保护层20；或者纤维材料以+10°的缠绕角度从钢筋10的一端起，随缠绕距离的增加线性增大缠绕角度并连续缠绕，至钢筋10的另一端止时缠绕角度达到+80°，形成单层变角度复材保护层20；至钢筋10的一半长度处改为+60°的缠绕角度继续缠绕至钢筋10的另一端止，形成+86°、+60°各半程的单层多角度复材保护层20；或者纤维材料先以+86°的缠绕角度全程缠绕至完全覆盖钢筋10的表面形成第一层，然后以-86°的缠绕角度反向全程缠绕至再次完全覆盖钢筋10的表面形成第二层，最终形成+86°、-86°的多层多角度复材保护层20；或者纤维材料先以+86°的缠绕角度全程缠绕至完全覆盖钢筋10的表面形成第一层，然后反向随缠绕距离的增加线性减小缠绕角度并连续缠绕，至缠绕起始端时缠绕角度达到-80°，形成多层变角度复材保护层20；
在一个较优的实施例中，当钢筋10为公称直径10mm、最大肋高约1mm的人字形肋变形钢筋时，纤维材料的缠绕层数为1-2层，缠绕层数与缠绕角度的组合为多层多角度方式。如此，复材保护层20既可以有一定的厚度为钢筋10提供足够的耐冲击、耐剥离、耐渗透、防腐蚀性能，还能最大限度的保留钢筋10的肋高和肋间距，令钢筋10与混凝土的粘结性能仍能满足工程应用的需求。
(5)将中间产品置于预定环境中进行固化，得到初产品。复材保护层20固化后形成一定的强度和刚度，从而为钢筋10提供必要的防护。
预定环境包括温度和压力环境。
可选地，固化的温度、压力环境包括常温常压、常温高压、高温高压、高温常压中的任意一个。其中，常温指室温(约25℃)，常压指1个标准大气 压(约101kPa)，高于常温、常压即高温、高压。固化环境的选取由树脂材料的类型、复材裹层钢筋1的耐久性需求等因素共同决定。
(6)根据需求对初产品进行切割，得到半成品。
根据具体工程应用的需求，对固化处理后的初产品进行定长切割，得到预定长度的半成品。
(7)端部密封，对定长切割处理后的半成品端部喷涂防水材料或包裹复材予以保护，得到成品复材裹层钢筋1。
可选地，包裹复材的方法包括湿铺、连续缠绕中的至少一种。
本申请实施例所提供的复材裹层钢筋1的制造方法，不仅适用于制造直线型复材裹层钢筋，也适用于制造非直线型复材裹层钢筋。其中，非直线型复材裹层钢筋包括但不限于U型筋、箍筋、弯起筋等。本申请实施例提供的复材裹层钢筋1的制造方法操作简便，适合工业化推广与大规模应用。
本申请实施例还提供了一种用于上述复材裹层钢筋1的现场弯折方法，如附图3所示，包括以下步骤：
(1)复材裹层钢筋弯折，根据锚固或搭接现场应用需求，对所述复材裹层钢筋进行至少一次弯折。
对复材裹层钢筋1进行一次或多次弯折,以满足施工现场因钢筋锚固、搭接等工序对复材裹层钢筋形状的要求。
(2)复材裹层钢筋弯折影响区域保护，对复材裹层钢筋弯折影响区域采取适当方法予以保护，以保证弯折影响区域的耐久性不低于非影响区域。
对复材保护层20已固化的复材裹层钢筋1进行弯折操作，会导致弯折影响区域内的复材保护层20出现微裂缝等损伤，从而对复材保护层20的耐冲击、耐剥离、耐渗透、防腐蚀性能带来不利的影响。因此，本申请实施例提供的现 场弯折方法通过在复材裹层钢筋的弯折影响区域外表面再次包裹复材，以保证弯折影响区域的耐冲击、耐剥离、耐渗透、防腐蚀性能不低于非影响区域。
可选地，对复材裹层钢筋弯折影响区域的保护方法为包裹复材。
可选地，对复材裹层钢筋1的弯折影响区域包裹复材的方法包括湿铺、连续缠绕中的至少一种。
下面借助三个具体的实施例，对本申请作进一步地说明。
实施例1
本实施例展示了一种连续缠绕玻璃纤维增强树脂基复材裹层月牙形肋钢筋(简称：玻纤复材裹层月牙形肋钢筋)及其制造方法，如图4所示。该玻纤复材裹层月牙形肋钢筋1由芯部的月牙形肋钢筋10和包裹在钢筋表面的玻纤复材保护层20两部分构成。
其中，钢筋10为总长1250mm、公称直径10mm、屈服强度567MPa、抗拉强度636MPa、具有月牙形肋的HRB500级商用标准化变形钢筋；纤维材料为线密度为1200Tex的硅烷型浸润剂处理玻璃纤维；树脂材料为粘度500mPa·s、抗拉强度不低于79MPa、玻璃转化温度不低于120℃的环氧树脂。
本实施例展示了上述玻纤复材裹层月牙形肋钢筋的制造方法，包括以下步骤：
(1)采用喷砂工艺对钢筋10表面进行预处理，去除锈斑、油脂及污垢，得到预处理后的钢筋。
(2)将钢筋固定于缠绕装置的可旋转夹具上，作为定长连续缠绕的芯模。
(3)将玻璃纤维材料由纱架导入盛有环氧树脂的浸胶槽，使玻璃纤维材料充分浸润，得到树脂浸润后的玻璃纤维材料。
(4)将树脂浸润后的玻璃纤维材料拉出浸胶槽，以张紧状态先后按+86° 和-86°的缠绕角度在钢筋表面各缠绕1层,总层数2层，得到中间产品。
(5)将复材裹层钢筋置于105℃常压环境进行高温常压固化15分钟，得到初产品。
(6)对初产品进行切割处理，切除两端受夹持区域，每端切除25mm，得到半成品。
(7)对总长1200mm、切割处理后的初产品两端分别喷涂快干型环氧树脂基防水涂料予以保护，得到成品玻纤复材裹层月牙形肋钢筋1。
在本实施例中，所选的月牙形肋变形钢筋为土木工程领域钢筋混凝土结构中应用最广泛的钢筋，因此，本实施例具有较普遍的代表意义。本实施例所采用的玻纤复材外包保护层，其本身具备优异的耐久性能，将能够很好地阻断氧气、水、氯离子与钢筋发生接触，从而达到防腐的目的；所采用环氧树脂的粘度较低(为500mPa·s)，其目的是为了尽可能保持钢筋原有的肋外形，以免影响复材裹层钢筋与混凝土的粘结性能；所采用的固化条件为105℃高温常压固化，能够有效缩短生产时间、提高玻璃纤维树脂基复材保护层的耐久性。
实施例2
本实施例展示了一种连续缠绕玻璃纤维增强树脂基复材裹层螺旋肋钢筋(简称：玻纤复材裹层螺旋形肋钢筋)及其制造方法，如图5所示。该玻纤复材裹层螺旋形肋钢筋1由芯部的螺旋形肋钢筋10和包裹在钢筋表面的玻纤复材保护层20两部分构成。
其中，钢筋10为总长1250mm、公称直径15mm、屈服强度不小于980MPa、抗拉强度不小于1120MPa、极限延伸率10％、具有螺旋形肋的PSB930级商用标准化精轧螺纹钢筋；纤维材料为线密度为1200Tex的硅烷型浸润剂处理玻璃纤维；树脂材料为粘度500mPa·s、抗拉强度不低于79MPa、玻璃转化温度不 低于120℃的环氧树脂。
本实施例展示了上述玻纤复材裹层月牙形肋钢筋的制造方法，包括以下步骤：
(1)采用酸洗工艺对钢筋10的表面进行预处理，去除锈斑、油脂及污垢，得到预处理后的钢筋。
(2)将钢筋固定于缠绕装置的可旋转夹具上，作为定长连续缠绕的芯模。
(3)将玻璃纤维材料由纱架导入盛有环氧树脂的浸胶槽，使玻璃纤维材料充分浸润，得到树脂浸润后的玻璃纤维材料。
(4)将步骤S03所述浸润后的玻璃纤维材料拉出浸胶槽，以张紧状态先后按+86°和-86°的缠绕角度在钢筋表面各缠绕1层，总层数2层，得到中间产品。
(5)将复材裹层钢筋置于105℃常压环境进行高温常压固化15分钟，得到初产品。
(6)对复材裹层钢筋进行切割处理，切除两端受夹持区域，每端切除25mm，得到半成品。
(7)对总长1200mm、切割处理后的初产品两端分别喷涂快干型环氧树脂基防水涂料予以保护，得到成品玻纤复材裹层螺旋形肋钢筋1。
在本实施例中，所选的螺旋形肋变形钢筋在土木工程领域常用于预应力结构以及地下结构的锚杆。该螺旋形肋变形钢筋与实例一中的月牙形肋普通钢筋相比将长时间承受更高的恒载应力幅，其工作环境将进一步导致其更易腐蚀，因此本实例采用两层玻纤复材缠绕，同时采用更高的固化温度及更长的固化时间，以达到更好的防腐效果。
实施例3
本实施例展示了一种多层多角度连续缠绕玻璃纤维增强树脂基复材裹层钢筋(简称：多层多角度玻纤复材裹层钢筋)及其制造方法，如图6所示。该多层多角度玻纤复材裹层钢筋1由芯部的钢筋10和包裹在钢筋表面的玻纤复材保护层20两部分构成。
其中，钢筋10为总长1250mm、公称直径12mm、屈服强度约550MPa、抗拉强度约650MPa、采用切削工艺定制的非标准螺旋形肋变形钢筋；(2)纤维材料为线密度为1200Tex的硅烷型浸润剂处理玻璃纤维；(3)树脂材料为粘度500mPa·s、抗拉强度不低于79MPa、玻璃转化温度不低于120℃的环氧树脂。
本实施例展示了上述玻纤复材裹层月牙形肋钢筋的制造方法,包括以下步骤：
(1)采用喷砂工艺对钢筋1的表面进行预处理，去除锈斑、油脂及污垢，得到预处理后的钢筋。
(2)将钢筋固定于缠绕装置的可旋转夹具上，作为定长连续缠绕的芯模。
(3)将玻璃纤维材料由纱架导入盛有环氧树脂的浸胶槽，使玻璃纤维材料充分浸润，得到树脂浸润后的玻璃纤维材料。
(4)将步骤S03所述浸润后的玻璃纤维材料拉出浸胶槽，保持张紧状态先后以+30°和-30°各缠绕1层；改变缠绕角度，先后以+86°和-86°各缠绕1层，使总层数达到4层，得到中间产品。
(5)将中间产品置于105℃常压环境进行高温常压固化15分钟，得到初产品。
(6)对初产品进行切割处理，切除初产品两端的受夹持区域，每端切除25mm，得到半成品。
(7)对总长1200mm、切割处理后的初产品两端包裹复材予以保护，得到成品多层多角度玻纤复材裹层钢筋1。
本实施例旨在示范一种与实施例一、二相比具有更强耐腐蚀、耐冲击性能的复材裹层钢筋及其制造方法。在本实施例中，复材裹层钢筋的复材保护层先后采用+30°、-30°、+86°、-86°的角度各缠绕1层，使复材保护层的总层数达到了4层。其中，±30°表明纤维方向比较接近平行钢筋长度方向,而±86°表明纤维方向接近垂直于钢筋长度方向。两者结合能够在两个接近正交的方向上增强树脂基体，使复材保护层具有更强的机械性能，从而为芯部的钢筋提供更好的保护。此外，所选螺旋形肋变形钢筋为定制的非标准变形钢，其肋外形相比公称直径相近的标准钢筋具有更高的肋和更大的相对肋面积，能够在多层复材包裹的情况下保证与混凝土的粘结性能。
以上所述仅为本申请的较佳案例，并不用以限制本申请，凡在本申请的精神和原则之内所作的任何修改、等同替换和改进等，均应包含在本申请的保护范围之内。

Claims (12)

  1. 一种复材裹层钢筋，其特征在于：包括芯部的钢筋和包裹于所述钢筋表面的复材保护层。
  2. 如权利要求1所述的复材裹层钢筋，其特征在于：所述钢筋为光圆钢筋；或者，所述钢筋为商业标准化变形钢筋，所述商业标准化变形钢筋包括带人字形、月牙形、十字形、竹节形、螺旋形肋中的任意一种；或者，所述钢筋为根据应用需求采用热轧、切削或增材制造方法定制的非标准变形钢筋；或者，所述钢筋为耐腐蚀钢筋，所述耐腐蚀钢筋包括环氧涂层钢筋、热浸锌钢筋、不锈钢筋中的任意一种。
  3. 如权利要求1所述的复材裹层钢筋，其特征在于：所述复材保护层采用纤维材料和树脂材料，经连续缠绕成形。
  4. 如权利要求3所述的复材裹层钢筋，其特征在于：所述纤维材料包括玻璃纤维、玄武岩纤维、芳纶纤维中的至少一种。
  5. 如权利要求3所述的复材裹层钢筋，其特征在于：所述树脂材料包括环氧树脂、乙烯基树脂、不饱和聚酯树脂、酚醛树脂中的至少一种；和/或，
    所述树脂材料的粘度介于200mPa·s至1500mPa·s之间。
  6. 一种如权利要求1至5任一项所述的复材裹层钢筋的制造方法，其特征在于：包括以下步骤：
    (1)对钢筋的表面进行预处理，得到预处理后的钢筋；
    (2)对所述钢筋进行夹持；
    (3)将纤维材料浸渍于树脂材料中，得到浸润所述树脂材料后的所述纤维材料；
    (4)将浸润所述树脂材料后的所述纤维材料拉出，以张紧状态沿所述钢 筋的长度方向按预定的一个固定缠绕角度或缠绕角度变化连续缠绕在钢筋表面至预定缠绕层数，得到中间产品；
    (5)将所述中间产品置于预定环境中进行固化，得到初产品；
    (6)根据需求对所述初产品进行切割，得到半成品；
    (7)端部密封，对所述半成品的切割端喷涂防水材料或包裹复材予以保护，得到复材裹层钢筋。
  7. 如权利要求6所述的复材裹层钢筋的制造方法，其特征在于：所述端部密封所采用的包裹复材的方法包括湿铺、连续缠绕中的至少一种。
  8. 如权利要求6所述的复材裹层钢筋的制造方法，其特征在于：所述复材裹层钢筋为直线型复材裹层钢筋或非直线型复材裹层钢筋；和/或，
    所述非直线型钢筋的种类包括U型筋、箍筋、弯起筋中的任意一种。
  9. 如权利要求6所述的复材裹层钢筋的制造方法，其特征在于，所述缠绕角度为±10°至±90°之间的任意角度；和/或，
    所述缠绕层数与缠绕角度的组合包括单层单角度、单层多角度、单层变角度、多层单角度、多层多角度、多层变角度中的至少一种。
  10. 一种复材裹层钢筋的现场弯折方法，用于现场弯折权利要求1至5任一项所述的复材裹层钢筋，以满足施工现场对复材裹层钢筋形状的要求，其特征在于：所述现场弯折方法包括以下步骤：
    (1)根据现场对钢筋形状、尺寸的需求，对所述复材裹层钢筋进行至少一次弯折；
    (2)对所述复材裹层钢筋弯折影响区域采取适当方法予以保护，以保证弯折影响区域的耐久性不低于非影响区域。
  11. 如权利要求10所述的复材裹层钢筋的现场弯折方法，其特征在于：对 所述复材裹层钢筋弯折影响区域的保护方法包括湿铺、连续缠绕复材中的至少一种。
  12. 如权利要求1至5任一项所述的复材裹层钢筋在腐蚀环境中的基础设施建设、采用海水和海砂直接拌合的混凝土结构以及海上岛礁建设中的应用。
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