共振碎石化技術(shù)的課件

1、Rubblization by Resonant Breaker共振碎石化What is Rubblization ？何謂碎裂技術(shù)？Process of fracturing PCC pavement into Angular Interlocked pieces. Highway pieces shall be from sand size on top up to 8 inches (20 cm) on the bottom. Airport sizes shall be up to 1.25 times the thickness of the slab. The steel shall

2、 be debonded from all the pieces of broken pavement.碎裂技術(shù)是指將舊的水泥混凝土路面一次碎化為緊密嵌鎖的礫石；其中公路的礫石尺寸從頂部的沙粒大小至底部的8英寸（20厘米）礫徑；機(jī)場(chǎng)的尺寸則高至路面厚度的1.25倍；并且原有鋼筋完全從破碎道路分離的技術(shù)。Why Rubblization?為何碎化？Full-depth Replacement全深度更換Most expensive最昂貴的方法Time consuming工期長(zhǎng)Disposal of rubbles鑿除的廢料處理難以處理Costly solution, seldom adopted

3、in US代價(jià)太大，美國(guó)已經(jīng)很少采用Overlay of asphalt or PCC on top of existing pavement在舊路面上覆蓋瀝青或者水泥混凝土Economic and popular solution 比較經(jīng)濟(jì)適用，很受歡迎Two Approaches for Highway Rehabilitation：水泥混凝土道路改造兩類辦法：But 但是Why Rubblization?為何碎化？World-class problem in PCC rehabilitation水泥混凝土路面改造的世界級(jí)難題反射裂紋！Reflective Cracking!2022/8/

4、125為什么不能直接加鋪？反射裂紋 層間結(jié)合不緊，導(dǎo)致表層脫層水滲透導(dǎo)致材料流失底基層基層原有的混凝土板塊瀝青加鋪層此方法在美國(guó)已經(jīng)很少采用國(guó)內(nèi)很多項(xiàng)目也表明此方法的臨時(shí)性和局限性每層要比下層有更高的強(qiáng)度，這樣才能避免反射裂紋 Why Rubblization?為何碎石化？彈性層狀體系理論 Elastic Layer Theory Material modulus (En) should increase with subsequent pavement layers in order to prevent reflective cracking 路基各層彈性模量要上強(qiáng)下弱，方可避免反射裂紋的

5、產(chǎn)生Subgrade 底基層Base 路基層Concrete Layer 混凝土層HMA 熱混合瀝青層E1E2E1E3E2E4E3Why Rubblization?為何碎石化？The modulus of PCC is higher,水泥砼的彈性模量大于瀝青， the slab needs to be broken so that it can serve as an elastic base to prevent reflective cracking因此在攤鋪瀝青前，需將原來(lái)的水泥砼碎化，令其變?yōu)槿嵝曰鶎?，方可避免上面瀝青層產(chǎn)生反射裂紋！E水泥砼E瀝青Why Rubblization?為何

6、碎石化？The purpose of rubblization is to turn the rigid PCC slab into a flexible layer through fracturing it into pieces可見(jiàn)，碎化的目的就是通過(guò)破碎，將水泥砼由剛性層轉(zhuǎn)化為柔性層 Will PCC slab be turned into a good base once it is broken?問(wèn)題是，水泥砼是否一經(jīng)破碎，就是合格的柔性路基?Requirements that Rubblization Must Meet什么是合格的碎石化工藝 ？If the rubbles ar

7、e too large, or sizes not consistent, reflective cracking will still develop 如果粒石尺寸太大，或者大小不均，反射裂紋仍然會(huì)產(chǎn)生If the rubbles are too small, or not interlocked with each other, the whole rubblized structure will fail如果破碎的尺寸過(guò)小，或者相互沒(méi)有嵌鎖，整個(gè)破碎后的水泥砼層就會(huì)因缺乏強(qiáng)度而失效All reinforcement must be totally de-bonded to prevent

8、 reflective cracking如果水泥砼內(nèi)有鋼筋，則水泥砼和鋼筋必須完全脫離Rubblization is NOT just slab destruction！ 碎石化不等于對(duì)水泥砼的簡(jiǎn)單破碎！Probability of Failure失效概率 100 0320 cm18 inch反射裂紋Reflective Cracking結(jié)構(gòu)失效Structural Failure理想碎石尺寸范圍Target Zone低 Low高High小 Small大 Large碎石名義尺寸 Nominal Frag. Size水泥混凝土模數(shù) PCC modulusRequirements that Rub

9、blization Must Meet什么是合格的碎石化工藝 ？Requirements that Rubblization Must Meet什么是合格的碎石化工藝 ？Ideal range of the rubbles should be 320 cmResonant rubblization can prevent both structural failure and reflective cracking:Microprocessor impact adjustment, consistency in particle sizeThorough de-bonding of steel

10、 from the slabs最佳碎石尺寸應(yīng)該在320cm間共振碎化確保既無(wú)反射裂紋，又避免結(jié)構(gòu)失效: 電腦瞬時(shí)調(diào)節(jié)以便控制碎石尺寸鋼筋完全同混凝土脫離3cm20cmIdeal Size最佳尺寸Requirements For A Good Rubblization合格的碎石化應(yīng)該滿足的要求：Rubble size ranges from 3 20 cm to avoid both Reflective Cracking and Structural Failure 碎石尺寸在320厘米之間，方可既避免反射裂紋、又防止結(jié)構(gòu)失效No Rough Riding/Faulting 破碎后沒(méi)有斷層，保

11、證行駛的舒適度Prevent Moisture Damage 防止水害Maintains integrity of base 保持路基的完好無(wú)損Utilities underneath are NOT damaged after rubblization 碎石后保持路基及路基下設(shè)施完好無(wú)損Present Alkali Silica Reaction (ASR) stops 防止混凝土內(nèi)酸（硅）堿反應(yīng)Resonant Rubblizing Can!共振碎化技術(shù)能夠滿足以上所有要求！緊密嵌鎖的結(jié)構(gòu)均勻的礫石尺寸絕不傷害地基消除酸堿反應(yīng)Provide properly fractured slabs

12、 with tightly interlocked piecesProduce consistent rubble sizeNo damage to basesMigration of ASR is eliminatedResonant Beam 振動(dòng)梁工作原理Resonant beam vibrates at 44 Hz 振動(dòng)梁以44赫茲的速度振動(dòng)Amplitude is 2 cm振幅只有2公分左右Two supporting points are still兩個(gè)支點(diǎn)靜止Sensor sense the pavement conditions and transmit to microcom

13、puter錘頭傳感器感應(yīng)路面狀況，并傳遞給電腦Microcomputer will adjust the frequency accordingly, thus keeping the rubble size consistent電腦自動(dòng)調(diào)整振動(dòng)頻率，改變力度，從而控制碎石尺寸保持均勻2 cmBreaking shoe破碎頭Resonant beam共振梁Counter weights配重塊Flotation tires加寬輪胎Principle Components of Resonant Pavement Breaker共振破碎機(jī)的主要組件How Does Resonant Rubbliz

14、ing Work共振碎化工作原理Specially made resonant beam generate harmonic wave between 42 46 Hz 特制振動(dòng)梁在偏心軸的驅(qū)動(dòng)下，在4246赫茲頻率下產(chǎn)生振動(dòng)諧波Amplitude at supporting point and counter weight point is zero 支點(diǎn)和配重點(diǎn)振幅為零Breaking shoe strikes the surface of the concrete with high frequency and low amplitude impacts 破碎頭以高頻低幅（2厘米）敲擊混

15、凝土路面 Factures generate under shear forces and expand at certain pattern until they reach the edge of the material 混凝土內(nèi)部因剪切力而產(chǎn)生裂紋，并隨著振動(dòng)迅速有規(guī)律地?cái)U(kuò)展，直到材料邊界No damage to the base due to low impact force and dissipation of the energy at the boundary of slabs 由于沖擊力很小，且裂紋只擴(kuò)展到邊界，所以對(duì)基層沒(méi)有任何損害高頻 (44Hz)低幅 (2 cm)混凝土

16、完全碎裂路基完好無(wú)損碎塊相互嵌鎖使承載均勻分布混凝土層沒(méi)有錯(cuò)位，不會(huì)壓入路基混凝土碎石層底部平整、整體承載能力巨大How Does Resonant Rubblizing Work共振碎石化工作原理2022/8/1218基層空陷基層的完整性遭到破壞承載力隨機(jī)削弱高幅（24-42”）高壓沖擊錘高幅低頻沖擊錘的破碎效果2022/8/1219普通高壓沖擊錘共振碎石化受力不能分散形成壓轍受力均勻分布個(gè)別點(diǎn)集中受力造成底基損壞缺少排水設(shè)施造成底基存水整個(gè)路面得到支撐不存在車(chē)轍碎石效果比較2022/8/1220破碎后(碾壓前）表面比原路面高0.6cm而采用多錘式破碎方式則破碎表面下沉5厘米2022/8/1

17、221只有共振碎石化能夠滿足以上所有要求！高頻低幅破碎錘板塊完全破碎，尺寸一致緊密?chē)Ш系乃槭托毕蛄鸭y鋼筋完全分離 (防止反射裂紋）破碎錘不會(huì)對(duì)基層產(chǎn)生任何影響，保持基層板結(jié)完好破碎力度和碎石尺寸能夠通過(guò)電腦自動(dòng)調(diào)整 Relief Trench 35至 40Angular Fracture Pattern for Greater Modulus斜向的嵌鎖結(jié)構(gòu)保證更大的路面模量Fracture Pattern RB500用RB500破碎的破裂形狀Cement Stabilized Base水泥穩(wěn)定基層 Memphis International Airport，15” Concrete Stee

18、l DebondedMemphis 國(guó)際機(jī)場(chǎng), 15” 鋼筋分離現(xiàn)場(chǎng)Steel Must Be De-bonded鋼筋必須完全分離Why Other Slab Destruction Methods Not Good Enough?為什么其他水泥砼破碎方法不夠理想？其他方法均采用自上而下的，強(qiáng)大的外部物理沖擊力，造成：破碎不均勻，無(wú)法避免反射裂紋路基破壞路基下面設(shè)施的傷害噪音擾民，周邊建筑物震動(dòng)All other methods apply low frequency, high amplitude and heavy impact to break the slabs apart, resu

19、lting in:Large and inconsistent rubbles leading to reflective crackingDamage of sub baseDamage of facilities underneath or nearbyNoises and impact will disturb residents and buildings nearbyResonant Rubblization is Your Best Solution共振碎裂技術(shù)是水泥砼路面改造的最佳方案！Eliminate possibility of reflective crackingKee

20、p integrity of the baseNo harm to the utilities underneathNo disturbance to neighborhoodThe loudest noise is from the diesel engine!No Rough Riding/Faulting Prevent Moisture Damage Present Alkali Silica Reaction (ASR) stops No need for another rehabilitation for many years to come杜絕反射裂紋絕不傷害路基碎裂后保持路基

21、及路基下設(shè)施完好無(wú)損噪音低、不擾民工作時(shí)最大的噪音來(lái)自柴油發(fā)動(dòng)機(jī)！沒(méi)有斷層，保證行駛的舒適度防止潮濕水氣的侵害防止混凝土內(nèi)酸（硅）堿反應(yīng)改造后很多年內(nèi)都無(wú)須再次修復(fù)Rubblization is gaining greater and greater market in US and the World在美國(guó)及全球的市場(chǎng)份額越來(lái)越大Rubblization Projects in US碎裂技術(shù)在美國(guó)的應(yīng)用五年前Rubblization Projects碎裂技術(shù)現(xiàn)在Jacksonville NAS Taxiway “A” Rubblized 1997, Picture in 2003 Jacks

22、onville NAS 滑道 “A” 1997年用碎石化技術(shù)建設(shè), 攝于2003年2022/8/1230Wright Patterson AFB 26- Inch PCC Wright Patterson AFB 26英寸水泥混凝土2022/8/1231Jax NAS 6” 罩面 C5s, P3Vs, 用于戰(zhàn)斗機(jī)，民用客機(jī)Historical Timeline歷史進(jìn)程1986- John Brizzell, NYDOT Materials Engineer, first used resonant breaker for “Rubblizing”1986- John Brizzell, 紐約州

23、運(yùn)輸部的工程師，首次使用Resonant破碎機(jī)械進(jìn)行道路破碎1991- PC Law Engineering study determines “Rubblizing” best method to rehabilitate PCC pavement.1991- PC Law Engineering 通過(guò)研究確認(rèn)“碎化”是進(jìn)行水泥混凝土路面修復(fù)的最好方法Historical Timeline歷史進(jìn)程Founded in 1986, as a contractor specialized in rubblization 成立于1986年，是從事碎石化工程承包商Started with buyin

24、g resonant breaking machines and now own all resonant machines in the market 26 units 公司創(chuàng)建之初開(kāi)始購(gòu)買(mǎi)別人制造的共振破碎機(jī)，最終擁有了市場(chǎng)中全部26臺(tái)設(shè)備RMI gradually started renovation and building its own machines 繼而，RMI開(kāi)始進(jìn)行技術(shù)改造，于兩年前推出自己制造的性能和穩(wěn)定性大大提高的設(shè)備Rubblizing Thickness of PCC碎石化技術(shù)的破碎厚度10 inch25 cm12 inch30 cm26 inch66 cm051

25、0152025301986-19941995-20012002-CurrentIncreases in Productivity生產(chǎn)率的增長(zhǎng)02,0004,0006,0008,00010,000Year19871989199119931995199719992001YearSquare Yards / DayAchievements of RMIRMI公司業(yè)績(jī)The only resonant rubblization contractor in the World全世界唯一的共振碎裂承包商Rubblized concrete of 66 cm破碎深度達(dá)到66厘米Largest Interst

26、ate project ever in the United States (276 miles of four-lane highway)美國(guó)迄今最大的州際公路改造項(xiàng)目（440公里/4車(chē)道）Successfully completed rubblization projects in Canada, Russia, Belarus and China在加拿大,俄羅斯，白俄羅斯和中國(guó)等國(guó)家成功開(kāi)展碎化工程Successfully completed every project we started所有工程全部成功When To Rubblize ?什么時(shí)候需要碎化When More Than

27、12% to 15% of Slabs Require CPR當(dāng)多于12%到15%的道路需要混凝土路面修復(fù)(CPR)時(shí)Cost Over Runs of 50% or Greater Are Typical on CPR當(dāng)50%以上的建設(shè)成本用于CPR時(shí)Cost of Rubblization Favored on 15 Year Design Life當(dāng)期望路面改造的設(shè)計(jì)使用壽命在15年以上時(shí)(CPR Concrete Pavement Rehabilitation, i.e., slab or joint replacement, jacking, grouting, grinding,

28、etc.)(CPR 混凝土路面修復(fù)，如：更換水泥板或接縫，破碎，灌漿，打磨等)TO RUBBLIZE, YOU MUST HAVE 4 ELEMENTS:應(yīng)用碎石化技術(shù) 之 必備四要素A Properly Designed Edge Drain System良好的側(cè)排水系統(tǒng)A Resonant Fractured, Interlocked Slab以共振破碎機(jī)械碎裂且緊密?chē)Ш系乃喟鍓KA Properly Rolled Surface路面合理壓實(shí)A Properly Designed Overlay設(shè)計(jì)恰當(dāng)?shù)拿鎸痈采wConstruction Process 施工程序Install edge d

29、rain system two weeks prior to rubblizationRubblize the PCC pavementRoll 2 coverages with 10-ton vibratory rollerUse high frequency, low amplitude rollerUse water to aid rolling processClose to traffic until first lift of HMA is placed碎石化前兩周安裝側(cè)排水系統(tǒng)對(duì)路面實(shí)行共振碎化施工用10噸振動(dòng)壓路機(jī)碾壓2遍用高頻低幅壓路機(jī)壓實(shí)少量灑水配合壓實(shí) 瀝青攤鋪前道路封閉

30、 Finished Surface After Rolling 碾壓后的路面Traffic Control 交通管制Cross Overs Head to Head (Safest and Most Productive) 交叉作業(yè)（安全而高效）Single lane construction zone (Good Shoulders Required, Lane Overlap Method) 單車(chē)道施工（需要堅(jiān)實(shí)的路肩，車(chē)道合并）Both have benefits 交通及施工均不受影響Three Most Damaging Things to a Highway公路的三大殺手Water水

31、Water水WATER水Sub-grade 底基層Permeable Zone 可滲透碎化層Rubblized PCC 不可滲透碎化層57號(hào)石礫過(guò)濾層2”dense-graded2” 高密度材料# 57 Stone# 57 石料 Filter Fabric 過(guò)濾材料Base Course 基層Shoulder Area路肩Rubblization Side Drainage 碎化施工的側(cè)排水系統(tǒng)Permeable/Crack-relief 可滲透/消除裂紋Semi-solid/Interlocked半封閉/嚙合3 % Slope Outlet3 % 傾斜排管Fabric outlet可透水排管Integral Curb & Gutter Rubblization Side Drainage路緣石盲溝一體化排水系統(tǒng) Full Depth Saw Cut全深度切割Backfill回填Permeable/Crack-relief 滲入/防止裂紋Semi-solid/Interlocked半固態(tài)/嚙合Bas