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CN-122013664-A - Preparation method of light high-bearing-capacity composite bridge deck and bearing capacity calculation method thereof

CN122013664ACN 122013664 ACN122013664 ACN 122013664ACN-122013664-A

Abstract

The invention relates to a light high-strength metal-FRP composite bridge deck and a bearing capacity calculation method thereof. The bridge deck plate consists of an edge-covered metal plate and an FRP sandwich structure, wherein the FRP sandwich is formed by adopting a pultrusion process and comprises an epoxy hyperbolic web plate and a panel, and the metal plate and the FRP are connected by adhesive riveting through an epoxy adhesive layer and a self-plugging rivet so as to realize reliable connection and buffering collaborative stress. The adhesive-rivet hybrid system can effectively inhibit interfacial cracking and peeling under the repeated heavy load action, and remarkably improves the integral structure and durability. Through the systematic optimization of structural configuration, connection form and key parameters, the bridge deck slab has the comprehensive advantages of light weight, high strength, bending resistance, shearing resistance, fatigue resistance, skid resistance, wear resistance, corrosion resistance and the like, the ultimate bearing capacity can reach 30 tons, the weight is less than 1/3 of the same steel bridge deck slab, the bridge deck slab is suitable for heavy load and strong dynamic load working conditions, the assembly construction and the quick replacement are convenient, and the efficient replacement of the traditional bridge deck system is realized.

Inventors

  • YANG CAIQIAN
  • Chen Shengge
  • ZHANG LIYE
  • GUO SHUYI

Assignees

  • 江苏梦联桥科技有限公司
  • 江苏中云筑智慧运维研究院有限公司

Dates

Publication Date
20260512
Application Date
20251230

Claims (9)

  1. 1. The preparation method of the light high-bearing-capacity composite bridge deck and the bearing capacity calculation method thereof are characterized by comprising the following steps: The FRP sandwich structure (11) is integrally formed by a pultrusion process, the FRP sandwich structure (11) comprises an epoxy hyperbolic web (6) and a rectangular edge web (4), an FRP upper panel (2) positioned above the epoxy hyperbolic web (6) and an FRP lower panel (5) positioned below the epoxy hyperbolic web (6), epoxy structural adhesive (3) is uniformly coated on the contact surface of the hemming metal plate (1) and the FRP upper panel (2) and used for bonding the hemming metal plate (1) and the FRP upper panel and buffering bearing capacity, and blind rivets (13) penetrate through the hemming metal plate (1) and the FRP upper panel (2) and are used for riveting the hemming metal plate and the FRP upper panel to form adhesive-rivet fusion connection.
  2. 2. The preparation method of the light high-bearing composite bridge deck and the bearing capacity calculation method thereof according to claim 1, wherein the FRP upper deck (2) and the FRP lower deck (5) are formed by combining fibers and epoxy resin, wherein the fiber content is 65% -78%, the composite bridge deck is prepared by a unidirectional pultrusion process, the fibers are crosswise paved on the FRP upper deck (2) and the FRP lower deck (5) along the longitudinal direction 0 DEG (+/-45 DEG) and the transverse direction 90 DEG so as to simultaneously enhance the longitudinal and transverse comprehensive tensile strength and modulus, the FRP upper deck (2) and the FRP lower deck (5) are one or more of aramid fibers, basalt fibers, carbon fibers or glass fibers, and foam cores (10), such as polyurethane foam cores, are filled between the FRP upper deck (2) and the FRP lower deck (5) for enhancing the local bearing capacity and the deformation resistance.
  3. 3. The method for preparing a lightweight high-bearing composite bridge deck and calculating the bearing capacity thereof according to claims 1-2, wherein the shape of the epoxy hyperbolic web is expressed by adopting the hyperbolic fiber web equation: wherein a is the real half-axis length of the hyperbolic equation, B is the virtual half-axis length, B is the web thickness, and H is the web height. When the cavity of the FRP bridge deck is filled with polyurethane foam cores, the height-thickness ratio of the web plates can be improved by about 10 percent, and the stress concentration effect of the connecting parts of the upper panel and the lower panel and the web plates can be obviously reduced.
  4. 4. The preparation method of the light high-bearing-capacity composite bridge deck and the bearing capacity calculation method thereof according to claims 1-3 are characterized in that the coating thickness of the epoxy structural adhesive (3) is 0.1-1.0 mm, the blind rivets (13) are uniformly distributed along the connecting surface of the edge-covered metal plate (1) and the FRP upper panel (2) in a plum blossom shape, and the riveting sequence is sequentially driven from the middle part to the two sides.
  5. 5. The preparation method of the light high-bearing composite bridge deck and the bearing capacity calculation method thereof according to claims 1-4 are characterized in that assembly holes are formed in two sides of the end portion of the edge-covered metal plate (1), a metal sleeve (9) is arranged at an opening of the edge-covered metal plate (1) through welding, an end cushion block (8) is arranged at the lower end of the metal sleeve (9), the cushion block is respectively bonded with the FRP upper panel (2) and the FRP lower panel (5) through epoxy structural adhesive so as to buffer load, reduce joint fatigue and prevent bolt loosening, and the high-strength bolt (7) is used for fixing the composite bridge deck to a bridge structure through the metal sleeve (9).
  6. 6. The method for preparing the light high-bearing composite bridge deck and calculating the bearing capacity thereof according to claims 1-5, wherein the bottom of the FRP lower deck (5) is provided with braces (14), and the inner sides of the grooves of the metal braces (14) are uniformly coated with epoxy structural adhesive and adhered to the FRP lower deck (5) and tightly connected with the side edges of the edge-covered metal plates (1) so as to enhance the transverse rigidity and the deformation resistance of the bridge deck.
  7. 7. A method for preparing a lightweight high-bearing composite bridge deck and calculating the bearing capacity thereof according to claims 1-6, wherein a model and a method for calculating equivalent flexural rigidity D b and shear rigidity D s of a metal-FRP composite bridge deck are provided, the flexural rigidity (D b ) and the shear rigidity (D s ) of the cross section centering (y) axis are: D b ＝E x,S I y,S +E x,A I y,A +E x,G I y,G D s＝ G xz,S A S +G xz,A A A +kG xz,G A G k=A w /A G Wherein P is concentrated load, E x,S ,E x,A and E x,G are equivalent elastic moduli of the metal plate, the structural adhesive and the FRP plate in the axial direction respectively, and I y is the section moment of inertia of each part to the y axis. G xz is the shear modulus, k is the shear coefficient of the section, A w is the web portion area of the FRP plate, and A is the total area of the section of the FRP plate.
  8. 8. The method for preparing a lightweight high-bearing composite bridge deck and calculating the bearing capacity thereof according to claims 1-7, wherein a bending ultimate bearing capacity equivalent model for calculating a metal-FRP composite bridge deck and a calculating method thereof are provided: M u ＝f S,u W S +f G,u W G Wherein M u is the bending ultimate bearing capacity, f S,u and f G,u are the yield strength of the metal plate and the design strength of the FRP plate respectively, and W S and W G are the cross section resisting moment of the metal plate and the GFRP plate.
  9. 9. The method for preparing the light high-bearing composite bridge deck and calculating the bearing capacity thereof according to claims 1-6, wherein the preparation process is characterized by comprising the following steps: S1, forming an FRP plate, namely placing the fiber on a creel, continuously drawing the fiber to a bundling device through a drawing device, carrying out resin infiltration on the bundling device, then carrying out extrusion forming through a die, carrying out curing forming at a high temperature of 100-150 ℃ after extrusion forming, and finally cutting according to the FRP size corresponding to the composite bridge deck. S2, surface treatment, namely, removing greasy dirt on the surface of the edge-covered metal plate (1) by using a solvent such as dimethylbenzene, alcohol or acetone, removing welding slag and burrs of welding seams and other welding points, ensuring smooth and flat surfaces, performing sand blasting on the edge-covered metal plate (1) to reach the Sa2.5-level rust removal standard, performing sand blasting on the part which cannot be processed by sand blasting by using metal sand or quartz sand, manually polishing the part by using an electric tool to reach the St 3-level standard, and priming to improve the adhesiveness and rust resistance, and finally, cleaning the surface of the edge-covered metal plate (1) by using oil-free and anhydrous compressed air to remove residual dirt. S3, performing surface treatment on the FRP sandwich structure (11), wherein the surface of the FRP is subjected to flattening treatment, the flatness is controlled within a range of +/-0.3 mm, the straight line perpendicularity is controlled within a range of +/-0.2 degrees, then, the surface of the FRP sandwich structure (11) is subjected to surface sand blasting treatment, the interface strength is enhanced, the tensile strength, bending resistance and shearing strength of the FRP plate are not affected, and then, the surface of the FRP sandwich structure (11) is wiped by a solvent, so that a release agent and greasy dirt are removed, and the cleanness of an adhesive surface is ensured. S4, assembling and positioning, namely firstly, combining the edge-covered metal plate (1) with the FRP sandwich structure (11) to ensure accurate matching of the positions of the holes, then, punching holes on the edge-covered metal plate (1) and the FRP sandwich structure (11) to ensure accurate positions of the holes, and after the holes are punched, chamfering the holes by 45 degrees to ensure the mounting accuracy and avoid stress concentration; S5 mounting of metal gasket (16) and end filling cushion block Coating a modified acrylic ester adhesive on the bottom of the rivet, and installing a sleeve-type metal gasket (16) with a boss at the bottom, so as to ensure the gasket to be tightly attached and prevent stress concentration; S6 FRP sandwich structure (11) surface gluing and pasting The thickness of the adhesive layer is controlled to be 0.1-1.0 mm, the weight control is adopted according to the density of the adhesive, the surface of the FRP upper panel (2) is uniformly coated with structural adhesive, the operation time is controlled within 40min, and the outdoor construction operation temperature is controlled to be above 5 ℃; polishing the bonding surface by using a grinding wheel polishing machine to obtain metallic luster, ensuring the surface roughness Ra of 3.2-12.5 mu m, suggesting Ra of 5-20 mu m on the FRP surface, controlling the included angle between the polished grain and the stress direction of the metal material to be 85-95 DEG, preferably perpendicular, and then wiping the polished grain clean, wherein the FRP surface needs to be polished to remove release agent and greasy dirt; Mixing the AB components of epoxy resin according to the proportion of A:B=2:1, uniformly stirring by an electric stirrer to ensure that the adhesive is fully mixed, uniformly coating the prepared epoxy structural adhesive on the surface of the FRP upper panel (2), ensuring a coating mode that the middle is 0.2-0.4 mm thicker than the two sides, paving the edge-covered metal plate (1) on the surface of the FRP upper panel (2), and pressurizing to ensure that the adhesive is uniformly overflowed; S7 rivet fixing and connecting The method comprises the steps of fixing a binding metal plate (1) and an FRP upper panel (2) by using a self-plugging rivet (13) to ensure firm connection of the binding metal plate (1) and the FRP upper panel (2), and installing the rivet, wherein the self-plugging rivet (13) is adopted to connect the binding metal plate (1) and the FRP upper panel (2), the rivet installation sequence is performed obliquely from the middle to the two sides and from the middle to the two sides, so that stress concentration is avoided, and uniform distribution of force is ensured; S8, pre-tightening force application and compaction Applying a pretightening force of 200-250 N.m through a high-strength bolt (7) for compaction, overturning the surface of the edge-covered metal plate (1) and the FRP upper panel (2), firmly adhering the surface of the edge-covered metal plate (1) and the surface of the FRP upper panel (2) together through the pretightening force of the bolt, the dead weight of the FRP upper panel (2) and the drawknot force of the self-plugging rivet (13), and increasing the adhering area of the structural adhesive; s9 metal brace (14) installation and connection Uniformly brushing epoxy structural adhesive on the inner side of a groove of a U-shaped metal brace (14), pasting the epoxy structural adhesive on the bottom surface of an FRP lower panel (5), paving a heat insulation film at a welding position of the lower edge of the FRP, preventing the strength of the lower surface of the FRP and the colloid from being influenced by the excessively high electric welding temperature, and welding and forming the metal brace (14) and the edge-covered part of the edge-covered metal plate (1); S10, solidifying and forming And heating and curing the structural adhesive on the surface of the edge-covered metal plate (1) by adopting a silica gel heating belt, wherein the normal-temperature curing time is 24 hours or 60 ℃ and heating is 4 hours, so that the strength of the structural adhesive can reach more than 95%, and finally the metal-FRP composite bridge deck is formed.

Description

Preparation method of light high-bearing-capacity composite bridge deck and bearing capacity calculation method thereof Technical Field The invention relates to the technical field of composite bridge deck preparation and bearing capacity analysis thereof, in particular to a novel adhesive-rivet fusion connected light-weight high-bearing capacity metal-FRP composite bridge deck preparation and a bearing capacity calculation method thereof. Background The bridge deck plate is used as a bridge deck system main component for directly bearing the load of a vehicle, and becomes one of components which are easy to generate diseases in a bridge under the combined action of factors such as environmental erosion, overload, vehicle impact and the like. The traditional steel materials have the problems of corrosion, metal fatigue, great self weight and the like in engineering, and the overload of a single plate can also lead to low working efficiency and resource consumption. The fiber reinforced composite material (FRP, fiberReinforcedPolymer) has the characteristics of high specific strength, specific rigidity, light weight, high strength, corrosion resistance, fatigue resistance, simple maintenance, good designability and the like, can improve and solve the durability problem caused by the traditional material, and is considered to be an ideal substitute material for realizing high performance and long service life. However, the FRP material is limited in application of some bridge deck structures due to high structural deformation caused by low elastic modulus, brittle fracture is easy to occur when bearing large load, and the surface is not wear-resistant, and the like, and meanwhile, the existing connection mode has the problems of difficult disassembly, difficult replacement and the like of the bridge deck, so that the risk of easy glue opening of the metal-FRP bonding node is effectively reduced, and in order to solve the problems, a material is urgently needed to replace or partially replace steel to be applied in engineering. At present, FRP bridge deck and related structures are mainly applied to pedestrian overpasses and other light load working condition scenes. The equivalent elastic modulus of FRP materials such as GFRP is usually 25-40 GPa, which leads to lower overall rigidity of the structure, the ratio of deflection to span is generally in the range of 1/50-1/100, and the limit requirement of the current standard on the vertical deformation of the bridge is difficult to meet, namely, the maximum vertical deflection of the reinforced concrete bridge is not more than 1/600 of the calculated span, and the steel bridge is not more than 1/500. Therefore, the existing FRP bridge deck system often has the problem that deflection control is not satisfied under the normal use state, and meanwhile, the bearing capacity of the FRP bridge deck structure is low overall. The existing research and engineering examples show that the ultimate bearing capacity of a mid-span single point is generally not more than 10 kN, the shearing bearing capacity near a support is generally not more than 20 kN, and the load requirements of a conventional highway bridge vehicle are difficult to meet. Therefore, even in the case of allowing traffic, there are many light two-axle vehicles whose total weight is not more than 2 t, and the range of application is significantly limited. In addition, the durability of conventional FRP materials and structures thereof remains insufficient. The ultraviolet resistance and the environmental aging resistance of the material are weak, the surface of the material usually starts to change color after being in service for 1-2 years under the long-term sunlight and environmental effects, the resin matrix is degraded and even microcracked, the phenomena of fiber exposure, interface degradation and even fiber fracture are gradually generated along with the increase of service life, and the integral performance and the safety of the structure are further affected. In addition, the FRP material cost is higher, and the cost of the FRP bridge deck system is obviously higher than that of the traditional concrete or steel structure, is about 13 percent higher than that of the prestressed concrete bridge and is about 7 percent higher than that of the steel girder bridge. And FRP wear resistance is poor, the resin matrix of FRP itself is softer, and the top surface of its decking often needs to add wearing layer to resist wheel-load friction and peeling. Research shows that cracks or delamination of the wear-resistant layer of the common FRP bridge deck can occur at the initial stage of service, the wear-resistant layer of the top layer of the FRP bridge deck needs to be suitable for improving the wear resistance under the load of a vehicle, the rapid degradation of the top of the deck due to the exposure of soft resin is avoided, and meanwhile, the wear-resistant layer is damaged in advance due to mismatchi