The construction process and requirements of laser leveling concrete wear-resistant floor
Definition
Laser leveling concrete wear-resistant floor refers to the use of laser leveling machines to perform high-precision and rapid leveling operations on concrete, thereby obtaining a concrete wear-resistant floor that meets high standards in terms of flatness, levelness, density and strength.
Working principle of concrete laser leveling machine
The concrete laser leveling machine uses laser as the reference plane, and emits rotating laser through the laser transmitter. The laser signal is captured by the laser receiver on the leveling machine. The received signal is deeply analyzed by the laser measurement and control system, and any deviation will be accurately identified and fed back to the highly sensitive computer control system on the leveling machine. Based on this feedback information, the leveling machine will intelligently adjust the height of the scraper or leveling head to ensure the accuracy of the leveling operation. At the same time, the hydraulically driven vibration motor drives the vibration plate to vibrate the concrete to further compact the ground.
Concrete laser leveling machine wear-resistant floor construction process
(1) Construction preparation Material preparation: Ensure the quality of concrete materials. Polycondensate high-efficiency water reducer can be added to reduce the risk of cracking. At the same time, prepare the required wear-resistant aggregates, interface agents and other materials.
Equipment preparation: Transport and place laser leveling machines, trowels, trimmers, vacuum cleaners and other equipment to the designated location on site, and perform maintenance work to ensure that the equipment is in good standby condition.
Base treatment: Mill the base to increase the adhesion between the leveling layer concrete and the base. Clean the surface of the concrete base plate and use a high-pressure water gun to thoroughly rinse the floor surface. Sweep mortar or apply special interface agent as needed.
(2) Formwork setting and steel bar laying
Formwork setting: Set the formwork according to the design requirements, ensure that the formwork support is on the same horizontal line as the elevation, and use a special formwork frame to set it at an inclined angle to facilitate subsequent construction.
Rebar laying: Adding steel bars to concrete can effectively increase the tensile strength of concrete and prevent cracking. The steel mesh should be placed 20mm~30mm away from the floor surface, which not only increases the tensile strength of concrete but also protects the surface from cracks.
(3) Concrete paving and laser leveling
Concrete paving: The mixed concrete is pumped and spread on the crushed stone base. The paving speed should be appropriate, and manual leveling should be assisted quickly. Ensure that the concrete construction thickness meets the design requirements.
Laser leveling: Use a laser transmitter to determine the height of the concrete paving construction, and use a laser leveling machine to perform leveling operations. During the leveling process, one person should be responsible for moving the laser leveling machine, and two people should be responsible for the front-end auxiliary leveling to ensure that the concrete surface remains at the designed height
(4) Initial grinding and slurry breaking and throwing wear-resistant aggregates
Initial grinding and slurry breaking: When the concrete is initially set, use a single-disc and double-disc trowel to repeatedly rub and level the concrete slurry. The best time is when there are no clear footprints left by people on the concrete.
Spreading wear-resistant aggregate: Spread the specified amount of wear-resistant material evenly on the surface of the concrete just after the slurry is broken. Special materials can be considered as specific conditions and spread more than twice. After each spreading, use a trowel to grind and compact the aggregate.
Finishing and maintenance
Finishing operation: Depending on the degree of hardening of the concrete, perform at least three trowel operations without a disc. The speed and angle of the trowel should be adjusted according to the degree of hardening of the concrete. The corners can be manually scraped.
Maintenance: After the construction is completed, it takes more than 28 days to maintain. Sprinkle water for maintenance and lay soil cloth to reduce water evaporation and keep the wear-resistant floor after construction in water.
(5) Cutting expansion joints and subsequent treatment
Cutting expansion joints: After the concrete has been sprinkled with water for a certain period of time (such as 24 hours), cut the expansion joints according to the design requirements. The setting of expansion joints should take into account the expansion and contraction space of concrete to prevent cracking.
Subsequent treatment: Clean and fill the expansion joints after cutting to ensure the beauty and practicality of the floor.
Requirements for the construction of laser-leveled concrete wear-resistant floor
The construction requirements of laser-leveled concrete wear-resistant floor are strict, covering material selection, construction equipment, construction process, construction environment and other aspects. The following is a detailed summary of these requirements:
(1) Material requirements:
Concrete
Strength grade: C25~C30 concrete, 28-day strength not less than 25MPa.
Water-cement ratio: not more than 0.5, no water should be added at will during the feeding process.
Cement: ordinary silicate cement with a grade not less than 42.5 should be used.
Bone material: well-graded, coarse bone material is crushed granite or pebble, with a maximum diameter not more than 25mm; fine bone material is clean river sand, with a fineness modulus of 2.4~2.7.
Concrete mix ratio: cement dosage is not less than 350Kg/m³, and the sand ratio is controlled at 35%~40%. Concrete slump: 14±2cm, maximum 16cm.
Setting time: The initial setting time is controlled within 3-5 hours.
Wear-resistant aggregate: The amount of wear-resistant aggregate is not less than 5kg/㎡, and it is evenly spread in batches to ensure wear resistance and flatness.
(2) Construction equipment requirements
Concrete laser leveling machine: Ensure that the laser transmitter and receiver work normally, without dead corners, and can monitor and control the ground elevation in real time.
Other auxiliary equipment: Including concrete mixing station, pumping equipment, trowel, trimmer, vacuum cleaner, etc., to ensure that the equipment is intact and meets the construction requirements.
(3) Construction process requirements
Preparation work: Including laying the base, steel mesh, setting the transmission rod, placing the buffer zone, etc., to ensure that the foundation is firm and flat.
Concrete paving: Pump concrete to the site and manually assist in leveling to ensure that the concrete is evenly distributed.
Laser leveling: Use a laser leveling machine for high-precision leveling to ensure that the ground flatness and levelness meet the requirements.
Initial grinding and breaking of slurry: When the concrete is initially set, use a trowel to perform initial grinding and breaking of slurry to remove the concrete slurry.
Spreading of wear-resistant aggregate: Spread wear-resistant aggregate evenly in batches and compact and grind with a trowel.
Finishing: Perform multiple finishing operations according to the hardening of the concrete to ensure that the floor is smooth and free of defects.
Maintenance: After the construction is completed, perform maintenance for more than 28 days to ensure the strength and durability of the concrete.
(4) Construction environment requirements
Temperature: Avoid construction in extremely high or low temperature environments to prevent the concrete from drying or condensing too quickly.
Humidity: Keep the construction environment moderately moist to prevent the concrete from losing water too quickly and causing cracks.
Avoid wind and rain: The newly constructed concrete floor should not be exposed to sunlight, wind, rain and other environments that are unfavorable to the health of concrete.
(5) Other requirements
Cutting expansion joints: Cut expansion joints in time to prevent concrete from cracking due to expansion and contraction.
Construction sequence: Ensure that the construction sequence such as concrete feeding speed, leveling speed, polishing time is reasonable to avoid problems such as cold joints.
Personnel coordination: Manual and mechanical construction to ensure construction quality and efficiency.
Safety requirements: Comply with construction safety regulations to ensure the safety of personnel and equipment.
Laser leveling concrete wear-resistant floor finished product protection
(1) Protection principles
Timeliness: After the construction is completed, protective measures should be taken as soon as possible to prevent the floor from being polluted and damaged.
Comprehensiveness: The protective measures should cover the entire floor, leaving no dead corners, to ensure comprehensive protection.
Targetedness: Develop targeted protection measures for different construction environments and floor uses.
(2) Protection measures
Covering protection
Maintenance blanket or non-woven fabric covering: Within 5-10 hours after the construction is completed, use a maintenance blanket or special maintenance non-woven fabric to cover the floor and water it to keep it moist to prevent the floor from drying out too quickly and causing cracks.
Film covering: In certain circumstances, such as before the steel structure is hoisted, a film can be used to cover the floor to prevent components from falling and damaging the floor.
Isolation protection
Set up guardrails: Set up guardrails for the completed floor area to prohibit people from entering at will to prevent trampling and pollution.
Warning signs: Set up eye-catching warning signs at places such as doors where people frequently enter and exit to remind people to pay attention to protecting the floor.
Anti-collision protection
Fully spread earth cloth or wooden formwork: During the hoisting operation, the floor is protected from collision by fully spread earth cloth or densely spread wooden formwork.
Take anti-fall measures: Small objects such as tools and screws (caps) should be packed in special tool bags to prevent them from falling and damaging the floor. Anti-pollution protection
Apply special concrete sealing wax: Apply special concrete sealing wax on the floor surface to form a surface wax coating to prevent pollution and damage.
Receiving bucket setting: During the hydraulic test of electromechanical installation, arrange the water inlet and outlet positions to prevent the test water from flowing into the floor. At the same time, place the receiving bucket at the joint position to prevent leakage from polluting the floor.
Repair measures
Small pit repair: If the floor has small pits and other damage, it can be repaired with a special adhesive SBR.
Finished product protection team: Establish a special finished product protection team to be responsible for daily inspection and maintenance of the floor, and promptly discover and deal with damage problems.
(3) Protection period and supervision
Protection period: According to the specific situation of the floor and construction requirements, determine a reasonable protection period to ensure that the floor is fully protected during the maintenance period.
Supervision and inspection: Regularly inspect the floor to ensure that the protection measures are effectively implemented. Violations of protection measures will be corrected and punished in a timely manner.
Precautions before construction of laser leveling concrete wear-resistant floor
①Material preparation:
Ensure the quality of concrete materials. The concrete specifications must meet the design requirements, such as C25~C30 concrete, and the 28-day strength is not less than 25MPa.
The aggregate grading is good, the maximum particle size of coarse aggregate is not more than 25mm, and the fineness modulus of fine aggregate is moderate. Ordinary silicate cement with a cement grade of not less than 42.5.
Equipment inspection:
The laser leveling machine and auxiliary equipment (such as mixing station, pumping equipment, trowel, etc.) should be intact and overhauled to ensure normal operation during construction.
Check whether the laser transmitter and receiver are working properly, ensure that the laser signal has no dead corners, and can monitor and control the ground elevation in real time.
Base treatment: The base should be flat, solid, free of oil and debris to ensure good bonding between the concrete and the base. After the base is treated, it should be inspected and accepted, and the next step can be carried out only after it is qualified.
② Matters needing attention during construction
Concrete paving: The minimum hourly feeding speed of concrete should be determined according to the ground thickness and pouring area to avoid cold joint problems. When manually assisted leveling, attention should be paid to the uniform distribution of concrete to avoid large piles falling.
Laser leveling: When using the laser leveling machine, the measured height of the vertical pole should be accurate to ensure the leveling accuracy.
During the leveling process, the laser leveling machine should be integrated with the paving machine to maintain good rigidity and avoid excessive vibration affecting the construction quality. Operators of laser leveling machines need to undergo professional training and be familiar with the performance and operating procedures of the equipment.
Spreading of wear-resistant bone materials: Wear-resistant bone materials should be spread evenly in batches, and after each spreading, they should be compacted and polished with a trowel to ensure wear resistance and flatness.
Finishing and maintenance: The finishing operation should be polished multiple times according to the hardening of the concrete to ensure that the floor is smooth and flawless.
The floor should be kept moist during maintenance, and a maintenance blanket, non-woven fabric or film should be used to cover and moisturize the floor to prevent the concrete from drying out too quickly and causing cracking.
③ Precautions after construction
Cutting and expansion joint treatment: After the construction of the laser-leveled concrete wear-resistant floor is completed, the expansion joint should be cut in time to prevent the concrete from cracking due to expansion and contraction.
Professional personnel should be assigned to the cutting operation to ensure that the cutting depth and spacing meet the design requirements.
Finished product protection:
Guardrails and warning signs should be set up for the completed floor area to prevent people from stepping on and contaminating.
Use maintenance blankets, non-woven fabrics or films to cover and protect the floor from external damage.
Quality inspection and acceptance:
After the construction is completed, the floor should be inspected for quality, including flatness, levelness, density, strength and other indicators.
It can only be delivered for use after acceptance to ensure that the floor meets the design requirements and usage functions.
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