1、Rubblization by Resonant Breaker 共振碎石化,What is Rubblization ？何谓碎裂技术？,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 sh
2、all be debonded from all the pieces of broken pavement. 碎裂技术是指将旧的水泥混凝土路面一次碎化为紧密嵌锁的砾石；其中公路的砾石尺寸从顶部的沙粒大小至底部的8英寸（20厘米）砾径；机场的尺寸则高至路面厚度的1.25倍；并且原有钢筋完全从破碎道路分离的技术。,Why Rubblization? 为何碎化？,Full-depth Replacement 全深度更换 Most expensive 最昂贵的方法 Time consuming 工期长 Disposal of rubbles 凿除的废料处理难以处理 Costly solution,
3、seldom adopted in US 代价太大，美国已经很少采用,Overlay of asphalt or PCC on top of existing pavement 在旧路面上覆盖沥青或者水泥混凝土 Economic and popular solution 比较经济适用，很受欢迎,Two Approaches for Highway Rehabilitation： 水泥混凝土道路改造两类办法：,But 但是,Why Rubblization? 为何碎化？,World-class problem in PCC rehabilitation 水泥混凝土路面改造的世界级难题,反射裂纹！
4、 Reflective Cracking!,2019/3/9,5,为什么不能直接加铺？,反射裂纹 层间结合不紧，导致表层脱层 水渗透导致材料流失,此方法在美国已经很少采用 国内很多项目也表明此方法的临时性和局限性,每层要比下层有更高的强度，这样才能避免反射裂纹,Why Rubblization? 为何碎石化？,弹性层状体系理论 Elastic Layer Theory Material modulus (En) should increase with subsequent pavement layers in order to prevent reflective cracking 路基各层
5、弹性模量要上强下弱，方可避免反射裂纹的产生,E1,E2E1,E3E2,E4E3,Why Rubblization? 为何碎石化？,The modulus of PCC is higher, 水泥砼的弹性模量大于沥青， the slab needs to be broken so that it can serve as an elastic base to prevent reflective cracking 因此在摊铺沥青前，需将原来的水泥砼碎化，令其变为柔性基层，方可避免上面沥青层产生反射裂纹！,E水泥砼E沥青,Why Rubblization? 为何碎石化？,The purpose o
6、f rubblization is to turn the rigid PCC slab into a flexible layer through fracturing it into pieces 可见，碎化的目的就是通过破碎，将水泥砼由刚性层转化为柔性层,Will PCC slab be turned into a good base once it is broken? 问题是，水泥砼是否一经破碎，就是合格的柔性路基?,Requirements that Rubblization Must Meet 什么是合格的碎石化工艺 ？,If the rubbles are too large,
7、 or sizes not consistent, reflective cracking will still develop 如果粒石尺寸太大，或者大小不均，反射裂纹仍然会产生 If the rubbles are too small, or not interlocked with each other, the whole rubblized structure will fail 如果破碎的尺寸过小，或者相互没有嵌锁，整个破碎后的水泥砼层就会因缺乏强度而失效 All reinforcement must be totally de-bonded to prevent reflecti
8、ve cracking 如果水泥砼内有钢筋，则水泥砼和钢筋必须完全脱离,Rubblization is NOT just slab destruction！ 碎石化不等于对水泥砼的简单破碎！,320 cm 18 inch,反射裂纹 Reflective Cracking,结构失效 Structural Failure,理想碎石尺寸范围 Target Zone,Requirements that Rubblization Must Meet 什么是合格的碎石化工艺 ？,Requirements that Rubblization Must Meet 什么是合格的碎石化工艺 ？,Ideal ran
9、ge of the rubbles should be 320 cm Resonant rubblization can prevent both structural failure and reflective cracking: Microprocessor impact adjustment, consistency in particle size Thorough de-bonding of steel from the slabs,最佳碎石尺寸应该在320cm间 共振碎化确保既无反射裂纹，又避免结构失效: 电脑瞬时调节以便控制碎石尺寸 钢筋完全同混凝土脱离,Requirement
10、s For A Good Rubblization 合格的碎石化应该满足的要求：,Rubble size ranges from 3 20 cm to avoid both Reflective Cracking and Structural Failure 碎石尺寸在320厘米之间，方可既避免反射裂纹、又防止结构失效 No Rough Riding/Faulting 破碎后没有断层，保证行驶的舒适度 Prevent Moisture Damage 防止水害 Maintains integrity of base 保持路基的完好无损 Utilities underneath are NOT d
11、amaged after rubblization 碎石后保持路基及路基下设施完好无损 Present Alkali Silica Reaction (ASR) stops 防止混凝土内酸（硅）碱反应,Resonant Rubblizing Can! 共振碎化技术能够满足以上所有要求！,紧密嵌锁的结构 均匀的砾石尺寸 绝不伤害地基 消除酸碱反应,Provide properly fractured slabs with tightly interlocked pieces,Produce consistent rubble size No damage to bases Migration o
12、f ASR is eliminated,Resonant Beam 振动梁工作原理,Resonant beam vibrates at 44 Hz 振动梁以44赫兹的速度振动 Amplitude is 2 cm 振幅只有2公分左右 Two supporting points are still 两个支点静止 Sensor sense the pavement conditions and transmit to microcomputer 锤头传感器感应路面状况，并传递给电脑 Microcomputer will adjust the frequency accordingly, thus k
13、eeping the rubble size consistent 电脑自动调整振动频率，改变力度，从而控制碎石尺寸保持均匀,Breaking shoe 破碎头,Resonant beam 共振梁,Counter weights配重块,Flotation tires加宽轮胎,Principle Components of Resonant Pavement Breaker 共振破碎机的主要组件,How Does Resonant Rubblizing Work 共振碎化工作原理,Specially made resonant beam generate harmonic wave betwee
14、n 42 46 Hz 特制振动梁在偏心轴的驱动下，在4246赫兹频率下产生振动谐波 Amplitude at supporting point and counter weight point is zero 支点和配重点振幅为零 Breaking shoe strikes the surface of the concrete with high frequency and low amplitude impacts 破碎头以高频低幅（2厘米）敲击混凝土路面 Factures generate under shear forces and expand at certain pattern
15、until they reach the edge of the material 混凝土内部因剪切力而产生裂纹，并随着振动迅速有规律地扩展，直到材料边界 No damage to the base due to low impact force and dissipation of the energy at the boundary of slabs 由于冲击力很小，且裂纹只扩展到边界，所以对基层没有任何损害,高频 (44Hz) 低幅 (2 cm),混凝土完全碎裂,路基完好无损,碎块相互嵌锁使承载均匀分布,混凝土层没有错位，不会压入路基,混凝土碎石层底部平整、整体承载能力巨大,How Do
16、es Resonant Rubblizing Work 共振碎石化工作原理,2019/3/9,18,基层空陷,基层的完整性遭到破坏,承载力随机削弱,高幅（24-42”） 高压冲击锤,高幅低频冲击锤的破碎效果,2019/3/9,19,普通高压冲击锤,共振碎石化,受力不能分散 形成压辙,受力均匀分布,个别点集中受力 造成底基损坏,缺少排水设施 造成底基存水,整个路面得到支撑,不存在车辙,碎石效果比较,2019/3/9,20,破碎后(碾压前）表面比原路面高0.6cm,而采用多锤式破碎方式则破碎表面下沉5厘米,2019/3/9,21,只有共振碎石化能够满足以上所有要求！,高频低幅破碎锤板块完全破碎，尺
17、寸一致紧密啮合的碎石和斜向裂纹钢筋完全分离 (防止反射裂纹）破碎锤不会对基层产生任何影响，保持基层板结完好破碎力度和碎石尺寸能够通过电脑自动调整,Relief Trench, 35至 40,Angular Fracture Pattern for Greater Modulus 斜向的嵌锁结构保证更大的路面模量,Fracture Pattern RB500 用RB500破碎的破裂形状,Cement Stabilized Base 水泥稳定基层,Memphis International Airport，15” Concrete Steel Debonded Memphis 国际机场, 15”
18、钢筋分离现场,Steel Must Be De-bonded 钢筋必须完全分离,Why Other Slab Destruction Methods Not Good Enough? 为什么其他水泥砼破碎方法不够理想？,其他方法均采用自上而下的，强大的外部物理冲击力，造成： 破碎不均匀，无法避免反射裂纹 路基破坏 路基下面设施的伤害 噪音扰民，周边建筑物震动,All other methods apply low frequency, high amplitude and heavy impact to break the slabs apart, resulting in: Large an
19、d inconsistent rubbles leading to reflective cracking Damage of sub base Damage of facilities underneath or nearby Noises and impact will disturb residents and buildings nearby,Resonant Rubblization is Your Best Solution 共振碎裂技术是水泥砼路面改造的最佳方案！,Eliminate possibility of reflective cracking Keep integrit
20、y of the base No harm to the utilities underneath No disturbance to neighborhood The 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,杜绝反射裂纹 绝不伤害路基 碎裂后保持路基及路基
21、下设施完好无损 噪音低、不扰民 工作时最大的噪音来自柴油发动机！ 没有断层，保证行驶的舒适度 防止潮湿水气的侵害 防止混凝土内酸（硅）碱反应 改造后很多年内都无须再次修复,Rubblization is gaining greater and greater market in US and the World 在美国及全球的市场份额越来越大,Rubblization Projects in US 碎裂技术在美国的应用,五年前,Rubblization Projects 碎裂技术,现在,Jacksonville NAS Taxiway “A” Rubblized 1997, Picture i
22、n 2003 Jacksonville NAS 滑道 “A” 1997年用碎石化技术建设, 摄于2003年,2019/3/9,30,Wright Patterson AFB 26- Inch PCC Wright Patterson AFB 26英寸水泥混凝土,2019/3/9,31,Jax NAS 6” 罩面 C5s, P3Vs, 用于战斗机，民用客机,Historical Timeline 历史进程,1986- John Brizzell, NYDOT Materials Engineer, first used resonant breaker for “Rubblizing” 1986
23、- John Brizzell, 纽约州运输部的工程师，首次使用Resonant破碎机械进行道路破碎1991- PC Law Engineering study determines “Rubblizing” best method to rehabilitate PCC pavement. 1991- PC Law Engineering 通过研究确认“碎化”是进行水泥混凝土路面修复的最好方法,Historical Timeline 历史进程,Founded in 1986, as a contractor specialized in rubblization 成立于1986年，是从事碎石
24、化工程承包商 Started with buying resonant breaking machines and now own all resonant machines in the market 26 units 公司创建之初开始购买别人制造的共振破碎机，最终拥有了市场中全部26台设备 RMI gradually started renovation and building its own machines 继而，RMI开始进行技术改造，于两年前推出自己制造的性能和稳定性大大提高的设备,Rubblizing Thickness of PCC 碎石化技术的破碎厚度,10 inch 25
25、 cm,12 inch 30 cm,26 inch 66 cm,0,5,10,15,20,25,30,1986-,1994,1995-,2001,2002-,Current,Increases in Productivity 生产率的增长,Achievements of RMI RMI公司业绩,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 破碎深度达到66厘米 Largest Interstate project ever in the Unite
26、d States (276 miles of four-lane highway) 美国迄今最大的州际公路改造项目（440公里/4车道） Successfully completed rubblization projects in Canada, Russia, Belarus and China 在加拿大,俄罗斯，白俄罗斯和中国等国家成功开展碎化工程 Successfully completed every project we started 所有工程全部成功,When To Rubblize ? 什么时候需要碎化,When More Than 12% to 15% of Slabs R
27、equire CPR 当多于12%到15%的道路需要混凝土路面修复(CPR)时 Cost Over Runs of 50% or Greater Are Typical on CPR 当50%以上的建设成本用于CPR时 Cost of Rubblization Favored on 15 Year Design Life 当期望路面改造的设计使用寿命在15年以上时(CPR Concrete Pavement Rehabilitation, i.e., slab or joint replacement, jacking, grouting, grinding, etc.) (CPR 混凝土路面
28、修复，如：更换水泥板或接缝，破碎，灌浆，打磨等),TO RUBBLIZE, YOU MUST HAVE 4 ELEMENTS: 应用碎石化技术 之 必备四要素,A Properly Designed Edge Drain System 良好的侧排水系统 A Resonant Fractured, Interlocked Slab 以共振破碎机械碎裂且紧密啮合的水泥板块 A Properly Rolled Surface 路面合理压实 A Properly Designed Overlay 设计恰当的面层覆盖,Construction Process 施工程序,Install edge drai
29、n system two weeks prior to rubblization Rubblize the PCC pavement Roll 2 coverages with 10-ton vibratory roller Use high frequency, low amplitude roller Use water to aid rolling process Close to traffic until first lift of HMA is placed,碎石化前两周安装侧排水系统 对路面实行共振碎化施工 用10吨振动压路机碾压2遍 用高频低幅压路机压实 少量洒水配合压实沥青摊
30、铺前道路封闭,Finished Surface After Rolling 碾压后的路面,Traffic Control 交通管制,Cross Overs Head to Head (Safest and Most Productive) 交叉作业（安全而高效） Single lane construction zone (Good Shoulders Required, Lane Overlap Method)单车道施工（需要坚实的路肩，车道合并） Both have benefits 交通及施工均不受影响,Three Most Damaging Things to a Highway 公路
31、的三大杀手,Water水 Water水 WATER水,Sub-grade 底基层,Permeable Zone 可渗透碎化层,Rubblized PCC 不可渗透碎化层,57号石砾 过滤层,2”dense-graded 2” 高密度材料,# 57 Stone # 57 石料,Filter Fabric 过滤材料,Base Course 基层,Shoulder Area路肩,Rubblization Side Drainage 碎化施工的侧排水系统,Permeable/Crack-relief 可渗透/消除裂纹,Semi-solid/Interlocked 半封闭/啮合,3 % Slope Ou
32、tlet 3 % 倾斜排管,Fabric outlet 可透水排管,Integral Curb & Gutter Rubblization Side Drainage 路缘石盲沟一体化排水系统,Full Depth Saw Cut 全深度切割,Backfill 回填,Permeable/Crack-relief 渗入/防止裂纹,Semi-solid/Interlocked 半固态/啮合,Base Course 基层,Sub-grade 底基层,Rubblized PCC 碎化后的水泥混凝土层,Permeable Zone 可渗入区域,# 57 Stone # 57 石料,Filter Fabr
33、ic 过滤材料,To drop inlet or daylight 管道/ 直排,Dual Outlets at Approximately 300 feet 约300英尺深的双排水口,双排水口,Dual Outlets - 0ne Each Direction 双排水口-每向一排,Placing Drainage System 埋设排水系统,AASHTO Layer Coefficient (ar) vs. Modulus (Mr) AASHTO 层级系数(ar)与模量的关系(Mr),Recommended Coefficients by AI AI 推荐系数,As low as 0.16
34、for unstablized bases对非稳定路基，降低至0.16Up to 0.30 for stabilized bases对稳定路基，高至0.30Minimum overlay thickness of 5”最小摊铺厚度5“,Summary: Advantages and Benefits of Rubblization 总结：共振碎石化技术的巨大优势,是世界上唯一的能够根除反射裂纹的工艺 通过低幅高频的振动令路面内部裂纹产生自行扩展，而非靠外部物理冲击力造成路面破碎 因此碎石尺寸均匀、破碎彻底 钢筋彻底与混凝土分离 保持二十年以上无反射裂纹 防止潮湿水气的侵害 破碎层上部具有排水功
35、能，能够有效将水分排到路侧 破碎层的下层不透水，防止水分渗透到路基 保持路基，及路基下设施的完好无损 没有外部冲击力对底层产生冲击 改造后斜向的破碎裂纹将路面压力均匀地分散到更大的面积上，减少对路基的局部压力 施工期间噪音和震动低，不扰民 最大的噪音来自柴油发动机 周边建筑物无法感到震动 防止混凝土内酸（硅）碱反应 完全和均匀的破碎使酸碱反应中断,国内外工程案例,Wright Patterson AFB 21“（53.3厘米）,Little Rock, AR AFB Superpave with PG binder,I-440, Raleigh Beltway, North Carolina,2019/3/9,73,Walla Walla, WA 碎化后压实前的跑道,2019/3/9,74,欢迎到施工现场参观指导！谢谢大家！主讲 ： 胡 安（手机13910033656),
