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1、 宝鸡峡倒虹工程输水混凝土管底部抗冲耐磨修复与加固处理摘要：宝鸡峡韦水倒虹工程输水混凝土管内壁严重磨损，需进行抗冲耐磨修复处理。通过方案比较，采用内壁表面粘结钢板和并使用自锁锚杆锚固的处理方法，修复后通水运行的监测数据说明效果良好，值得在涵洞、渡槽等灌溉工程和其它水利水电工程中推广应用。 关键词：粘钢 自锁锚杆 倒虹工程 抗冲耐磨 修复加固 一、引 言陕西省宝鸡峡韦水倒虹工程全长880m，其中钢筋混凝土管长623m，内径3.25m。设计流量52m3/s，校核流量55m3/s，控制灌溉面积159万亩。该倒虹工程于1971年建成，至今已运行30多年。由于30多年前施工技术限制和质量不佳，加之长期的
2、高水头水流冲刷及水中重推移质（砖头、石块等）的撞击，倒虹的钢筋混凝土管普遍存在着内壁磨损现象，尤其管底部位最为严重，据1999年实测结果，磨损深度56cm的有12节管子（平均每节砼管10米长），35cm的有60节管子，小于3cm的有28节管子，磨损最大宽度1.7m，最大深度6cm。磨损严重部位的表面积约1300m2，占管内壁面积12715 m2的10.2%。且有44节管子出现了不同程度的钢筋外露，露筋根数565根，累计长度104m。最严重的一节管子露筋40根，占该节管子主筋根数（77根）的52%，外露最长的一根露筋80cm，部分钢筋磨损部分已超过钢筋截面的50%。输水混凝土管内壁的严重磨损直接
3、影响着运行安全，2001年11月，该倒虹工程列入全国灌区续建配套与节水改造项目。鉴于砼管内壁磨损现象集中于管底部位，决定对管上部及中部的270范围的混凝土内壁采用刷涂WSP防碳化处理，对钢筋混凝土管底部进行抗冲耐磨修复处理，使其恢复正常，继续发挥应有的效益，并满足对输水能力的更高要求。二、 方案比较管底部90范围混凝土抗冲耐磨修复比较了如下几种方案：（1）采用环氧砂浆或防水混凝土修补。因内壁凿除深度有限（否则会裸露主筋），环氧砂浆或防水混凝土与老混凝土界面的结合很难保证，同时施工麻烦、成
4、本较高。（2）粘贴玻纤布或碳纤维布修复。目前市场使用的粘结胶通常耐水性较差，在水的长期浸泡作用下粘结强度会不断降低，加之水流速度较快，水头压力较高，易将布剥离使得修复失效。（3）外粘钢板修复。在内壁先用自锁锚杆嵌固钢板，在内壁与钢板之间的缝隙中用压力灌注WSJ建筑结构胶。钢板在自锁锚杆的锚固力和结构胶的粘结力作用下，能与原混凝土共同受力工作。钢板补充了混凝土内部的配筋损失，同时可防混凝土构件的进一步碳化和在流水中的腐蚀及冲磨，因此，该方法具有强度高，抗冲磨、抗空蚀性能好和可靠性高等优点，是本工程的最优处理方案。三、所用材料及其特点粘钢所用的粘结剂为WSJ建筑结构胶，高强、无毒、内聚1、粘结性能
5、好，其剪切强度大于18MPa，且耐老化性能好，2000h人工加速老化试验各项力学指标不降低。嵌固钢板时采用“巨成”牌自锁锚杆成套产品。该产品的技术特点是：在混凝土结构上先用普通钻头钻直孔至设计深度，然后改用扩孔钻头将直孔底部扩成倒锥面，锚杆安装时，在轴压力作用下锚杆端部开槽部位受楔块顶撑张开形成自锁，最后灌注无机粘结灌注材料ICG-填充锚杆与混凝土孔壁之间的空隙。这项技术很好地解决了耐久、耐水、耐温性的问题，与传统的直孔植筋锚固方法相比，可靠性极大地提高，且具有锚固速度快等特点。解决了弧形钢板安装时的对孔困难和焊接时的热效应，大大加快了施工速度，更能保证管底粘钢加固的质量。所用的无机粘结灌注材
6、料ICG-具有优异的技术性能：浆液：流动性大（自流）、析水率低、可灌性好、自密实性能好；硬化体：早强、高强且持久高强；与混凝土孔壁、钢筋有良好的粘结性能，不收缩；耐老化、耐化学腐蚀、耐水、耐中温（500），适合永久性工程。四、修复施工步骤及技术要点修复的具体措施包括：（1）在管底90范围将基面混凝土下凿不小于15mm，并稍作平整，原冲刷较深超过15mm处要求表面凿毛，用C25细石混凝土填补至12mm的粘钢深度要求。（2）待新做C25细石混凝土充分干燥后，在表面划线定出自锁锚杆孔位并钻孔：孔深300mm，孔径为D25，间距500500mm，梅花形布孔，钻孔方向垂直基面；若遇钢筋，则将孔位适当调整
7、；并在弧形钢板（Q235B钢板，=10 mm）上按相应孔位钻孔，成孔后，将钢板需贴合的表面打磨处理好。（3）将锚杆孔内壁吹净润湿后，在钢板下适当垫置2mm的小钢垫块以保证胶层的厚度，将钢板对孔就位；向孔内灌注ICG-无机粘结材料，然后植入自锁锚杆，材质为I级钢，直径为20，自锁锚杆套装完毕，割掉高出钢板面的部分，将锚杆与钢板焊接，并将相邻钢板之间的环向缝对接焊好。（4）在嵌固好的钢板周边密封并埋置排气管；在弧形钢板底部埋置进浆管，采用压力灌注WSJ建筑结构胶。（5）待WSJ胶液固化后，对钢板表面采用抗冲耐磨涂层防护处理。施工要点包括：（1）弧形钢板的卷板曲率要根据实际情况确定因30年前混凝土管
8、浇筑施工时内模变形，管壁成形不规整，造成实测的管底内壁弧形的拟合半径主要分布在1600-1700 mm范围内，该范围外的数据小于10%，故管底粘钢按2552 mm2000 mm下料，按半径1700 mm卷板成弧形。统一的卷板曲率，既便于加工厂内的卷板质量保证，又便于混凝土管内的粘钢放线和孔位放样。（2）钢板孔位的布置及钻孔要求一定要按混凝土表面自锁锚杆实际成孔孔位确定钢板上的孔位，确保自锁锚杆与钢板孔口的同心偏差在容许范围内，以便自锁锚杆的套装顺利到位。在钢板上用磁座钻钻孔要求钻孔方向垂直钢板面，成孔后，再用大一号的钻头将孔口扩成坡口，以便安装后锚杆与钢板的焊接和焊缝厚度的保证。（3）粘钢基面
9、下凿深度的确定粘钢基面下凿不小于15mm，是为了保证粘结后钢板表面和管内壁平滑过渡，不影响管内过流。 （4）自锁锚杆安装用电锤在混凝土内钻孔至设计深度，再改用扩孔钻头在孔底进行扩孔。自锁锚杆只对专用扩孔钻头所成形的钢筋混凝土倒锥形孔有效，扩孔钻头的钻杆需进至要求的进深才算扩孔合格。孔内用压缩空气吹净，润湿内壁后，注入无机灌注料ICG-，充填2/3满。将自锁锚杆表面化学清洗后配上插楔，稍用力夹紧后，插入扩孔内。在露出杆端上做标记，将锚杆用锤敲击加压，使锚杆下移不少于5 mm 达到进深要求为止。（5）压力灌胶及效果检测将嵌固好的钢板周边用密封材料封口，按适当间距埋置排气管，在弧形管段底部上下游钻孔
10、埋置进浆管。灌注WSJ建筑结构胶的顺序自下游向上游逐步进行，注胶压力不超过0.2MPa（注胶压力的上限是以锚杆的抗拉能力来计算确定，并视气温作适当调整），直至所有排气管出浆。灌胶效果采用非破损检验，即在WSJ胶液固化后，外观检查钢板边缘溢胶色泽、硬化程度，以及小锤敲击钢板从音响判断粘结效果，如无空洞声，表示粘贴密实。（6）粘钢表面抗冲耐磨涂层防护处理底涂环氧富锌重防腐防锈漆具有优异的附着力和耐冲击性能，漆膜中含大量锌粉，具有阴极保护作用，具有优异的防锈性能和耐久性。中涂环氧云铁中间封闭防锈漆具有优良的附着力和封闭性能，能在长时间内保持优良的抗冲击性能和柔韧性，与面涂具有良好的层间附着力。面涂环
11、氧沥青厚浆型防锈漆，具有优异的耐水性和防锈性能，具有良好的抗化学品性能和耐油性，对水及多种腐蚀介质具有优异的抗渗透性，具有良好的耐阴极保护性能，具有良好的附着力、耐冲击性、耐磨性，能有效抵抗砼管内长期的水流冲刷及水中推移质的撞击，起到钢板面抗冲耐磨的作用。五、结束语 2003年7月，全国灌区续建配套与节水改造项目会议在该倒虹工程现场召开，来自全国的专家和代表一致认为这次应用外粘钢板和自锁锚杆锚固的修复技术，成功地解决了对输水混凝土管底部进行抗冲耐磨修复问题，对这种加固新材料新技术在工程实践取得的经济效益给予了充分的肯定。修复后已通水运行将近一年，停水间歇入洞检查，监测
12、数据显示一切正常，修复加固效果良好，能确保运行安全和发挥应有的效益并满足期望的输水能力。 实践经验证明，将外粘钢板技术和自锁锚杆锚固技术结合应用于混凝土管抗冲耐磨修复，值得在涵洞、渡槽等灌溉工程和其它水利水电工程中推广应用。/Porganization system and working mode, the selection of a number of municipal strengthening group to build innovation and strengthen the organization of the basic level organizations adva
13、nced model.(seven) the manual work of the Communist Youth League Organization published and League branch of manual work, to promote the use of two manuals in the citys organizations at various levels. The county committee, directly under the group (work) is under the jurisdiction of grassroots Leag
14、ue and group (total) using branch ratio shall not be less than 70%.Three, to further strengthen the groups leadership and team building(a) to strengthen the leagues leadership at all levels of construction. Continue to do a good job of municipal Party Committee Organization Department on the strengt
15、hening of the Communist Youth League cadres management opinions implementation. To promote the group counties (autonomous counties, cities) Commission and city directly under the group (workers) appointed to carry out the Five team building activities. Improve the League Association Department worki
16、ng mechanism. Conscientiously fulfill the duties of CO, combined with the city group directly under (the) Committee of the general election and the adjustment, actively jointly with the unit where the party organization department good group leadership selection with the work. Do a good job in munic
17、ipal Party committee assistant committee leadership and leading cadres of the annual assessment work, adhere to and improve the assistant secretary of the Communist Youth League talk system group To weave individual conversation and collective conversation, to strengthen the committees of all levels
18、, the Standing Committee of the Standing Committee, the establishment of a sound system of central group learning, the system of investigation and study, the system of important issues and the reporting system.(two) to strengthen the work of education and training of cadres to conscientiously implem
19、ent the Central Committee. On the implementation of grassroots cadres training project and opinions on carrying out the mission municipal CYL Cadres training project implementation opinions, full implementation of the project of the City Youth League cadres training education. Focus on the county gr
20、assroots cadres and workers focused on training, the new school system vocational training League cadres, for the Municipal Organization Department jointly held the third session of the Communist Youth League system training cadres in party. Focusing on the construction of new socialist countryside,
21、 strengthening village cadres and rural construction team group member of the young team, the county organizations at various levels throughout the year is expected to train 100 00 rural grassroots cadres, plans to train 1000 village secretary of the village Party branch.(three) actively promote gra
22、ssroots cadres election work. Under the unified leadership of the party organization, to strengthen grassroots organizations direct work, standardize the election work rules and procedures, in the designated candidate, open competition to democratically elected branch secretary at the same time, act
23、ively and steadily the development of Township, streets and other grassroots organizations in the direct election of the pilot work, on the basis of summarizing the experience and gradually expand the scope of the pilot, and gradually formed a set of measures and cadres election system.(four) to str
24、engthen the cadres testing exercise. To study the development of XX city from 2006 to 2008 cadres testing exercise planning. To select outstanding cadres to the central mission in Beijing, Shanghai, Guangzhou and other central organs and sending work in developed areas. With the Central Committee th
25、e implementation of the western region and ethnic minorities cadres training plan . To carry out the eighth batch of municipal organs attachment cadre management, selection, training work. The outstanding cadres to start the National Development Bank XX branch testing exercise.(five) to strengthen t
26、he group construction. The main position to play the role of Youth League cadre education and training as the city, in accordance with the requirements of post training, further curriculum scientifically and rationally, adopt arrangement menu course, basic theory includes group work, focus, hot and
27、difficult issues, to enhance the content and practice; to strengthen the construction of teaching staff, the integration of teachers, establish a quality teacher training team, establish and implement course evaluation system; take delivery of training to the countryside, on-site training, and incre
28、ase the rural grassroots cadres training efforts.Four, efforts to strengthen the work of young talent(a) to tenth XX young 54 medal in recognition of the publicity, and actively explore the XX youth service. 54 Medal of institutionalization, standardization and socialization mechanism. Give full pla
29、y to the XX award in recognition of 54 youth medal Association, Youth Award winner in the 54 chapter, investigation activities. Who won the Youth Service medal, dedication to the society to create conditions, build the stage. During the 54, named in recognition of the tenth XX young 54 medal. The as
30、sociation of XX editing of young talent , the exchange of information and communication platform for the XX of outstanding young talents.(two) the establishment of municipal Party committee of young talent information database. In accordance with the feasible, effective, classification management, i
31、mplement step by step principle, the establishment of municipal Party committee of youth talent database; guiding organizations at various levels generally established the young talent database, construction of city, county (directly under the Communist Youth League), grassroots organizations three
32、young talent information database the relevant information collection system, and gradually establish the citys young people, the Communist Youth League youth talent information network, provide information platform for young talent resource development.Five, take effective measures to strengthen th
33、e mission management(a) to strengthen the mission management work. Strengthen the dues collection and management, continue to adhere to the dues collection regularly reporting system, the annual comprehensive award in recognition of the tour and the tour one vote veto system audit system. Do statist
34、ical work in the group. The group service award in recognition of the advanced units, standardization, promoting group management work institutionalized.(two) to strengthen the organization of research and information exchange efforts. Grassroots carry out research, efforts to form a number of theor
35、etical results. Make full use of the network carrier, to explore the establishment of electronic group service system, promote the work of Communist Youth League information.Attachment 4:XX municipal Party Committee Propaganda Department of the Communist Youth League work pointsIn 2006, the Communis
36、t Youth League propaganda ideological work XX to Deng Xiaoping theory and the important thought of Three Represents as guidance, study and implement the partys sixteen and the spirit of the the fifth Plenary Session of the 16th CPC Central Committee implementation of the eight plenary session of the
37、 two committee, the citys cultural work conference, the Propaganda Department of the meeting and the the fourth Plenary Session of the 15th CPC Central Committee permanent mission spirit, closely around 11th Five-Year XX the goal of full implementation of Scientific Outlook on Development, emancipat
38、ing the mind, seeking truth from facts, keep pace with the times, close to reality, close to life, close to the young, persevere grasp orientation, grasping deepening, grasping construction innovation, further improve the groups propaganda and ideological work ability, unity To guide the majority of
39、 members of the youth to achieve the 11th Five-Year planning tasks, the overall construction of a well-off society, building a socialist harmonious society to make new contributions.One, adhere to the Three Represents important thought and Scientific Outlook on Development education to guide the you
40、th, to further strengthen the ideological and political education of youth(a) armed with youth science theory. Unremittingly with Deng Xiaoping theory and the important thought of Three Represents armed members of youth education, to promote the study and implement to expand the depth and breadth. T
41、o study and implement the important thought of Three Represents with the establishment and implementation of Scientific Outlook on Development combine with the implementation of the requirements of constructing socialist harmonious society with Scientific Outlook on Development, carry out education
42、as an important part of the theory of armed youth in the new period, strengthen the establishment and implementation of Scientific Outlook on Development education, educate and guide the youth to fully understand the great significance of establishment and implementation of Scientific Outlook on Dev
43、elopment, in-depth understanding of the Scientific Outlook on Development era back The king, the practice foundation, basic connotation, historical status, spirit and practice requirements, a profound understanding of Scientific Outlook on Development with Marxism Leninism, Mao Zedong thought, inher
44、iting and developing relationship between Deng Xiaoping theory and the important thought of Three Represents, to help young people establish and consciously practice Scientific Outlook on Development. Persist in learning, grasping the backbone, grasp the practice, grasp the opportunity. Catch club,
45、effective way to grasp the network, with the group of cadres, young students and young backbone fronts as the focus, to promote the work of the armed youth theory to develop in depth, to help the youth continue to firm ideals and beliefs, to build a powerful spiritual pillar. To carry out the study
46、and implementation of the partys sixteen session of the five Eight plenary session of the two plenary session of the Central Committee and the party spirit, to the citys Youth League members thinking into the spirit of the meeting, to achieve the goal of national consciousness and XX economic and so
47、cial development in 11th Five-Year period. Contribute to help and guide the youth to a profound understanding of the significance and main task of building a socialist harmonious society, actively join the construction of socialist harmonious society.(two) to strengthen the ideological and moral con
48、struction of teenagers. Thoroughly implement the central spirit of the document No. 8, No. 16 and the program for Improving Civic Morality to minors and students as focus groups, to strengthen and improve the ideological and moral construction of minors and the ideological and political education of
49、 college students. Make full use of the spirit and the spirit of the Three Gorges migrants Hongyan XX unique the use of educational resources, school, into the team, the league, to join the party, adult occasions, extensive Hongyan spirit generation theme education activities. Use of holidays and leisure time, youth