荒料真空灌注加固操作规程

The Operation Instructions of Block Vacuum Perfusion

一、前言 Introduction

为规范施工人员操作，保证真空灌注工艺加固荒料的质量和效率，湖南柯盛新材料有限公司依据大量真空灌注加固荒料的成功实施案例，编制本操作规程。

In order to regulate the operation, to insure the quality and efficiency, Hunan Kosen New Material C o.,LTD compile this Operation introduction according to abundant successful case

二、操作流程 Operation Procedure

1. 制袋：根据客户提供的荒料尺寸提前制作好立体真空袋，并确认气密性合格（湖南柯盛新材料有限公司制作）。

Prepare the Vacuum bag: according to the size of block, make a stereoscopic vacuum bagand ensure the Air tightness of the bag.

2. 清洗：将荒料用高压水枪冲洗干净，特别是裂缝孔洞处，并晾晒干燥。荒料干燥后开始施工。

Clear the block: use the High-pressure water gun to clear the block, take more attention to the cracks and holes. Keep the block clean and dry. The operation can be start after theblock is dry.

3. 枕木处理：采用软质泡沫或者橡胶等材料将枕木上部包覆平整，并用透明胶带固定。

Prepare the crosstie: Use the flexible Foam pad or rubber to cover the upper of crosstie, fix it by the Scotch tape.

4. 铺袋：将立体塑料袋（沿长度方向）按照枕木垂直方向展开，铺放平整，四周向里侧收卷。

Place the Vacuum bag: unfold the bag (along the length direction) according to the verticaldirection of crosstie, make it laying flat, rolling from the round to the inside.

5. 铺导流网：将导流网沿塑料袋底部长度方向铺开，需保证荒料吊入后能完全包裹其底部。

Place flow medium: Unfold the flow medium along the length of the bag and make sure it can cover the whole bottom side of the block.

6. 荒料入袋：将荒料吊入塑料袋内，注意底部与塑料袋四边要大致吻合。同时注意吊入过程中荒 料对塑料袋的破坏，以及收钢索时对塑料袋的破坏。

Put the block into Vacuum bag: lift up the block and put into the bag, pay attention if there is damage of bag in the process of place block and pick up the cable wire.

7. 导流网安装：首先检查荒料四周是否有尖角及明显凹陷，若存在则尖角则覆盖一层透气毡，若 存在较大孔洞则用荒料同类碎石填充后，再覆盖一层透气毡。最后将底部的导流网从荒料顶部 展开，与另一端对接，将其平整包覆。另外两侧裁剪适量导流网包覆平整。

Install the flow medium: Firstly, check every side of the block. If there is sharp corner,cover a layer of breather net. If there is big hole, fill up the same smash stones and thencover breather net. Secondly, cover the flow medium from the bottom to the upper of blockand close it smoothly. Beside, use flow medium to the cover the edge appropriately.

8. 管路安装：在荒料中心底部及四周底部铺设导流管（用尼龙扎带固定好），以及合适位置安装 导气管、压力表孔、抽气嘴、进胶嘴。

Install pipes: Install the guide pipe in the center of bottom side and around side of block (fixby Nylon cable ties) and find the most suitable position to install the air pipe, vacuum manometer, pipe base for air & epoxy.

9. 密封：用密封胶将塑料袋口密封好。

Seal: seal the Vacuum bag completely by sealing glue.

10. 抽气检验：密封好后，安装好压力表，连接好抽气嘴与树脂收集器（预先涂好脱模剂）、真空泵。启动真空泵进行抽气，同时检查气密性。即：将袋内压力抽到压力表不再变化为止，压力表读数要低于-0.095Mpa,再停泵，观察压力表读数，半小时内不高于-0.09Mpa 为合格。若压力上升快，则表示有明显泄露处，应详细检查直到排除漏点（采用密封胶进行补），满足上述要求为止。

Air tightness test: after sealing the bag, then install the Vacuum manometer; connect the pipe base for air, epoxy collector (smear Stripping wax in advance) and automatic vacuum perfusion machine. At the same time, check the air tightness, that is no more change and the value is lower than -0.095Mpa indicating in the Vacuum manometer. Stop the machine, and observe the value. Keep it and no higher than -0.09Mpa is OK. If the value rises up quickly, it means leak obviously. Check it carefully and exclude the leakingpoint (sealing by the sealingepoxy) until the air tightness is OK.

11. 进胶：气密性检验合格后，安装好进胶管线，并用夹具夹住管线末端。依据荒料大小及环境 气温配置适量胶水，将管线末端插入胶水底部，停真空泵，松开夹具，进行进胶。胶水快进完时，在此快速夹住管线，防止空气进入。荒料顶部被胶水浸渍可视为进胶完毕。进胶过程中， 荒料内部真空度会下降，若压力表压力稳定在-0.07Mpa 以下，则无需启动真空泵，若压力表超过此值则启动真空泵至最低压力，再停泵进胶直至进胶完成。

Inject the epoxy: After the air tightness is qualified, install the pipe for epoxy, and clamp the end of pipe. Prepare the vacuum perfusion epoxy according to the sizeofblock and temperature. Put the pipe into the bottom of epoxy, stop the pump, andloosen the clamp and start to inject the epoxy. When the epoxy is almost finished, that is the top of block is dipping by the epoxy, clamp the epoxy pipe quickly to avoid air entrance. In the process of injection, the vacuum degree drops. If the value is lower than-0.07Mpa steadily, no need for vacuum machine. Or start the vacuum pump until -0.07Mpa. and stop it until the epoxy is finished.

12. 稳压：胶水进毕，持续开启真空泵至胶水初固化，停泵。切断真空管路，清理树脂收集器中

树脂，进行下一颗荒料的操作。

Keep the pressure: After the epoxy is finished, turn on the machine continuously until thePreliminary curing, stop the machine. Switch off the vacuum pipe. Clear up the epoxy inepoxy collector and proceed another block.

三． 注意事项 Precautions

1. 真空泵：定期更换真空泵油，详细情况请参照真空泵说明书。

Vacuum perfusion machine: change oil for the machine regularly, pls see <The instructionof vacuum perfusion machine >accordingly.

2. 控制柜：请参照指令说明书进行设定参数。

Control cabinet: see < Instruction manual> to setting parameters

3. 树脂收集器：树脂收集器内胆使用前要均匀涂覆一层脱模剂，每次操作完成需及时清理收集器

固化的胶水。

Epoxy collector: smear a Stripping wax before operation and clear up the curing epoxy intime.

4. 安全

施工现场接电需通知专业人士并确认，设备需放置于干燥、阴凉场地。

Safety: If connect the power supply in the construction site, it must inform and be confirmed by professional. The equipment must be place in dry and cool

附：工艺流程示意图 Att: Process flow chart

清洗、晾干荒料 --枕木包覆 --铺放立体塑料 --铺放导流 --荒料入 --尖锐边角处铺放透气毡，裁剪并连接 --预留压力表座、抽气口 --座、进胶座，铺放导流管、导气管 --塑料袋密 --安装压力表，连接抽气嘴、树脂收集器、真空泵， --启动真空泵抽气并检查 --安装进胶嘴，视荒料具体情况称量胶 --水平调和均匀 --停泵，进胶 --静态渗透，视情况补胶--启泵至胶水初固 --静置固化--三到七天可锯切。