3.1. Creation of an Analysis Model
In world practice, there are two methods for constructing multilayer rigid layers of reinforcement of floor slabs: according to the splicing scheme, when structural and technological measures are used to “glue” the coating layers, and according to the build-up scheme, when the sliding of the coating layers relative to each other is ensured. The most inexpedient application of the splicing method is due to the high labor intensity and the presence of a large number of through cracks in the lower layer after a certain time of the coating operation. On the other hand, in the design plan, the coatings built by the splicing method do not fundamentally differ from single-layer when calculating the effect of operational loads. The BFM reinforcement layer technology ensures reliable adhesion of the layers, and the bearing capacity of the multilayer system practically does not differ from the corresponding single-layer monolithic one. In this case, the design moment can be determined by the formulas for calculating single-layer floor slabs, based on the value of the characteristics of the layered coating [
40,
41,
42,
43].
When calculating the thickness of the BFM reinforcement layer, it was proceeded from the solutions of structural mechanics for slabs. For slabs, this condition is expressed by the general differential equation [
44,
45].
where ω—slab deflection;
x,
y—coordinates of the middle plane of the slab;
P0(
x,
y)—normal response function;
q0(
x,
y)—external load function;
D—cylindrical stiffness of the slab
D =
;
Eb, ν—respectively, the modulus of elasticity and Poisson’s ratio of the slab material;
t—slab thickness.
The method for solving problems of the operation of multilayer coatings under the influence of operational loads was taken as the basis for substantiating the design scheme and principles of designing layers from dispersed reinforced concrete of the reinforcement layer in the study. It simplifies, if possible, the model prerequisites for describing the operation of layers, where the bearing layers are represented by classical Kirchhoff-Love plates. In this case, when solving problems, the maximum possible number of design features of coatings is taken into account and, in combination with appropriate experimental studies, the method allows us to consider the whole variety of coatings designs and meet the needs of their practical application.
As a design scheme, a model was adopted, according to which the planned operational loads affect the floor slab with a reinforcement layer from the BFM. It has believed that the layers do not peel off from each other during deformation. Within each layer, elastic modulus, density and thickness are constant, but not the same for different layers. These hypotheses, together with Hooke’s law, make it possible to obtain well-known formulas for the forces acting on a rectangular element of the wear layer from the BFM.
The calculation of multilayer slabs according to the Kirchhoff-Love theory is typical for slabs with a ratio of thicknesses of rigid layers of 1:1, since it allows one to determine the stress-strain state of a slab from the action of bending moments caused by a vertical load. The influence of horizontal loads in calculating the strength of a multilayer slab structure is not taken into account by the existing methods and regulations, since the growth of longitudinal tangential stresses along the depth of the upper layer of reinforcement from the BFM is slower than the very effect on this layer of the vertical load.
The stress in the BFM amplification layer is determined by the formula [
45,
46]:
where
φ—stress function;
uz—displacement by horizontal forces.
To numerically implement the adopted model and find the values of deflections ω of the slab structures and displacements u of the reinforcement layer, SCAD software is used.
3.2. Experimental Part
The production of a reinforcement BFM layer includes technological processes for the preparation, transportation, laying and distribution of the mix into the coating, its processing, care of the laid concrete and curing until the demolding strength.
The issues of introducing fibers into mortar are of great importance. High-quality production of a fiber-reinforced mortar can be achieved provided that a uniform and gradual supply of BFM to the concrete mixer is ensured while the components of the basalt-fiber concrete mixture are mixed in it. The homogeneity of the mix and the strength of the concrete are greatly influenced by the mixing time. In case of insufficient duration of concrete mixing, the homogeneity of the concrete deteriorates and its strength decreases. An increase in the mixing time beyond the optimal one (the strength of concrete increases, but extremely insignificantly) negatively affects the properties of the BFM. This is due to the fact that an increase in the mixing time of the basalt fiber mortar mix leads to a decrease in the reinforcing effect of basalt fiber (the ratio of the fiber length to its diameter) due to the mechanical action on the fiber and its crushing. The optimum mixing time can only be determined experimentally.
In slab reinforcement layer technology, the most important task is to achieve maximum layer density and a strong bond with old concrete.
According to [
47], for basalt fiber concrete mixes, the vibration amplitude should be within 0.5 mm for vibrating bars with a vibration frequency of 50 Hz (3000 per min). Large vibration amplitudes (A = 1–2 mm) without weights cause loosening of the basalt fiber concrete mix and worsen the properties of the BFM.
It is known that the physical and mechanical properties of concrete also depend on the voidness of the aggregates and its changes during the preparation of mortar mixes [
48,
49]. Previous studies [
47] show that when the sand is saturated with fiber, the porosity of the mix decreases until the optimum degree of saturation is reached (with the BF content μ
s = 8% of the sand mass). After that, the decrease in the porosity of the mix ceases, and with a further increase in the BF content, its growth is observed, characterized by an excess amount of the mix that did not enter the measuring vessel. Then a moment comes when the porosity of the basalt fiber-reinforced concrete mix turns out to be greater than the porosity of the original sand and lumps are formed from the interwoven BF (when the BF content μ
s > 16% of the sand mass). This can be explained by the fact that when the BF content is μ
s ≤ 8% of the mass of sand, in the process of compaction, BFs are additional vibration centers, occupy part of the voids in the sand, and are composited more densely than sand without BF. With an increase in the content of BF 8 < μ
s ≤ 16% of the mass of sand, BF forms spatial frameworks in the sand, thereby worsening compaction and increasing the porosity of the basalt fiber mortar. It is known that the porosity of the basalt fiber mortar mainly depends on the voidness of the original sand, while the porosity of the basalt fiber mortar remains constant regardless of the type of sand.
The results of studies of the duration of vibration treatment of coatings using the BFM reinforcement layers, depending on the stiffness of the basalt fiber mortar mixture, according to the experiment planning matrix and 17 points of the plan, are given in
Table 4. The duration of vibration treatment was measured using a stopwatch with an accuracy of 1 s in a series of 6 specimens. The specimens were made according to the developed research methodology, in accordance with the plan for the laboratory experiment.
The prepared basalt fiber mortar was unloaded from the concrete mixer and layer-by-layer, according to the plan of the experiment, was placed in metal molds, which were fixed on the vibration platform (
Figure 2a). The molds were preliminarily lubricated from the inside with machine oil with a layer of about 0.5 mm. During the first 30 s of vibration, all mold nests were uniformly filled with solution (
Figure 2b). For the complete filling of the form, the total vibration time was 1.5 min. The excess solution was removed with a wiped with a damp cloth with a knife at a slight angle to the surface and smoothed with light pressure.
The required degree of compaction of coatings with special-purpose layers made of BFM is ensured when using vibrating platforms with an oscillation amplitude of A = 0.3–0.5 mm and a frequency of f = 75–50 Hz, and the compaction duration t depends on the stiffness of the basalt fiber-reinforced concrete mix tq and is t = 2.5tq.
The results of the investigated factors are presented in
Table 5.
After two years of operation, a survey of the reinforcement layer of the floor slabs was carried out (
Figure 3), based on the results of which a defective statement was drawn up (
Table 6).
Using the MatLab software, regression equations are obtained for calculating the physical and mechanical properties of the coating specimens:
Thus, the experimental and theoretical methods were adopted as the main research ones. There are based on theoretical studies of the interaction of a layer of the BFM reinforcement from with traditional concrete and technological factors in layer-by-layer concreting of coatings.
As a result of the economic calculations, it was revealed that the introduction of the proposed technology makes it possible to completely eliminate the consumption of reinforcing steel; reduce energy consumption by 8–10%, as well as decrease the cost of coating production by 20–30%. In addition, harmful emissions of products of electric or gas welding into the atmospheric air are excluded due to their complete reduction.