CN103496926B - A kind of manufacture method of producing prestressed concrete waveform sheet pile - Google Patents
A kind of manufacture method of producing prestressed concrete waveform sheet pile Download PDFInfo
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Abstract
The present invention relates to a kind of manufacture method of producing prestressed concrete waveform sheet pile, it is characterized in that, carry out as follows: the preparation of concrete mixture; The making of Steel Reinforcement Cage; Die-filling; Prestressed stretch-draw; Concrete material cast and vibratory compaction; Prestress is put and is opened and form removal; A unitary mould after putting is transported to assembling pedestal, adopts ad hoc automatic switch device to open limit mould, can take out finished product sheet pile, and cleaning mould, coating release agent, turn next Production Flow Chart; Inspection warehouse-in.Production efficiency of the present invention is high; Working environment improves; Labor strength reduces; Constant product quality; Safety coefficient is high; Energy consumption is low; Product mechanical property is better.
Description
Technical field
The present invention relates to the material of construction, particularly a kind of prestressed concrete waveform sheet pile of the architectural exterior-protecting constructions such as a kind of novel gear soil of field of civil engineering, bank protection, cofferdam.
Background technology
Current field of civil engineering, the material of construction form of the architectural exterior-protecting construction existed is more, and the conventional supporting structures such as provisional gear soil, bank protection, cofferdam have: steel sheet pile, rail pile, H profile steel stake, three axle cement mixing pile diaphragm walls (stake of SMW engineering method), rotary churning pile, continuous wall, flat type piling bar, pre-base stake and other engineering method or wooden sheet pile etc.; Permanent retaining support structures have: cast-in-place method underground diaphragm wall, gravity type boat davit Reinforced Concrete Retaining Walls, cast-in-place cast-in place pile, the prefabricated U-shaped concrete sheet-piling of pedestal method etc.
Traditional supporting construction adopts the method for cast-in-site mostly, and the construction period is long, work efficiency is low, construction costs is high, working procedure is complicated, texture quality is unstable.
Within nearly 2 years, there is a kind of prefabricated U-shaped concrete sheet-piling of close product of pedestal method explained hereafter in support engineering at home and abroad, because have the advantages such as the native area of gear is large, pile body flex resistance is good, construction organization is simple and easy, obtained in part engineering and apply among a small circle.But because prefabricated U-shaped concrete sheet-piling adopts the manufacture method of traditional fixing punching block pedestal method explained hereafter, production model limitation causes production capacity low, molding mode is backward causes overall degree of compactness uneven, therefore its production efficiency low, work under bad environment, labor strength is large, unstable product quality, potential safety hazard are large, vapor cure mode is limited to and caused curing time long and intensity is irregular, energy consumption is excessive, and energy consumption is high; In addition, its end is not because have special-purpose metal part guard member, so pile body durable resistance is bad; make its antifatigue damage capability poor, in hammer-impact construction pile driving process, the hammer impact power of hammer body directly acts on pile crown concrete; in injection, pile crown is very easily damaged, affects construction quality.Therefore, traditional processing technology has limited to the raising of quality product and production capacity.
In sum, the technological deficiency of product is caused for the rudimentary of the existing manufacture method due to fixing punching block pedestal method explained hereafter, the manufacture method of a kind of unit flowing water of special needs explained hereafter prestressed concrete waveform sheet pile, to solve above-mentioned technical problem.
Summary of the invention
The present invention is to provide a kind of manufacture method of producing prestressed concrete waveform sheet pile, contribute to solving the rudimentary of the existing manufacture method due to fixing punching block pedestal method explained hereafter and causing the problems such as the technological deficiency of product.
The invention is characterized in: a kind of manufacture method of producing prestressed concrete waveform sheet pile, is characterized in that, carries out as follows:
1) preparation of concrete mixture: the technical requirements according to waveform sheet pile product of main raw material(s) cement, stone, sand, water, admixture and the requirement of production technique, the concrete mix of design specialized, concrete strength design grade is C60; Requirement for main raw material(s) is: cement should adopt strength grade to be not less than silicate cement, ordinary Portland cement, the Portland blast furnace slag cement of 42.5 grades, and quality should meet the regulation of GB175; Fine aggregate should adopt clean natural hard medium coarse sand or artificial sand, and fineness modulus is preferably 2.5-3.2, and quality should meet the relevant regulations of GB/T14684, and chloride ion content is not more than 0.01%, and sulfide and sulphate content are not more than 0.5%; Coarse aggregate should adopt the cobble of rubble or fragmentation, its maximum particle diameter should not be greater than 25mm, and must not exceed 3/4 of distance of reinforcing bar, and quality should meet the relevant regulations of GB/T14685, and the silt content of coarse aggregate is not more than 0.5%, sulfide and sulphate content are not more than 0.5%; For the waveform sheet pile having freeze proof, impervious or other particular requirement, its aggregate used should meet the regulation of relevant criterion; The concrete batching and mixing tower automatic charging controlled by Computerized intelligent, precisely weighing, order feed intake, stir, the concrete mixture made, its serviceability such as workability, the slump could be realized good, meet the requirement of on-the-spot punching block casting, ensure that strength grade of concrete reaches intrinsic requirement simultaneously; ;
2) making of Steel Reinforcement Cage: deformed bar carries out accurate straightening, cut-out on Reinforcing Steel Adjusting Cutter, send into mechanical upsetting press heading, then on Steel Reinforcement Cage workbench, jointly carry out with manufactured stirrup the reinforcement cage skeleton that colligation becomes waveform sheet pile;
3) die-filling: the punching block adopting a kind of entirety, there is intensity high, rigidity is strong, be out of shape little, electric power, pneumatic automatic shutter mode structure, punching block can be installed the end plate of prefabricated prestressed reinforcement of tensioning, pre-buried jetting hole pipe fitting accessory easily, and the reinforcement cage skeleton of waveform sheet pile good for colligation is inserted in the stretch-draw groove making prestress main muscle heading embedding end plate, so that next step prestressed stretch-draw;
4) prestressed stretch-draw: be equipped with end plate at the two ends of reinforcement cage skeleton, realizes carrying out Pretensioned prestressing stretch-drawing technique on punching block;
5) concrete material cast and vibratory compaction: after prestressed stretch-draw operation completes, the concrete material stirred through concrete batching and mixing tower is distributed in mould by concrete distributing car, require to carry out the vibration of frequency low-amplitude formula by the shaking table be arranged under punching block according to technological standards during cloth, make concrete material evenly, shaping densely, to ensure pile concrete structural strength;
6) component conservation: quietly under normal temperature state after molding procedure completes stop maintenance 90-120 minute, again unitary mould is put into curing pool to carry out have employed thermal medium directed circulation high temperature steam curing technique, thermal medium steam is circulated at curing pool interior orientation, give full play to its thermo-efficiency effect, ensure the thermal curing effect of product;
7) prestress is put and is opened and form removal: after completing curing cycle according to steam curing process system, unitary mould is hung and sends curing pool and all with claiming unclamp prestressed stretch-draw securing gear;
8) unitary mould after putting is transported to assembling pedestal, adopts ad hoc automatic switch device to open limit mould, can take out finished product sheet pile, and cleaning mould, coating release agent, turn next Production Flow Chart;
9) inspection warehouse-in: the inspection carrying out product appearance quality and size by root sheet pile by company standard, carry out physical and mechanical property detection by regulation sampling, brush mark by regulation, finished product is put in storage, stacks and maintenance by regulation.
Wherein, if when engine request waveform sheet pile pile concrete design strength reaches C80, then in step 8) adopt secondary autoclave curing technology afterwards, waveform sheet pile pile body after the demoulding must be sent in autoclave and carry out secondary autoclave curing, or adopt non-evaporating pressure concrete formulation technology, namely waveform sheet pile concrete strength of pile design grade can be brought up to C80.
Advantage of the present invention: tool of the present invention has the following advantages:
1, production efficiency is high: adopt workshop streamline operration in factory, mechanization degree is high, and plant factor is high, and workman's staffing is determined a post, highly specialized, and flow beat is stablized, and production efficiency is high.
2, Working environment improves: owing to being that in factory floor, streamline operration is produced, avoid the harsh environments that the outdoor direct labor of pedestal method is exposed to wind and rain year in year out, throughout the year can continuous and stable production, good work environment.
3, labor strength reduces: because workman is that staffing is determined a post, workpiece flowing water, and is equipped with mechanical means by processing requirement, so mechanization degree is high, greatly reduces the labour intensity of workman.
4, constant product quality: this product structure design is reasonable, and production environment streamline is stablized, have employed a lot of science, advanced production technique, staffs training is on duty, and each procedure is rigid in checking up, detects, and ensure that the excellent of end product quality.
5, safety coefficient is high: because streamline is the production process that the continuous print completing process operation according to unified production rate (beat) repeats, so place of working is highly specialized, technological process is closed, unidirectional, so compared with pedestal method, when workman produces, safety coefficient is high.
6, energy consumption is low: this streamline is according to the professional steam curing pond of structure design of product, have employed thermal medium directed circulation maintaining process, thermal medium steam is circulated at curing pool interior orientation by specific equipment, give full play to its thermo-efficiency effect, ensure the thermal curing effect of product, the energy (steam) simultaneously greatly reducing unit product consumes, and reaches the object of save energy.
7, product mechanical property is better: closely knit by the product concrete structure of this production line balance, effective prestress value is high, particularly the two ends of waveform sheet pile are provided with special steel plate end plate, loss of prestress is few, product stable mechanical property, bending resistance, resistance to cleavage are good, and pile body antifatigue damage capability improves greatly, thus can ensure the quality of whole engineering.
Embodiment
The present invention relates to a kind of manufacture method of producing prestressed concrete waveform sheet pile, carry out as follows:
1) preparation of concrete mixture: the technical requirements according to waveform sheet pile product of main raw material(s) cement, stone, sand, water, admixture and the requirement of production technique, the concrete mix of design specialized, concrete strength design grade is C60; Requirement for main raw material(s) is: cement should adopt strength grade to be not less than silicate cement, ordinary Portland cement, the Portland blast furnace slag cement of 42.5 grades, and quality should meet the regulation of GB175; Fine aggregate should adopt clean natural hard medium coarse sand or artificial sand, and fineness modulus is preferably 2.5-3.2, and quality should meet the relevant regulations of GB/T14684, and chloride ion content is not more than 0.01%, and sulfide and sulphate content are not more than 0.5%; Coarse aggregate should adopt the cobble of rubble or fragmentation, its maximum particle diameter should not be greater than 25mm, and must not exceed 3/4 of distance of reinforcing bar, and quality should meet the relevant regulations of GB/T14685, and the silt content of coarse aggregate is not more than 0.5%, sulfide and sulphate content are not more than 0.5%; For the waveform sheet pile having freeze proof, impervious or other particular requirement, its aggregate used should meet the regulation of relevant criterion; The concrete batching and mixing tower automatic charging controlled by Computerized intelligent, precisely weighing, order feed intake, stir, the concrete mixture made, its serviceability such as workability, the slump could be realized good, meet the requirement of on-the-spot punching block casting, ensure that strength grade of concrete reaches intrinsic requirement simultaneously;
2) making of Steel Reinforcement Cage: deformed bar carries out accurate straightening, cut-out on Reinforcing Steel Adjusting Cutter, send into mechanical upsetting press heading, then on Steel Reinforcement Cage workbench, jointly carry out with manufactured stirrup the reinforcement cage skeleton that colligation becomes waveform sheet pile;
3) die-filling: the punching block adopting a kind of entirety, there is intensity high, rigidity is strong, be out of shape little, electric power, pneumatic automatic shutter mode structure, punching block can be installed the end plate of prefabricated prestressed reinforcement of tensioning, pre-buried jetting hole pipe fitting accessory easily, and the reinforcement cage skeleton of waveform sheet pile good for colligation is inserted in the stretch-draw groove making prestress main muscle heading embedding end plate, so that next step prestressed stretch-draw;
4) prestressed stretch-draw: be equipped with end plate at the two ends of reinforcement cage skeleton, realizes carrying out Pretensioned prestressing stretch-drawing technique on punching block;
5) concrete material cast and vibratory compaction: after prestressed stretch-draw operation completes, the concrete material stirred through concrete batching and mixing tower is distributed in mould by concrete distributing car, require to carry out the vibration of frequency low-amplitude formula by the shaking table be arranged under punching block according to technological standards during cloth, make concrete material evenly, shaping densely, to ensure pile concrete structural strength;
6) component conservation: quietly under normal temperature state after molding procedure completes stop maintenance 90-120 minute, again unitary mould is put into curing pool to carry out have employed thermal medium directed circulation high temperature steam curing technique, thermal medium steam is circulated at curing pool interior orientation, give full play to its thermo-efficiency effect, ensure the thermal curing effect of product;
7) prestress is put and is opened and form removal: after completing curing cycle according to steam curing process system, unitary mould is hung and sends curing pool and all with claiming unclamp prestressed stretch-draw securing gear;
8) unitary mould after putting is transported to assembling pedestal, adopts ad hoc automatic switch device to open limit mould, can take out finished product waveform sheet pile, and cleaning mould, coating release agent, turn next Production Flow Chart;
9) inspection warehouse-in: the inspection carrying out product appearance quality and size by root waveform sheet pile by company standard, carry out physical and mechanical property detection by regulation sampling, brush mark by regulation, finished product is put in storage, stacks and maintenance by regulation.
If when engine request waveform sheet pile pile concrete design strength reaches C80, then in step 8) adopt secondary autoclave curing technology afterwards, waveform sheet pile pile body after the demoulding must be sent in autoclave and carry out secondary autoclave curing, or adopt non-evaporating pressure concrete formulation technology, namely waveform sheet pile concrete strength of pile design grade can be brought up to C80.
Specific implementation process:
The manufacture method of employing unit flowing water explained hereafter prestressed concrete waveform sheet pile is:
1) preparation of concrete mixture: the technical requirements according to waveform sheet pile product of main raw material(s) cement, stone, sand, water, admixture and the requirement of production technique, the concrete mix of design specialized, concrete strength design grade is C60; Requirement for main raw material(s) is: cement should adopt strength grade to be not less than silicate cement, ordinary Portland cement, the Portland blast furnace slag cement of 42.5 grades, and quality should meet the regulation of GB175.Fine aggregate should adopt clean natural hard medium coarse sand or artificial sand, and fineness modulus is preferably 2.5-3.2, and quality should meet the relevant regulations of GB/T14684, and chloride ion content is not more than 0.01%, and sulfide and sulphate content are not more than 0.5%.Coarse aggregate should adopt the cobble of rubble or fragmentation, its maximum particle diameter should not be greater than 25mm, and must not exceed 3/4 of distance of reinforcing bar, and quality should meet the relevant regulations of GB/T14685, and the silt content of coarse aggregate is not more than 0.5%, sulfide and sulphate content are not more than 0.5%.For the waveform sheet pile having freeze proof, impervious or other particular requirement, its aggregate used should meet the regulation of relevant criterion.The concrete batching and mixing tower automatic charging controlled by Computerized intelligent, precisely weighing, order feed intake, stir, the concrete mixture made, its serviceability such as workability, the slump could be realized good, meet the requirement of on-the-spot punching block casting, ensure that strength grade of concrete reaches intrinsic requirement simultaneously.
2) making of Steel Reinforcement Cage: deformed bar carries out accurate straightening, cut-out on special Reinforcing Steel Adjusting Cutter, send into mechanical upsetting press heading, then on Steel Reinforcement Cage workbench, jointly carry out with manufactured stirrup the reinforcement cage skeleton that colligation becomes waveform sheet pile.
3) die-filling: this streamline uses a kind of punching block of entirety, has intensity high, rigidity is strong, is out of shape little, electric power, pneumatic automatic shutter mode structure.Punching block can be installed the accessory such as the end plate of prefabricated prestressed reinforcement of tensioning, pre-buried jetting hole pipe fitting easily, and the reinforcement cage skeleton of waveform sheet pile good for colligation is inserted in the stretch-draw groove making prestress main muscle heading embedding end plate, so that next step prestressed stretch-draw.
4) prestressed stretch-draw: this manufacturing process is owing to have employed a kind of punching block of entirety, end plate is equipped with at the two ends of reinforcement cage skeleton, therefore can be implemented on punching block and carry out Pretensioned prestressing stretch-drawing technique, it is high that this technique has stretching control force precision, the benefits such as anchoring is reliable, easy and simple to handle.
5) concrete material cast and vibratory compaction: after prestressed stretch-draw operation completes, the concrete material stirred through concrete batching and mixing tower is distributed in mould by concrete distributing car, require to carry out the vibration of frequency low-amplitude formula by the shaking table be arranged under punching block according to technological standards during cloth, make concrete material evenly, shaping densely, to ensure pile concrete structural strength.
6) component conservation: quietly under normal temperature state after molding procedure completes stop maintenance 90-120 minute, again unitary mould is put into curing pool to carry out have employed thermal medium directed circulation high temperature steam curing technique, thermal medium steam is circulated at curing pool interior orientation by specific equipment, give full play to its thermo-efficiency effect, ensure the thermal curing effect of product
7) prestress is put and is opened and form removal: after completing curing cycle according to steam curing process system, unitary mould is hung and sends curing pool and all with claiming unclamp prestressed stretch-draw securing gear, the form of end plate anchoring not only can allow the main muscle of all prestress even tension in stretching process, and efficiently solve to put after loss of prestress problem, effective prestress value is avoided to reduce, improve pile body bending resistance and resistance to cleavage, steel end plate is set, pile crown can be protected better, substantially increase durable resistance, cut down the stressed disrepair phenomenon of pile crown fatigability in construction process, ensure construction quality.
8) unitary mould after putting is transported to assembling pedestal, adopts ad hoc automatic switch device to open limit mould, can take out finished product waveform sheet pile.Cleaning mould, coating release agent, turn next Production Flow Chart.
9) secondary autoclave curing technology: if engineering has particular requirement, waveform sheet pile concrete strength of pile design grade can bring up to C80, then the waveform sheet pile pile body after the demoulding must be sent in autoclave and carry out secondary autoclave curing, or adopt non-evaporating pressure concrete formulation technology, the mechanical property of such product is better, and suitability is wider.
10) inspection warehouse-in: the inspection carrying out product appearance quality and size by root waveform sheet pile by company standard, carry out physical and mechanical property detection by regulation sampling, brush mark by regulation, finished product is put in storage, stacks and maintenance by regulation.
The foregoing is only preferred embodiment of the present invention, all equalizations done according to the present patent application the scope of the claims change and modify, and all should belong to covering scope of the present invention.
Claims (1)
1. produce a manufacture method for prestressed concrete waveform sheet pile, it is characterized in that, carry out as follows:
1) preparation of concrete mixture: the technical requirements according to waveform sheet pile product of main raw material(s) cement, stone, sand, water, admixture and the requirement of production technique, the concrete mix of design specialized, concrete strength design grade is C60; Requirement for main raw material(s) is: cement should adopt strength grade to be not less than silicate cement, ordinary Portland cement, the Portland blast furnace slag cement of 42.5 grades, and quality should meet the regulation of GB175; Fine aggregate should adopt clean natural hard medium coarse sand or artificial sand, and fineness modulus is preferably 2.5-3.2, and quality should meet the relevant regulations of GB/T14684, and chloride ion content is not more than 0.01%, and sulfide and sulphate content are not more than 0.5%; Coarse aggregate should adopt the cobble of rubble or fragmentation, its maximum particle diameter should not be greater than 25mm, and must not exceed 3/4 of distance of reinforcing bar, and quality should meet the relevant regulations of GB/T14685, and the silt content of coarse aggregate is not more than 0.5%, sulfide and sulphate content are not more than 0.5%; For the waveform sheet pile having freeze proof, impervious or other particular requirement, its aggregate used should meet the regulation of relevant criterion; The concrete batching and mixing tower automatic charging controlled by Computerized intelligent, precisely weighing, order feed intake, stir, the concrete mixture made, its serviceability such as workability, the slump could be realized good, meet the requirement of on-the-spot punching block casting, ensure that strength grade of concrete reaches intrinsic requirement simultaneously;
2) making of Steel Reinforcement Cage: deformed bar carries out accurate straightening, cut-out on Reinforcing Steel Adjusting Cutter, sends into mechanical upsetting press heading, then on Steel Reinforcement Cage workbench, jointly carries out the reinforcement cage skeleton that colligation becomes waveform sheet pile with manufactured stirrup;
3) die-filling: the punching block adopting a kind of entirety, there is intensity high, rigidity is strong, be out of shape little, electric power, pneumatic automatic shutter mode structure, punching block can be installed the end plate of prefabricated prestressed reinforcement of tensioning, pre-buried jetting hole pipe fitting accessory easily, and the reinforcement cage skeleton of waveform sheet pile good for colligation is inserted in the stretch-draw groove making prestress main muscle heading embedding end plate, so that next step prestressed stretch-draw;
4) prestressed stretch-draw: be equipped with end plate at the two ends of reinforcement cage skeleton, realizes carrying out Pretensioned prestressing stretch-drawing technique on punching block;
5) concrete material cast and vibratory compaction: after prestressed stretch-draw operation completes, the concrete material stirred through concrete batching and mixing tower is distributed in mould by concrete distributing car, require to carry out the vibration of frequency low-amplitude formula by the shaking table be arranged under punching block according to technological standards during cloth, make concrete material evenly, shaping densely, to ensure pile concrete structural strength;
6) component conservation: quietly under normal temperature state after molding procedure completes stop maintenance 90-120 minute, again unitary mould is put into curing pool to carry out have employed thermal medium directed circulation high temperature steam curing technique, thermal medium steam is circulated at curing pool interior orientation, give full play to its thermo-efficiency effect, ensure the thermal curing effect of product;
7) prestress is put and is opened and form removal: after completing curing cycle according to steam curing process system, unitary mould is hung and sends curing pool and all with claiming unclamp prestressed stretch-draw securing gear;
8) prestress to put after unitary mould be transported to assembling pedestal, adopt ad hoc automatic switch device to open limit mould, can take out finished product waveform sheet pile, cleaning mould, coating release agent, turn next Production Flow Chart;
9) inspection warehouse-in: the inspection carrying out product appearance quality and size by root waveform sheet pile by company standard, carry out physical and mechanical property detection by regulation sampling, brush mark by regulation, finished product is put in storage, stacks and maintenance by regulation.
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| CN103979892B (en) * | 2014-05-13 | 2016-03-23 | 河南省第二公路工程有限公司 | Concrete prefabricated element that a kind of stone is evenly distributed and preparation method thereof |
| CN104609798B (en) * | 2014-12-26 | 2018-04-27 | 北京惠诚基业工程技术有限责任公司 | A kind of manufacturing technique method of Reactive Powder Concrete noise barrier structure component |
| CN105672249A (en) * | 2016-03-28 | 2016-06-15 | 福建省闽工新型建材有限公司 | Concrete channel plate pile and manufacturing method thereof |
| CN109760198A (en) * | 2017-11-09 | 2019-05-17 | 温州强宏建材有限公司 | A kind of prestressing force prefabricated pile production technology |
| CN110258190B (en) * | 2019-07-05 | 2024-05-28 | 中铁第四勘察设计院集团有限公司 | Ballast blocking wall structure of corrugated steel web of common-speed and heavy-load railway and construction method of ballast blocking wall structure |
| CN112557216B (en) * | 2020-11-16 | 2023-07-18 | 中冶集团武汉勘察研究院有限公司 | Method and device for testing shear strength index of foundation pit support |
| CN113650130A (en) * | 2021-08-12 | 2021-11-16 | 国网吉林省电力有限公司延边供电公司 | Method for processing wall member steel formwork |
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| CN103317596A (en) * | 2013-05-30 | 2013-09-25 | 上海大禺预制构件有限公司 | Method for manufacturing prestressed centrifugal anti-corrosion concrete hollow square piles through pre-tensioning method |
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| CN103317596A (en) * | 2013-05-30 | 2013-09-25 | 上海大禺预制构件有限公司 | Method for manufacturing prestressed centrifugal anti-corrosion concrete hollow square piles through pre-tensioning method |
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