Summary of the invention
The object of the invention is to overcome above-mentioned deficiency existing in prior art, one is provided to prevent pre-tensioning system precast track plate four side ixoderms, occur too much pore or occur macropore, prevent from building local segregation when vibrating, control the vibrating method to pre-tensioning system precast track plate of laitance thickness at below 12mm.
In order to realize foregoing invention object, the invention provides following technical scheme:
The vibrating method of pre-tensioning system precast track plate, the steps include:
A, with rectangular array deployment rails board mold, around array, arrange anchor plate, outside anchor plate, arrange stretch-draw counter force wall, all reserved anchor hole on described mould, anchor plate, stretch-draw counter force wall;
B, arrangement prestress reinforcing bar, make it in horizontal cross, vertical be upward through described anchor hole, two ends are fixed on anchor plate or stretch-draw counter force wall, all arrange steel bar tensioning device in the middle part of the deformed bar in the middle part of the deformed bar between mould adjacent on same straight line, between mould and anchor plate;
C, the crossbeam being provided with the motor that vibrates is horizontally disposed with at mold bottom, the motor that vibrates also is installed in mould side, adopt the end shake combination limit shake, alternately vibration is (if vibrated simultaneously, to cancel out each other Sasser, weaken oscillation effect, alternately vibration can make the vibration of mould not only in a direction simultaneously, prevent the mould inside of the concrete in mould to a direction from repeatedly pasting, there is side ixoderm) mode mould is vibrated, on the same beam installing the motor that vibrates, the distance of two motors that vibrate is greater than 2.0m, find in test, with concrete, whether slump size occurs that local segregation phenomenon phenomenon is relevant, the slump is large, particularly react and to vibrate between motor and local segregation easily appears in model corner at two, so make after improving installation vibrate motor same beam on the distance of two motors that vibrate be greater than 2.0m, coordinate the control of the slump again, eliminate local segregation phenomenon,
D, in units of the speed of the height change of concrete in mould, slump 60-120mm is built (as above-mentioned with the speed of 7-12mm/min, control the scope of the slump) concrete, vibrate motor with 105-115Hz (slump size and the frequency dependence that vibrates during building, the slump vibrate greatly need frequency low, otherwise frequency is high, and concrete slump within the specific limits in, the frequency of motor of vibrating also has impact to the manufacturing effect of track plates) vibration frequency vibrates, simultaneously, vibrate with said method, can ensure in 0-12mm laitance thickness, simultaneously in the application's data area, too much pore can be prevented or occur macropore.
As preferred version of the present invention, in step D process, to die edge bleeding, when interior formwork amount no longer increases, (normal condition has a large amount of bubble and occurs, when bubble no longer increases, illustrate that the discharge of the air in concrete reaches requirement), stop building and vibrating.
As preferred version of the present invention, in step D, pour in two stages by groundwater increment, and corresponding two benches vibrates, first stage perfusion is cloth perfusion, groundwater increment 0-80%, the motor that vibrates vibrates with 105Hz vibration frequency, second stage perfusion is froth breaking perfusion, groundwater increment 80-100%, and the motor that vibrates vibrates with 115Hz vibration frequency, in the froth breaking stage, need the vibration of high frequency, so the vibration frequency of the motor that vibrates needs high frequency, to reach the object of froth breaking.
As preferred version of the present invention, described anchor plate surrounds rectangular frame around mould, the crossbeam being provided with the motor that vibrates that described mold bottom is arranged comprises girder and auxiliary girder, and girder is parallel with the length direction of anchor plate rectangular frame, between two row's moulds, connecting mold side, two ends, it is all provided with the motor that vibrates, and described auxiliary girder is arranged in parallel, all parallel with girder, connecting mold side, two ends, the motor that vibrates is installed in the mould side that this junction upwards extends.
As preferred version of the present invention, described girder controls amplitude at 0.8mm-1.3mm, its motor that vibrates is mainly through girder transmitting vibrations stress, control vibrate motor produce vibration stress, to ensure that the amplitude of girder is in safe handling scope, amplitude can also be controlled, as the mode of the torsion of adjusting bolt by bolt etc.
As preferred version of the present invention, described concrete slump is 60mm, and speed of perfusion is 12mm/min, and it can ensure that without laitance, without ixoderm phenomenon, just there is indivedual macropore track plates end and side without local segregation phenomenon.
As preferred version of the present invention, described concrete slump is 80mm, and speed of perfusion is 9mm/min, and it can ensure that without laitance, without ixoderm phenomenon, there is minute quantity pore track plates end and side without local segregation phenomenon.
As preferred version of the present invention, described concrete slump is 100mm, and speed of perfusion is 8mm/min, and it can ensure that laitance thickness 5-8mm, without ixoderm phenomenon, there is minute quantity pore track plates end and side without local segregation phenomenon.
As preferred version of the present invention, described concrete slump is 120mm, and speed of perfusion is 7mm/min, and it can ensure that laitance thickness 8-12mm, without ixoderm phenomenon, there is minute quantity pore track plates end and side without local segregation phenomenon.
Compared with prior art, beneficial effect of the present invention:
1, pre-tensioning system precast track plate four side ixoderms are prevented;
2, prevent pre-tensioning system precast track plate side from occurring too much pore or occurring macropore;
3, local segregation when vibrating is prevented from building;
4, laitance thickness is controlled at below 12mm when building and vibrating.
Detailed description of the invention
Below in conjunction with embodiment and detailed description of the invention, the present invention is described in further detail.But this should be interpreted as that the scope of the above-mentioned theme of the present invention is only limitted to following embodiment, all technology realized based on content of the present invention all belong to scope of the present invention.
Embodiment 1
Clear stipulaties " concrete should adopt attached vibrator to vibrate, and should determine the technological parameters such as vibration frequency, amplitude and time of vibration before concreting according to test " in middle iron 23 intra-office portion is to the manufacturing technology condition of CTRS III type dual-direction pre-tensioning system prestressed concrete track slab; " concrete slump should not be greater than 140mm "; Technical requirements such as " track plates bottom surfaces do not have laitance ".The engineering practice of 23 innings in recent years shows, there are the quality problems of the more or ixoderm of bubble in precast track plate four sides, need during production to make up this open defect by repairing, add labor cost, meanwhile, also there is concrete vibrating segregation problem and local mortar accumulation problem, have a strong impact on the durability of track plates, and wherein laitance thickness also duration exceed standard, a lot of trouble is caused to manufacture process, reduces efficiency and the quality of manufacture.
The compaction rate of concrete perfusion is by vibrating, adhesion type quality of vibrating is subject to the impact of the multiple factors such as the slump, rigidity of model, structural thickness, frequency of vibrating, vibrating time, amplitude simultaneously, so, before steps A, need by concreting speed, local segregation, laitance is observed, product appearance pore quality index is carried out quantitatively, qualitative evaluation, set up concrete vibrating basis, based on this, then the vibrating method tested for CTRS III type dual-direction pre-tensioning system prestressed concrete track slab.
First basic technology condition is determined, dual-direction pre-tensioning system prestressed concrete track slab deformed bar 4 adopts fixed length to design, two ends have screw thread, add anchor plate 2, different from traditional pre-tensioning system production technology, deformed bar 4 needs to carry out stretch-draw (i.e. described steel bar tensioning device 5) by connecting rod and connector, and connecting rod needs to penetrate into model inside, have certain loss to the stress that vibrates, amplitude has certain effect of contraction; Therefore, need stretch-draw counter force wall 3 to reserve between anchor hole, mould anchor hole, anchor plate anchor hole and form a horizontal line, its error≤± 1.5mm.Connecting rod diameter ф 24mm, on model, opening diameter is 30mm, by rubber seal between connecting rod and model, avoids model and connecting rod to vibrate and spillage simultaneously.
Be subject to the impact of deformed bar 4 stretching extension value and anchor plate 2 position, track plates is produced and be have employed 2 × 4 rectangular layout production decisions.
During the demoulding, for eliminating the residual stress between connecting rod, have employed the thick flexible rubber bearing scheme of rectangle 40mm.Rubber support is embedded with steel spring plate, and its Static stiffness index is at upper load 145kN effect deflection≤0.3mm.
Joining Technology layout is shown in Fig. 1.
First carry out controlling amplitude adjustment:
Model manufacturing producer its rigidity different is different, is also the factor that cannot adjust in test, but needs to consider the impact of stress intensity on model fatigue deformation of vibrating in test, therefore, needs the service life of improving model by controlling amplitude in principle.And amplitude is except the power size of vibrating has impact, can also be adjusted by the dynamic stiffness of model bearing, therefore, technique generally installs elastomeric material at model bearing, and elastomeric material needs predefined Static stiffness just can carry out design production, the Static stiffness of this programme elastomeric material equals model quality and product quality sum.Material detects rubber support Static stiffness after arriving factory, requires rubber deformation≤0.3mm under regulation compression.The test of laggard row amplitude installed by model, and under 96kN vibration stress, amplitude is 0.8mm ~ 1.3mm, if do not reach requirement, adjusts amplitude by bolt torque magnitude.
Study the slump again and the relation of frequency of vibrating:
Arrange different from frequency of vibrating according to slump difference, relativeness is in table 1.
The slump and vibrating time arrange table 1
Continue research to vibrate motor 6 position:
The position of motor 6 of vibrating is also comparatively large to quality influence of vibrating, and test adopts asymmetric limit to shake scheme, and model specification is P5600, and model weight is about 65kN, and vibrate motor 6 power 1.5kw, quantity 8, arrangement as Fig. 2,
Analysis result:
1, affect several flaws of quality of vibrating:
Concrete is originally as nonuniformity body, and adhesion type vibrates to have and makes concrete produce the trend of emanating, and therefore, this is a pair Disadvantageous combination, needs to carry out Comprehensive Control by adjustment related process parameters aborning.Up to the present, various specification is not described concrete vibrating quality or is controlled, and pre-manufactured product durability is relevant with quality of vibrating to a great extent, therefore, is necessary to be controlled in process of production.According to the direct relation produced that vibrates, quality of vibrating is carried out quantitatively and qualitative evaluation.
Vibrating time: with the index that production efficiency is relevant.From concrete enters mould, to edge of model bleeding, concrete surface occurs that a large amount of bubble terminates, and uses stopwatch record.
Local segregation (locally " boiling "): the concrete local segregation phenomenon produced for the Stress superposition that vibrates, shows as funnel-form mortar and piles up.By local " boiling " sign, the relation that the same slump of motor 6 position that can judge to vibrate, frequency of vibrating, vibrating time are mutual.Be different from and carry slurry, carry slurry and show as edge of model generation even slurry.
Laitance thickness: be the phenomenon that after vibrating, diameter is less than 0.2mm slurry floating.It is low that laitance has intensity, the feature of the easy peeling of cold and hot change.With the long straight steel ruler test laitance thickness of 30cm.Method stands up in concrete surface by straight steel ruler, treats that it sinks naturally with hand steered, and extract straight steel ruler reading and record after stable, every block board test edge of model quantity is 9 points.Owing to containing large quantity of moisture in laitance, according to test experience, laitance thickness should take advantage of the coefficient in 0.6.
End ixoderm: for concrete roll in a model produce releasing agent obscission, product stripping trailing flank occur decortication, with the naked eye can observe.
Side pore: the phenomenon do not got rid of completely for the bubble that vibrates, after the demoulding, product side occurs that diameter is greater than 2mm hole, can describe with hole diameter and area.
Track plates side pore, end face local ixoderm, movement locus is relevant in a model with concrete for laitance at the bottom of local segregation, plate at the bottom of plate, and horizontal bilateral reciprocation is the basic reason of generation common quality defect, if the A in Fig. 4 is to back and forth.
2, carry out limit and to shake quality evaluation
By in the concrete of the different slump at twice perfusion model, and vibrate at twice.Filling concrete amount is about 80% for the first time, second time groundwater increment 20%.Second time is vibrated complete to quality evaluation of vibrating.Observation situation of vibrating is as follows:
(1) concrete slump is different, required time difference of vibrating, and the slump is larger, and the time is shorter, otherwise longer;
(2) slump size is relevant with frequency of vibrating, and the slump frequency needed of vibrating greatly is low, otherwise frequency is high; (3) whether slump size there is " boiling " phenomenon relevant (segregation) with local, and greatly, particularly reacting vibrates between motor 6 at two easily occurs " boiling " phenomenon with model corner to the slump; See the B place in Fig. 4.
(4) place a handstone can find in edge of model, model does traverse motion.Concrete rolls, and makes the releasing agent of edge of model suck in concrete, has sucked air simultaneously.That ixoderm and pore main cause appear in track plates edge.
(5) edge stress propagation of vibrating meets the principle of interference of ripple, and the ripple that concrete " boiling " is two row vibration frequencies, phase place is identical produces caused by vibration superposition in intersection;
Concrete test parameters as table 2,
Edge is vibrated scheme quality evaluation table 2
Vibration Technology scheme of the present invention is developed after test:
Retain above-mentioned basic technology condition, amplitude adjusting range, vibrate motor 6 basic parameter, other carry out as follows;
A, with rectangular array deployment rails board mold 1, around array, arrange anchor plate 2, outside anchor plate 2, arrange stretch-draw counter force wall 3, all reserved anchor hole on described mould 1, anchor plate 2, stretch-draw counter force wall 3;
B, arrangement prestress reinforcing bar 4, make it in horizontal cross, vertical be upward through described anchor hole, two ends are fixed on anchor plate 2 or stretch-draw counter force wall 3, all arrange steel bar tensioning device 5 in the middle part of the deformed bar 4 in the middle part of the deformed bar 4 between mould 1 adjacent on same straight line, between mould 1 and anchor plate 2;
C, to arrange at mould 1 bottom level the crossbeam of the motor 6 that vibrates is installed, the motor 6 that vibrates also is installed in mould 1 side, adopt the combination limit that shakes, the end to shake, the mode of alternately vibration is vibrated to mould 1, and on the same beam installing the motor 6 that vibrates, the distance of two motors 6 that vibrate is greater than 2.0m;
D, in units of the speed of the height change of concrete in mould 1, build the concrete of slump 60-120mm with the speed of 7-12mm/min, build the period motor 6 that vibrates and vibrate with 105-115Hz vibration frequency.
To shake test result according to limit, adjustment is vibrated motor 6 position, and see Fig. 3, the motor 6 that vibrates is installed and followed following setting principle:
(1) on same beam, the distance of two motors 6 that vibrate should be greater than 2.0m, avoids stress to resonate;
(2) to be vibrated stress by girder 7 transmission, (described anchor plate surrounds rectangular frame around mould to control the upper and lower 0.8mm ~ 1.3mm of amplitude, the crossbeam being provided with the motor that vibrates that described mold bottom is arranged comprises girder 7 and auxiliary girder 8, girder 7 is parallel with the length direction of anchor plate rectangular frame, between two row's moulds, connecting mold side, two ends, it is all provided with the motor that vibrates, described auxiliary girder 8 is arranged in parallel, all parallel with girder 7, connecting mold side, two ends, the motor that vibrates is installed in the mould side that this junction upwards extends);
(3) uniform layout, low slump, high-frequency, produces concrete liquidization and flow.
This programme is vibrated quality evaluation:
Higher according to vibration frequency, the experience that concrete liquefying speed is faster, frequency of fixedly vibrating, adjustment concrete slump result of the test is shown in and is combined into quality evaluation of vibrating in table 3.
Combine the quality evaluation table 3 that vibrates
As shown in Table, the present invention program can be divided into several groups:
1, described concrete slump is 60mm, and speed of perfusion is 12mm/min.
2, described concrete slump is 80mm, and speed of perfusion is 9mm/min.
3, described concrete slump is 100mm, and speed of perfusion is 8mm/min.
4, described concrete slump is 120mm, and speed of perfusion is 7mm/min.
Other effect of its point is as shown in table 3, by track plates Appearance Visual after concreting field observation and the demoulding, the end of the present invention shakes+and the limit integrated mode stress distribution that makes to vibrate of shaking is even, in process of vibrating, concrete rate of dispersion is very fast, there is not local segregation phenomenon, after the demoulding, track plates four side pores significantly reduce, and do not have ixoderm phenomenon to occur, accomplish the end in view.