CN110170799B - Steel box girder manufacturing process - Google Patents

Steel box girder manufacturing process Download PDF

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Publication number
CN110170799B
CN110170799B CN201910482950.5A CN201910482950A CN110170799B CN 110170799 B CN110170799 B CN 110170799B CN 201910482950 A CN201910482950 A CN 201910482950A CN 110170799 B CN110170799 B CN 110170799B
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Prior art keywords
plate
panel
welding
steel
blanking
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Chinese (zh)
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CN110170799A (en
Inventor
夏恺恺
金钱华
严建军
高岗
姚力
严绕军
刘震文
陆强
周炎
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Shanghai Greenland Construction Steel Structure Co ltd
Shanghai Greenland Construction Group Co Ltd
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Shanghai Greenland Construction Steel Structure Co ltd
Shanghai Greenland Construction Group Co Ltd
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Priority to CN201910482950.5A priority Critical patent/CN110170799B/en
Publication of CN110170799A publication Critical patent/CN110170799A/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • EFIXED CONSTRUCTIONS
    • E01CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01DCONSTRUCTION OF BRIDGES, ELEVATED ROADWAYS OR VIADUCTS; ASSEMBLY OF BRIDGES
    • E01D2/00Bridges characterised by the cross-section of their bearing spanning structure
    • E01D2/04Bridges characterised by the cross-section of their bearing spanning structure of the box-girder type
    • EFIXED CONSTRUCTIONS
    • E01CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01DCONSTRUCTION OF BRIDGES, ELEVATED ROADWAYS OR VIADUCTS; ASSEMBLY OF BRIDGES
    • E01D21/00Methods or apparatus specially adapted for erecting or assembling bridges
    • EFIXED CONSTRUCTIONS
    • E01CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01DCONSTRUCTION OF BRIDGES, ELEVATED ROADWAYS OR VIADUCTS; ASSEMBLY OF BRIDGES
    • E01D2101/00Material constitution of bridges
    • E01D2101/30Metal

Abstract

The invention discloses a steel box girder manufacturing process, which belongs to the technical field of bridge construction and solves the problem of large later-stage correction workload caused by large deformation after welding of the existing panel, and the technical scheme is characterized by comprising the following steps of: A. pretreating a steel plate; B. blanking: a. blanking and processing the diaphragm plate; b. blanking a web plate; c. blanking of the panel and the bottom plate; blanking d.U type rib plates; C. building a jig frame; welding the U-shaped rib plate; E. assembling steel box girder components; F. and coating, namely welding the U-shaped rib plates on the panel, then performing subsequent welding assembly, and controlling the deformation of the panel through the U-shaped rib plates, so that the shrinkage of the panel after welding is reduced, the deformation of the panel is reduced, and the workload of correction after welding is smaller.

Description

Steel box girder manufacturing process
Technical Field
The invention relates to the technical field of bridge construction, in particular to a manufacturing process of a steel box girder.
Background
The steel box girder is also called a steel plate box girder, is a common structural form of a large-span bridge, is generally used on a bridge with a larger span, and is called a steel box girder because the shape is like a box. In a large-span cable supported bridge, the span of a steel box girder reaches hundreds of meters or even thousands of meters, the steel box girder is generally divided into a plurality of girder sections for manufacturing and installation, and the cross section of the steel box girder has the characteristics of wide width and flat appearance.
The existing steel box girder is completely connected together in a welding mode among all the components in the manufacturing process, the structure of the steel box girder is complex, the length of a panel welding part is long, the shrinkage of the panel after welding is difficult to control, and after the welding is finished, the panel is always deformed greatly, so that the workload during correction after the welding is finished is large.
Disclosure of Invention
In view of the defects in the prior art, the invention aims to provide a steel box girder manufacturing process, which is characterized in that during assembly, a U-shaped rib plate is welded on a panel, then subsequent welding and assembly are carried out, and the deformation of the panel is controlled through the U-shaped rib plate, so that the shrinkage of the panel after welding is reduced, the deformation of the panel is reduced, and the workload of correction after welding is smaller.
In order to achieve the purpose, the invention provides the following technical scheme: a steel box girder manufacturing process comprises the following steps:
A. pretreatment of a steel plate: carrying out rust removal pretreatment on the steel plate before blanking, and then spraying a layer of pretreatment primer on the surface of the steel plate within four hours;
B. blanking: the blanking process of the plate comprises the following steps:
a. blanking processing of a diaphragm plate: cutting a diaphragm plate according to a blanking processing list, a layout drawing and a part sketch, and forming a through welding hole fillet with a proper size at the corner of the diaphragm plate according to the requirements of a design drawing;
b. web blanking: according to the design requirement, lofting the web plate of the steel beam; during lofting, calculating a pre-arching value of the lofting; splicing the camber of the steel plates according to the pre-arching lofting size and the typesetting size of the web plate, reserving a welding shrinkage allowance of 0.8 mm/m for the longitudinal length during the length lofting of the web plate, and welding the spliced steel plates together; carrying out nondestructive testing on the welding seam of the steel plate after welding is finished, cutting and blanking after the welding seam is qualified, forming a groove at the edge and polishing burrs at the edge;
c. blanking of the panel and the bottom plate: grooving the steel plates according to an operation instruction, splicing the steel plates according to the rolling direction of the steel plates when splicing the steel plates, splicing the partition plates to the total length according to a layout drawing when splicing, paying attention to the fact that transverse welding seams need to be staggered by more than 200mm when splicing, welding the spliced plates together in a submerged-arc welding mode, and turning over a special carrying pole hanging beam when turning over and welding a panel and a bottom plate; after the submerged-arc welding of the panel and the bottom plate is finished, carrying out ultrasonic flaw detection on transverse welding seams, longitudinal welding seams and T-shaped welding seams at intervals of 24 hours, and after the flaw detection is qualified, respectively hoisting the panel and the bottom plate on a numerical control cutting machine to carry out cutting and blanking;
blanking processing of d.U type rib plates: cutting and blanking the steel plate according to the designed size, bending the steel plate into a U shape after blanking, heating the steel plate by flame during processing, and then bending the steel plate into the U shape;
C. building a jig frame: reversely building the jig frame according to the sample of the box girder, wherein the jig frame is required to be kept to have higher rigidity when building the jig frame, so that the jig frame is prevented from deforming after bearing load, and the jig frame is required to be repeatedly detected after building the jig frame;
welding the U-shaped rib plate: correcting the blanked panel to be in flatness, horizontally hanging the panel into an assembly jig frame, placing a U-shaped rib plate on the surface of the panel, enabling a U-shaped opening of the U-shaped rib plate to face the surface of the panel, primarily fixing the U-shaped rib plate on the surface of the panel in a spot welding mode, and then completely welding and fixing the U-shaped rib plate on the panel;
E. assembling the steel box girder member: drawing a position line for assembling a web plate, a transverse partition plate and longitudinal ribs on one side of the panel, which is welded with the U-shaped rib plate, and fixing the transverse partition plate on the panel according to the position of the scribing line; fixing the diaphragm plate on the panel by spot welding, and then installing the longitudinal ribs on the panel; hoisting a web plate onto a jig frame to enable the center point of the web plate and the center point of a panel to be superposed with each other, then pressing the web plate onto the diaphragm plate in an outer side jacking mode, and fixing the web plate in a mode of spot welding section by section from the middle to two ends; hoisting the bottom plate onto a jig frame, and fixing the bottom plate by adopting a spot welding mode from the middle to two ends; firstly reinforcing welding seams of an upper panel and a web plate of the reverse jig frame and welding seams of a bottom plate and the web plate, welding the turnover lifting lug after the reinforcement is completed, then turning the steel beam and hoisting the steel beam onto the forward jig frame to reinforce the welding seams of the panel and the web plate on the other side and the welding seams of the bottom plate and the web plate on the other side;
F. coating: and spraying an anti-rust layer on the surface of the welded steel box girder, inspecting the anti-rust layer, and loading and transporting after the anti-rust layer is qualified.
Through adopting above-mentioned technical scheme, when assembling, weld the panel with U type floor earlier for the panel can receive the restriction of U type floor when subsequent welded in-process, produce the shrink, thereby make the panel reduce through subsequent welding postshrinkage, thereby reduced the deflection after the panel welding, thereby reduced the later stage and carried out the work load when rectifying to the steel box girder.
The invention is further configured to: in the step A, when the steel plate is subjected to rust removal pretreatment, rust removal is performed in a shot blasting rust removal mode, the roughness of the surface of the steel is controlled to be 25-100 mu m, and after the shot blasting rust removal is finished, the impurities on the surface of the steel plate need to be cleaned up by using compressed air.
By adopting the technical scheme, the surface of the steel can be better adhered by the subsequent pretreatment primer through controlling the roughness of the surface of the steel.
The invention is further configured to: in the step A, the pretreatment primer is inorganic zinc silicate primer, and the spraying thickness is 25 μm.
The invention is further configured to: in the step a, when the inner hole of the diaphragm plate is machined, a numerical control flame cutting machine is used for cutting, and the cut part is polished and corrected until the size and the shape meet the requirements of a drawing.
Through adopting above-mentioned technical scheme, make the trompil of hole convenient and fast more through flame cutting machine.
The invention is further configured to: in the step b, the pre-arching values of the web are sequentially calculated by taking 500mm as a unit, and a table record is formed.
By adopting the technical scheme, the web plate is used for calculating the pre-arching value by taking 500mm as a unit, so that the lofting precision can be improved.
The invention is further configured to: and d, placing the U-shaped rib plate bent into the U shape on a U-shaped frame, and keeping the shape of the U-shaped rib plate through the U-shaped frame until the U-shaped rib plate is cooled to the room temperature.
Through adopting above-mentioned technical scheme, come to restrict the shape of U type floor through U type frame, prevent that U type floor from taking place the change of shape in the middle of the cooling process.
The invention is further configured to: and D, after the U-shaped rib plate is preliminarily fixed on the panel, clamping and fixing four side edges of the panel on the jig frame by adopting a clamp.
Through adopting above-mentioned technical scheme, all fix the centre gripping everywhere of four sides of panel on the bed-jig through anchor clamps, can further reduce the shrinkage of panel, reduce the deformation volume of panel through the spacing of four sides to the panel.
The invention is further configured to: and E, after the transverse partition plates are fixed on the panel, fixing rods fixed on the jig frame are arranged on two sides of each transverse partition plate, and the fixing rods are in mutual contact with the transverse partition plates.
Through adopting above-mentioned technical scheme, can carry on spacingly to the cross slab through the fixed plate for the vertical state of keeping that the cross slab can be better.
In summary, compared with the prior art, the invention has the following beneficial effects:
1. according to the invention, the panel is limited by the U-shaped rib plates when being contracted in the subsequent welding process by adopting the welding mode of the U-shaped rib plates, so that the contraction quantity of the panel after subsequent welding is reduced, the deformation quantity of the panel after welding is reduced, and the workload for correcting the steel box girder in the later period is reduced;
2. the invention clamps and fixes all parts of the four sides of the panel on the jig frame through the clamps, and can further reduce the shrinkage of the panel and the deformation of the panel through limiting the four sides of the panel.
Detailed Description
Example (b): a steel box girder manufacturing process comprises the following steps:
A. pretreatment of a steel plate: the method comprises the steps of carrying out rust removal pretreatment on a steel plate before blanking, wherein the rust removal is carried out by adopting a shot blasting rust removal mode, the roughness of the surface of steel is controlled to be 25-100 mu m, after the shot blasting rust removal is finished, impurities such as dust and the like on the surface of the steel plate are cleaned up by using compressed air, and then a layer of pretreatment primer is sprayed on the surface of the steel plate within four hours, wherein the primer is an inorganic zinc silicate primer, and the spraying thickness is 25 mu m;
B. blanking: the blanking process of the plate comprises the following steps:
a. blanking processing of a diaphragm plate: cutting a diaphragm plate by using a numerical control flame cutting machine according to a blanking processing list, a layout and a part sketch, and forming a through welding hole fillet with a proper size at the corner of the diaphragm plate according to the requirements of a design drawing; when the inner hole of the diaphragm plate is machined, a numerical control flame cutting machine is adopted for cutting machining, and the cut part is polished and corrected until the size and the shape meet the requirements of a drawing;
b. web blanking: according to the design requirement, lofting the web plate of the steel beam; calculating a pre-arching value of lofting firstly during lofting, sequentially calculating the pre-arching values of all parts of a web by taking 500mm as a unit for reducing lofting errors during calculation of the pre-arching value, and forming a table record; splicing the camber of the steel plates according to the pre-arching lofting size and the typesetting size of the web plate, reserving a welding shrinkage allowance of 0.8 mm/m for the longitudinal length during the length lofting of the web plate, and welding the spliced steel plates together; carrying out nondestructive testing on the welding seam of the steel plate after welding is finished, cutting and blanking on a numerical control flame cutting machine after the welding seam is qualified, forming a groove at the edge and polishing burrs at the edge;
c. blanking of the panel and the bottom plate: the method comprises the following steps of grooving steel plates according to an operation instruction, splicing the steel plates according to the rolling direction of the steel plates when splicing the steel plates, splicing the partition plates to the total length according to a layout drawing when splicing, paying attention to the fact that transverse welding seams need to be staggered by more than 200mm when splicing, welding the spliced plates together in a submerged arc welding mode, and turning over the panels and the bottom plates when the panels and the bottom plates are welded, wherein the length and the width of the panels and the bottom plates are large, and a specially-made carrying pole hanging beam needs to be used for turning over; after the submerged-arc welding of the panel and the bottom plate is finished, carrying out ultrasonic flaw detection on transverse welding seams, longitudinal welding seams and T-shaped welding seams at intervals of 24 hours, and after the flaw detection is qualified, respectively hoisting the panel and the bottom plate on a numerical control cutting machine to carry out cutting and blanking;
blanking processing of d.U type rib plates: cutting and blanking the steel plate according to the designed size, after blanking, bending the steel plate into a U shape, performing flame heating on the steel plate during processing, then bending the steel plate into the U shape, placing the U-shaped rib plate bent into the U shape on a U-shaped frame, and keeping the shape of the U-shaped rib plate through the U-shaped frame until the U-shaped rib plate is cooled to room temperature;
C. building a jig frame: reversely building the jig frame according to the sample of the box girder, wherein the jig frame is required to be kept to have higher rigidity when building the jig frame, so that the jig frame is prevented from deforming after bearing load, and the jig frame is required to be repeatedly detected after building the jig frame;
welding the U-shaped rib plate: correcting the flatness of the blanked panel, horizontally hanging the panel into an assembling jig frame, placing a U-shaped rib plate on the surface of the panel, enabling a U-shaped opening of the U-shaped rib plate to face the surface of the panel, preliminarily fixing the U-shaped rib plate on the surface of the panel in a spot welding mode, clamping and fixing all the four side edges of the panel on the jig frame by using a clamp after finishing preliminary fixing of all the U-shaped rib plates, enabling the four side edges of the panel not to move, and then completely welding and fixing the U-shaped rib plate on the panel;
E. assembling the steel box girder member: the method comprises the following steps that position lines for assembling a web plate, a transverse partition plate and longitudinal ribs are drawn on one side, where a U-shaped rib plate is welded, of a panel, the transverse partition plate is fixed on the panel according to the positions of marking lines, a fixing rod fixed on a jig frame is arranged on each of two sides of each transverse partition plate, and the fixing rods are in contact with the transverse partition plates, so that the transverse partition plates are kept in a vertical state; fixing the diaphragm plate on the panel by spot welding, and then installing the longitudinal ribs on the panel; hoisting a web plate onto a jig frame to enable the center point of the web plate and the center point of a panel to be superposed with each other, then pressing the web plate onto the diaphragm plate in an outer side jacking mode, and fixing the web plate in a mode of spot welding section by section from the middle to two ends; hoisting the bottom plate onto a jig frame, and fixing the bottom plate by adopting a spot welding mode from the middle to two ends; firstly reinforcing welding seams of a panel and a web plate on a reverse jig frame and a bottom plate and the web plate, welding a turnover lifting lug after the reinforcement is finished, carrying out magnetic powder inspection on the lifting lug after the welding is finished, then turning a steel beam and hanging the steel beam onto a forward jig frame, and reinforcing the welding seams of the panel and the web plate on the other side and the welding seams of the bottom plate and the web plate on the other side;
F. coating: and spraying an anti-rust layer on the surface of the welded steel box girder, inspecting the anti-rust layer, and loading and transporting after the anti-rust layer is qualified.
The above description is only a preferred embodiment of the present invention, and the protection scope of the present invention is not limited to the above embodiments, and all technical solutions belonging to the idea of the present invention belong to the protection scope of the present invention. It should be noted that modifications and embellishments within the scope of the invention may occur to those skilled in the art without departing from the principle of the invention, and are considered to be within the scope of the invention.

Claims (8)

1. A steel box girder manufacturing process is characterized in that: the method comprises the following steps:
A. pretreatment of a steel plate: carrying out rust removal pretreatment on the steel plate before blanking, and then spraying a layer of pretreatment primer on the surface of the steel plate within four hours;
B. blanking: the blanking process of the plate comprises the following steps:
a. blanking processing of a diaphragm plate: cutting a diaphragm plate according to a blanking processing list, a layout drawing and a part sketch, and forming a through welding hole fillet with a proper size at the corner of the diaphragm plate according to the requirements of a design drawing;
b. web blanking: according to the design requirement, lofting the web plate of the steel beam; during lofting, calculating a pre-arching value of the lofting; splicing the camber of the steel plates according to the pre-arching lofting size and the typesetting size of the web plate, reserving a welding shrinkage allowance of 0.8 mm/m for the longitudinal length during the length lofting of the web plate, and welding the spliced steel plates together; carrying out nondestructive testing on the welding seam of the steel plate after welding is finished, cutting and blanking after the welding seam is qualified, forming a groove at the edge and polishing burrs at the edge;
c. blanking of the panel and the bottom plate: grooving the steel plates according to an operation instruction, splicing the steel plates according to the rolling direction of the steel plates when splicing the steel plates, splicing the partition plates to the total length according to a layout drawing when splicing, paying attention to the fact that transverse welding seams need to be staggered by more than 200mm when splicing, welding the spliced plates together in a submerged-arc welding mode, and turning over a special carrying pole hanging beam when turning over and welding a panel and a bottom plate; after the submerged-arc welding of the panel and the bottom plate is finished, carrying out ultrasonic flaw detection on transverse welding seams, longitudinal welding seams and T-shaped welding seams at intervals of 24 hours, and after the flaw detection is qualified, respectively hoisting the panel and the bottom plate on a numerical control cutting machine to carry out cutting and blanking;
blanking processing of d.U type rib plates: cutting and blanking the steel plate according to the designed size, bending the steel plate into a U shape after blanking, heating the steel plate by flame during processing, and then bending the steel plate into the U shape;
C. building a jig frame: reversely building the jig frame according to the sample of the box girder, wherein the jig frame is required to be kept to have higher rigidity when building the jig frame, so that the jig frame is prevented from deforming after bearing load, and the jig frame is required to be repeatedly detected after building the jig frame;
welding the U-shaped rib plate: correcting the blanked panel to be in flatness, horizontally hanging the panel into an assembly jig frame, placing a U-shaped rib plate on the surface of the panel, enabling a U-shaped opening of the U-shaped rib plate to face the surface of the panel, primarily fixing the U-shaped rib plate on the surface of the panel in a spot welding mode, and then completely welding and fixing the U-shaped rib plate on the panel;
E. assembling the steel box girder member: drawing a position line for assembling a web plate, a transverse partition plate and longitudinal ribs on one side of the panel, which is welded with the U-shaped rib plate, and fixing the transverse partition plate on the panel according to the position of the scribing line; fixing the diaphragm plate on the panel by spot welding, and then installing the longitudinal ribs on the panel; hoisting a web plate onto a jig frame to enable the center point of the web plate and the center point of a panel to be superposed with each other, then pressing the web plate onto the diaphragm plate in an outer side jacking mode, and fixing the web plate in a mode of spot welding section by section from the middle to two ends; hoisting the bottom plate onto a jig frame, and fixing the bottom plate by adopting a spot welding mode from the middle to two ends; firstly reinforcing welding seams of an upper panel and a web plate of the reverse jig frame and welding seams of a bottom plate and the web plate, welding the turnover lifting lug after the reinforcement is completed, then turning the steel beam and hoisting the steel beam onto the forward jig frame to reinforce the welding seams of the panel and the web plate on the other side and the welding seams of the bottom plate and the web plate on the other side;
F. coating: and spraying an anti-rust layer on the surface of the welded steel box girder, inspecting the anti-rust layer, and loading and transporting after the anti-rust layer is qualified.
2. The steel box girder manufacturing process according to claim 1, wherein: in the step A, when the steel plate is subjected to rust removal pretreatment, rust removal is performed in a shot blasting rust removal mode, the roughness of the surface of the steel is controlled to be 25-100 mu m, and after the shot blasting rust removal is finished, the impurities on the surface of the steel plate need to be cleaned up by using compressed air.
3. The steel box girder manufacturing process according to claim 1, wherein: in the step A, the pretreatment primer is inorganic zinc silicate primer, and the spraying thickness is 25 μm.
4. The steel box girder manufacturing process according to claim 1, wherein: in the step a, when the inner hole of the diaphragm plate is machined, a numerical control flame cutting machine is used for cutting, and the cut part is polished and corrected until the size and the shape meet the requirements of a drawing.
5. The steel box girder manufacturing process according to claim 1, wherein: in the step b, the pre-arching values of the web are sequentially calculated by taking 500mm as a unit, and a table record is formed.
6. The steel box girder manufacturing process according to claim 1, wherein: and d, placing the U-shaped rib plate bent into the U shape on a U-shaped frame, and keeping the shape of the U-shaped rib plate through the U-shaped frame until the U-shaped rib plate is cooled to the room temperature.
7. The steel box girder manufacturing process according to claim 1, wherein: and D, after the U-shaped rib plate is preliminarily fixed on the panel, clamping and fixing four side edges of the panel on the jig frame by adopting a clamp.
8. The steel box girder manufacturing process according to claim 1, wherein: and E, after the transverse partition plates are fixed on the panel, fixing rods fixed on the jig frame are arranged on two sides of each transverse partition plate, and the fixing rods are in mutual contact with the transverse partition plates.
CN201910482950.5A 2019-06-04 2019-06-04 Steel box girder manufacturing process Active CN110170799B (en)

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CN111790995B (en) * 2020-05-17 2022-01-07 北京市政建设集团有限责任公司 Construction process for welding steel beam
CN111644818B (en) * 2020-06-15 2021-09-10 宝鸡中铁宝桥天元实业发展有限公司 Manufacturing method of high-precision hollow steel tower steel anchor box
CN112077532B (en) * 2020-08-10 2022-05-13 南通贝思特机械工程有限公司 Groove body assembling and welding method
CN112719795A (en) * 2020-12-17 2021-04-30 江苏恒睿杰钢结构工程有限公司 Manufacturing method of large steel box girder
CN113020813B (en) * 2021-03-17 2023-10-24 嘉兴职业技术学院 Design cutting and welding integrated production system and production method thereof
CN113458718A (en) * 2021-06-07 2021-10-01 中铁十八局集团隧道工程有限公司 Steel box girder manufacturing process
CN113560829B (en) * 2021-08-20 2023-05-16 江苏京沪重工有限公司 Semi-arc small tie beam processing technology
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