CN112692980A - Prefabricated T-beam assembly line and using method thereof - Google Patents
Prefabricated T-beam assembly line and using method thereof Download PDFInfo
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Abstract
The invention relates to a prefabricated T-beam assembly line and a using method thereof, wherein the assembly line mainly comprises a pedestal conveying line, at least two production lines and a gantry crane conveying line; the gantry crane conveying line comprises two gantry crane running rails which are parallel to each other and at least one gantry crane, the pedestal conveying line comprises a first pedestal running rail, the production line comprises a second pedestal running rail, at least one pedestal which can move along the second pedestal running rail is arranged on the second pedestal running rail, and the second pedestal running rail sequentially penetrates through a steel bar binding station, a concrete pouring station, a steam curing station and a tensioning and grouting station; under the synergistic effect of the pedestal conveying line, the production line and the gantry crane conveying line, the production line has the advantages of small occupied area, short production period and high production efficiency, and particularly has the advantages of fast operation and cost reduction in the case of narrow site and large-batch production of prefabricated T-beams.
Description
Technical Field
The invention relates to the technical field of concrete T-beam prefabrication, in particular to a prefabricated T-beam assembly line and a using method thereof.
Background
In traditional construction, prefabricated T roof beam production mainly uses fixed pedestal, the natural spraying health preserving as the owner, and the health preserving time is greater than 7 days, and production efficiency is low, and the production cycle is long, and area is big, receives the climate influence greatly. Along with the gradual expansion of the infrastructure scale, the existing projects such as expressways, railways and the like have large scale, short construction period and difficult land acquisition, the traditional construction method for prefabricating the T-beam on site cannot meet the actual requirement, and the novel mode of fixed construction procedures and circulating assembly line operation in a construction area is concerned by more and more people.
However, the prefabricated T beam assembly line arrangement and the arrangement of each station process in the prior art still cannot meet the requirements of mass production of prefabricated T beams and narrow site, and the problems of large occupied area, long production period, low production efficiency and large weather influence still exist.
Disclosure of Invention
The invention aims to: the prefabricated T beam assembly line in the prior art is not suitable for the situation that the prefabricated T beams are produced in large scale and the site is narrow, and the problems of large occupied area, long production period and low production efficiency still exist. Provided are a prefabricated T-beam assembly line and a use method thereof. The prefabricated T-beam production line provided by the invention has the advantages of small floor area, short production period and high production efficiency, and particularly has the advantages of fast operation and cost reduction in the case of narrow site and large-batch production of prefabricated T-beams.
In order to achieve the purpose, the invention adopts the technical scheme that:
a prefabricated T-beam assembly line mainly comprises a pedestal conveying line, at least two production lines and a gantry crane conveying line;
the gantry crane transport line comprises two gantry crane operation tracks and at least one gantry crane, and the gantry crane can move along the gantry crane operation tracks;
a pedestal conveying line and at least two production lines are arranged between the two parallel gantry crane operation tracks, and the pedestal conveying line and the production lines are arranged oppositely;
the pedestal transport line comprises a first pedestal running track, and the first pedestal running track is used as a track substrate for transporting and moving a pedestal after receiving the pedestal transported by the gantry crane;
the production line comprises a second pedestal running track, at least one pedestal capable of moving along the second pedestal running track is arranged on the second pedestal running track, and the second pedestal running track sequentially penetrates through a steel bar binding station, a concrete pouring station, a steam curing station and a tension grouting station;
the steel bar binding station is used for hoisting the bound and formed steel bar framework to the pedestal by using a gantry crane and is fixedly installed on the pedestal;
the concrete pouring station is used for receiving the pedestal conveyed by the steel bar binding station, installing a template and a top plate steel bar on a steel bar framework on the pedestal, pouring concrete, and removing the template to obtain a beam body after the concrete reaches a form removal condition;
the steam curing station is used for receiving the pedestal conveyed by the concrete pouring station and performing steam curing on the beam body on the pedestal;
the stretching and grouting station is used for receiving the pedestal conveyed by the steam-curing station, prestress stretching and grouting treatment is carried out on the beam body on the pedestal, then the beam body on the pedestal is lifted away by the gantry crane, and then the idle pedestal is transferred to the reinforcement binding station through the cooperation of the gantry crane and a pedestal conveying line to carry out circulating operation.
The invention discloses a prefabricated T-beam production line which mainly comprises a pedestal conveying line, at least two production lines and a gantry crane conveying line; in actual operation, the production line mainly moves through the pedestal, a bound and formed reinforcement cage fixed on the pedestal forms a qualified prefabricated T beam after the steps of concrete pouring, form removal, steam curing, prestress tensioning and grouting and the like, in the production line operation process, the gantry crane is used for moving materials, equipment and the like, after the qualified prefabricated T beam is formed, the gantry crane lifts the prefabricated T beam away from the pedestal, the pedestal is lifted to the pedestal transportation line by the gantry crane, after the pedestal on the pedestal transportation line moves to a proper position, for example, after one end of the pedestal transportation line closer to a reinforcement binding station, the gantry crane lifts the pedestal on the pedestal transportation line to a second pedestal operation track of the production line again for circulation operation. Through the synergistic effect of the pedestal conveying line, the production line and the gantry crane conveying line, the production line has the advantages of small occupied area, short production period and high production efficiency under the mutual cooperation, and particularly has the advantages of fast operation and cost reduction in the case that the site is narrow and the prefabricated T-shaped beams need to be produced in large batch.
Further, the pedestal is connected with self-propelled pedestal intelligence control system. The intelligent control system can make the pedestal intelligently and stably move in the front and back directions on the track according to a set program (moving speed, distance, time and direction).
Further, the first pedestal operation track and the second pedestal operation track are double-line parallel tracks.
Furthermore, 2 to 4 bases which can move along the second base operation track are arranged on the second base operation track. Researches show that the operation time of the pedestals at a steel bar binding station is 4-5 hours, the operation time of pouring a beam at a concrete pouring station is 3-4 hours, the formwork can be disassembled after the pouring is completed for more than 10-12 hours, the steam curing time at a steam curing station is about 18-22 hours, the tension and grouting time at a tension and grouting station can be controlled to be 10 hours, a plurality of pedestals can be simultaneously used for the operation of different stations on a second pedestal running track, and the production efficiency and the production period of the prefabricated T beam can be effectively improved.
Further, the speed of the stage moving on the second stage travel rail is controlled to be within 0.5 m/s. Preferably, the speed of the stage moving on the second stage travel rail is 0.3m/s to 0.5 m/s. The reasonable moving speed can effectively improve the quality and stability of the T beam body, the speed is too high, and the beam body cracks can be easily caused by slight vibration.
Furthermore, the prefabricated T-beam assembly line further comprises a steel bar processing area, and the steel bar processing area is used for bundling steel bars to form the prefabricated T-beam assembly line. Furthermore, the reinforcing steel bar processing area is arranged at one end close to the reinforcing steel bar binding station of the production line.
Furthermore, the prefabricated T-beam assembly line further comprises a beam storage area, when secondary tensioning is adopted, the beam storage area is used for receiving a beam body which is lifted from a tensioning and grouting station by a gantry crane and is subjected to primary tensioning, and secondary tensioning and grouting treatment is carried out after the beam body is subjected to spray maintenance. Furthermore, the beam storage area is arranged at one end close to a tensioning and grouting station of the production line.
Furthermore, the prefabricated T-beam assembly line further comprises a finished product area, and the finished product area is used for receiving the prefabricated T-beam after being tensioned by the tensioning and grouting station or receiving the prefabricated T-beam after being tensioned for the second time by the beam storage area. Furthermore, the finished product area is arranged at one end close to a tensioning and grouting station of the production line.
Furthermore, the first pedestal orbit, the second pedestal orbit and the gantry crane orbit are arranged in parallel relatively, wherein the first pedestal orbit is equal to the second pedestal orbit in length.
Furthermore, the gantry crane transport line comprises two gantry cranes, one gantry crane is used for being responsible for the operation of a steel bar binding station and a concrete pouring station, and the other gantry crane is used for being responsible for the operation of a tensioning grouting station. The production efficiency can be effectively improved. Furthermore, the gantry crane transport line is also provided with a gantry crane, and the gantry crane is mainly used for hoisting operation in a beam storage area and a finished product area.
Further, the length of the pedestal is greater than that of the prefabricated T-beam, and the difference between the length of the pedestal and the length of the prefabricated T-beam is 0.5-1 m. Therefore, a certain construction space can be provided for the end template, and the construction efficiency is effectively improved.
Furthermore, the first pedestal operation track and the second pedestal operation track are I-shaped steel rails, and the flatness is controlled within +/-3 mm.
Furthermore, a plurality of strain sensors are installed in the reinforcement cage formed by binding, and the strain sensors are used for monitoring the stress and temperature change conditions of the beam body in the steam-curing station, the tensioning grouting station and the hoisting process.
Furthermore, the steam curing station is a closed steam curing room, a plurality of steam pipelines are arranged around the inside of the steam curing room, a plurality of steam outlets are arranged on the steam pipelines, the distance between every two adjacent steam outlets is 0.8-1.1 m, and a sensor and an automatic adjusting controller for automatically detecting temperature and humidity are arranged in the steam curing room. Furthermore, the side face and the top face of the steam curing room are made of heat-insulating and water-proof plates, and heat-insulating and water-proof doors are arranged at two ends of the steam curing room. The steam-curing station adopts a totally-enclosed intelligent steam curing technology, the traditional covering spray curing process is abandoned, the temperature and the humidity are controllable by building a steam heat-preservation and moisture-preservation curing chamber and a steam generating system on site, the temperature and the humidity are observed and controlled in real time by an intelligent observation system on steam-curing conditions, and the optimal parameter combination is obtained by performing a contrast test on the temperature rise, the constant temperature, the temperature drop and the speed of steam-curing, so that the aim of rapidly improving the strength and the elastic modulus of concrete is fulfilled, and the design tension requirement is met.
Furthermore, the tensioning grouting station is provided with an intelligent tensioning system. An operator can control the equipment to perform prestress tensioning through a computer program, the tensioning process is intuitively reflected on computer software, the device has the characteristic of accurately controlling the elements such as tensioning stress, extension, loading rate, stop point, load holding time and the like, and the data of tensioning construction is automatically stored in the software program, so that the management functions of implementing monitoring and standard management, ensuring the truth and reliability of the data and the like are realized.
Furthermore, the prefabricated T-beam assembly line comprises a workshop, the area covered by the workshop comprises a position from one end of the second pedestal running track close to the reinforcement binding station to the position between the concrete pouring station and the steam curing station, and an area with the same length as the first pedestal running track,
the factory building is provided with the purlin on the top of pedestal moving direction's both sides and hangs the orbit, be provided with on the purlin hangs the orbit and can follow the purlin of purlin overhead rail operation and hang, the purlin hangs the handling operation that is used for the reinforcement station in the factory building and pours the concrete station. The traditional T-beam prefabricating process is in a field open-air operation mode and is greatly influenced by weather. The assembly line is positioned in a closed workshop of a factory building, can ensure all-weather production of all procedures, is not influenced by severe conditions such as strong wind, rainfall, construction in winter (alpine regions) and the like, and obviously improves the capacity of a beam factory.
The invention also aims to provide a using method of the prefabricated T-beam production line.
A use method of a prefabricated T-beam assembly line comprises the following steps: each line is independently operated by the same prefabrication method, and each line can operate in the following mode:
and 4, after the first pedestal moving out of the steam curing station in the step 3 enters a tensioning and grouting station, carrying out prestress tensioning and grouting treatment on a beam body on the first pedestal, then hoisting the beam body on the first pedestal away from the pedestal by using a gantry crane to be conveyed to a beam storage area, then hoisting the first pedestal to a first pedestal running track of a pedestal conveying line by using the gantry crane, moving the first pedestal to one end closer to a steel bar binding station of the production line on the first pedestal running track, then conveying the first pedestal to a second pedestal running track of the production line by using the gantry crane, and repeating the operation in the step 1.
The use method of the prefabricated T beam assembly line disclosed by the invention is simple to operate, and the assembly line can stably operate under the mutual cooperation among the pedestal conveying line, the at least two production lines and the gantry crane conveying line, so that the production cycle and the production efficiency of the prefabricated T beam are effectively improved.
Furthermore, 2-4 pedestals can be arranged on one production line to perform simultaneous operation. When a plurality of pedestals on one production line operate simultaneously, the production efficiency of the prefabricated T-shaped beam can be effectively improved. For example, when 3 pedestals are arranged on a production line for simultaneous operation, after a first pedestal enters the concrete pouring station in the step 2, a second pedestal can be placed on the second pedestal running track for the same operation of the first pedestal in the step 1; and (3) after the first pedestal enters the steam-curing station in the step (3), after the second pedestal enters the concrete pouring station, the second pedestal can be placed on the second pedestal running track to carry out the same operation of the first pedestal in the step (1), or after the first pedestal enters the tensioning and grouting station in the step (4), the second pedestal enters the corresponding next station operation, and the third pedestal can be placed on the third pedestal running track to carry out the same operation of the first pedestal in the step (1). When a plurality of pedestals on one production line operate simultaneously, the production efficiency of the prefabricated T-shaped beam can be effectively improved.
For example, when 4 pedestals are arranged on a production line for simultaneous operation, after a first pedestal enters the concrete pouring station in the step 2, a second pedestal can be placed on the second pedestal running track for the same operation of the first pedestal in the step 1; after the first pedestal enters the steam-curing station in the step 3 and the second pedestal enters the concrete pouring station, a third pedestal can be placed on the running track of the second pedestal to perform the same operation as the first pedestal in the step 1; and (4) after the first pedestal enters the tensioning and grouting station in the step (4), the second pedestal and the third pedestal enter corresponding next station operation, and the fourth pedestal running track can be used for placing the third pedestal to perform the same operation of the first pedestal in the step (1). When a plurality of pedestals on one production line operate simultaneously, the production efficiency of the prefabricated T-shaped beam can be effectively improved.
Further, the speed of the movement of the stage when it travels on the second stage travel path is controlled to be within 0.5m/s, and preferably, the speed of the movement of the stage when it travels on the second stage travel path is 0.3m/s to 0.5 m/s. The reasonable moving speed can effectively improve the quality and stability of the T beam body, the speed is too high, and the beam body cracks can be easily caused by slight vibration.
Further, in the step 3, the curing condition is that the strength of the beam body reaches more than 90% of the designed concrete strength grade; and 4, after the beam body on the first pedestal is subjected to prestress tensioning treatment, the beam body on the first pedestal is lifted away from the pedestal by a gantry crane and conveyed to a finished product area for storage. The mode of 'steam curing + one-time tensioning' provided by the invention can effectively improve the early performance of concrete, simultaneously reduce the later prestress loss, greatly shorten the production time on the premise of ensuring that the production quality of the prefabricated T-shaped beam is not reduced, improve the production efficiency, simultaneously effectively reduce the complexity in the process and effectively increase the smoothness of the operation process.
Further, in the step 3, the curing condition is that the strength of the beam body reaches 75% -80% of the designed concrete strength level, the elastic modulus of the beam body reaches 75% -80% of the designed concrete strength level, and simultaneously, in the step 4, after the primary prestress tensioning treatment is performed on the beam body on the first pedestal, the beam body on the first pedestal is lifted away from the pedestal and conveyed to the beam storage area for spray curing by using a gantry crane, when the strength of the beam body reaches more than 90% of the designed concrete strength level, and the elastic modulus of the beam body reaches more than 90% of the designed concrete strength level, the T beam is tensioned and grouted for the second time. The steam curing and secondary tensioning mode provided by the invention can reduce the steam curing time, effectively improve the early performance of concrete, reduce the prestress loss in the later period, accelerate the turnover of the pedestal, further improve the production speed, greatly shorten the production time and improve the production efficiency on the premise of ensuring that the production quality of the prefabricated T beam is not reduced. Furthermore, the control values of the tension stress of all the prestressed steel strands in the primary prestressed tension are 0.44-0.46 fpk，fpkThe standard value of the strength of the steel strand.
Further, in the step 3, the time for steam curing the beam on the pedestal is 15 hours or more.
Further, in the step 3, after the pedestal moved out of the concrete pouring station in the step 2 enters the steam-curing station, the temperature of the steam-curing station sequentially changes through a temperature rise stage, a constant temperature stage and a temperature reduction stage, wherein the temperature rise rate of the temperature rise stage is not more than 15 ℃/h; the temperature of the constant temperature stage is not more than 70 ℃, and the cooling rate of the cooling stage is not more than 15 ℃/h; the relative humidity of the steam-curing station is above 95% RH. Through a large amount of researches of the inventor, the lifting speed of the temperature at the steam-curing station has a very important relation to the quality of the T beam and the steam-curing efficiency, the beam body is easy to crack due to the fact that the temperature lifting speed is too high, the temperature lifting speed is too low, the prefabrication progress can be influenced, and the cost can be increased. Meanwhile, the strength of the beam body can be effectively ensured when the temperature is not more than 70 ℃ in the constant temperature stage, the beam body is useless and has high cost when the temperature is too high, and the progress is influenced and the cost is high when the time is too long. Preferably, the heating rate of the heating stage is 8-15 ℃/h; the temperature of the constant temperature stage is 50-60 ℃, and the cooling rate of the cooling stage is 8-15 ℃/h.
Further, in the step 3, in the constant temperature stage, when the strength of the beam body reaches more than 90% of the strength grade of the designed concrete; when the elastic modulus of the beam body reaches more than 90% of the elastic modulus of the designed concrete grade, cooling treatment can be carried out, and one-time tensioning can be carried out at a tensioning grouting station; in the step 3, in the constant temperature stage, when the strength of the beam body reaches 75% -80% of the designed concrete strength grade; when the elastic modulus of the beam reaches 75% -80% of that of the designed concrete grade, cooling treatment can be carried out, and after primary tensioning is carried out at a tensioning and grouting station, secondary tensioning and grouting is carried out in a beam storage area.
In summary, due to the adoption of the technical scheme, the invention has the beneficial effects that:
1. the invention discloses a prefabricated T-beam production line which mainly comprises a pedestal conveying line, at least two production lines and a gantry crane conveying line; in actual operation, the production line mainly moves through the pedestal, the steel reinforcement framework which is fixed on the pedestal and is subjected to binding forming forms a qualified prefabricated T beam after the steps of concrete pouring, form removal, steam curing, prestress tensioning and the like, in the production line operation process, the gantry crane is used for moving materials, equipment and the like to form the qualified prefabricated T beam, the gantry crane lifts the prefabricated T beam away from the pedestal, the pedestal is lifted to the pedestal transportation line by the gantry crane, and after the pedestal on the pedestal transportation line moves to a proper position, for example, after one end of the pedestal transportation line which is closer to a steel reinforcement binding station, the gantry crane lifts the pedestal on the pedestal transportation line to a second pedestal operation track of the production line again for circulation operation. Through the synergistic effect of the pedestal conveying line, the production line and the gantry crane conveying line, the production line has the advantages of small occupied area, short production period and high production efficiency under the mutual cooperation, and particularly has the advantages of fast operation and cost reduction in the case that the site is narrow and the prefabricated T-shaped beams need to be produced in large batch.
2. The steel bar binding station and the concrete pouring station in the prefabricated T-beam production line are arranged in a workshop. The traditional T-beam prefabricating process is in a field open-air operation mode and is greatly influenced by weather. The production line can ensure all-weather production of each procedure, is not influenced by severe conditions such as strong wind, rainfall, construction in winter (alpine regions) and the like, obviously improves the capacity of a beam plant, and can improve the capacity by more than 30 percent in rainy seasons and winter.
3. The production line is provided with a plurality of pedestals for simultaneous operation at different stations, so that the production efficiency and the production period of the prefabricated T-shaped beam can be effectively improved.
4. The steam-curing station adopts a totally-enclosed intelligent steam curing technology, the traditional covering spray curing process is abandoned, the temperature and the humidity are controllable by building a steam heat-preservation and moisture-preservation curing chamber and a steam generating system on site, the temperature and the humidity are observed and controlled in real time by an intelligent observation system on steam-curing conditions, and the optimal parameter combination is obtained by performing a contrast test on the temperature rise, the constant temperature, the temperature drop and the speed of steam-curing, so that the aim of rapidly improving the strength and the elastic modulus of concrete is fulfilled, and the design tension requirement is met. The steam curing system has the advantages of short steam curing time, short beam manufacturing period and high efficiency, greatly accelerates the construction speed of the bridge, obviously shortens the construction period and reduces the construction cost.
5. The application method of the prefabricated T-beam assembly line disclosed by the invention is simple to operate, and implements a brand new mode of fixed construction procedures and circulating assembly line operation in a construction area.
6. The invention provides different modes of steam curing and primary tensioning as well as steam curing and secondary tensioning, can effectively improve the early performance of concrete, simultaneously reduces the prestress loss in the later period, greatly shortens the production time and improves the production efficiency on the premise of ensuring that the production quality of the prefabricated T-beam is not reduced.
Drawings
FIG. 1 is a schematic layout of a prefabricated T-beam pipeline configuration of example 1.
FIG. 2 is a layout diagram of a prefabricated T-beam pipeline structure in example 2.
FIG. 3 is a distribution diagram of a prefabricated T-beam flow line structure in example 3.
Icon: 1-gantry crane orbit; 12-gantry crane; 2-a first pedestal running track; 3-a second pedestal running track; 31-a steel bar binding station; 32-concrete pouring station; 33-steam-curing station; 34-a tension grouting station; 35-a first stage; 36-a second stage; 37-a third stage; 38-a fourth stage; 4-beam storage area; 5-a finished product area; 6-factory building, 7-reinforcing steel bar processing area.
Detailed Description
The present invention will be described in detail below with reference to the accompanying drawings.
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
Example 1
On a certain high-speed road section, 1684T beams need to be prefabricated, the total construction period needs to be 13 months, and in a traditional beam yard, 44 pedestals are needed to be built according to 3 beams/pedestal. The project is short in construction period, the quantity of the prefabricated T-shaped beams is large, the project is located in a valley section of a mountain area, the natural gradient of the original ground is 25-60 degrees, the mountain area is mostly in a deep V shape, and the ground of the prefabricated beams is short due to limited terrain.
The prefabricated T-beam production line shown in FIG. 1 mainly comprises a pedestal transport line, four production lines, a gantry crane transport line, a beam storage area 4, a finished product area 5 and a steel bar processing area 7; the gantry crane 12 transportation line comprises two parallel gantry crane operation rails 1 and three gantry cranes 12, the gantry cranes 12 are connected with the two parallel gantry crane operation rails 1, and the gantry cranes 12 can move along the gantry crane operation rails 1; the first gantry crane 12 is used for being responsible for the operation of a steel bar binding station 31 and a concrete pouring station 32, and the second gantry crane 12 is used for being responsible for the operation of a tensioning grouting station 34. The production efficiency can be effectively improved. The third gantry is mainly used for hoisting operation of the beam storage area 4 and the finished product area 5.
A pedestal conveying line and four production lines are sequentially arranged between the two parallel gantry crane running rails 1, and the pedestal conveying line and the four production lines are arranged in parallel with the gantry crane running rails 1; the pedestal transport line comprises a first pedestal running track 2, and the first pedestal running track 2 is used for receiving a pedestal transported by the gantry crane 12 and then is used as a track substrate for transporting and moving the pedestal; the production line comprises a second pedestal running track 3, at least one pedestal capable of moving along the second pedestal running track 3 is arranged on the second pedestal running track 3, and the second pedestal running track 3 sequentially passes through a steel bar binding station 31, a concrete pouring station 32, a steam curing station 33 and a tensioning and grouting station 34;
The steam curing station 33 comprises a closed steam curing room, a plurality of steam pipelines are arranged around the inside of the steam curing room, a plurality of steam outlets are arranged on the steam pipelines, the distance between every two adjacent steam outlets is 1m, and a sensor and an automatic adjusting controller for automatically detecting temperature and humidity are arranged in the steam curing room. The side face and the top face of the steam curing room are made of heat-insulating and water-proof plates, and heat-insulating and water-proof doors are arranged at two ends of the steam curing room.
The tensioning mud jacking station 34 is provided with an intelligent tensioning system. An operator can control the equipment to perform prestress tensioning through a computer program, the tensioning process is intuitively reflected on computer software, the device has the characteristic of accurately controlling the elements such as tensioning stress, extension, loading rate, stop point, load holding time and the like, and the data of tensioning construction is automatically stored in the software program, so that the management functions of implementing monitoring and standard management, ensuring the truth and reliability of the data and the like are realized.
The reinforcing steel bar processing area 7 is arranged at one end close to the reinforcing steel bar binding station 31 of the production line.
The beam storage area 4 and the finished product area 5 are sequentially arranged at one end of a tensioning grouting station 34 close to the production line.
In the using process, each production line is independently operated by the same prefabricating method, and one production line is selected to operate in the following mode:
step 4, after the first pedestal 35 which is moved out of the steam-curing station 33 in the step 3 enters the tensioning and grouting station 34, performing primary prestress tensioning treatment on the beam body on the first pedestal 35, wherein the tensioning stress control values of all prestressed steel strands in the primary prestress tensioning are 0.45fpk(fpkFor the standard value of the strength of the steel strand, the beam body on the first pedestal 35 is lifted away from the pedestal by the gantry crane 12 and conveyed to the beam storage area 4, the first pedestal 35 is lifted to the first pedestal running track 2 of the pedestal conveying line by the gantry crane 12, the first pedestal 35 moves to the end closer to the steel bar binding station of the production line on the first pedestal running track 2, then the gantry crane 12 lifts the first pedestal 35 to the second pedestal running track 3 of the production line, and the operation of the step 1 is repeated. After the first pedestal 35 enters the concrete pouring station 32 in the step 2, a second pedestal 36 can be placed on the second pedestal running track 3 to perform the same operation as the first pedestal 35 in the step 1; after the first pedestal 35 enters the steam curing station 33 in the step 3 and the second pedestal 36 enters the concrete pouring station 32, a third pedestal 37 can be placed on the second pedestal running track 3 to perform the same operation as the first pedestal 35 in the step 1; after the first pedestal 35 enters the tension grouting station 34 in the step 4, the second pedestal 36 and the third pedestal 37 enter corresponding next station operation, and the fourth pedestal 38 can be placed on the running track of the third pedestal 37 to perform the same operation as the first pedestal 35 in the step 1; the speed at which the stage moves while traveling on the second stage travel rail 3 is 0.4 m/s. The beam body of the beam storage area 4 is maintained in a spraying mode until the strength of the beam body reaches more than 90% of the designed concrete strength grade, and the elastic modulus of the beam body reaches the elasticity of the designed concrete gradeAnd when the modulus is more than 90%, performing secondary tensioning and grouting treatment on the T beam. And then hanging the beam body after the secondary tensioning away to a finished product area 5 for storage.
As shown in fig. 1, → a denotes a direction in which the stage moves on the first stage travel rail 2, and → B denotes a method in which the stage moves on the second stage travel rail 3.
The invention discloses a prefabricated T-beam production line which mainly comprises a pedestal conveying line, at least two production lines and a gantry crane 12 conveying line; in actual operation, the production line mainly moves through the pedestal, the steel reinforcement framework which is bound and formed and fixed on the pedestal forms a qualified prefabricated T beam after the steps of concrete pouring, form removal, steam curing, prestress tensioning and the like, in the production line operation process, the gantry crane 12 is used for moving materials, equipment and the like, after the qualified prefabricated T beam is formed, the gantry crane 12 lifts the prefabricated T beam away from the pedestal, the gantry crane 12 lifts the pedestal to the pedestal transportation line, the pedestal on the pedestal transportation line moves to one end of the pedestal transportation line which is closer to the steel reinforcement binding station 31, and the gantry crane 12 lifts the pedestal on the pedestal transportation line to the second pedestal running track 3 of the production line for circulation operation again. Through the synergism of pedestal supply line, production line and gantry crane 12 supply line, under mutually supporting, it is little to have an area, and production cycle is short and the high advantage of production efficiency, and simultaneously, the production line has set up the simultaneous operation that a plurality of pedestals carry out different stations, can effectively improve the production efficiency and the production cycle of prefabricated T roof beam. The steam curing station 33 adopts a totally-enclosed intelligent steam curing technology and a 'steam curing + secondary tensioning' mode, so that the early performance of concrete is effectively improved, the prestress loss in the later period is reduced, the production time is greatly shortened on the premise of ensuring that the production quality of the prefabricated T-beam is not reduced, and the production efficiency is improved.
By adopting the process, the construction period can be ensured only by building 4 production lines and producing 4.5 beams in daily life, and the construction area only needs 16580m2The existing roadbed can completely meet the construction requirement of a beam yard, land acquisition is not needed, and practice proves that the comprehensive benefit is obvious.
Example 2
The prefabricated T-beam production line shown in FIG. 2 mainly comprises a pedestal transport line, four production lines, a gantry crane transport line, a beam storage area 4, a finished product area 5 and a steel bar processing area 7;
a pedestal conveying line and four production lines are sequentially arranged between the two parallel gantry crane running rails 1, and the pedestal conveying line and the four production lines are arranged in parallel with the gantry crane running rails 1; the gantry crane transport line comprises two parallel gantry crane running rails 1 and two gantry cranes 12, the gantry cranes 12 are connected with the two parallel gantry crane running rails 1, and the gantry cranes 12 can move along the gantry crane running rails 1; one gantry crane 12 is responsible for the operation of tensioning the mud jacking station 34. The production efficiency can be effectively improved. The other gantry is mainly used for hoisting operation of the beam storage area 4 and the finished product area 5.
The pedestal transport line comprises a first pedestal running track 2, and the first pedestal running track 2 is used for receiving a pedestal transported by the gantry crane 12 and then is used as a track substrate for transporting and moving the pedestal; the production line comprises a second pedestal running track 3, at least one pedestal capable of moving along the second pedestal running track 3 is arranged on the second pedestal running track 3, and the second pedestal running track 3 sequentially passes through a steel bar binding station 31, a concrete pouring station 32, a steam curing station 33 and a tension grouting station 34;
prefabricated T roof beam assembly line includes factory building 6, the region that 6 covers of factory building includes that second pedestal orbit 3 is close to the position between reinforcement station 31 one end to pouring concrete station 32 and the steam-curing station 33 to and the region of the same length of first pedestal orbit 2, wherein, the direction of arrow C is length direction in as shown in fig. 2. The top of 6 both sides along the pedestal moving direction of factory building is provided with the purlin and hangs the orbit, be provided with on the purlin hangs the orbit and hang the purlin that can follow the purlin and hang the orbit operation, the purlin hangs the handling operation that is used for the reinforcement station 31 in factory building 6 and pours concrete station 32. The traditional T-beam prefabricating process is in a field open-air operation mode and is greatly influenced by weather. The workshop is arranged above the steel bar binding station and the concrete pouring station, all-weather production of all procedures can be ensured, the workshop is not influenced by severe conditions such as strong wind, rainfall, construction in winter (alpine regions) and the like, the capacity of the beam factory is obviously improved, and the capacity can be improved by more than 30% in rainy seasons and winter.
The steam curing station 33 comprises a closed steam curing room, a plurality of steam pipelines are arranged around the inside of the steam curing room, a plurality of steam outlets are arranged on the steam pipelines, the distance between every two adjacent steam outlets is 1m, and a sensor and an automatic adjusting controller for automatically detecting temperature and humidity are arranged in the steam curing room. The side face and the top face of the steam curing room are made of heat-insulating and water-proof plates, and heat-insulating and water-proof doors are arranged at two ends of the steam curing room.
The tensioning mud jacking station 34 is provided with an intelligent tensioning system. An operator can control the equipment to perform prestress tensioning through a computer program, the tensioning process is intuitively reflected on computer software, the device has the characteristic of accurately controlling the elements such as tensioning stress, extension, loading rate, stop point, load holding time and the like, and the data of tensioning construction is automatically stored in the software program, so that the management functions of implementing monitoring and standard management, ensuring the truth and reliability of the data and the like are realized.
The reinforcing steel bar processing area 7 is arranged at one end close to the reinforcing steel bar binding station 31 of the production line.
The beam storage area 4 and the finished product area 5 are sequentially arranged at one end of a tensioning grouting station 34 close to the production line.
As shown in fig. 2, → a denotes a direction in which the stage moves on the first stage travel rail 2, and → B denotes a method in which the stage moves on the second stage travel rail 3.
Example 3
The prefabricated T-beam production line shown in FIG. 3 mainly comprises a pedestal conveying line, three production lines, a gantry crane 12 conveying line, a finished product area 5 and a reinforcing steel bar processing area 7; the gantry crane 12 transportation line comprises two parallel gantry crane operation rails 1 and two gantry cranes 12, the gantry cranes 12 are connected with the two parallel gantry crane operation rails 1, and the gantry cranes 12 can move along the gantry crane operation rails 1; the first gantry crane 12 is used for being responsible for operations of a steel bar binding station 31 and a concrete pouring station 32, and the second gantry crane 12 is used for being responsible for operations of a tensioning grouting station 34 and lifting operations of a finished product area 5.
A pedestal conveying line and three production lines are sequentially arranged between the two parallel gantry crane operation tracks 1, and the three production lines of the pedestal conveying line are arranged in parallel with the gantry crane operation tracks 1; the pedestal transport line comprises a first pedestal running track 2, and the first pedestal running track 2 is used for receiving a pedestal transported by the gantry crane 12 and then is used as a track substrate for transporting and moving the pedestal; the production line comprises a second pedestal running track 3, at least one pedestal capable of moving along the second pedestal running track 3 is arranged on the second pedestal running track 3, and the second pedestal running track 3 sequentially passes through a steel bar binding station 31, a concrete pouring station 32, a steam curing station 33 and a tension grouting station 34; first pedestal orbit 2, relative parallel arrangement between second pedestal orbit 3 and the portal crane orbit 1, wherein, first pedestal orbit 2 with second pedestal orbit 3 length equals.
The pedestal is connected with a self-propelled pedestal intelligent control system. The intelligent control system can make the pedestal intelligently and stably move in the front and back directions on the track according to a set program (moving speed, distance, time and direction). Pedestal: 1. the pedestal adopts shaped steel integrated configuration, and girder deformation is less than 1 mm. 2. The thickness of the steel plate on the top surface of the pedestal is 13mm, and the reverse camber meets the design requirement. 3. The length of the pedestal exceeds 1.1m of the length of the precast beam, and the construction space of the end mould is ensured. 4. The moving track adopts an I-shaped steel rail, and the flatness of a track line is controlled within +/-3 mm.
The steam curing station 33 comprises a closed steam curing room, a plurality of steam pipelines are arranged around the inside of the steam curing room, a plurality of intensive steam outlets are arranged on the steam pipelines, the interval between the steam outlets is 0.8m, and a sensor and an automatic adjusting controller for automatically detecting temperature and humidity are arranged in the steam curing room. The side face and the top face of the steam curing room are made of heat-insulating and water-proof plates, and heat-insulating and water-proof doors are arranged at two ends of the steam curing room.
The tensioning mud jacking station 34 is provided with an intelligent tensioning system. An operator can control the equipment to perform prestress tensioning through a computer program, the tensioning process is intuitively reflected on computer software, the device has the characteristic of accurately controlling the elements such as tensioning stress, extension, loading rate, stop point, load holding time and the like, and the data of tensioning construction is automatically stored in the software program, so that the management functions of implementing monitoring and standard management, ensuring the truth and reliability of the data and the like are realized.
The reinforcing steel bar processing area 7 is arranged at one end close to the reinforcing steel bar binding station 31 of the production line.
In the using process, each production line is independently operated by the same prefabricating method, and one production line is selected to operate in the following mode:
and 4, after the first pedestal 35 which is moved out of the steam curing station 33 in the step 3 enters a tensioning and grouting station 34, performing prestress tensioning and grouting treatment on a beam on the first pedestal 35, then lifting the beam on the first pedestal 35 away from the pedestal by using a gantry crane 12 and conveying the beam to a finished product area 5 for storage, then lifting the first pedestal 35 to a first pedestal running track 2 of a pedestal conveying line by using the gantry crane 12, moving the first pedestal 35 to one end which is closer to a steel binding station of the production line on the first pedestal running track 2, then lifting the first pedestal 35 to a second pedestal running track 3 of the production line by using the gantry crane 12, and repeating the operation in the step 1. After the first pedestal 35 enters the concrete pouring station 32 in the step 2, a second pedestal 36 can be placed on the second pedestal running track 3 to perform the same operation as the first pedestal 35 in the step 1; after the first pedestal 35 enters the steam curing station 33 in the step 3 and the second pedestal 36 enters the concrete pouring station 32, a third pedestal 37 can be placed on the second pedestal running track 3 to perform the same operation as the first pedestal 35 in the step 1; after the first pedestal 35 enters the tension grouting station 34 in the step 4, the second pedestal 36 and the third pedestal 37 enter corresponding next station operation, and the fourth pedestal 38 can be placed on the running track of the third pedestal 37 to perform the same operation as the first pedestal 35 in the step 1; the speed at which the stage moves while traveling on the second stage travel rail 3 is 0.5 m/s.
As shown in fig. 3, → a denotes a direction in which the stage moves on the first stage travel rail 2, and → B denotes a method in which the stage moves on the second stage travel rail 3.
The invention discloses a prefabricated T-beam production line which mainly comprises a pedestal conveying line, at least two production lines and a gantry crane 12 conveying line; in actual operation, the production line mainly moves through the pedestal, the steel reinforcement framework which is bound and formed and fixed on the pedestal forms a qualified prefabricated T beam after the steps of concrete pouring, form removal, steam curing, prestress tensioning and the like, in the production line operation process, the gantry crane 12 is used for moving materials, equipment and the like, after the qualified prefabricated T beam is formed, the gantry crane 12 lifts the prefabricated T beam away from the pedestal, the gantry crane 12 lifts the pedestal to the pedestal transportation line, the pedestal on the pedestal transportation line moves to one end of the pedestal transportation line which is closer to the steel reinforcement binding station 31, and the gantry crane 12 lifts the pedestal on the pedestal transportation line to the second pedestal running track 3 of the production line for circulation operation again. Through the synergism of pedestal supply line, production line and gantry crane 12 supply line, under mutually supporting, it is little to have an area, and production cycle is short and the high advantage of production efficiency, and simultaneously, the production line has set up the simultaneous operation that a plurality of pedestals carry out different stations, can effectively improve the production efficiency and the production cycle of prefabricated T roof beam. The steam curing station 33 adopts a totally-enclosed intelligent steam curing technology and a mode of steam curing and one-time tensioning, so that the early performance of concrete is effectively improved, the prestress loss in the later period is reduced, the production time is greatly shortened on the premise of ensuring that the production quality of the prefabricated T-beam is not reduced, and the production efficiency is improved.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents and improvements made within the spirit and principle of the present invention are intended to be included within the scope of the present invention.
Claims (10)
1. A prefabricated T-beam assembly line is characterized by mainly comprising a pedestal conveying line, at least two production lines and a gantry crane conveying line;
the gantry crane transport line comprises two gantry crane operation tracks (1) and at least one gantry crane (12), and the gantry crane (12) can move along the gantry crane operation tracks (1);
a pedestal conveying line and at least two production lines are arranged between the two gantry crane operation tracks (1), and the pedestal conveying line and the production lines are arranged oppositely;
the pedestal transport line comprises a first pedestal running track (2), and the first pedestal running track (2) is used as a track substrate for pedestal transport movement after receiving a pedestal transported by the gantry crane (12);
the production line comprises a second pedestal running track (3), at least one pedestal capable of moving along the second pedestal running track (3) is arranged on the second pedestal running track (3), and the second pedestal running track (3) sequentially penetrates through a steel bar binding station (31), a concrete pouring station (32), a steam curing station (33) and a tensioning and grouting station (34);
the steel bar binding station (31) is used for hoisting the binding-formed steel bar framework to the pedestal by using a gantry crane (12) and is fixedly installed on the pedestal;
the concrete pouring station (32) is used for receiving the pedestal conveyed by the steel bar binding station (31), installing a template and a top plate steel bar on a steel bar framework on the pedestal, pouring concrete, and removing the template to obtain a beam body after the concrete reaches a form removal condition;
the steam curing station (33) is used for receiving the pedestal conveyed by the concrete pouring station (32) and performing steam curing on a beam body on the pedestal;
the tensioning and grouting station (34) is used for receiving the pedestal conveyed by the steam-curing station (33) and carrying out prestress tensioning and grouting treatment on the beam body on the pedestal, then the beam body on the pedestal is lifted away by the gantry crane (12), and then the idle pedestal is transferred to the steel bar binding station (31) through the cooperation of the gantry crane (12) and a pedestal conveying line to carry out circulating operation.
2. The precast T beam assembly line of claim 1, wherein a self-propelled pedestal intelligent control system is connected to the pedestal; the speed of the movement of the stage when it travels on the second stage travel track (3) is controlled to be within 0.5 m/s.
3. The prefabricated T-beam assembly line of claim 1, further comprising a beam storage area (4), wherein when secondary tensioning is adopted, the beam storage area (4) is used for receiving a beam body lifted by a gantry crane from a tensioning and grouting station (34) after primary tensioning is completed, and performing secondary tensioning and grouting treatment after spraying maintenance on the beam body.
4. The precast T beam production line of claim 3, further comprising a finishing area (5), the finishing area (5) being adapted to receive a precast T beam after being tensioned by the tensioned grouting station (34) or a precast T beam after being tensioned a second time by the beam storage area (4).
5. The prefabricated T-beam assembly line of claim 1, wherein the steam curing station (33) is a closed steam curing room, a plurality of steam pipelines are arranged around the inside of the steam curing room, a plurality of steam outlets are arranged on the steam pipelines, the distance between every two adjacent steam outlets is 0.8-1.1 m, and a sensor and an automatic adjusting controller for automatically detecting temperature and humidity are arranged in the steam curing room.
6. The prefabricated T-beam production line of any one of claims 1 to 5, wherein the prefabricated T-beam production line comprises a factory building (6), the area covered by the factory building (6) comprises a position from one end of the second pedestal running rail (3) close to the reinforcement binding station (31) to a position between the concrete pouring station (32) and the steam curing station (33), and an area with the same length as the first pedestal running rail (2);
the top of factory building (6) along the both sides of pedestal direction of movement is provided with the purlin and hangs the orbit, the purlin is hung and is provided with the purlin that can follow the operation of purlin swing orbit on the orbit and hangs, the purlin hangs the handling operation that is used for steel reinforcement station (31) and pouring concrete station (32) in factory building (6).
7. A method of using a prefabricated T-beam production line as claimed in any one of claims 1 to 6, comprising the steps of: each line is independently operated by the same prefabrication method, and each line can operate in the following mode:
step 1, a first pedestal (35) is hoisted to a second pedestal running track (3) of a production line by using a gantry crane (12), the first pedestal (35) moves on the second pedestal running track (3), after the first pedestal (35) moves to a reinforcement binding station (31), a binding formed reinforcement framework is hoisted to the pedestal, the reinforcement framework and the first pedestal (35) are installed and fixed, and then the first pedestal (35) moves to the steel reinforcement binding station (31);
step 2, after the first pedestal (35) moved out of the reinforcement binding station (31) in the step 1 enters a concrete pouring station (32), installing a template and a top plate steel bar on a steel bar framework on the first pedestal (35), pouring concrete, removing the template to obtain a beam body after the concrete reaches a form removal condition, and then moving the first pedestal (35) out of the concrete pouring station (32);
step 3, after the first pedestal (35) which is moved out of the concrete pouring station (32) in the step 2 enters the steam curing station (33), performing steam curing on the beam body on the first pedestal (35), and after curing conditions are met, moving the first pedestal (35) out of the steam curing station (33);
and 4, after the first pedestal (35) which is moved out of the steam curing station (33) in the step 3 enters a tensioning and grouting station (34), carrying out prestress tensioning and grouting treatment on the beam body on the first pedestal (35), then hoisting the beam body on the first pedestal (35) away from the pedestal by using a gantry crane (12) to be conveyed to a beam storage area, then hoisting the first pedestal (35) to a first pedestal running rail (2) of a pedestal conveying line by using the gantry crane (12), moving the first pedestal (35) on the first pedestal running rail (2) to one end away from a reinforcing steel bar binding station of the production line, then hoisting the first pedestal (35) to a second pedestal running rail (3) of the production line by using the gantry crane (12), and repeating the operation in the step 1.
8. The use method of the prefabricated T beam assembly line of claim 7, wherein 2-4 pedestals can be arranged on one production line for simultaneous operation.
9. The use method of the precast T beam assembly line of claim 7, wherein in the step 3, the curing condition is that the strength of the beam body reaches more than 90% of the designed concrete strength grade; the elastic modulus of the beam body reaches more than 90 percent of the elastic modulus of the designed concrete grade,
meanwhile, in the step 4, after the beam body on the first pedestal (35) is subjected to prestress tensioning and grouting treatment, the beam body on the first pedestal (35) is lifted away from the pedestal by a gantry crane (12) and conveyed to a finished product area (5) for storage;
or, in the step 3, the curing conditions are that the strength of the beam body reaches 75% -80% of the designed concrete strength grade, the elastic modulus of the beam body reaches 75% -80% of the designed concrete grade,
and meanwhile, in the step 4, after the beam body on the first pedestal (35) is subjected to primary prestress tensioning treatment, the beam body on the first pedestal (35) is lifted away from the pedestal by using a gantry crane (2) and conveyed to a beam storage area (4) for spray maintenance, and when the strength of the beam body reaches more than 90% of the strength grade of the designed concrete and the elastic modulus of the beam body reaches more than 90% of the elastic modulus of the grade of the designed concrete, secondary tensioning and grouting treatment is carried out on the T beam.
10. The use method of the prefabricated T beam assembly line according to any one of claims 7 to 9, wherein in the step 3, after the pedestal of the concrete pouring station (32) is moved out in the step 2 and enters the steam curing station (33), the temperature of the steam curing station (33) is changed sequentially through three stages, namely a temperature rising stage, a constant temperature stage and a temperature reducing stage, wherein the temperature rising rate of the temperature rising stage is not more than 15 ℃/h; the temperature of the constant temperature stage is not more than 70 ℃, and the cooling rate of the cooling stage is not more than 15 ℃/h; the relative humidity of the steam-curing station (33) is above 95% RH.
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113752379A (en) * | 2021-09-15 | 2021-12-07 | 浙江交工集团股份有限公司 | Concrete T-beam prefabricating method adopting secondary tensioning process and movable pedestal |
| CN114261013A (en) * | 2021-10-18 | 2022-04-01 | 中铁十二局集团有限公司 | Box girder production line and system of wisdom roof beam field |
| CN114474338A (en) * | 2022-01-05 | 2022-05-13 | 中铁八局集团第七工程有限公司 | Prefabrication production method for railway T beam in high-cold high-altitude area |
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2020
- 2020-12-31 CN CN202011642149.1A patent/CN112692980A/en active Pending
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113752379A (en) * | 2021-09-15 | 2021-12-07 | 浙江交工集团股份有限公司 | Concrete T-beam prefabricating method adopting secondary tensioning process and movable pedestal |
| CN114261013A (en) * | 2021-10-18 | 2022-04-01 | 中铁十二局集团有限公司 | Box girder production line and system of wisdom roof beam field |
| CN114261013B (en) * | 2021-10-18 | 2023-10-13 | 中铁十二局集团有限公司 | Box girder production line of wisdom roof beam field and system thereof |
| CN114474338A (en) * | 2022-01-05 | 2022-05-13 | 中铁八局集团第七工程有限公司 | Prefabrication production method for railway T beam in high-cold high-altitude area |
| CN114474338B (en) * | 2022-01-05 | 2024-05-28 | 中铁八局集团第七工程有限公司 | Prefabrication production method for railway T-beam in high-cold high-altitude area |
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