CN112873518B - Factory prefabrication production method for airport assembly type pavement slab - Google Patents
Factory prefabrication production method for airport assembly type pavement slab Download PDFInfo
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- 238000012545 processing Methods 0.000 claims abstract description 26
- 238000004898 kneading Methods 0.000 claims abstract description 24
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- 238000010521 absorption reaction Methods 0.000 claims abstract description 19
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B15/00—General arrangement or layout of plant ; Industrial outlines or plant installations
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/04—Producing shaped prefabricated articles from the material by tamping or ramming
- B28B1/045—Producing shaped prefabricated articles from the material by tamping or ramming combined with vibrating or jolting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
- B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
- Y02A30/00—Adapting or protecting infrastructure or their operation
- Y02A30/60—Planning or developing urban green infrastructure
Abstract
The invention discloses an airport fabricated pavement slab factory prefabricating production method which sequentially comprises the steps of mould positioning, steel reinforcement cage installation, embedded part installation, concrete pouring and vibrating, concrete vacuum water absorption, pressurized kneading, face collection static curing, steam curing and pavement slab demolding to realize rapid and safe processing of fabricated pavement slabs, and accurate processing and curing of the fabricated pavement slabs through pavement slab surface texture manufacturing, panel surface reinforcing agent coating and stacking curing. The system method effectively discharges the excessive moisture in the concrete, so that the concrete is more compact, the bending strength and the bending tensile strength of the plate are improved, and the surface strength reduction caused by vibration is reduced; the pressing and kneading process ensures that the compactness of the concrete on the face of the plate is better, and the durability of the concrete is improved; the milling process is adopted to manufacture the surface texture of the prefabricated plate, so that the depth and density of the texture can be met, and the strength of the texture is improved; the brushing surface reinforcing agent is effective in increasing the durability of concrete.
Description
Technical Field
The invention relates to the field of assembly type construction, in particular to an airport assembly type pavement slab factory prefabrication production method.
Background
In the airport fabricated concrete pavement system, the precision and the strength of the prefabricated plate need to be controlled in a key way. The precision of the plate can be controlled by adopting a high-precision shaping steel template, and how to improve the strength and the durability of the plate is further solved. The simple increase of the concrete strength mark is not beneficial to cost control. The traditional vibration-formed prefabricated plate has more surface floating slurry and reduced strength; in cast-in-place pavement construction, the later-stage pavement roughening is also performed on a low-strength surface, so that the texture durability after roughening is insufficient.
Disclosure of Invention
The invention aims to provide an airport assembly type pavement slab factory prefabrication production method, which further improves the compactness and durability of precast slab concrete, improves the bending strength and the bending tensile strength of slabs and simultaneously reduces the surface strength reduction caused by vibration; meanwhile, the texture strength and the durability of the concrete surface are improved.
In order to achieve the purpose, the invention adopts the technical scheme that:
the factory prefabrication production method of the airport assembly type pavement slab comprises the steps of sequentially carrying out die in-place, reinforcing cage installation, embedded part installation, concrete pouring and vibrating, concrete vacuum water absorption, pressurization kneading, face collection static maintenance, steam maintenance and pavement slab demolding to realize rapid and safe processing of the assembly type pavement slab, and realizing accurate processing and maintenance of the assembly type pavement slab through pavement slab surface texture manufacturing, panel surface reinforcing agent coating and stacking maintenance.
Preferably, the method for controlling the position of the mould comprises the following steps:
step A1, processing and molding the precast slab mold in the mold position by adopting high-quality steel on a numerical control machine;
step A2, completing the hoisting and transportation of the prefabricated plate mould by adopting special hoisting tools and equipment, and preventing the prefabricated plate mould from deforming;
step A3, installing the prefabricated plate mould on a production line, and then performing quality inspection; the quality acceptance content comprises the detection of the precision of the die and the detection of the structural strength of the die.
Step A4, after the main board part of the prefabricated board mould is used, the template oil is coated in time to prevent the template oil from rusting and prevent screw holes of the main board part from entering sundries such as mortar and the like; the screw holes and the bolts at the installation part of the prefabricated plate mould are coated with oil before and after each use, so that rusting is prevented, and smooth assembly is facilitated.
Preferably, the main plate part of the prefabricated plate mould comprises a mould base, a mould bottom mould, a mould side mould plate and a mould end mould plate, wherein the mould base is a welded integral steel structure bracket and is a self-bearing system; the die base is formed by cutting and processing a whole high-quality steel plate, and the four sides and the bottom are all formed by welding stiffened plates;
the mounting precision of the die side template on the bottom plate is ensured by positioning pins/holes of the bottom die support; the mould is provided with a self-locking fastening system to prevent any structural deformation.
Preferably, the control method for installing the reinforcement cage comprises the following steps:
step B1, preparing the steel bars according to the approved steel bar graph, and conforming to the shape, diameter, length, number and weight of the steel bars marked in the graph;
step B2, reinforcing bars adopt reinforcing bar net sheets and truss bars, numerical control blanking and automatic welding technology is introduced, and mechanical batch welding forming production is carried out through welding equipment;
step B3, paying attention to accurate welding of welding points, and avoiding the phenomena of meat biting, false welding and slag inclusion in the welding process;
step B4, carrying out quality inspection on the finished steel bar skeleton according to the standard requirements, and entering the finished steel bar skeleton into a finished product stacking area for later use after the finished steel bar skeleton is qualified;
and step B5, avoiding collision with the die during installation of the steel bar framework, and placing the steel bar parts and the embedded accessories by a specially-assigned person.
Preferably, the installation control method of the embedded part comprises the following steps:
step C1, the embedded part comprises a pull rod and a dowel bar embedded bolt sleeve, and the pull rod and the dowel bar embedded bolt sleeve are firmly fixed on the die to prevent casting displacement and deformation; the reserved lamp pit is firmly positioned by adopting a template top support frame;
and C2, inserting a bending core rod between the hole edge and the embedded part to prevent cement slurry from entering the reserved hole edge of the side surface, and preventing the hole edge from being blocked.
Preferably, the concrete pouring vibration control method includes the following steps:
d1, pouring concrete mortar in the mould after the embedded part is installed, and pouring by adopting a vibrating table or a vibrating rod as a pouring tool;
step D2, in the pouring process, concrete enters the upper part of the vibration table through the conveying frame for pouring, and multiple times of blanking are carried out during pouring;
and D3, visually checking the fastening bolt, the fixing bolt base, the connecting bolt base and the grouting hole bolt base in the vibration process to ensure the vibration safety.
Preferably, the concrete vacuum water absorption control method comprises the following steps:
e1, after concrete pouring and vibrating, paving a layer of plastic mesh on the surface of the concrete, and sealing the top of the plastic mesh by using non-air-permeable covering cloth;
step E2, pumping out redundant air and water between the top cover cloth and the concrete surface by using a vacuum pump; the water cement ratio of the concrete is reduced, and the compactness of the concrete is improved;
the pressure kneading control method comprises the following steps:
step F1, a mechanical arm on the production line is utilized to additionally install and knead a pressing bar;
step F2, after the concrete vacuum water absorption control is finished, pressurizing and kneading the surface of the concrete in the mould; the concrete is used for improving the compactness of the concrete, further promoting the discharge of water and air and further controlling the shrinkage rate of the concrete volume.
Preferably, the method for controlling the harvest time rest comprises the following steps:
g1, after all the materials are vibrated, kneaded and molded, rough surface, intermediate surface and fine surface are carried out, wherein the rough surface is a water collecting process; the rough plastering surface is formed by using a high-strength steel plate scraper bar, scraping off redundant concrete and carrying out coarse grinding;
g2, plastering, namely plastering by using a steel trowel after the concrete receives water to enable the outer arc surface of the pavement slab to be flat and smooth;
g3, finely wiping the surface, further finely wiping the surface, and trying to obtain a bright surface without trowel marks, wherein the error range value of the flatness is +/-0.5 mm.
Preferably, the steam curing control method includes the steps of:
h1, adopting a tunnel kiln for steam curing, wherein the steam curing kiln is divided into a static curing heat preservation area, a steam curing temperature rising area, a steam curing constant temperature area and a steam curing temperature reduction area according to requirements, a temperature range is set on a temperature controller in each area, and the temperature controller can automatically control the temperature of each area according to the temperature fed back by a sensor;
h2, standing for 3-4H after the pouring and tamping are finished, and starting heating up and steaming;
step H3, controlling the steam curing temperature in the temperature-rising steam curing process; the pavement panel is subjected to nutrient steaming, standing T, temperature rising S, constant temperature H and temperature reduction J;
step H4, the temperature rising speed is not more than 15 ℃ per hour, and the highest temperature is not more than 55 ℃; the constant temperature time is more than 2h, the relative humidity is not less than 90%, and the constant temperature time is correspondingly adjusted according to seasonal changes; the cooling speed is not more than 20 ℃ per hour, and the temperature is uniformly cooled to the room temperature with the difference of not more than 15 ℃;
step H5, faithfully recording the temperature change value of each temperature measuring point in the steam curing process;
in the demolding control process, in order to prevent the corner falling phenomenon of the pavement slab in the demolding process, when the strength of the steam-cured test piece under the same condition of the pavement slab is set to be 40% of the design strength, demolding can be performed, and hard prying and hard knocking are strictly forbidden during demolding.
Preferably, the method for controlling the road surface texture manufacturing comprises the following steps:
step I1, fixing the plate on the production line, and entering a milling channel; step I2, a milling channel is arranged, a milling drum is configured according to the surface texture requirement of the prefabricated plate, and a milling cutter head is installed; step I3, controlling the milling depth by using a digital technology, and milling the surface texture of the prefabricated plate; step I4, washing the plate, and recycling a washing system;
the panel surface reinforcing agent brushing control method comprises the following steps:
step J1, the surface of the prefabricated plate to be washed clean is dried in the air and enters a painting channel; step J2, uniformly coating the surface reinforcing agent on the surface of the prefabricated plate by using a mechanical roller
The invention has the beneficial effects that:
the invention further optimizes the manufacturing process of the precast slab in the traditional process while keeping the traditional prefabrication process, improves the processing speed and the processing accuracy of the precast slab of the airport pavement, and ensures that the process method for processing the precast pavement slab is safer and more reliable. Meanwhile, in the invention, vacuum water absorption and pressurization dough kneading procedures are added after concrete pouring, so that the surface compactness and strength of the concrete are increased, the durability and wear resistance are improved, and the concrete shrinkage rate is improved; after the steam curing is finished, a working procedure of manufacturing the surface texture by a milling process is added, so that the depth and the density of the texture can be met, and the strength of the texture is also improved. The durability of the concrete is effectively improved by coating the reinforcing agent on the surface of the concrete.
The road panel factory prefabrication production line is tied on a basic process system, so that the compactness and durability of precast slab concrete are further improved, the bending strength and the bending tensile strength of a precast road panel are improved, and the surface strength reduction caused by vibration is reduced; meanwhile, the texture strength and the durability of the concrete surface are improved.
Drawings
In order to clearly illustrate the embodiments or technical solutions of the present invention in the prior art, the drawings used in the description of the embodiments or prior art will be briefly introduced below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and it is obvious for those skilled in the art that other drawings can be obtained based on these drawings without creative efforts.
Fig. 1 is a flow chart of a factory prefabrication production method of an airport fabricated pavement slab.
Detailed Description
The invention provides an airport assembly type pavement slab factory prefabricating production method, and in order to make the purpose, technical scheme and effect of the invention clearer and clearer, the invention is further described in detail below. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
The invention is described in detail below with reference to the attached drawing figures:
example 1
With reference to fig. 1, the factory prefabrication production method of the airport assembly type pavement slab sequentially comprises the steps of mold positioning, reinforcement cage installation, embedded part installation, concrete pouring and vibrating, concrete vacuum water absorption, pressurization and kneading, face collection and static curing, steam curing and pavement slab demolding to realize rapid and safe processing of the assembly type pavement slab, and accurate processing and curing of the assembly type pavement slab are realized through pavement slab surface texture manufacturing, panel surface reinforcing agent coating and stacking curing.
The control method for the mold in position comprises the following steps: step A1, processing and molding the precast slab mold in the mold position by adopting high-quality steel on a numerical control machine;
and step A2, completing the hoisting and transportation of the prefabricated plate mould by adopting special hoisting tools and equipment, and preventing the prefabricated plate mould from deforming.
Step A3, installing the prefabricated plate mould on a production line, and then carrying out quality inspection and acceptance; the quality acceptance content comprises the detection of the precision of the die and the detection of the structural strength of the die.
Step A4, after the main board part of the prefabricated board mould is used, the template oil is coated in time to prevent the template oil from rusting and prevent screw holes of the main board part from entering sundries such as mortar and the like; the screw holes and the bolts at the installation part of the prefabricated plate mould are coated with oil before and after each use, so that rusting is prevented, and smooth assembly is facilitated.
The main board part of the prefabricated board mould comprises a mould base, a mould bottom mould, a mould side mould plate and a mould end mould plate, wherein the mould base is a welded integral steel structure bracket and is a self-bearing system; the die base is formed by cutting and processing a whole high-quality steel plate, and the four sides and the bottom are all formed by welding stiffened plates;
the mounting precision of the die sideform on the bottom plate is ensured by a positioning pin/hole of the bottom die support; the mould is provided with a self-locking fastening system to prevent any structural deformation.
The control method for installing the reinforcement cage comprises the following steps: and step B1, preparing the steel bars according to the approved steel bar graph, and according to the shape, diameter, length, number and weight of the steel bars marked in the graph.
And step B2, reinforcing bars adopt reinforcing steel bar meshes and truss bars, numerical control blanking and automatic welding technologies are introduced, and mechanical batch welding forming production is carried out through welding equipment.
And step B3, paying attention to accurate welding of welding points, and avoiding the phenomena of meat biting, false welding and slag inclusion in the welding process.
And step B4, performing quality inspection on the finished steel reinforcement framework according to the standard requirements, and after the finished steel reinforcement framework is qualified, hanging a brand mark and entering a finished product stacking area for later use.
And step B5, avoiding collision with the die during installation of the steel bar framework, and placing the steel bar parts and the embedded accessories by a specially-assigned person.
The embedded part installation control method comprises the following steps: step C1, the embedded part comprises a pull rod and a dowel bar embedded bolt sleeve, and the pull rod and the dowel bar embedded bolt sleeve are firmly fixed on the die to prevent casting displacement and deformation; the reserved lamp pit is firmly positioned by adopting a template top support frame.
And C2, inserting a bending core rod between the hole edge and the embedded part to prevent cement slurry from entering the reserved hole edge of the side surface, and preventing the hole edge from being blocked.
The concrete pouring and vibrating control method comprises the following steps: d1, pouring concrete mortar in the mould after the embedded part is installed, and pouring by adopting a vibrating table or a vibrating rod as a pouring tool;
step D2, in the pouring process, concrete enters the upper part of the vibration table through the conveying frame for pouring, and multiple times of blanking are carried out during pouring; and D3, visually checking the fastening bolt, the fixing bolt base, the connecting bolt base and the grouting hole bolt base in the vibration process to ensure the vibration safety.
The concrete vacuum water absorption control method comprises the following steps: and E1, after concrete pouring and vibrating, paving a layer of plastic mesh on the surface of the concrete, and sealing the top of the plastic mesh by using non-air-permeable covering cloth.
Step E2, pumping out redundant air and water between the top cover cloth and the concrete surface by using a vacuum pump; the water cement ratio of the concrete is reduced, and the compactness of the concrete is improved.
The control method of the pressure kneading comprises the following steps: and F1, additionally installing and kneading the pressing bar by using a mechanical arm on the production line. Step F2, after the concrete vacuum water absorption control is finished, pressurizing and kneading the surface of the concrete in the mould; the concrete is used for improving the compactness of the concrete, further promoting the discharge of water and air and further controlling the shrinkage rate of the concrete volume.
The noodle-harvesting resting control method comprises the following steps: g1, after all the materials are vibrated, kneaded and molded, rough surface, intermediate surface and fine surface are carried out, wherein the rough surface is a water collecting process; and the rough surface is formed by using a high-strength steel plate scraper to scrape off excessive concrete and performing rough grinding. G2, plastering, namely plastering by using a steel trowel after the concrete receives water to enable the outer arc surface of the pavement slab to be flat and smooth; g3, finely wiping the surface, further finely wiping the surface, and striving for the bright surface without the float mark, wherein the error range value of the flatness is +/-0.5 mm.
The steam curing control method comprises the following steps: h1, adopting a tunnel kiln for steam curing, wherein the steam curing kiln is divided into a static curing heat preservation area, a steam curing temperature rising area, a steam curing constant temperature area and a steam curing temperature reduction area according to requirements, a temperature range is set on a temperature controller in each area, and the temperature controller can automatically control the temperature of each area according to the temperature fed back by a sensor;
h2, standing for 3-4H after the pouring and tamping are finished, and starting heating up and steaming; step H3, controlling the steam curing temperature in the temperature-rising steam curing process; the pavement panel is subjected to nutrient steaming, standing T, temperature rising S, constant temperature H and temperature reduction J;
step H4, the temperature rising speed is not more than 15 ℃ per hour, and the highest temperature is not more than 55 ℃; the constant temperature time is more than 2h, the relative humidity is not less than 90%, and the constant temperature time is correspondingly adjusted according to seasonal changes; the cooling speed is not more than 20 ℃ per hour, and the temperature is uniformly cooled to the room temperature with the difference of not more than 15 ℃; and step H5, faithfully recording the temperature change value of each temperature measuring point in the steam curing process.
In the demolding control process, in order to prevent the corner falling phenomenon of the pavement slab in the demolding process, when the strength of the steam-cured test piece under the same condition of the pavement slab is set to be 40% of the design strength, demolding can be performed, and hard prying and hard knocking are strictly forbidden during demolding.
The method for manufacturing and controlling the surface texture of the pavement slab comprises the following steps: step I1, fixing the plate on the production line, and entering a milling channel; step I2, a milling channel is arranged, a milling drum is configured according to the surface texture requirement of the prefabricated plate, and a milling cutter head is installed; step I3, controlling the milling depth by using a digital technology, and milling the surface texture of the prefabricated plate; step I4, washing the plate, and recycling a washing system;
the panel surface reinforcing agent brushing control method comprises the following steps: step J1, the surface of the prefabricated plate to be washed clean is dried in the air and enters a painting channel; and step J2, uniformly coating the surface reinforcing agent on the surface of the prefabricated plate by using a mechanical roller.
Example 2
An airport assembly type pavement slab factory prefabricating production method comprises the steps of mold positioning, reinforcement cage installation, embedded part installation, concrete pouring and vibrating, concrete vacuum water absorption, pressurization kneading, face collection and static curing, steam curing, demolding, surface texture manufacturing through milling and planing, surface reinforcing agent coating and the like. The concrete vacuum water absorption process effectively discharges the excessive water in the concrete, so that the concrete is more compact, the bending strength and the bending tensile strength of the plate are improved, and the surface strength reduction caused by vibration is reduced; the procedure of pressurizing and kneading enables the concrete compactness of the plate face to be better and improves the durability of the concrete; the milling process is adopted to manufacture the surface texture of the prefabricated plate, so that the depth and density of the texture can be met, and the strength of the texture is improved; the brushing surface reinforcing agent is effective in increasing the durability of concrete.
Example 3
With reference to fig. 1, the factory prefabrication production method of the airport assembly type pavement slab comprises the steps of mold positioning, reinforcement cage installation, embedded part installation, concrete pouring and vibrating, concrete vacuum water absorption, pressurization and kneading, face collection and static curing, steam curing, demolding, surface texture manufacturing through milling and planing, surface reinforcing agent coating and stacking and curing.
The mould positioning control method comprises the following steps: the mould is made of high-quality steel and is formed on a numerical control machine tool, the main body of the mould consists of a base, a bottom mould, side templates and end templates, and the base of the mould is a welded integral steel structure bracket and is a self-bearing system. The steel plate is formed by cutting and processing a whole high-quality steel plate, and the four sides and the bottom are all formed by welding stiffened plates.
The mounting precision of the surrounding templates on the bottom plate is ensured by the positioning pins/holes of the bottom die support. The mould is provided with a self-locking fastening system to prevent any structural deformation. The hoisting and the transportation of the steel template are carried out by adopting special hoisting tools and equipment, so that the template is prevented from deforming. After the die is installed on a production line, quality inspection and acceptance including indexes of precision, strength and the like are carried out. The daily maintenance work of the template is noticed, and the template oil is coated in time after the template is used, so that the template oil is prevented from rusting. The screw holes of all parts are strictly prohibited from entering sundries such as mortar and the like. The screw holes and the bolts of all parts are coated with oil before and after each use, so that the rust is prevented, and meanwhile, the smooth assembly is facilitated.
The installation control method of the reinforcement cage comprises the following steps: the rebar is prepared according to an approved rebar map, conforming to the rebar shape, diameter, length, number, and weight indicated in the map. The reinforcing bars adopt reinforcing mesh sheets and truss ribs, numerical control blanking and automatic welding technologies are introduced, and mechanical batch welding forming production can be carried out. The phenomena of meat biting, false welding and slag inclusion of welding seams cannot occur in the welding process, and the spot welding is firm, so that the reinforcing steel bar framework is prevented from loosening and deforming during hoisting; and (4) carrying out quality inspection on the finished product steel reinforcement framework strictly according to the standard requirements, and entering the finished product stacking area for later use after the finished product steel reinforcement framework is qualified. The steel bar framework can not collide with the die during installation, and a specially-assigned person can place steel bar components and embedded accessories.
The embedded part installation control method comprises the following steps: the pull rod and the dowel bar are embedded with bolt sleeves and firmly fixed on a mold, so that the pouring displacement and deformation are prevented. The reserved lamp pit is firmly positioned by adopting a template top support frame. In order to prevent cement slurry from entering the reserved hole edge of the side face, a bent core rod is inserted between the hole edge and the embedded part, and the hole edge is prevented from being blocked.
The concrete pouring and vibrating control method comprises the following steps: the pouring can be carried out by adopting a vibrating table or a vibrating rod; concrete enters the upper part of the vibration table through the conveying frame for pouring, and can be discharged for multiple times; the fastening bolt and the fixing bolt base, the connecting bolt base and the grouting hole bolt base need to be visually checked in the vibration process.
The concrete vacuum water absorption control method comprises the following steps: after the preliminary vibration, a layer of plastic mesh is paved on the surface of the concrete, and then the top of the plastic mesh is sealed by using non-air-permeable covering cloth; pumping redundant air and water between the top cover cloth and the concrete surface by using a vacuum pump according to a vacuum negative pressure principle; the water-cement ratio is reduced, the compactness of the concrete is improved, and the aims of impermeability and water resistance are fulfilled.
The control method of the pressure kneading comprises the following steps: a mechanical arm on a production line is utilized to additionally install a kneading and pressing bar; pressurizing and kneading the surface of the concrete in a steel mould; the compactness of the concrete is obviously improved, water and air are further promoted to be discharged, and the volume shrinkage rate of the concrete is also controlled.
The noodle-harvesting resting control method comprises the following steps: and (5) after all the materials are vibrated, kneaded, pressed and formed, smearing is carried out. Rough surface (water collection): scraping off redundant concrete by using a high-strength steel plate scraper, and performing coarse grinding; performing intermediate plastering, namely plastering by using a steel trowel after the concrete is collected to enable the outer arc surface of the pavement slab to be flat and smooth; finely plastering: the surface is bright without the smear printing, and the error value of the flatness is not more than plus or minus 0.5 mm.
The steam curing control method comprises the following steps: the steam curing adopts a tunnel kiln, the steam curing kiln is divided into a static curing heat preservation area, a steam curing temperature rising area, a steam curing constant temperature area and a steam curing temperature reduction area according to requirements, a temperature range is set on a temperature controller in each area, and the temperature controller can automatically control the temperature of each area according to the temperature fed back by a sensor, so that the steam curing condition of the road panel is ensured. And (4) after the pouring and tamping are finished, standing for 3-4 hours, and starting heating and steaming (the standing time is changed correspondingly according to different temperatures). Controlling the steam curing temperature: and (3) performing nutrient steaming on the pavement slab, standing for T, heating for S, keeping the temperature for H, and cooling for J. The temperature rise speed is not more than 15 ℃ per hour, and the highest temperature is not more than 55 ℃; keeping the temperature for more than 2 hours, keeping the relative humidity not less than 90%, and correspondingly adjusting the constant temperature time according to seasonal changes; the temperature reduction speed is not more than 20 ℃ per hour, and the temperature is reduced at a constant speed until the temperature difference with the room temperature is not more than 15 ℃. And faithfully recording the temperature change value of each temperature measuring point in the steam curing process.
The demolding control method comprises the following steps: in order to prevent the corner falling phenomenon of the pavement slab in the stripping process, when the strength of the steam-cured test piece under the same condition of the pavement slab reaches 40% of the design strength, the pavement slab can be stripped, and the hard prying and the hard knocking are strictly forbidden during the stripping.
The control method for manufacturing the surface texture by the milling process comprises the following steps: fixing the plate on the production line, and entering a milling channel; arranging a milling channel, configuring a milling drum according to the surface texture requirement of the prefabricated plate, and installing a milling cutter head; controlling the milling depth by using a digital technology, and milling the surface texture of the prefabricated plate; and (4) washing the plate, and recycling a washing system.
The control method of the coating surface reinforcing agent comprises the following steps: the surface of the prefabricated plate to be washed clean is air-dried and enters a painting channel; uniformly brushing the surface reinforcing agent on the surface of the prefabricated plate by using a mechanical roller; then, the maintenance is carried out.
Example 4
The factory prefabrication production method of the airport fabricated pavement slab sequentially comprises the steps of mould positioning, steel reinforcement cage installation, embedded part installation, concrete pouring and vibrating, concrete vacuum water absorption, pressurized kneading, face collection and static curing, steam curing and pavement slab demolding to realize the rapid and safe processing of the fabricated pavement slab, so that the production and processing of a large number of fabricated pavement slabs special for airport pavement slabs are realized.
The control method for the mold in position comprises the following steps: step A1, processing and molding the precast slab mold in the mold position by adopting high-quality steel on a numerical control machine;
and step A2, completing the hoisting and transportation of the prefabricated plate mould by adopting special hoisting tools and equipment, and preventing the prefabricated plate mould from deforming.
Step A3, installing the prefabricated plate mould on a production line, and then performing quality inspection; the quality acceptance content comprises the detection of the precision of the die and the detection of the structural strength of the die.
Step A4, after the main board part of the prefabricated board mould is used, the template oil is coated in time to prevent the template oil from rusting and prevent screw holes of the main board part from entering sundries such as mortar and the like; the screw holes and the bolts at the installation part of the prefabricated plate mould are coated with oil before and after each use, so that rusting is prevented, and smooth assembly is facilitated.
The main board part of the prefabricated board mould comprises a mould base, a mould bottom mould, a mould side mould plate and a mould end mould plate, wherein the mould base is a welded integral steel structure bracket and is a self-bearing system; the die base is formed by cutting and processing a whole high-quality steel plate, and the four sides and the bottom are all formed by welding stiffened plates;
the mounting precision of the die side template on the bottom plate is ensured by positioning pins/holes of the bottom die support; the mould is provided with a self-locking fastening system to prevent any structural deformation.
The control method for installing the reinforcement cage comprises the following steps: and step B1, preparing the steel bars according to the approved steel bar graph, and according to the shape, diameter, length, number and weight of the steel bars marked in the graph.
And step B2, reinforcing bars adopt reinforcing steel bar meshes and truss bars, numerical control blanking and automatic welding technologies are introduced, and mechanical batch welding forming production is carried out through welding equipment.
And step B3, paying attention to accurate welding of welding points, and avoiding the phenomena of meat biting, false welding and slag inclusion in the welding process.
And step B4, performing quality inspection on the finished steel bar skeleton according to the standard requirements, and entering the finished steel bar skeleton into a finished steel bar stacking area for later use after the finished steel bar skeleton is qualified.
And step B5, avoiding collision with the die during installation of the steel bar framework, and placing the steel bar parts and the embedded accessories by a specially-assigned person.
The embedded part installation control method comprises the following steps: step C1, the embedded part comprises a pull rod and a dowel bar embedded bolt sleeve, and the pull rod and the dowel bar embedded bolt sleeve are firmly fixed on the die to prevent casting displacement and deformation; the reserved lamp pit is firmly positioned by adopting a template top support frame.
And C2, inserting a bending core rod between the hole edge and the embedded part to prevent cement slurry from entering the reserved hole edge of the side surface, and preventing the hole edge from being blocked.
The concrete pouring and vibrating control method comprises the following steps: d1, pouring concrete mortar in the mould after the embedded part is installed, and pouring by adopting a vibrating table or a vibrating rod as a pouring tool;
step D2, in the pouring process, concrete enters the upper part of the vibration table through the conveying frame for pouring, and multiple times of blanking are carried out during pouring; and D3, visually checking the fastening bolt, the fixing bolt base, the connecting bolt base and the grouting hole bolt base in the vibration process to ensure the vibration safety.
The concrete vacuum water absorption control method comprises the following steps: and E1, after concrete pouring and vibrating, paving a layer of plastic mesh on the surface of the concrete, and sealing the top of the plastic mesh by using non-air-permeable covering cloth.
Step E2, pumping out redundant air and water between the top cover cloth and the concrete surface by using a vacuum pump; the water cement ratio of the concrete is reduced, and the compactness of the concrete is improved.
The control method of the pressure kneading comprises the following steps: and F1, additionally installing and kneading the pressing bar by using a mechanical arm on the production line. Step F2, after the concrete vacuum water absorption control is finished, pressurizing and kneading the surface of the concrete in the mould; for improving the compactness of concrete, further facilitating the discharge of water and air, and further controlling the shrinkage of the concrete volume.
The noodle-harvesting resting control method comprises the following steps: g1, after all the materials are vibrated, kneaded and molded, rough surface, intermediate surface and fine surface are carried out, wherein the rough surface is a water collecting process; and the rough surface is formed by using a high-strength steel plate scraper to scrape off excessive concrete and performing rough grinding. G2, plastering, namely plastering by using a steel trowel after the concrete receives water to enable the outer arc surface of the pavement slab to be flat and smooth; g3, finely wiping the surface, further finely wiping the surface, and striving for the bright surface without the float mark, wherein the error range value of the flatness is +/-0.5 mm.
The steam curing control method comprises the following steps: h1, adopting a tunnel kiln for steam curing, wherein the steam curing kiln is divided into a static curing heat preservation area, a steam curing temperature rising area, a steam curing constant temperature area and a steam curing temperature reduction area according to requirements, the temperature range of each area is set on a temperature controller, and the temperature controller can automatically control the temperature of each area according to the temperature fed back by a sensor;
h2, standing for 3-4H after the pouring and tamping are finished, and starting heating up and steaming; step H3, controlling the steam curing temperature in the temperature-rising steam curing process; the pavement panel is subjected to nutrient steaming, standing T, temperature rising S, constant temperature H and temperature reduction J;
step H4, the temperature rising speed is not more than 15 ℃ per hour, and the highest temperature is not more than 55 ℃; the constant temperature time is more than 2h, the relative humidity is not less than 90%, and the constant temperature time is correspondingly adjusted according to seasonal changes; the cooling speed is not more than 20 ℃ per hour, and the temperature is uniformly cooled to the room temperature with the difference of not more than 15 ℃; and step H5, faithfully recording the temperature change value of each temperature measuring point in the steam curing process.
In the demolding control process, in order to prevent the corner falling phenomenon of the pavement slab in the demolding process, when the strength of the steam-cured test piece under the same condition of the pavement slab is set to be 40% of the design strength, demolding can be performed, and hard prying and hard knocking are strictly forbidden during demolding.
Example 5
The precise processing and maintenance of the assembled pavement slab are realized through the pavement slab surface texture manufacturing, the slab surface reinforcing agent coating and the stacking maintenance.
The method for manufacturing and controlling the surface texture of the pavement slab comprises the following steps: step I1, fixing the plate on the production line, and entering a milling channel; step I2, a milling channel is arranged, a milling drum is configured according to the surface texture requirement of the prefabricated plate, and a milling cutter head is installed; step I3, controlling the milling depth by using a digital technology, and milling the surface texture of the prefabricated plate; step I4, washing the plate, and recycling the washing system.
The panel surface reinforcing agent brushing control method comprises the following steps: step J1, the surface of the prefabricated plate to be washed clean is dried in the air and enters a painting channel; and step J2, uniformly coating the surface reinforcing agent on the surface of the prefabricated plate by using a mechanical roller.
The invention further optimizes the manufacturing process of the precast slab in the traditional process while keeping the traditional prefabrication process, improves the processing speed and the processing accuracy of the precast slab of the airport pavement, and ensures that the process method for processing the precast pavement slab is safer and more reliable. Meanwhile, in the invention, the vacuum water absorption and pressurization kneading process is added after the concrete pouring work, so that the surface compactness and strength of the concrete are increased, the durability and wear resistance are improved, and the concrete shrinkage rate is improved; after the steam curing is finished, a working procedure of manufacturing the surface texture by a milling process is added, so that the depth and the density of the texture can be met, and the strength of the texture is also improved. The durability of the concrete is effectively improved by coating the reinforcing agent on the surface of the concrete.
The road panel factory prefabrication production line is tied on a basic process system, so that the compactness and durability of precast slab concrete are further improved, the bending strength and the bending tensile strength of a precast road panel are improved, and the surface strength reduction caused by vibration is reduced; meanwhile, the texture strength and the durability of the concrete surface are improved.
It is to be understood that the above description is not intended to limit the present invention, and the present invention is not limited to the above examples, and those skilled in the art may make modifications, alterations, additions or substitutions within the spirit and scope of the present invention.
Claims (4)
1. The factory prefabrication production method of the airport assembly type pavement slab is characterized in that the rapid and safe processing of the assembly type pavement slab is realized through mould in-place, reinforcement cage installation, embedded part installation, concrete pouring and vibrating, concrete vacuum water absorption, pressurization and kneading, face collection and static curing, steam curing and pavement slab demoulding in sequence, and the accurate processing and curing of the assembly type pavement slab are realized through pavement slab surface texture manufacturing, panel surface reinforcing agent coating and stacking curing;
the installation control method of the embedded part comprises the following steps:
step C1, the embedded part comprises a pull rod and a dowel bar embedded bolt sleeve, and the pull rod and the dowel bar embedded bolt sleeve are firmly fixed on the die to prevent casting displacement and deformation; the reserved lamp pit is firmly positioned by adopting a template top support frame; step C2, in order to prevent cement slurry from entering the reserved hole edge of the side surface, a bent core rod is inserted between the hole edge and the embedded part to prevent the hole edge from being blocked;
the concrete pouring and vibrating control method comprises the following steps:
d1, pouring concrete mortar in the mould after the embedded part is installed, and pouring by adopting a vibrating table or a vibrating rod as a pouring tool; step D2, in the pouring process, concrete enters the upper part of the vibration table through the conveying frame for pouring, and multiple times of blanking are carried out during pouring; step D3, the fastening bolt, the fixing bolt base, the connecting bolt base and the grouting hole bolt base need to be visually checked in the vibration process, and the vibration safety is ensured;
the concrete vacuum water absorption control method comprises the following steps:
e1, after concrete pouring and vibrating, paving a layer of plastic mesh on the surface of the concrete, and sealing the top of the plastic mesh by using non-air-permeable covering cloth; step E2, pumping out redundant air and water between the top cover cloth and the concrete surface by using a vacuum pump; the water-cement ratio of the concrete is reduced, and the compactness of the concrete is improved;
the pressure kneading control method comprises the following steps:
step F1, a mechanical arm on the production line is utilized to additionally install and knead a pressing bar; step F2, after the concrete vacuum water absorption control is finished, pressurizing and kneading the surface of the concrete in the mould; the concrete is used for improving the compactness of the concrete, further promoting the discharge of water and air and further controlling the shrinkage rate of the concrete volume;
the noodle-harvesting resting control method comprises the following steps:
g1, after all the materials are vibrated, kneaded and molded, rough-plastering, medium-plastering and fine-plastering are carried out, wherein the rough-plastering is a water collecting process; the rough surface is formed by using a high-strength steel plate scraper bar, scraping off redundant concrete and carrying out coarse grinding; g2, plastering, namely plastering by using a steel trowel after the concrete receives water to enable the outer arc surface of the pavement slab to be flat and smooth; g3, finely wiping the surface, further finely wiping the surface, striving for the surface to be bright without trowel prints, and the error range value of the flatness is +/-0.5 mm;
the steam curing control method comprises the following steps:
h1, adopting a tunnel kiln for steam curing, wherein the steam curing kiln is divided into a static curing heat preservation area, a steam curing temperature rising area, a steam curing constant temperature area and a steam curing temperature reduction area according to requirements, a temperature range is set on a temperature controller in each area, and the temperature controller can automatically control the temperature of each area according to the temperature fed back by a sensor; h2, standing for 3-4H after the pouring and tamping are finished, and starting heating up and steaming; step H3, controlling the steam curing temperature in the temperature-rising steam curing process; the pavement panel is subjected to nutrient steaming, standing T, temperature rising S, constant temperature H and temperature reduction J; step H4, the temperature rising speed is not more than 15 ℃ per hour, and the highest temperature is not more than 55 ℃; the constant temperature time is more than 2h, the relative humidity is not less than 90%, and the constant temperature time is correspondingly adjusted according to seasonal changes; the cooling speed is not more than 20 ℃ per hour, and the temperature is uniformly cooled to the room temperature with the difference of not more than 15 ℃; step H5, faithfully recording the temperature change value of each temperature measuring point in the steam curing process;
in the demolding control process, in order to prevent the corner falling phenomenon of the pavement slab in the demolding process, when the strength of the steam-cured test piece under the same condition of the pavement slab is set to be 40% of the design strength, demolding can be carried out, and hard prying and hard knocking are strictly forbidden during demolding;
the method for manufacturing and controlling the surface texture of the road panel comprises the following steps:
step I1, fixing the plate on the production line, and entering a milling channel; step I2, a milling channel is arranged, a milling drum is configured according to the surface texture requirement of the prefabricated plate, and a milling cutter head is installed; step I3, controlling the milling depth by using a digital technology, and milling the surface texture of the prefabricated plate; step I4, washing the plate, and recycling a washing system;
the panel surface reinforcing agent brushing control method comprises the following steps:
step J1, the surface of the prefabricated plate to be washed clean is dried in the air and enters a painting channel; and step J2, uniformly coating the surface reinforcing agent on the surface of the prefabricated plate by using a mechanical roller.
2. The factory prefabrication production method of the airport assembly type pavement slab as claimed in claim 1, wherein the control method of the mold in position comprises the following steps:
step A1, processing and molding the precast slab die in the die positioning by adopting high-quality steel on a numerical control machine;
step A2, completing the hoisting and transportation of the prefabricated plate mould by adopting special hoisting tools and equipment, and preventing the prefabricated plate mould from deforming;
step A3, installing the prefabricated plate mould on a production line, and then performing quality inspection; the quality acceptance content comprises the detection of the precision of the die and the detection of the structural strength of the die;
step A4, after the main board part of the prefabricated board mould is used, the template oil is coated in time to prevent the main board part from rusting and prevent screw holes of the main board part from entering mortar sundries; the screw holes and the bolts at the installation part of the prefabricated plate mould are coated with oil before and after each use, so that rusting is prevented, and smooth assembly is facilitated.
3. The factory prefabrication production method of the airport assembly type pavement slab as claimed in claim 2, wherein the main slab part of the prefabricated slab mold comprises a mold base, a mold bottom mold, mold side templates and a mold end template, the mold base is a welded integral steel structure bracket and is a self-bearing system; the die base is formed by cutting and processing a whole high-quality steel plate, and the four sides and the bottom are all formed by welding stiffened plates;
the mounting precision of the die side template on the bottom plate is ensured by positioning pins/holes of the bottom die support; the mould is provided with a self-locking fastening system to prevent any structural deformation.
4. The factory prefabrication production method of the airport assembly type pavement slab as claimed in claim 1, wherein the control method for installation of the reinforcement cage comprises the following steps:
step B1, preparing the steel bars according to the approved steel bar graph, and conforming to the shape, diameter, length, number and weight of the steel bars marked in the graph;
step B2, reinforcing bars adopt reinforcing steel bar meshes and truss bars, numerical control blanking and automatic welding technologies are introduced, and mechanical batch welding forming production is carried out through welding equipment;
step B3, paying attention to accurate welding of welding points, and avoiding the phenomena of meat biting, false welding and slag inclusion in the welding process;
step B4, carrying out quality inspection on the finished steel bar skeleton according to the standard requirements, and entering the finished steel bar skeleton into a finished product stacking area for later use after the finished steel bar skeleton is qualified;
and step B5, avoiding collision with the die during installation of the steel bar framework, and placing the steel bar parts and the embedded accessories by a specially-assigned person.
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