CN113400450A - Production process flow of bare concrete prefabricated external wall panel - Google Patents
Production process flow of bare concrete prefabricated external wall panel Download PDFInfo
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- CN113400450A CN113400450A CN202110736837.2A CN202110736837A CN113400450A CN 113400450 A CN113400450 A CN 113400450A CN 202110736837 A CN202110736837 A CN 202110736837A CN 113400450 A CN113400450 A CN 113400450A
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Classifications
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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
- B28B23/022—Means for inserting reinforcing members into the mould or for supporting them in the mould
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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
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
- B28B11/245—Curing concrete articles
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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
- B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
- B28B13/02—Feeding the unshaped material to moulds or apparatus for producing shaped articles
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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
- B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
- B28B13/04—Discharging the shaped articles
- B28B13/06—Removing the shaped articles from moulds
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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
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/22—Moulds for making units for prefabricated buildings, i.e. units each comprising an important section of at least two limiting planes of a room or space, e.g. cells; Moulds for making prefabricated stair units
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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
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/38—Treating surfaces of moulds, cores, or mandrels to prevent sticking
- B28B7/384—Treating agents
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- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Structural Engineering (AREA)
- Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
Abstract
The invention discloses a production process flow of an exposed concrete prefabricated external wall panel, which comprises the following steps: s1, deepening design; s2, judging whether the original design has problems, if no, executing step S3, if yes, executing step S3 after the original design is changed; s3, manufacturing a mould and processing and installing steel bars of the prefabricated external wall panel; s4, pouring and curing the concrete, wherein the curing and heating speed is controlled to be 15-20 ℃/h; when the highest temperature is not more than 60 ℃, a special oilcloth bracket is arranged on the surface of the component when the oilcloth is covered, the oilcloth is separated from the surface of the concrete by 200-400mm, a steam circulating space S5 is formed, and demoulding and hoisting are carried out; and S6, protecting the finished product. The invention improves the standardized operation by various unified standards, reduces the error by various measures and reduces the repair and rejection rate.
Description
Technical Field
The invention relates to the technical field of production processes of external wall boards, in particular to a production process flow of a bare concrete prefabricated external wall board.
Background
At the present stage, along with the continuous acceleration of the urbanization process in China, corresponding measures are taken by countries and governments to accelerate the promotion of building industrialization, wherein the industrialization is an important content, and the assembled external wall board is particularly the key point because the assembled external wall board relates to the effect of an external vertical surface. How to carry out related technical research on the basis of combining national conditions and engineering practice, theoretical research and engineering practice show a parallel relationship, how to really realize design standardization, structural part industrialization and construction mechanization, and how to carry out innovative design and construction in projects is a difficult problem in front of engineering companies.
The integral concrete building is assembled, the construction is relatively quick, and the requirements on the construction and installation technology of workers are relatively high. The construction method of combining on-site wet operation is similar to the current construction mode of China, is more suitable for the current national conditions of China, is suitable for vigorous popularization, is particularly suitable for the vigorous popularization of mass construction of houses, arrangement houses, public rental houses and other districts in the current government, and is one of the most suitable industrialized construction modes at present.
Disclosure of Invention
The invention aims to provide a production process flow of an as-cast finish concrete prefabricated external wall panel, which aims to solve the problems in the background technology.
In order to achieve the purpose, the invention provides the following technical scheme: a production process flow of an exposed concrete prefabricated external wall panel comprises the following steps:
s1, deepening design;
s2, judging whether the original design has problems, if no, executing step S3, if yes, executing step S3 after the original design is changed;
s3, manufacturing a mould and processing and installing steel bars of the prefabricated external wall panel;
s4, pouring and curing concrete;
s5, demolding and lifting;
and S6, protecting the finished product.
Preferably, the mold manufacturing comprises the following steps:
cleaning a table film, a steel die and a spraying release agent → positioning a side die and a hole template → aligning the sizes of the components according to a graph and a core → continuously entering the next procedure if the components are qualified, and performing unqualified rework → fixing the template, arranging embedded parts → checking the quantity and the positions of the embedded parts according to the graph and the core → continuously entering the next procedure if the components are qualified, and performing unqualified rework.
Preferably, the steel bar processing and installing process comprises the following steps:
turning the design drawing for blanking → processing and forming → installing and bundling → forming → checking the size, the number and the position of the reinforcing steel bar and the additional reinforcing steel bar, continuing to enter the next procedure if the reinforcing steel bar is qualified, and performing unqualified repair → acceptance → recording the signature.
Preferably, the step S4 includes the following steps:
the concrete enters the field → the mix proportion parameter is checked → the concrete enters the next procedure continuously, the goods returned is not met → the material is discharged → the slump is tested → the same maintenance is carried out, the standard maintenance test block → the mechanical vibration → the leveling of the scraper → the initial press polish → the cover → the maintenance.
Preferably, the curing specifically comprises the following steps: after concrete is poured for 2 hours, tightly wrapping the member by using color strip cloth, and curing by using steam; a steam curing system: standing for 1h, heating for 3h, keeping the temperature for 6h, and cooling for 4 h; the temperature rising speed is controlled to be 15-20 ℃/h; the highest temperature is not more than 60 ℃; the temperature reduction time is adjusted according to the actual temperature on site, the temperature of the component for demolding and the atmospheric temperature are not more than 20 ℃, the temperature measurement work is carried out by a specially-assigned person, and the temperature is measured for 1 time per hour; when the prefabricated part needs to be steamed and cured at low temperature, a corresponding curing system is set, the prefabricated part is preferably kept still for 2 to 6 hours at normal temperature, the heating and cooling speed is not more than 20 ℃/h, the highest curing temperature is not more than 70 ℃, and the difference between the temperature of the prefabricated part out of a steam curing box and the ambient temperature is not more than 25 ℃; when covering the oil cloth, arranging a special oil cloth bracket on the surface of the component to separate the oil cloth from the concrete surface by 200-400mm to form a space for steam circulation, wherein the two oil cloths are overlapped tightly without steam leakage, the overlapping size is not smaller than 500mm, the periphery of the oil cloths is dragged to the ground and pressed by a heavy object; to form a relatively sealed steam curing hood; steam is supplied to a production area from a central boiler room in a factory through a special pipeline, the steam is sent to each production mould position through a steam distributing cylinder, and steam is uniformly sprayed through a perforated pipe of each mould position for steam curing; in order to ensure the quality of the steam-cured concrete, the steam-curing process is finished in an automatic control curing device, the foreign members produced on a fixed type bench formwork cannot enter a curing room for automatic curing, a special person is arranged in a workshop for manual semi-automatic control, the static stop time is set to be noticed, and the static stop can be timed after the concrete is completely poured and mashed; in addition, two pressure type temperature detection sensor probes of 0-100 ℃ are respectively arranged in the steam curing covers on the two sides of the plate mold to monitor the uniformity of temperature, temperature measurement personnel must make temperature measurement records, and the recording time is as follows: and in the temperature rise stage, the temperature is once every 30 minutes, in the constant temperature stage, the temperature is once every 60 minutes, and whether the pressure of the steam distributing cylinder is in the range of 0.5 +/-0.1 Mp or not is frequently checked in the same way, and if the difference is large, the steam distributing cylinder needs to be timely connected with a central boiler room to remove faults.
Preferably, the step S5 specifically includes:
the formwork stripping time of the formwork is not less than 24 hours after the concrete pouring is finished, the construction formwork stripping time in winter is not less than 48 hours, and the concrete strength during the concrete formwork stripping is not less than 80% of the design strength;
the template disassembly and installation sequence is opposite, the template is slightly pried away from the wall body during template disassembly, the disassembled template is slightly lifted away from the wall body, cleaning and finishing are immediately carried out after the template is disassembled, and a release agent is uniformly coated for later use;
the demoulding hoisting is to adopt a beam mode to hoist, so that the hoisting point on the member is vertically stressed, and the triangular mode hoisting is strictly forbidden between the beam and the member. The positions of the hanging points and the form of the lifting hooks need to be placed according to the positions of the pre-buried points after design calculation;
after demolding, checking the component, and coating a protective agent on the surface after finished products are put in storage;
the process flow comprises the following steps: removing the template fixing part → dismantling the side mold → cleaning the residual pulp on the side face → picking and chiseling to clean the embedded part → cleaning;
and (3) hoisting after the prefabricated external wall panel reaches the specified strength, adjusting the position of a crane to be matched with the gravity center of the member, adjusting the length and the size of the sling, checking whether the rigging is smooth, hooking after the rigging is ready, and hoisting at a low speed, wherein each sling is uniformly stressed. Lifting the component at a low speed to fully separate the component from the bench formwork, lifting the component to a flat car after observing the safety of the periphery, and then conveying the component to a designated position for stacking;
in order to prevent the surface of the member from generating irregular cracks, a special person is arranged for water spraying maintenance after the member is demoulded; ensuring the component to be fully wet;
the number of times of repair is not more than two, and if the product is not qualified after two times of repair, the product is treated as a waste product.
Preferably, the step S6 includes:
and (3) protecting a finished product in a mould removal stage: the PC cladding panel must use the specialized form removal tool in the course of the form removal of shaping, can hoist when the concrete strength reaches more than 75%, guarantee the concrete member is not damaged in the course of form removal and handling;
and (3) finished product protection in the in-plant storage stage: the external corner is wrapped and protected by the special corner protection strip, so that the corner damage caused by collision of the members in the hoisting and transporting process is prevented;
protection of finished products in the transportation process: corner protectors are used at four corners of the wallboard, and battens or rubber cushion blocks are supported at the lower part of the wallboard so as to ensure that the corners of the wallboard are not damaged;
protection of finished products during transport: the transport vehicle adopts a special transport vehicle for components produced by heavy steam groups, the chassis can automatically adjust balance according to road conditions, a special frame is arranged on the vehicle, a rubber pad is arranged at the contact position of the frame body and the PC component to serve as a buffer, and a colorless plastic film is covered on the surface of the rubber pad to prevent the rubber pad from discoloring and polluting the components;
protection of finished product during installation: the corner protecting strips installed in the storage stage in the factory are removed before being installed in place, so that the collision damage in the process of transport and hoisting in the factory can be reduced;
in order to prevent the prefabricated external wall panel from being damaged during stacking, the stacking of the site is required to be finished, the foundation of the site is required to be solid, and the site is free of accumulated water and is basically flat; the skid is wrapped by tarpaulin to prevent the surface of the clear water concrete from being polluted, and the skid is ensured not to be bent or warped during stacking;
and (3) protecting finished products after installation:
arranging corner protecting strips at the positions of the window frames;
the protection below the climbing frame keeps closed tightly;
and arranging a specially-assigned person to clean the non-operation layer.
Preferably, the method also comprises data acquisition, precipitation, comparison and selection and the like through software to form a guide experience, and the process is as shown in fig. 2:
stage one: establishing a base material database through software;
and a second stage: recording from multiple dimensions forms data precipitates such as: the composition materials, the mixing proportion, the composition components, the process sequence, the time length and the like;
and a third stage: the most effective production mode which is most easy to operate in a standardized way is obtained according to different requirements or limitations by comparing and selecting a large amount of data according to different conditions, so that guiding experience is formed for design deepening and each stage rectification scheme, and the whole process forms a closed loop.
Compared with the prior art, the invention has the beneficial effects that:
the invention improves the standardized operation by various unified standards, reduces the error by various measures and reduces the repair and rejection rate.
Drawings
FIG. 1 is a process flow diagram of the present invention.
FIG. 2 is a software flow diagram of the present invention.
Detailed Description
The invention will now be further described with reference to the accompanying drawings.
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1, the present invention provides a technical solution: a production process flow of an exposed concrete prefabricated external wall panel comprises the following steps:
firstly, a production early-stage scheme:
deepening the design: the method comprises the following steps of organizing design, technology, quality inspection and production parties to review drawings, and if problems exist, adjusting an original scheme until implementation requirements are met;
designing a mold: organizing the technology, quality inspection and production of design, mold production factory and component manufacturing factory to conduct consultation and inspection, and making a consultation record and conducting written transaction;
and (4) checking and accepting the die: after the die arrives at the factory, a first party and a supervisor are informed to check, the die is subjected to size and specification inspection by technical and quality inspection, unqualified products cannot be used, and the die is refurbished or returned to the factory;
material preparation and procurement: and (4) counting the planned consumption of each material according to the drawing, and making a material consumption statistical table of a single project. According to the material usage and the production plan, making a material purchasing plan according to the actual condition of the material use condition;
and (3) production planning: and (4) making a total production plan, a monthly production plan and the yield per shift according to the progress and the requirements of the project. Advance is made, inventory is controlled, and emergency production scheme is made
II, a production process flow:
the clear water fabricated concrete exterior wall has quite strict requirements on the construction process and very high requirements on the performance of a template system and concrete, and the production process flow is as shown in figure 1:
requirements of the mold
The key of the precision control of the prefabricated external wallboard manufacture lies in the mould. The processing, transportation and storage of the mould should be provided with measures for preventing the mould from deforming and damaging.
And the mould is reasonably selected according to the production plan, so that the mould platform is fully utilized, and the mould with deformation exceeding the regulation requirement cannot be used uniformly.
And selecting the die material in the steel for manufacturing and processing. And (5) designing and processing the die by a professional manufacturer. Before designing a die drawing of a professional manufacturer, firstly, exchanging quality and technology of a die processing factory; and after the die drawing is issued, the multi-party audit is carried out, and finally the die drawing is signed and sealed and then processed by a die processing unit.
The size and the shape of the die are required to be accurate and convenient to control and adjust, and the die can be always in the state of correct size and good appearance when being repeatedly used for many times.
The templates after the first use and overhaul of the die are inspected totally, the templates in use are inspected regularly, and inspection records are made.
The template is kept clean, and cleaning work is timely done before concrete is particularly poured and after the template is removed, so that the manufacturing quality of the component is ensured. The special clear water concrete release agent-oil (paraffin wax added) release agent is adopted. The release agent must not be stained with moisture, ensuring even brushing and preventing brush leakage. The uniform coating of the release agent can ensure that the contact surface of the component is smooth, does not peel off and is not damaged when the component is released.
The process flow comprises the following steps: cleaning a table film and a steel die, spraying a release agent → positioning a side die and a cave template → fixing a component size according to a figure core → (qualified to continue to enter the next procedure and unqualified to be reworked) → fixing a template, and setting an embedded part (hanging part and embedded iron) → checking the quantity and the position of the embedded part according to the figure core → (qualified to continue to enter the next procedure and unqualified to be reworked)
Processing and mounting of reinforcing steel bars
The processing and installation of the steel bars of the prefabricated external wall-hanging plate are strictly processed and installed according to the size and the shape of the drawing, and the related requirements are the same as the requirements of the cast-in-situ reinforced concrete.
The distance between the steel bars of the prefabricated external wall-hanging plate must be well controlled and the cushion blocks of the protective layer cannot be leaked. The manufacturing process needs regular and quantitative inspection, the uniform binding which does not meet the design requirements and exceed the allowable deviation is not required, the longitudinal steel bars and the steel bars needing threading are treated according to waste materials, a cutting machine is not required to be used for blanking, the two ends of the steel bars need to be ensured to be flat, the length, the wire distance and the angle of the threading need to be strictly designed according to drawings, the longitudinal steel bars need to be sheathed with large wires, the longitudinal bars (connected by straight thread sleeves) at the bottom of the beam need to be sheathed with national standard wires, a threading machine needs to be operated by appointed special persons and experienced workers, and quality inspection personnel perform irregular sampling inspection;
after the hole of the prefabricated external wallboard is reserved, formed weak links and parts need to be reinforced according to the specification and the design requirements of drawings. The supporting and hoisting embedded part cannot be leaked, and the position correctness of the embedded part is ensured. The embedded parts must be manufactured and installed strictly according to the size requirements given by design, and the sizes of all the embedded parts must be checked and accepted after the embedded parts are manufactured and installed.
The process flow comprises the following steps: turning a design drawing for blanking → machining and forming → installing and bundling → forming (adding a cushion block) → checking the positions of the sizes and the quantities of the specifications of the reinforcing steel bars, adding the reinforcing steel bars (the reinforcing steel bars are qualified and continue to enter the next procedure, and the reinforcing steel bars are unqualified and repaired) → checking and accepting → recording signatures.
Preventing the prefabricated parts from generating color difference:
portland cement is selected, manufacturers, strength grades and batch numbers are required to be determined, and the same clinker is strictly adopted.
Broken stones which have high strength, the grain diameter of 5-25 mm, good continuous grading, the same color, the mud content of less than 0.5 percent and no impurities are selected as coarse aggregates.
Selecting medium coarse sand with fineness modulus of 2.5-2.8 and mud content of less than 2%, and requiring no impurities, determining production area, determining fineness modulus of sand and determining color.
Strictly feeding and stirring according to the mixing proportion, randomly detecting the water content at any time according to the change of climate and raw materials, and adjusting the water-cement ratio in time;
adopting colorless release agent;
concrete pouring and curing
The concrete pouring, the maintenance and the test block retention of the prefabricated external wall panel are operated according to the current acceptance standard of the construction quality of the concrete structural engineering and the related standard requirements.
The raw material supplier of the whole project should adopt the same cement and admixture of one manufacturer, the sand-stone content and other impurity components should be strictly controlled when selecting coarse and fine aggregate, and the selection of admixture should be determined by trial-and-error.
The prefabricated external wall-hanging plate is characterized by industrial flow operation, and the concrete is supplied into the mould from the design of the mixing ratio to the mixing, thus completely realizing the industrial production. The method has the advantages of simple and convenient operation, fast construction progress and less noise pollution, can save concrete raw materials, and solves the defects of complex traditional construction process, long construction period, more common defects of engineering quality and the like.
And (3) performing workability trial mixing on the concrete before each pouring, and confirming and rechecking whether indexes such as air content, slump loss, bleeding performance, setting time and the like of the concrete meet the specified requirements according to the construction conditions at that time so as to ensure the quality stability of the concrete entering the mold. It is strictly forbidden to use concrete that is either wet or too viscous.
The control of the slump and the feeding height is an important measure for ensuring that the concrete is not separated. In the concrete pouring process, the material distribution is uniform, and the side die is prevented from vibrating during vibrating, and the vibrating and the vibration leakage are avoided by sequentially carrying out the vibrating and the vibrating. The template, the reinforcing steel bar and the pre-buried worker need to be watched by a specially-assigned person.
The continuous concrete pouring of the single prefabricated external wall-hung panel can avoid the occurrence of construction joints or cold joints of single members, ensure the integrity and use functions of the members and highlight the shaping control advantages of the mold. The concrete end of the member is subjected to exposed surface treatment according to the characteristics of the concrete end.
The process flow comprises the following steps: the concrete enters the field → the matching proportion parameter is checked → the material is discharged → the slump is tested → the same maintenance is done, the standard maintenance test block → the mechanical vibration → the leveling of the scraper → the initial press polish → the cover → the maintenance.
Curing and steam curing of concrete
And (5) unifying the maintenance conditions. After concrete is poured for 2 hours, tightly wrapping the member by using color strip cloth, and curing by using steam; a steam curing system: standing for 1h, heating for 3h, keeping the temperature for 6h, and cooling for 4 h; the temperature rising speed is controlled to be 15-20 ℃/h; the highest temperature is not more than 60 ℃; the temperature reduction time is adjusted according to the actual temperature on site, the temperature of the component subjected to mold stripping and the atmospheric temperature are not more than 20 ℃, and the phenomenon that the temperature reduction speed is too high after mold stripping to cause the surface of the component to crack is avoided. The temperature measurement is carried out by a specially-assigned person for 1 time per hour.
When the prefabricated part needs to be steamed and cured at low temperature, a corresponding curing system is set, the prefabricated part is preferably kept still for 2 to 6 hours at normal temperature, the heating and cooling speed is not more than 20 ℃/h, the highest curing temperature is not more than 70 ℃, and the difference between the temperature of the prefabricated part out of a steam curing box and the ambient temperature is not more than 25 ℃.
When covering the oil cloth, a special oil cloth bracket is arranged on the surface of the component, so that the oil cloth is separated from the surface of the concrete by 200mm to 400mm to form a space for steam circulation. The two tarpaulins are overlapped tightly without steam leakage, the overlapping size is not smaller than 500mm, the peripheries of the tarpaulins are dragged to the ground and pressed by weights, and a sealed steam curing cover is formed.
Steam is supplied to the production area from a central boiler room in the factory through a special pipeline, the steam is sent to each production mould position through a steam distributing cylinder, and steam curing is carried out by uniformly spraying the steam through a perforated pipe of each mould position.
In order to ensure the quality of the steam-cured concrete, the steam-curing process is completed in an automatic control curing chamber, the foreign members produced on the fixed bench formwork cannot enter a curing chamber for automatic curing, and a special person needs to be arranged in a workshop for manual semi-automatic control. Setting the rest time should be noted that the rest can be timed after the concrete is completely poured and pounded.
In addition, two pressure type temperature detection sensor probes of 0-100 ℃ are respectively arranged in the steam curing covers on the two sides of the plate mold to monitor the uniformity of temperature, temperature measurement personnel must make temperature measurement records, and the recording time is as follows: the temperature raising stage is carried out once for 30 minutes, and the constant temperature stage is carried out once for 60 minutes. At the same time, the pressure of the cylinder is usually checked to be within the range of 0.5 +/-0.1 Mp, and if the difference is large, the cylinder needs to be timely communicated with a central boiler room to remove the fault.
Demoulding lifting
The formwork stripping time of the formwork is not less than 24 hours after the concrete pouring is finished, and the formwork stripping time of the construction in winter is not less than 48 hours. The concrete strength when the concrete is demolded should be not less than 80% of the design strength.
The template disassembly should be opposite to the installation sequence, the template is pried away from the wall body gently during template disassembly, and the disassembled template is hung away from the wall body gently. And cleaning and finishing the template immediately after the template is removed, and uniformly brushing a release agent for later use.
The demoulding hoisting is to adopt a beam mode to hoist, so that the hoisting point on the member is vertically stressed, and the triangular mode hoisting is strictly forbidden between the beam and the member. The positions of the hanging points and the form of the lifting hooks need to be placed according to the positions of the pre-embedded points after design calculation.
And (4) after demolding, checking the component, and coating a protective agent on the surface after warehousing the finished product.
The process flow comprises the following steps: removing the template fixing part → dismantling the side mold → cleaning the residual pulp on the side face → chiseling and cleaning the embedded part → cleaning.
And (3) hoisting after the prefabricated external wall panel reaches the specified strength, adjusting the position of a crane to be matched with the gravity center of the member, adjusting the length and the size of the sling, checking whether the rigging is smooth, hooking after the rigging is ready, and hoisting at a low speed, wherein each sling is uniformly stressed. And (4) lifting the component at a low speed to fully separate the component from the bench formwork, observing the safety of the periphery, hoisting the component to a flat car, and then transporting the component to a specified position for stacking.
In order to prevent the surface of the member from generating irregular cracks, a special person is arranged for water spraying maintenance after the member is demoulded. Ensuring that the member is sufficiently wetted.
The number of times of repair is not more than two, and if the product is not qualified after two times of repair, the product is treated as a waste product.
Finished product protection
And (3) protecting a finished product in a mould removal stage: the PC cladding must use special form removal instrument at the shaping form removal in-process, can hoist when the concrete strength reaches more than 75%, guarantees that concrete member is not damaged at form removal and handling in-process.
And (3) finished product protection in the in-plant storage stage: the special corner protection strip is used for wrapping and protecting the external corner, so that the corner damage caused by collision of the members in the lifting and transporting process is prevented.
Protection of finished products in the transportation process: corner protectors are used at four corners of the wallboard, and battens or rubber cushion blocks are erected at the lower portion of the wallboard so as to ensure that corners of the wallboard are not damaged.
Protection of finished products during transport: the transport vehicle is a special transport vehicle for components produced by heavy steam groups. The chassis can be automatically adjusted to be balanced according to road conditions, a special frame is arranged on the vehicle, a rubber pad is arranged at the contact position of the frame body and the PC component and used as a buffer, and a colorless plastic film is covered on the surface of the rubber pad to prevent the rubber pad from being decolored and polluting the component
Protection of finished product during installation: the corner protecting strips installed in the storage stage in the factory are removed before being installed in place, so that collision and damage in the process of transport and hoisting in the factory can be reduced.
In order to prevent the prefabricated external wall panel from being damaged during stacking, the stacking of the site is required to be finished, the foundation of the site is required to be solid, and the site is free of accumulated water and is basically flat; the skid is wrapped by tarpaulin to prevent the surface of the clear water concrete from being polluted and to ensure that no bending or warping deformation occurs during stacking.
And (3) protecting finished products after installation:
and corner protecting strips are arranged at the positions of the window frames.
The protection below the climbing frame keeps closed tightly.
And arranging a specially-assigned person to clean the non-operation layer.
See fig. 2, the guiding experience is formed by data acquisition, precipitation, comparison and selection and the like through software
Stage one: establishing a base material database through software;
and a second stage: recording from multiple dimensions forms data precipitates such as: the composition materials, the mixing proportion, the composition components, the process sequence, the time length and the like;
and a third stage: the most effective production mode which is most easy to operate in a standardized way is obtained according to different requirements or limitations by comparing and selecting a large amount of data according to different conditions, so that guiding experience is formed for design deepening and each stage rectification scheme, and the whole process forms a closed loop.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (8)
1. A production process flow of an exposed concrete prefabricated external wall panel is characterized by comprising the following steps:
s1, deepening design;
s2, judging whether the original design has problems, if no, executing step S3, if yes, executing step S3 after the original design is changed;
s3, manufacturing a mould and processing and installing steel bars of the prefabricated external wall panel;
s4, pouring and curing concrete;
s5, demolding and lifting;
and S6, protecting the finished product.
2. The production process flow of the bare concrete prefabricated external hanging wallboard according to claim 1, characterized in that: the mold manufacturing comprises the following processes:
cleaning a table film, a steel die and a spraying release agent → positioning a side die and a hole template → aligning the sizes of the components according to a graph and a core → continuously entering the next procedure if the components are qualified, and performing unqualified rework → fixing the template, arranging embedded parts → checking the quantity and the positions of the embedded parts according to the graph and the core → continuously entering the next procedure if the components are qualified, and performing unqualified rework.
3. The production process flow of the bare concrete prefabricated external hanging wallboard according to claim 1, characterized in that: the steel bar processing and mounting comprises the following processes:
turning the design drawing for blanking → processing and forming → installing and bundling → forming → checking the size, the number and the position of the reinforcing steel bar and the additional reinforcing steel bar, continuing to enter the next procedure if the reinforcing steel bar is qualified, and performing unqualified repair → acceptance → recording the signature.
4. The production process flow of the bare concrete prefabricated external hanging wallboard according to claim 1, characterized in that: the step S4 includes the following steps:
the concrete enters the field → the mix proportion parameter is checked → the concrete enters the next procedure continuously, the goods returned is not met → the material is discharged → the slump is tested → the same maintenance is carried out, the standard maintenance test block → the mechanical vibration → the leveling of the scraper → the initial press polish → the cover → the maintenance.
5. The production process flow of the bare concrete prefabricated external hanging wallboard according to claim 4, characterized in that: the concrete steps of the maintenance are as follows: after concrete is poured for 2 hours, tightly wrapping the member by using color strip cloth, and curing by using steam; a steam curing system: standing for 1h, heating for 3h, keeping the temperature for 6h, and cooling for 4 h; the temperature rising speed is controlled to be 15-20 ℃/h; the highest temperature is not more than 60 ℃; the temperature reduction time is adjusted according to the actual temperature on site, the temperature of the component for demolding and the atmospheric temperature are not more than 20 ℃, the temperature measurement work is carried out by a specially-assigned person, and the temperature is measured for 1 time per hour; when the prefabricated part needs to be steamed and cured at low temperature, a corresponding curing system is set, the prefabricated part is preferably kept still for 2 to 6 hours at normal temperature, the heating and cooling speed is not more than 20 ℃/h, the highest curing temperature is not more than 70 ℃, and the difference between the temperature of the prefabricated part out of a steam curing box and the ambient temperature is not more than 25 ℃; when covering the tarpaulin, the surface of the component is provided with a special tarpaulin bracket, so that the tarpaulin is separated from the surface of the concrete by 200mm-400mm to form a space for steam circulation, two tarpaulins are overlapped to be compact and non-steam-tight, the overlapping size is not more than 500mm, the periphery of the two tarpaulins is dragged and dropped to the ground and pressed by a heavy object; to form a relatively sealed steam curing hood; steam is supplied to a production area from a central boiler room in a factory through a special pipeline, the steam is sent to each production mould position through a steam distributing cylinder, and steam is uniformly sprayed through a perforated pipe of each mould position for steam curing; in order to ensure the quality of the steam-cured concrete, the steam-curing process is finished in an automatic control curing device, the foreign members produced on a fixed type bench formwork cannot enter a curing room for automatic curing, a special person is arranged in a workshop for manual semi-automatic control, the static stop time is set to be noticed, and the static stop can be timed after the concrete is completely poured and mashed; in addition, two pressure type temperature detection sensor probes of 0-100 ℃ are respectively arranged in the steam curing covers on the two sides of the plate mold to monitor the uniformity of temperature, temperature measurement personnel must make temperature measurement records, and the recording time is as follows: the temperature rise stage is carried out once every 30 minutes, the constant temperature stage is carried out once every 60 minutes, whether the pressure of the cylinder is in the range of 0.5 +/-0.1 Mp or not is checked frequently, and if the difference is large, the cylinder needs to be timely connected with a central boiler room to remove faults.
6. The production process flow of the bare concrete prefabricated external hanging wallboard according to claim 1, characterized in that: the step S5 specifically includes:
the formwork stripping time of the formwork is not less than 24 hours after the concrete pouring is finished, the construction formwork stripping time in winter is not less than 48 hours, and the concrete strength during the concrete formwork stripping is not less than 80% of the design strength;
the template disassembly and installation sequence is opposite, the template is slightly pried away from the wall body during template disassembly, the disassembled template is slightly lifted away from the wall body, cleaning and finishing are immediately carried out after the template is disassembled, and a release agent is uniformly coated for later use;
the demoulding hoisting adopts a beam mode to hoist, so that the hoisting point on the member is vertically stressed, and the triangular mode hoisting is strictly forbidden between the beam and the member. The positions of the hanging points and the form of the lifting hooks need to be placed according to the positions of the pre-buried points after design calculation;
after demolding, checking the component, and coating a protective agent on the surface after finished products are put in storage;
the process flow comprises the following steps: removing the template fixing part → dismantling the side mold → cleaning the residual pulp on the side face → picking and chiseling to clean the embedded part → cleaning; and (3) hoisting after the prefabricated external wall panel reaches the specified strength, adjusting the position of a crane to be matched with the gravity center of the member, adjusting the length and the size of the sling, checking whether the rigging is smooth, hooking after the rigging is ready, and hoisting at a low speed, wherein each sling is uniformly stressed. Lifting the component at a low speed to fully separate the component from the bench formwork, lifting the component to a flat car after observing the safety of the periphery, and then conveying the component to a designated position for stacking;
in order to prevent the surface of the member from generating irregular cracks, a special person is arranged for water spraying maintenance after the member is demoulded; ensuring the component to be fully wet;
the number of times of repair is not more than two, and if the product is not qualified after two times of repair, the product is treated as a waste product.
7. The production process flow of the bare concrete prefabricated external hanging wallboard according to claim 1, characterized in that: the step S6 includes:
and (3) protecting a finished product in a mould removal stage: the PC cladding panel must use the specialized form removal tool in the course of the form removal of shaping, can hoist when the concrete strength reaches more than 75%, guarantee the concrete member is not damaged in the course of form removal and handling;
and (3) finished product protection in the in-plant storage stage: the external corner is wrapped and protected by the special corner protection strip, so that the corner damage caused by collision of the members in the hoisting and transporting process is prevented;
protection of finished products in the transportation process: corner protectors are used at four corners of the wallboard, and battens or rubber cushion blocks are supported at the lower part of the wallboard so as to ensure that the corners of the wallboard are not damaged;
protection of finished products during transport: the transport vehicle adopts a special transport vehicle for components produced by heavy steam groups, the chassis can automatically adjust balance according to road conditions, a special frame is arranged on the vehicle, a rubber pad is arranged at the contact position of the frame body and the PC component to serve as a buffer, and a colorless plastic film is covered on the surface of the rubber pad to prevent the rubber pad from discoloring and polluting the components;
protection of finished product during installation: the corner protecting strips installed in the storage stage in the factory are removed before being installed in place, so that the collision damage in the process of transport and hoisting in the factory can be reduced;
in order to prevent the prefabricated external wall panel from being damaged during stacking, the stacking of the site is required to be finished, the foundation of the site is required to be solid, and the site is free of accumulated water and is basically flat; the skid is wrapped by tarpaulin to prevent the surface of the clear water concrete from being polluted, and the skid is ensured not to be bent or warped during stacking;
and (3) protecting finished products after installation:
arranging corner protecting strips at the positions of the window frames;
the protection below the climbing frame keeps closed tightly;
and arranging a specially-assigned person to clean the non-operation layer.
8. The production process flow of the bare concrete prefabricated external hanging wallboard according to claim 1, characterized in that: the method also comprises the following steps of carrying out data acquisition, precipitation and comparison and selection through software to form guiding experience:
stage one: establishing a base material database through software;
and a second stage: recording from multiple dimensions forms data precipitates such as: the composition materials, the mixing proportion, the composition components, the process sequence and the time length;
and a third stage: the most effective production mode which is most easy to operate in a standardized way is obtained according to different requirements or limitations by comparing and selecting a large amount of data according to different conditions, so that guiding experience is formed for design deepening and each stage rectification scheme, and the whole process forms a closed loop.
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Application publication date: 20210917 |