CN113771204A - Circulation production method of prefabricated box girder and box girder template device - Google Patents
Circulation production method of prefabricated box girder and box girder template device Download PDFInfo
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- CN113771204A CN113771204A CN202111261698.9A CN202111261698A CN113771204A CN 113771204 A CN113771204 A CN 113771204A CN 202111261698 A CN202111261698 A CN 202111261698A CN 113771204 A CN113771204 A CN 113771204A
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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
- B28B15/00—General arrangement or layout of plant ; Industrial outlines or plant installations
-
- 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
-
- 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
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/0002—Auxiliary parts or elements of the mould
-
- 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
- B28B7/0002—Auxiliary parts or elements of the mould
- B28B7/0014—Fastening means for mould parts, e.g. for attaching mould walls on mould tables; Mould clamps
-
- 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
- B28B7/02—Moulds with adjustable parts specially for modifying at will the dimensions or form of the moulded article
Abstract
A method for circularly producing a prefabricated box girder and a box girder template device. Batch and streamline prefabrication of the box girder is realized on the premise that the position of the side mould does not move. The production method comprises three links of prefabrication, maintenance hoisting and storage, wherein tracks are arranged in a prefabrication area and a spraying maintenance area and are used for maneuvering transition of the bottom die module; the tracks in the prefabrication area and the spraying maintenance area are in parallel rows, transverse connecting lines are arranged to form a multi-chain rectangular structure, and the bottom die template circulates between the prefabrication area and the spraying maintenance area; and after the spraying maintenance area needs to be maintained to the designed hardness, the spraying maintenance area is hoisted to a beam storage area for storage, and the bottom die module automatically returns to the prefabrication area. The accessible die block template removes on the track, directly transports prefabricated case roof beam to fixed maintenance canopy and carries out various forms maintenance, realizes the line production in the true sense, improves the availability factor of maintenance canopy.
Description
Technical Field
The invention relates to the technical field of a method for manufacturing a prefabricated box girder.
Background
The box girder is a hollow thin-wall type which is most commonly adopted in the process of erecting highway and railway bridges, and has the advantages of stable structure, reliable construction period and the like because the box girder can be cast and molded at one time in an independent field and then erected by large-scale construction operation machines such as a girder transporting vehicle, a carrying vehicle and the like. At present, still need adopt the steel form to erect and carry out the concrete placement operation after getting the space in the prefabricated in-process of case roof beam, consequently, different case roof beams need carry out the hoist and mount of template and erect before concrete placement, and concrete placement maintenance is finished, still need carry out the template and dismantle, and the dismouting process is loaded down with trivial details, very easily induces the incident, and moreover, simple template dismouting still has the template piece many, assemble inefficiency, pour a great deal of problems such as case roof beam apparent quality is poor.
Referring to fig. 1 to 3, schematic diagrams of a beam field and prefabricated formworks of a conventional prefabricated box beam are provided by way of example, in the beam field, a prefabricating station is a station for prefabricating the box beam and a station for maintenance, namely, demolishing and long-term maintenance are performed after prefabrication and forming. That is to say, in the traditional precast beam field, the position of the pedestal is fixed, a section of precast box beam is precast, and the outer die and the die core need to be disassembled, hoisted and transferred, so that safety accidents are easily caused in the transfer process of the template.
In the traditional design concept, if the external mold template is designed into a movable module, the defects of poor safety and low efficiency caused by external mold disassembly can be overcome, for example, a self-propelled integral hydraulic prefabricated box girder template device disclosed in CN104859048B enables the whole side mold to longitudinally move by arranging a track and a walking trolley, and the side mold is moved from one prefabricated pedestal to another prefabricated pedestal; the lateral die is transversely moved by arranging a hydraulic system and a transverse jack, so that the lateral die is transversely butted or separated with or from the bottom die; through setting up hydraulic system and vertical jack, make the whole vertical removal that takes place of side form, realize the whole vertical butt joint or the separation with the die block of side form and can realize batch production, the automated production of case roof beam. The design idea still does not escape the design idea of transferring the template, and the pedestal is still fixed.
Disclosure of Invention
Aiming at the defects of the existing box girder prefabrication pedestal template technology, the invention aims to make up the defects of the prior art and provide a device and a production method which can realize box girder prefabrication without prefabrication of a pedestal and only by moving a bottom template. The device can realize batch and streamlined prefabrication of the box girder on the premise that the position of the side mold does not move, can realize elevation adjustment of any point of the bottom mold of the box girder, avoids height deviation of the bottom of the box girder caused by pre-camber setting, ensures that the bottom mold is perfectly matched with the side mold at any point of elevation, facilitates self-adaptive change of box girders of various sizes without a pedestal in the prefabrication process in the future, and can convey the prefabricated box girder to a girder storage area through a rail, thereby saving the field.
The technical scheme adopted by the invention for solving the technical problems is as follows:
a prefabricated box girder operation mode capable of realizing assembly line operation is designed.
A circulation production method of a prefabricated box girder is characterized by comprising the following steps:
s1 beam yard site design and layout:
the beam yard layout comprises a steel bar processing area, a prefabricating area, a spraying maintenance area and a beam storage area which are sequentially arranged, wherein tracks are arranged in the prefabricating area and the spraying maintenance area and are used for the maneuvering transition of the bottom die module; the tracks in the prefabrication area and the spraying maintenance area are in parallel rows, transverse connecting lines are arranged to form a multi-chain rectangular structure, and the bottom die template circulates between the prefabrication area and the spraying maintenance area; side die modules are arranged on two sides of a prefabricating station of the prefabricating area, and the side die modules are arranged in pairs and fixedly arranged in the prefabricating area;
s2 precast box girder:
after the bottom die template moves to a prefabricating station, locking the bottom die module, rapidly assembling an outer die module, a die core module and the bottom die module in a prefabricating area, detecting whether a splicing seam is complete and closed, and pouring and tamping concrete; curing the formed prefabricated box girder for 12 hours to remove the outer mold module and the mold core module after the hardness of the prefabricated box girder reaches the designed hardness, then releasing the locking of the bottom mold module, and driving the prefabricated box girder above to move to the spraying curing area by the bottom mold module;
s3 constant temperature and humidity maintenance:
curing in a spraying curing area;
s4 hoisting and storing:
and after the spraying maintenance area needs to be maintained to the designed hardness, the spraying maintenance area is hoisted to a beam storage area for storage, and the bottom die module automatically returns to the prefabrication area.
Furthermore, the number of the stations of the prefabricating stations in the prefabricating area and the stations of the maintenance station in the maintenance area is configured to be 1:10 to 1:20, so that the using number of prefabricated templates is greatly reduced, and the investment cost is obviously reduced under the same production efficiency.
Further, this maintenance district adopts maintenance canopy or maintenance kiln design, carries out the maintenance through the mode that sprays to cooperation humidification and heating system realize the maintenance under constant temperature and the constant humidity, improve the maintenance level.
Further, road and gantry crane hoisting equipment are arranged in the beam yard, and the equipment is arranged for hoisting the prefabricated box beam after maintenance and assisting in completing the installation of the inner and outer template modules.
The utility model provides a prefabricated box girder template device, includes die block module and side form module for the prefabrication shaping of prefabricated box girder, its characterized in that:
the bottom die module is a maneuvering module advancing along a rail and comprises a bottom die template, hydraulic jacks II, a steel truss II and electric drive chassis, wherein the lower part of the bottom die template is installed on the steel truss II through the vertical hydraulic jacks II existing in a plurality of arraying modes, a group of electric drive chassis is respectively arranged on the left side and the right side of the steel truss II, each group of electric drive chassis is matched with one rail, and the bottom die template is driven by the power of the hydraulic jacks II to have a low-stroke height adjusting function relative to the steel truss in the height direction;
the side mold modules are non-motorized modules fixed on a precast beam yard, are symmetrically arranged on the left and right sides of a prefabricating station, and are used for closing and removing molds from the two sides of the prefabricating station.
Furthermore, the supports of the electric drive chassis are of an automatic telescopic rod structure, a static level gauge is installed on the upper edge of each chassis support of the electric drive chassis to perform local elevation control, and leveling bases are provided for subsequent leveling rods.
The side form module includes fixed baseplate, hydraulic jack I, steel truss I, side form template, and wherein, the side form template outside sets up steel truss I to and set up the fixed baseplate of steel construction in the outside of side form template, this fixed baseplate is used for installing hydraulic jack I, and wherein, hydraulic jack quantity is a plurality of, and hydraulic jack I transmits thrust for stainless steel side form template through steel truss I.
The side form module comprises a fixed base, a hydraulic jack III, a hydraulic jack IV, an L-shaped support and a side form template, wherein the L-shaped support is fixed on the fixed base through the hydraulic jack III, the side form template is connected through the hydraulic jack IV, a horizontal sliding mechanism is arranged between the L-shaped support and the hydraulic jack IV, and the side form template has horizontal movement and vertical movement stroke.
Furthermore, the side die module comprises a fixed base, a hydraulic cylinder assembly and a side die template, and the side die template is supported by a plurality of groups of hydraulic cylinder assemblies arranged between the fixed base and the side die template, so that the side die template can be supported in the same way.
Further, in order to reduce the force application deformation of the hydraulic jack to the side die template, one or more rows of trusses can be added to the outer side of the side die template, the deformation of the side die template is reduced by increasing the stress area, and one steel truss III is added below the bottom die template, so that the hydraulic jack II directly acts on the steel truss III, the jacking force is transmitted to the bottom die template through the steel truss III, and the deformation of the bottom die template is favorably controlled and reduced.
Furthermore, a special auxiliary locking clamp is arranged at the position of a splicing seam of the bottom die template and the side die template.
The invention has the beneficial effects that:
the invention can realize the prefabrication of box girders with different heights by changing the elevation of the bottom die, namely the height of the bottom die is adjustable and the level is adjustable.
The prefabrication of box girders with different structural sizes is realized by lifting and adjusting the elevation of the bottom die template without prefabricating a box girder pedestal, and the prefabrication can be realized by replacing the side die.
The bottom die template can be finely leveled, and the point control on the bottom flatness and the appearance quality of the prefabricated box girder can be realized.
The movable bottom die replaces a pedestal of the existing fixed structure, so that box girders can be prefabricated and transported on the device, and repeated hoisting in the transfer operation in the traditional process is avoided.
The accessible die block template removes on the track, directly transports prefabricated case roof beam to fixed maintenance canopy and carries out various forms maintenance, realizes the line production in the true sense, improves the availability factor of maintenance canopy.
Operation in the factory can be realized in the maintenance process, and influence caused by adverse factors such as weather is avoided.
The movable bottom die template supporting technology is adopted, the movable bottom die template supporting method belongs to the overall design scheme, the problems of slab staggering, large splicing seams and the like in the traditional template assembly can be effectively solved, the operation rate can be improved, and the construction cost can be reduced.
Drawings
Fig. 1 is an assembly view of a pedestal, an outer die and a die core in the prior art.
Fig. 2 is a plan view of a conventional beam field.
FIG. 3 is a schematic view of a conventional beamyard gantry crane.
Fig. 4 is a plane layout diagram of the improved beam field of the present invention.
FIG. 5 is a cross-sectional view of a prefabrication process of the invention.
Fig. 6 is a partially enlarged view of the electrically driven chassis.
Fig. 7 is a perspective view of the telescopic bracket.
Fig. 8 is a schematic illustration of the stripping process.
FIG. 9 is a schematic view of a curing station.
Fig. 10 is a schematic view of the box girder in the length direction (no camber).
Fig. 11 is a schematic view of the length direction of the box girder (with camber).
Fig. 12 is a schematic view of a side mold module modification.
Fig. 13 is a schematic diagram of a side mold module according to the second embodiment (mold clamping).
Fig. 14 is a schematic view of a side mold block (mold open) according to the second embodiment.
Fig. 15 is a schematic diagram of a side mold module according to a third embodiment.
Fig. 16 is a schematic view of the clamping of the special clamp.
In the figure:
100 bottom die modules, 110 bottom die templates, 120 hydraulic jacks II, 130 steel trusses II, 140 electric driving chassis, 141 steel wheels, 142 driving motors, 143 speed reducers, 144 supports, 145 worm and gear mechanisms,
200 side die modules, 210 fixed bases, 220 hydraulic jacks I, 230 steel trusses I and 240 side die plates,
220 'hydraulic scissors lifting platform, 230' L-shaped bracket,
300 the prefabricated box girder is prefabricated,
the angle iron of 11 degrees, the fastener of 12 degrees,
01 reinforcing bar processing district, 02 prefabricated district, 03 spray maintenance district, 04 deposit roof beam district, 05 tracks.
Detailed Description
The automatic prefabricated template device comprises a bottom die module 100 and side die modules 200 and is used for prefabricating and forming a prefabricated box girder 300, wherein the bottom die module 100 has maneuverability and performance, and the side die modules 200 are non-motorized modules fixed on a prefabricated girder field in a symmetric mode and are symmetrically arranged on the left side and the right side of a prefabricating station. The invention fundamentally changes the traditional design concept of bottom die module fixation and side die module maneuvering, and has breakthrough of concept. Through the improvement of the method, the maintenance mode is effectively changed, and particularly, after the bottom die module has the mobility, the bottom die module can automatically travel to the maintenance area for maintenance, so that the separation of the prefabrication process and the maintenance process is realized, the number of prefabricated templates is effectively reduced, and the investment is further reduced.
Referring to fig. 5, 8 and 9, the side form module 200 includes a fixing base 210, hydraulic jacks i 220, a steel truss i 230, and a side form 240, wherein the side form 240 adopts a stainless steel side form, the steel truss i 230 is arranged outside the stainless steel side form for reinforcement and fixation, so that the stainless steel form has sufficient flatness, and the fixing base 210 of a steel structure is arranged outside the side form, and is used for installing the hydraulic jacks i, wherein the number of the hydraulic jacks is multiple, and the hydraulic jacks i transmit thrust to the stainless steel side form through the steel truss i.
Further, the hydraulic jack i 220 can be designed as a hydraulic scissors lifting platform 220' for lateral sliding and demoulding, referring to fig. 12.
The bottom die module 100 is a motorized module with a power system, has a motorized walking function, and comprises a bottom die template 110, a hydraulic jack II 120, a steel truss II 130, an electric drive chassis 140 and other mechanical structures, wherein the lower part of the bottom die template 110 is installed on the steel truss II 130 through the vertical hydraulic jacks II 120 existing in a plurality of array modes to form a stable bottom die template, and the power of the hydraulic jacks is utilized to drive the bottom die template to have a low-stroke height adjusting function in the height direction relative to the steel truss.
Further, a steel truss III can be added below the bottom die template 110, so that the hydraulic jack II 120 directly acts on the steel truss III, the jacking force is transmitted to the bottom die template 110 through the steel truss III, and the deformation of the bottom die template 110 is favorably controlled and reduced.
The electric drive chassis is a commodity purchasing module and provides power for the maneuvering of the bottom die module.
The bottom mold platen in this embodiment is also made of stainless steel plate.
A group of electric driving chassis 140 is respectively arranged on the left side and the right side (vertical to the length direction of the prefabricated box girder) of the steel truss II 130, wherein the electric driving chassis 140 is composed of steel wheels 141, a driving motor 142 and a speed reducer 143, the electric driving chassis are arranged in a group at intervals of 2m, and the steel truss II and the electric driving chassis on the two sides form a shoulder pole type installation.
The electric drive chassis and the steel wheel are connected by adopting a high-strength bolt and a heavy-duty bearing, wherein the strength grade of the bolt is 10.9.
A static level gauge is arranged on the upper edge of the chassis bracket 144 of each electric drive chassis to control local elevation and provide leveling basis for subsequent leveling rods.
Referring to fig. 6 and 7, the bracket 144 of each electric driving chassis is a telescopic rod structure with adjustable height, specifically, the bracket is composed of steel cylinders nested with each other, and a worm gear and worm mechanism 145 is arranged between the upper and lower steel cylinders, i.e., the bracket is driven by a worm to adjust in the height direction, the worm driving force is from a driving motor, so that the height of each electric driving chassis is adjustable, thereby realizing that the height of each electric driving chassis can be adjusted, solving the problem that the pre-camber of the existing traditional formwork bottom die formwork is not adjustable, the device can be suitable for box girders with camber and also can be suitable for flat-bottom box girders, referring to fig. 10 and 11, and enabling the size of the box girder prefabrication molding to be more accurate.
A22 KW soft start synchronous driving motor is arranged on a support 144 in the electric driving chassis, the rotating speed of the motor is 1200r/min, the traveling speed of the electric driving chassis is controlled to be less than or equal to 5m/min, the driving motor is provided with a wireless remote controller, and the cross section size of a control cabinet is less than or equal to 0.7 multiplied by 0.35 m. The driving motor drives the gear engagement on through reduction gear and steel wheel, and after targetting in place, the reduction gear breaks away from with the gear position on the steel wheel, opens steel wheel locker simultaneously, realizes the locking to the electric drive chassis through this steel wheel locker, realizes the fixed to the die block template, prevents that the die block from removing.
After the electric drive chassis is in place, the drive steel wheels 141 drive the bottom die template to ascend, the side die template 240 moves inwards, the bottom die template and the side die template are connected preliminarily, template assembly is completed, and the splicing seams are guaranteed to be tightly attached.
In the splicing process of the splicing seam, the joint surface between the bottom die template and the side die template is of an inclined surface structure, the splicing seam is formed after die assembly, self-adaptive adjustment is realized, and the tightness of the splicing seam is good.
Furthermore, the auxiliary locking special fixture is arranged at the splicing seam of the bottom die template and the side die template, the special fixture comprises two L-shaped angle irons 11 and a fastener 12, the angle irons are welded or riveted at the edges of the bottom die template and the side die template and arranged in an aligned mode, the two angle irons are tensioned through the fastener, the splicing seam is locked, the splicing seam has enough rigidity, and slurry leakage at the seam is prevented. Fig. 16 shows a specific implementation structure, which is not limited by the present invention.
And (3) starting the hydraulic jacks II according to the design height of the prefabricated box girder to adjust the height of the bottom die, setting one hydraulic jack every 5m in the length direction of the steel truss II, and synchronously jacking by matching with an electric control system and a hydraulic control system.
And (3) observing the elevations of all points on the upper part of the steel wheel by taking the static leveling instrument as a support, and adjusting the elevations of the local single electrically-driven chassis by rotating the turbine worm mechanism for the uneven measuring points.
In order to match with the new maneuvering performance of the bottom die module, a bottom die transfer track is installed and processed in a foundation region between the prefabrication area and the spraying maintenance area, referring to fig. 4, the track is a rail and matched with a sleeper for settlement, the track is required to have no settlement, and the height difference of the left track and the right track is less than or equal to 1 mm.
The tracks are designed to be parallel in multiple rows, and are provided with transverse connecting lines to form a multi-branch-chain square-shaped structure, so that the bottom die template can be recycled, and the production efficiency is improved.
A production method of a circulating prefabricated box girder is carried out based on a specially designed automatic prefabricated template device, and the prefabricated method comprises the following steps:
(1) beam yard site design and layout
The beam yard is arranged to include reinforcing bar processing district 01, prefabricated district 02, spray maintenance district 03 and deposit the roof beam district 04, and wherein, reinforcing bar processing district 01 and deposit the roof beam district and basically the same with current design, set up respectively in the front end and the rear end in beam yard. And meanwhile, road and gantry crane hoisting equipment is arranged in the beam yard, and the equipment is used for hoisting the prefabricated box beam after maintenance and assisting in completing the installation of the inner and outer template modules.
A circulating rail 05 is arranged in the prefabrication area 02 and the spray maintenance area 03 and is used for the maneuvering transition of the bottom die module.
And side die modules are arranged on two sides of a prefabricating station of the prefabricating area 02, are arranged in pairs and are fixedly arranged in the prefabricating area.
The side form template of side form module adopts the stainless steel side form board, this stainless steel side form board outside sets up steel truss I and consolidates and fix, sufficient roughness to and set up the fixed baseplate of steel construction in the outside of side form template, this fixed baseplate is used for installing hydraulic jack I, wherein, I quantity of hydraulic jack is a plurality of, through the convenient angle modulation that carries out the stainless steel side form board of hydraulic jack I that this department set up, and carry out the drawing of patterns that laterally slides after the box girder prefabrication is accomplished.
The bottom die module can move and be temporarily fixed on a track 05 between the prefabrication area and the spraying maintenance area, specifically, a bottom die transfer track is installed and processed between the prefabrication area and the spraying maintenance area, the track 05 is a rail and is matched with a sleeper to sink, the track is required to be free of settlement, and the height difference of the left track and the right track is less than or equal to 1 mm.
The tracks are designed to be parallel in multiple rows, and are provided with transverse connecting lines to form a multi-branch-chain square-shaped structure, so that the bottom die template can be recycled, and the production efficiency is improved.
(2) Prefabricated box girder
And (4) rapidly assembling the outer mold module, the mold core module and the bottom mold module in the prefabricating area, and detecting whether the splicing seams are complete and closed after the assembly is finished. In the process, the bottom die template is driven by the power of the hydraulic jack II to be adjusted in the height direction relative to the steel truss II. And (3) observing the elevations of all points on the upper part of the steel wheel by taking static leveling as a support, and performing elevation adjustment on a local single electric drive chassis by adopting a rotating worm and gear mechanism for an uneven measuring point.
The steel wheel locker is used for locking the electric drive chassis, fixing the bottom die template and preventing the bottom die from moving.
In the splicing process of the splicing seam, the joint surface between the bottom die template and the side die template is of an inclined surface structure, self-adaptive adjustment is realized, and the tightness of the splicing seam is good. And the special fixture is used for locally clamping the spliced seam from the outer side to prevent slurry leakage.
And starting the hydraulic jack to adjust the height of the bottom die according to the design height of the box girder.
And pouring, tamping and leveling commercial concrete.
(3) Constant temperature and humidity curing
(4) Hoisting and storing
In general, at least 14 days of maintenance are needed in the maintenance area, and the steel plate can be hoisted to the beam storage area for storage, and the steel plate is stored temporarily.
The prefabricated box girder has the advantages that the prefabricated box girder is designed separately from the maintenance process, the prefabricated box girder is transferred to a maintenance area for professional maintenance after short-term maintenance after prefabricated forming, and the maintenance is carried out by using constant-temperature and constant-humidity maintenance equipment in the maintenance area, so that the maintenance quality is improved, the maintenance time is shortened, and the defects that the prefabrication and the maintenance are carried out on the same prefabricated pedestal station in the manufacturing process of the traditional prefabricated box girder are effectively overcome. The number of prefabricated templates is reduced, and the investment cost is reduced.
The accessible die block template moves on the track, directly transports prefabricated case roof beam to fixed maintenance canopy and carries out various forms maintenance.
Generally, the number of the stations of the prefabricating stations in the prefabricating area and the stations of the maintenance area is configured to be 1:10 to 1:20, so that the using number of the prefabricated formworks is greatly reduced, and the investment cost is obviously reduced under the same production efficiency.
According to the box girder transporting device, through the separated design of the prefabricating station and the maintenance station, the box girder can be prefabricated, maintained and stored on the device to achieve new balance, repeated hoisting in the transporting operation of the traditional process is avoided, and the cost is reduced.
Example two
Referring to fig. 13 and 14, in the present embodiment, the side form module 200 is optimally designed, and includes a fixed base, hydraulic jacks iii and iv, an L-shaped bracket 230 ', and a side form template, where the L-shaped bracket 230' is fixed on the fixed base through the hydraulic jack iii, and has a vertical adjustment capability, and meanwhile, the side form template is connected through the hydraulic jack iv, and a horizontal sliding mechanism is provided between the two, so that the side form template has a horizontal movement capability. The mold closing and releasing process can be understood by itself with reference to fig. 13 and 14.
EXAMPLE III
Referring to fig. 15, after the design is simplified, the side formwork panels can be directly supported through a plurality of groups of hydraulic oil cylinders, and the support of the side formwork panels can also be realized.
In the second embodiment and the third embodiment, in order to reduce the deformation of the side die plate due to the force applied by the hydraulic jack, one or more rows of trusses can be added on the outer side of the side die plate, and the deformation of the side die plate can be reduced by increasing the stressed area.
The above-described embodiments are merely illustrative of the preferred embodiments of the present invention and do not limit the scope of the present invention, and various modifications and improvements of the present invention by those skilled in the art without departing from the spirit of the present invention are intended to fall within the scope of the present invention defined by the claims.
Claims (10)
1. A circulation production method of a prefabricated box girder is characterized by comprising the following steps:
s1 beam yard site design and layout:
the beam yard arrangement comprises a steel bar processing area (01), a prefabricating area (02), a spraying maintenance area (03) and a beam storage area (04) which are arranged in sequence, a track (05) is arranged in the prefabricating area (02) and the spraying maintenance area (03), and a bottom die module is maneuverable along the track; the tracks in the prefabrication area (02) and the spraying maintenance area (03) are in multiple rows, transverse connecting lines are arranged to form a multi-chain zigzag structure, and the bottom die module circulates between the prefabrication area (02) and the spraying maintenance area (03); side die modules are arranged on two sides of a prefabricating station of the prefabricating area (02), and the side die modules are arranged in pairs and fixedly installed in the prefabricating area;
s2 prefabrication:
after the bottom die template moves to a prefabricating station, locking the bottom die module, rapidly closing the outer die module, the die core module and the bottom die module in a prefabricating area (02), detecting whether a splicing seam is complete and closed, and pouring and tamping concrete in a die cavity; after the prefabricated box girder is formed, maintaining until the prefabricated box girder reaches the designed hardness, removing the mold, removing the outer mold module and the mold core module, then removing the locking of the bottom mold module, and driving the prefabricated box girder above to move to the spraying maintenance area (03) by the bottom mold module;
s3 constant temperature and humidity maintenance:
curing in a spraying curing area (03);
s4 hoisting and storing:
and after the box girder is maintained to the designed hardness in the spraying maintenance area, the box girder is hoisted to a girder storage area for storing the prefabricated box girder, and the bottom mould module automatically returns to the prefabrication area (02).
2. The method for circularly producing the precast box girder according to claim 1, wherein the number of the prefabrication stations and the maintenance stations in the maintenance area is configured to be 1:10 to 1: 20.
3. The method for circularly producing the precast box girder according to claim 1, wherein the curing area is designed as a curing shed or a curing kiln, and the curing is performed under constant temperature and constant humidity by spraying and matching with a humidifying and heating system.
4. The utility model provides a prefabricated box girder template device, includes die block module (100) and side form module (200), its characterized in that:
the bottom die module (100) is a motorized module advancing along a rail and comprises a bottom die template (110), a hydraulic jack II (120), a steel truss II (130) and an electric drive chassis (140), wherein the lower part of the bottom die template (110) is installed on the steel truss II (130) through the vertical hydraulic jacks II (120) existing in a plurality of arraying modes, a group of electric drive chassis (140) is respectively arranged on the left side and the right side of the steel truss II (130), each group of electric drive chassis (140) is matched with one rail, and the bottom die template is driven by power of the hydraulic jack II to have a low-stroke height adjusting function in the height direction relative to the steel truss;
the side die modules (200) are non-motorized modules fixed on a precast beam field, are symmetrically arranged on the left side and the right side of a prefabricating station respectively, and are used for carrying out die assembly and die disassembly from the two sides of the prefabricating station.
5. A precast box girder template device according to claim 4, wherein the supports (144) of the electrically driven chassis are of an automatic telescopic rod structure, and a hydrostatic level for local elevation control is installed on the chassis support (144) of each electrically driven chassis.
6. The prefabricated box girder template device according to claim 4, wherein the side die module (200) comprises a fixed base (210), a hydraulic jack I (220), a steel truss I (230) and a side die template (240), wherein the steel truss I (230) is arranged on the outer side of the side die template (240), and the fixed base (210) of a steel structure is arranged on the outer side of the side die template and is used for installing the hydraulic jack I, the number of the hydraulic jacks is multiple, and the hydraulic jack I transmits the thrust to the stainless steel side die plate through the steel truss I.
7. The precast box girder template device according to claim 4, wherein the side mold module (200) comprises a fixed base, a hydraulic jack III, a hydraulic jack IV, an L-shaped bracket (230 '), and a side mold plate, wherein the L-shaped bracket (230') is fixed on the fixed base by the hydraulic jack III, the side mold plate is connected by the hydraulic jack IV, a horizontal sliding mechanism is arranged between the L-shaped bracket and the side mold plate, and the side mold plate has horizontal movement and vertical movement strokes.
8. The precast box girder template device according to claim 4, wherein the side mold modules (200) comprise a fixed base, hydraulic cylinder assemblies and side mold plates, and the side mold plates are supported by a plurality of sets of hydraulic cylinder assemblies provided between the fixed base and the side mold plates.
9. The prefabricated box girder formwork assembly of claim 7, 8 or 9, wherein one or more rows of trusses are added to the outer sides of the side formwork, and a steel truss iii is added below the bottom formwork, so that the hydraulic jacks ii directly act on the steel truss iii to transmit the lifting force to the bottom formwork through the steel truss iii.
10. The precast box girder template device according to claim 4, wherein a special auxiliary locking clamp is provided at a joint of the bottom die template and the side die templates.
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| CN202111261698.9A CN113771204A (en) | 2021-10-28 | 2021-10-28 | Circulation production method of prefabricated box girder and box girder template device |
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| CN202111261698.9A CN113771204A (en) | 2021-10-28 | 2021-10-28 | Circulation production method of prefabricated box girder and box girder template device |
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| CN113771204A true CN113771204A (en) | 2021-12-10 |
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Cited By (1)
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