CN114102836A - Efficient production process of duct piece - Google Patents
Efficient production process of duct piece Download PDFInfo
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- CN114102836A CN114102836A CN202111282526.XA CN202111282526A CN114102836A CN 114102836 A CN114102836 A CN 114102836A CN 202111282526 A CN202111282526 A CN 202111282526A CN 114102836 A CN114102836 A CN 114102836A
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- 230000002787 reinforcement Effects 0.000 claims abstract description 67
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- 238000012360 testing method Methods 0.000 claims abstract description 28
- 238000001514 detection method Methods 0.000 claims abstract description 27
- 238000003860 storage Methods 0.000 claims abstract description 23
- 238000003756 stirring Methods 0.000 claims abstract description 22
- 238000007689 inspection Methods 0.000 claims abstract description 10
- 238000012423 maintenance Methods 0.000 claims abstract description 8
- 238000012545 processing Methods 0.000 claims abstract description 7
- 229910000831 Steel Inorganic materials 0.000 claims description 84
- 239000010959 steel Substances 0.000 claims description 84
- 238000000034 method Methods 0.000 claims description 35
- 230000008569 process Effects 0.000 claims description 33
- 238000005452 bending Methods 0.000 claims description 30
- 238000003466 welding Methods 0.000 claims description 27
- 239000003795 chemical substances by application Substances 0.000 claims description 18
- 238000004140 cleaning Methods 0.000 claims description 17
- 230000008439 repair process Effects 0.000 claims description 15
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- 238000013461 design Methods 0.000 claims description 10
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- 238000002156 mixing Methods 0.000 claims description 5
- 239000004570 mortar (masonry) Substances 0.000 claims description 5
- 239000004576 sand Substances 0.000 claims description 5
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- 238000003825 pressing Methods 0.000 claims description 4
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- 238000009966 trimming Methods 0.000 claims description 2
- 210000003205 muscle Anatomy 0.000 claims 7
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- 238000000465 moulding Methods 0.000 claims 1
- 239000010410 layer Substances 0.000 description 11
- 229910001294 Reinforcing steel Inorganic materials 0.000 description 4
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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
- B28B1/08—Producing shaped prefabricated articles from the material by vibrating or jolting
-
- 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
- B28B1/29—Producing shaped prefabricated articles from the material by profiling or strickling the material in open moulds or on moulding surfaces
-
- 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
- B28B17/00—Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
- B28B17/0063—Control arrangements
- B28B17/0072—Product control or inspection
-
- 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
- B28B17/00—Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
- B28B17/0063—Control arrangements
- B28B17/0081—Process control
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
- B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Automation & Control Theory (AREA)
- On-Site Construction Work That Accompanies The Preparation And Application Of Concrete (AREA)
Abstract
The invention discloses a high-efficiency production process of a duct piece, which comprises the following production steps: processing and assembling a mould; manufacturing a reinforcement cage; stirring concrete; pouring concrete; collecting the pipe piece; removing the die from the duct piece; maintaining the pipe piece in water; segment storage; a duct piece leakage detection test is characterized in that before duct piece production, strict inspection is respectively carried out on a production mold of the duct piece, mold assembly requirements, reinforcement cage manufacturing quality, concrete stirring quality, concrete pouring quality and reinforcement cage manufacturing and mold assembly requirements, after the duct piece is produced, the appearance shape, a surface repairing mode, maintenance and storage conditions of the duct piece are strictly controlled, each production step of the duct piece before and after production can meet the requirements of a production process, the duct piece is manufactured and produced on the premise of meeting production standards, quality safety after subsequent manufacturing is guaranteed to the maximum extent, and the duct piece is internally and externally beautiful after production.
Description
Technical Field
The invention relates to the technical field of track segment production, in particular to an efficient segment production process.
Background
The segment is a main assembly component for shield construction, is an innermost barrier of a tunnel and plays a role in resisting soil layer pressure, underground water pressure and some special loads, the shield segment is a permanent lining structure of the shield tunnel, the quality of the shield segment is directly related to the overall quality and safety of the tunnel, and the waterproof performance and the durability of the tunnel are influenced, so that strict control on the segment manufacturing process is required in the segment production and manufacturing process;
at present, the production process of the duct piece is usually only used for pouring production through a traditional concrete filling process in the production process, and because of the lack of means for strictly controlling each manufacturing step of the duct piece, the duct piece is poor in appearance quality after being formed, and meanwhile, the actual application effect of the duct piece cannot be guaranteed, so that the follow-up use quality and safety of the duct piece after installation are influenced.
Disclosure of Invention
The invention provides an efficient production process of a duct piece, which can effectively solve the problems that the prior art proposes that only the traditional concrete filling process is used for pouring production, and the duct piece is poor in appearance quality after being formed and the actual application effect of the duct piece cannot be guaranteed due to the lack of means for strictly controlling each manufacturing step of the duct piece, so that the use quality and the safety of the duct piece after being subsequently installed are influenced.
In order to achieve the purpose, the invention provides the following technical scheme: an efficient production process of a duct piece comprises the following production steps:
s1, processing and assembling the die;
s2, manufacturing a reinforcement cage;
s3, stirring concrete;
s4, pouring concrete;
s5, segment collection;
s6, removing the die from the segment;
s7, maintaining the pipe piece in water;
and S8, storing the segments.
According to the technical scheme, in the S1, the processing and assembling of the die comprises die cleaning, die release agent spraying, die assembly, steel bar cage die entering and embedded part installation;
the mould cleaning means that concrete residues on a mould are required to be completely removed before the mould is produced, the concrete residues cannot be accumulated on any part of the inner surface of the cleaned mould, sponge blocks, asbestos cloth and a special plastic shovel are required to be matched for cleaning when the inner surface of the mould is cleaned, particularly, the concrete residues on a grouting hole base and a hand hole at key parts in the mould are required to be completely cleaned, when the outer surface of the mould is cleaned, the concrete residues on the side and the top surface of an end mould are particularly required to be cleaned, after the concrete residues are completely peeled off, all the impurities are timely cleaned, no residual impurities are required, the contact surfaces of the side and end moulds and the base are cleaned by using a cleaning cloth after the mould is cleaned every time, and engine oil is applied for maintenance;
the step of spraying the release agent is that after the interior of the mold is cleaned, whether concrete residues are left on the inner surface of the mold is checked before the release agent is sprayed, the release agent is sprayed after the mold is checked to be qualified, reworking cleaning is carried out if the mold is not qualified, and when the release agent is sprayed, pressure control is taken care to enable the inner surface of the mold to form a uniform release agent protective film;
the die assembly is to assemble the die, the end die plate is screwed in place by a torque wrench during die assembly, the side plate is slightly pushed in place, a positioning bolt is screwed by a hand, a connecting bolt of the end die plate and the side die plate is assembled, the end die plate and the connecting bolt of the side die plate are screwed by a hand primarily and then are screwed to be firm by a special tool in a balanced and forceful manner, special attention must be paid to ensure that the coincidence mark is completely aligned, the bolt is screwed and is not too violent, then the fixing bolt of the side die plate and the bottom die plate is assembled, the side die plate and the bottom die plate are sequentially screwed from the middle position to the two ends by the special tool after being screwed by the hand, the sequential operation is strictly forbidden so as to avoid the loss of the deformation precision of the die, the coincidence check mark is coincided after the steel die is assembled, the quality of the die is checked by a quality inspector, the width of the inner arc surface of the die is measured by an inner diameter micrometer, the inspection is not carried out, and the concrete is not poured strictly forbidden.
According to the technical scheme, in the S2, the steel bar cage manufacturing comprises bending and arc bending of steel bars, framework forming and welding;
the bending and arc bending of the steel bar means that the steel bar is bent according to the requirements of design drawings strictly, the dimension marked on the drawing refers to the dimension from the center to the center of the axis of the steel bar, the end of the steel bar is provided with a standard hook, the marked size is calculated from the intersection point of the top tangent line of the outer skin of the hook and the axis of the steel bar, the position of the driven wheel and the diameter of the mandrel are adjusted according to the specifications of the bent arc and the bent steel bar, the steel bars are subjected to trial bending according to an operation table, and after the steel bars are qualified by being calibrated with a standard large sample, arc bending and bending operations are performed, the intact condition of equipment must be checked before arc bending, abnormal timely repair is found, the steel bars must be lightly fed when the arc bending operation is fed, the steel bars should be kept balanced and at a constant speed when entering an arc bending machine, plane warping is prevented, cracks cannot be generated on the surface after forming, the bent steel bars must be calibrated on a mould one by one, the steel bars can be used after being qualified, and the steel bars must be bent again when the radian is not proper;
the framework forming and welding are characterized in that a reinforcement cage part is welded on a mould meeting design requirements, the bent reinforcement cage part is placed at a designated position on the mould, various sizes and welding point positions are measured and adjusted, and CO is adopted during welding2An arc welding machine, spot welding the stirrup and the inner arc main reinforcement, after the position of the stirrup is determined, sequentially penetrating the outer arc main reinforcement into the stirrup according to the position marked by a drawing, firmly spot welding the upper main reinforcement and the lower main reinforcement at one end with the positioning baffle, sequentially welding the main reinforcement and the stirrup from the middle position to two ends respectively until the other ends of the inner arc main reinforcement and the outer arc main reinforcement are firmly welded, and finally welding the waist reinforcement, the vertical reinforcement, the end reinforcing ribs and the hand hole reinforcing ribs according to the position and the mould mark in the drawing;
the welded and formed steel bar framework is lifted away from the mould, placed in a designated place, and a quality inspector measures the welding quality, the number of steel bars, the width, the thickness, the chord length, the arc length, the upper arch height, the lower arch height, the torsion resistance, the main and auxiliary bar spacing and other item dimensions, and after the inspection is qualified, the steel bar framework is put into use, and is unqualified and informed of repair.
According to the technical scheme, the steel reinforcement cage is placed into the mold by a crane matched with a special lifting appliance after the steel reinforcement cage is manufactured, the steel reinforcement cage is lifted and placed into the mold lightly in the lifting process so as to prevent the steel reinforcement cage from colliding with the mold, the steel reinforcement cage is placed into the mold and then is checked and corrected, the checking content comprises whether the lifting position of the steel reinforcement cage has influence on the installation of the embedded part, whether the bottom protective layer is uniform or not, whether the protective layer on any side is larger than the specified tolerance or the steel reinforcement cage which is seriously twisted cannot be used, and the steel reinforcement cage is lifted away from the mold and is transported away.
The embedded part installation means that after the steel reinforcement cage is hoisted and placed, and after quality inspector inspects and approves, the embedded part is installed, during installation, a grouting pipe and a mold positioning core are assembled at first, whether the grouting pipe is tightened is inspected, and slurry leakage is prevented.
According to the technical scheme, in the step S3, concrete stirring refers to stirring concrete raw materials, wherein the concrete raw materials comprise cement, fine aggregate, coarse aggregate, fly ash, a water reducing agent, water and steel, the concrete raw materials are stirred by adopting an HZS120 type double-horizontal-shaft forced stirrer, river sand and the cement are sequentially stirred for 20S, then a water aqua solution and the water are added and reduced for 30S, finally broken stone is added, the total stirring time is controlled to be 120-180S, and the stirring time in winter is prolonged by 50% compared with the specified time;
concrete mixing is finished, the concrete needs to be inspected, a sample is taken to perform a concrete slump test, the concrete can be used after being inspected to be qualified, and the concrete is rejected after being inspected to be unqualified.
According to the technical scheme, in the step S4, concrete pouring refers to pouring the concrete which is mixed and checked into the mold, the assembled mold needs to be checked and accepted according to the regulations before pouring, any unqualified project is found to be informed to the previous procedure for rework, and pouring can be performed after the experience collection grid;
the concrete is poured in layers during pouring, the concrete is placed for a plurality of times and a small number of times during blanking, the interval time of each blanking is taken into consideration, the concrete is ensured to be uniformly arranged in the mould, oversized stones or sundries are found in the blanking process and must be timely picked up, and a blending personnel is informed to check the condition of raw materials in the storage bin.
The concrete of the model adopting pneumatic vibration is intensively poured from the middle part of the template, the concrete is filled in the whole model by utilizing the fluidity of the concrete, the vibration time is proper when the concrete surface stops sinking or the sinking is not obvious, the foaming of the concrete surface is not obvious, the concrete fills the corner part of the mould and the surface is filled with mortar and the mortar is discharged, the vibration time is not less than 3 minutes each time, the vibration leakage or the over vibration is avoided, after the complete vibration forming is finished, the middle concrete is leveled, and the radian of the outer ring surface is trimmed.
According to the technical scheme, in the step S5, the segment collecting is that the top plate is opened to collect the segment in the initial setting process of the concrete after pouring, the time for opening the top plate is generally 20 minutes after the concrete is poured, the specific time is determined according to the air temperature and the setting condition, when the segment is collected, channel steel is used for scraping to remove redundant concrete or filling the sunken part, coarse grinding is carried out, the initial collecting is timely, and water sprinkling and dry ash are avoided;
after the surface of the concrete is polished, entering a resting stage, needing the concrete to be statically held and formed, and carrying out secondary surface collection before a mould enters a ferry vehicle, wherein the secondary surface collection requires the surface of the concrete to be flat and smooth without the phenomena of bulging and collapse;
covering plastic cloth after the primary and secondary concrete recovery surfaces, entering a resting station according to the beat, then entering the secondary concrete recovery surface, and recovering the surface by using a spatula for the third time, so that the surface of the duct piece is flat and smooth, the surface is bright without spatula marks, the inside and outside beauty of the produced duct piece are ensured, and the outer arc surface is flat and smooth.
After the formed concrete pipe piece is subjected to surface collection treatment and is statically maintained for not less than 1 hour, the concrete pipe piece is sent into a steam curing kiln for steam curing, the temperature rising speed is not more than 15 ℃/h, the highest temperature is not more than 55 ℃, the temperature reducing speed is not more than 20 ℃/h, the constant temperature is not less than 4 hours, and the concrete pipe piece can be moved out of the steam curing kiln for external form removal until the difference between the surface temperature of the pipe piece and the temperature in a workshop is less than 20 ℃.
According to the technical scheme, in the S6, the duct piece demolding treatment specifically comprises duct piece demolding, duct piece repairing and duct piece marking;
in the operation process of the duct piece demoulding, firstly, a top cover bolt is disassembled, concrete residues are removed, then a sleeve positioning rod and a grouting pipe positioning shaft are disassembled, the duct piece is cleaned and placed at a specified position, then a side mould and a bottom mould fixing bolt are disassembled, a side plate is pulled out slightly, finally, an end mould and a bottom mould connecting bolt are disassembled, an end mould plate is opened, the disassembling sequence of the mould plate is symmetrically disassembled from two sides and cannot be reversed, and the side plates are required to be fully opened;
the duct piece repairing refers to the process of trimming and repairing a small amount of appearance defects which do not influence the use of the structure and exist on the surface of a duct piece in the production process of the duct piece;
the section of jurisdiction is repaired and is gone on at once behind the section of jurisdiction drawing of patterns, hangs the section of jurisdiction from the model with horizontal hoist or vacuum chuck, puts on dedicated repair support, and the repair personnel cleans the section of jurisdiction surface with moist cloth or cotton yarn, finds out the bubble on concrete surface and repairs with hidden bubble, and repair tools includes ash spoon, little spiller, steel brush and steel chisel, and repair materials includes primary color cement: white cement, fine sand and 101 building glue;
the section of jurisdiction mark is according to the design requirement of section of jurisdiction, carves the section of jurisdiction model on the intrados of mould man-hour, and the section of jurisdiction is pour the shaping and through repairing the back, forms permanent reference numeral on the intrados of section of jurisdiction, and the content of section of jurisdiction mark includes arrangement of reinforcement type, section of jurisdiction model, mould serial number, section of jurisdiction production line number, section of jurisdiction date of production and inspection state.
According to the technical scheme, in the step S7, the underwater curing of the pipe piece means that the pipe piece is turned over by 90 degrees through a turnover machine after being demoulded, and is hung into a water curing pool for curing, the water can be filled only when the temperature difference between the surface temperature of the pipe piece and water is less than 20 ℃ when the pipe piece is filled with water, the pipe piece is transported to a storage field for watering curing for 7 days by using a gantry crane after being cured in the pool, and then the pipe piece is naturally cured to 28 days;
in S8, the segment storage means that segments are transported to a storage field for continuous maintenance and storage after being cultured in water for 7d, the segment storage field is solid and flat, water drainage is smooth, support pads are stable and reliable, the segments are respectively stacked according to lifting, mounting sequence and types when stored, a transportation channel is reserved between stacks and meets the requirement of the lifting distance of a crane, the segments are placed on flexible support strips, the segments are separated from the segments by the flexible support strips, the positions where the support strips are placed are uniform and consistent in thickness, the segments are vertically placed on the side faces or stacked with the inner cambered surfaces upward, the bottom of each flexible support is provided with pine strips of 20cm x 2m, the upper portion of each flexible support is provided with pine strips of 10cm x 2m, the layers are horizontally padded and practically padded by the wood pads, the upper and lower layers of the support strips are arranged on a vertical line, the segments are stored with the side faces not more than 4 layers, and the inner cambered surfaces of the segments are horizontally stacked not more than 6 layers.
According to the technical scheme, in the S9, the duct piece leakage detection test is that after the duct piece is naturally maintained to 28d, the leakage detection test is carried out on a finished duct piece, the leakage detection standard is constant pressure for 2h under the designed seepage pressure of 0.8MPa, the seepage depth is less than or equal to 5cm, after the duct piece is produced, 1 duct piece is extracted for each 50 rings of production to carry out the leakage detection test, the detection standard is continuously reached for three times, instead, 1 duct piece is extracted for each 100 rings of production, the detection standard is continuously reached for three times, the final detection frequency is 200 rings, 1 duct piece is extracted for carrying out the leakage detection test, if the final detection frequency is not reached to the standard, the initial detection frequency of extracting 1 duct piece for each 50 rings is recovered, and the extraction test is carried out according to the requirements, and a test instrument comprises a pressure gauge, an electronic stopwatch and a pressure pump;
the duct piece leak detection test specifically comprises the following steps:
step 1, stably placing the duct piece on a test stand, and checking whether a sealing rubber pad is tightly attached to the outer arc surface of the duct piece;
step 2, three rubber strips are arranged on the axial line of the inner arc surface of the duct piece, the middle rubber strip is arranged, the edge of the middle rubber strip is arranged, and the distance between the duct piece sealing gasket and the edge of the duct piece is 50 mm;
step 3, pressing a fastening cross rod on the width direction of the intrados of the duct piece, connecting the fastening cross rod with the fastening cross rod on the lower supporting seat by using a bolt, and tightening the fastening cross rod from the middle to two sides;
step 4, opening an exhaust valve, then connecting a water inlet valve, injecting tap water, closing the exhaust valve after discharging water from an exhaust hole, starting a pressure pump, pressurizing to 0.2MPa at a pressurizing speed of 0.05MPa/min for 10min at constant pressure, checking the water leakage phenomenon, observing the side permeation height, and recording;
and 5, continuously pressurizing to 0.4MPa, 0.6MPa and 0.8MPa, keeping the constant pressure time of each stage for 10 minutes, observing for 2 hours at the constant pressure after the pressure reaches 0.8MPa, and ensuring that the water seepage line of each end surface of the member does not exceed 50mm, wherein the requirement that the impermeability strength grade is P12 is met.
Compared with the prior art, the invention has the beneficial effects that:
when the duct piece is actually produced, the assembled mould, the manufactured reinforcement cage, the concrete stirring and pouring quality can be respectively checked in different aspects in the mould assembling process, the reinforcement cage manufacturing process and the concrete stirring and pouring process, and the position of the reinforcement cage can be checked and adjusted in time when the reinforcement cage is placed in the mould after the mould is assembled, so that the mould, the reinforcement cage and the concrete quality of the duct piece can be effectively guaranteed before the duct piece is actually produced through a plurality of checking steps in different aspects, and a foundation is laid for the subsequent production of the duct piece meeting the process quality requirement;
in the production process of the duct piece, the outer arc surface of the duct piece after production is smoother and smoother by carrying out face collecting treatment on the duct piece for many times in different modes, and simultaneously, in the form removing process, the maintenance process and the storage process during the production of the duct piece, each treatment step of the duct piece is strictly controlled respectively, so that the duct piece can be effectively maintained after production, the duct piece can be effectively put into use after production, the abandonment rate is reduced, the cost is saved, and the quality of subsequent forming is ensured;
and, before putting into the application after the section of jurisdiction production, through carrying out leak hunting test to the section of jurisdiction for whether the section of jurisdiction can accord with the design requirement to inside and outside diameter and circumferential weld and longitudinal joint width before formally putting into operation and examine, whether so that the section of jurisdiction that accords with the condition can possess higher connection compactness in follow-up application process, and then avoid it to appear the phenomenon of gap and seepage, guaranteed follow-up track building's security, make the section of jurisdiction can be put into operation in order to ensure reliable bearing capacity and waterproof performance in the application.
In summary, the production mold, the mold assembly requirement, the steel reinforcement cage manufacturing quality, the concrete stirring quality, the concrete pouring quality, the steel reinforcement cage manufacturing and mold assembly requirement of the duct piece are strictly checked respectively before the duct piece is produced, after the duct piece is produced, the appearance shape, the face repairing mode, the maintenance and storage condition of the duct piece and the leakage detection test process of the duct piece are strictly controlled respectively, so that each production step of the duct piece before and after production can meet the requirement of the production process, the duct piece is produced and produced on the premise of meeting the production standard, the quality safety after the subsequent production is ensured to the maximum extent, and the duct piece is internally and externally beautiful after the production.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention and not to limit the invention. In the drawings:
FIG. 1 is a block flow diagram of a process for producing a duct piece according to the present invention;
FIG. 2 is an elevational view of the finished cage abutment block of the present invention;
FIG. 3 is a plan view of a finished cage abutment block of the present invention;
FIG. 4 is a side view of a finished cage abutment block of the present invention;
FIG. 5 is an elevational view of a finished rebar cage standard of the present invention;
FIG. 6 is a plan view of a finished modular rebar cage block of the present invention;
FIG. 7 is a side view of a finished modular rebar cage block of the present invention;
FIG. 8 is an elevational view of the finished reinforcement cage top block of the present invention;
fig. 9 is a plan view of the finished reinforcement cage capping block of the present invention;
FIG. 10 is a side view of the finished reinforcement cage top block of the present invention;
FIG. 11 is a schematic illustration of the placement of the segment storage of the present invention;
fig. 12 is a schematic view of a duct piece leak detection of the present invention.
Detailed Description
The preferred embodiments of the present invention will be described in conjunction with the accompanying drawings, and it will be understood that they are described herein for the purpose of illustration and explanation and not limitation.
Example (b): as shown in fig. 1, the invention provides a technical solution, and an efficient production process of duct pieces comprises the following production steps:
s1, processing and assembling the die;
s2, manufacturing a reinforcement cage;
s3, stirring concrete;
s4, pouring concrete;
s5, segment collection;
s6, removing the die from the segment;
s7, maintaining the pipe piece in water;
and S8, storing the segments.
Based on the technical scheme, in S1, the die processing and assembling comprises die cleaning, die release agent spraying, die assembly, steel bar cage die entering and embedded part installation;
the cleaning of the mould refers to that concrete residues on the mould are completely removed before the mould is produced, the concrete residues cannot be accumulated on any part of the inner surface of the cleaned mould, the cleaning of the inner surface of the mould requires the use of a sponge block, asbestos cloth and a special plastic shovel, particularly, the concrete residues on the grouting hole base and the hand hole at the key part in the mould must be completely cleaned, when the outer surface of the mould is cleaned, the cleaning of the concrete residues on the side and the top surface of the end mould is particularly required, after the concrete residues are completely peeled off, all the impurities are timely cleaned away, no residual impurities are required, the contact surfaces of the side and the end mould and the base are cleaned by using a cleaning cloth, and engine oil is smeared for maintenance;
spraying the release agent, namely, after cleaning the interior of the mold, checking whether concrete residues are left on the inner surface of the mold before spraying the release agent, spraying the release agent after checking the concrete residues, reworking and cleaning if the concrete residues are not checked, and when spraying the release agent, paying attention to pressure control to form a uniform release agent protective film on the inner surface of the mold;
the die assembly means that the die is assembled, an end template is screwed in place by a torque wrench during die assembly, a side plate is slightly pushed in place, a positioning bolt is screwed by a hand, a connecting bolt of the end template and a side template is assembled, the end template and the side template are screwed by a special tool after being screwed by the hand primarily until the side template and the side template are screwed firmly by balanced force, special attention must be paid to ensure that an inosculation mark is completely aligned, the bolt is screwed without too strong force, then a fixing bolt of the side template and a bottom template is assembled, the side template and the bottom template are sequentially screwed by the special tool from the middle position to two ends after being screwed by the hand, sequential operation is strictly forbidden so as to avoid the loss of the deformation precision of the die, the inosculation mark is checked after the steel die is assembled, the quality of the die is visually inspected by a quality inspector, the width of an inner arc surface of the die is measured by an inner diameter micrometer, the inspection is not performed, and the concrete is not strictly poured.
As shown in fig. 2-10, based on the above technical solution, in S2, the manufacturing of the reinforcement cage includes bending and curving of the reinforcement, and forming and welding of the framework;
the bending and the arc bending of the reinforcing steel bar refer to bending the reinforcing steel bar according to the requirements of design drawings, the dimension marked by the drawings refers to the dimension from the center to the center of the axis of the reinforcing steel bar, the end part of the reinforcing steel bar is provided with a standard hook, the marked size is calculated from the intersection point of the top tangent line of the outer skin of the hook and the axis of the steel bar, the position of the driven wheel and the diameter of the mandrel are adjusted according to the specifications of the bent arc and the bent steel bar, the steel bars are subjected to trial bending according to an operation table, and after the steel bars are qualified by being calibrated with a standard large sample, arc bending and bending operations are performed, the intact condition of equipment must be checked before arc bending, abnormal timely repair is found, the steel bars must be lightly fed when the arc bending operation is fed, the steel bars should be kept balanced and at a constant speed when entering an arc bending machine, plane warping is prevented, cracks cannot be generated on the surface after forming, the bent steel bars must be calibrated on a mould one by one, the steel bars can be used after being qualified, and the steel bars must be bent again when the radian is not proper;
the skeleton forming and welding are that the reinforcement cage part is welded on the mould meeting the design requirement, the bent reinforcement cage part is firstly placed at the appointed position on the mould, the sizes and the welding spot positions are measured and adjusted, and CO is adopted during welding2An arc welding machine, spot welding the stirrup and the inner arc main reinforcement, after the position of the stirrup is determined, sequentially penetrating the outer arc main reinforcement into the stirrup according to the position marked by a drawing, firmly spot welding the upper main reinforcement and the lower main reinforcement at one end with the positioning baffle, sequentially welding the main reinforcement and the stirrup from the middle position to two ends respectively until the other ends of the inner arc main reinforcement and the outer arc main reinforcement are firmly welded, and finally welding the waist reinforcement, the vertical reinforcement, the end reinforcing ribs and the hand hole reinforcing ribs according to the position and the mould mark in the drawing;
the welded and formed steel bar framework is lifted away from the mould, placed in an appointed place, and a quality inspector measures the welding quality, the number of steel bars, the width, the thickness, the chord length, the arc length, the upper arch height, the lower arch height, the torsion resistance and the distance between the main and auxiliary bars, and after the welding quality is qualified, the steel bar framework is put into use, unqualified in inspection and informed of repair.
Based on the technical scheme, the steel reinforcement cage is placed into the mold by a crane matched with a special lifting appliance after the steel reinforcement cage is manufactured, the steel reinforcement cage is lifted and placed into the mold in a light lifting and placing process so as to prevent the steel reinforcement cage from colliding with the mold, the steel reinforcement cage is placed into the mold and then is checked and corrected, the checking content comprises whether the lifting and placing position of the steel reinforcement cage has influence on the installation of the embedded part, whether the bottom protective layer is uniform or not, whether the protective layer on any side is larger than a specified tolerance or the steel reinforcement cage which is seriously distorted cannot be used, and the steel reinforcement cage is lifted away from the mold and is transported away.
The embedded part is installed after the steel reinforcement cage is hoisted and placed and is inspected and approved by a quality inspector, the embedded part is installed, a grouting pipe and a mold positioning core are assembled firstly during installation, whether the grouting pipe is tightened is inspected to prevent slurry leakage, a plastic sleeve is sleeved firstly during installation of a hand hole bolt hole forming device, then a spiral steel bar is placed in place, finally a positioning bent core is inserted into a mold positioning hole and is tightly pushed after placement, the head part of the positioning core must be completely inserted into a mold hole of a hand hole seat to prevent slurry leakage or cause hole forming device offset caused by loose connection, after the embedded part is completely installed, a top mold cover plate is closed by a pneumatic vibrating template, a cover plate bolt is screwed, and cast duct piece concrete.
Based on the technical scheme, in S3, concrete stirring refers to stirring concrete raw materials, wherein the concrete raw materials comprise cement, fine aggregate, coarse aggregate, fly ash, a water reducing agent, water and steel, the concrete raw materials are stirred by using an HZS120 type double-horizontal-shaft forced stirrer, river sand and the cement are sequentially stirred for 20S, then a water aqua solution and the water are added and reduced for 30S, finally broken stones are added, the total stirring time is controlled to be 150S, and the stirring time in winter is prolonged by 50% compared with the specified time;
concrete mixing is finished, the concrete needs to be inspected, a sample is taken to perform a concrete slump test, the concrete can be used after being inspected to be qualified, and the concrete is rejected after being inspected to be unqualified.
Based on the technical scheme, in S4, concrete pouring refers to pouring the mixed and inspected concrete into a mold, the assembled mold must be checked and accepted according to the regulations before pouring, any unqualified project is found, the previous procedure is informed to be reworked, and pouring can be performed after the experience collection grid;
the concrete is poured in layers during pouring, the concrete is placed for a plurality of times and a small number of times during blanking, the interval time of each blanking is taken into consideration, the concrete is ensured to be uniformly arranged in the mould, oversized stones or sundries are found in the blanking process and must be timely picked up, and a blending personnel is informed to check the condition of raw materials in the storage bin.
The concrete of the model adopting pneumatic vibration is intensively poured from the middle part of the template, the concrete is filled in the whole model by utilizing the fluidity of the concrete, the vibration time is proper when the concrete surface stops sinking or the sinking is not obvious, the foaming of the concrete surface is not obvious, the concrete fills the corner part of the mould and the surface is filled with mortar and the mortar is discharged, the vibration time is not less than 3 minutes each time, the vibration leakage or the over vibration is avoided, after the complete vibration forming is finished, the middle concrete is leveled, and the radian of the outer ring surface is trimmed.
Based on the technical scheme, in S5, the segment collecting is that the top plate is opened to collect the segment in the initial setting process of the concrete after pouring, the time for opening the top plate is generally 20 minutes after the concrete is poured, the specific time is determined according to the air temperature and the setting condition, when the segment is collected, channel steel is used for scraping off redundant concrete or filling the sunken part, coarse grinding is carried out, the initial collecting needs to be in time, and water spraying and dry ash are avoided;
after the surface of the concrete is polished, entering a resting stage, needing the concrete to be statically held and formed, and carrying out secondary surface collection before a mould enters a ferry vehicle, wherein the secondary surface collection requires the surface of the concrete to be flat and smooth without the phenomena of bulging and collapse;
covering plastic cloth after the primary and secondary concrete recovery surfaces, entering a resting station according to the beat, then entering the secondary concrete recovery surface, and recovering the surface by using a spatula for the third time, so that the surface of the duct piece is flat and smooth, the surface is bright without spatula marks, the inside and outside beauty of the produced duct piece are ensured, and the outer arc surface is flat and smooth.
After the formed concrete pipe piece is subjected to surface collection treatment and is statically maintained for not less than 1 hour, the concrete pipe piece is sent into a steam curing kiln for steam curing, the temperature rising speed is not more than 15 ℃/h, the highest temperature is not more than 55 ℃, the temperature reducing speed is not more than 20 ℃/h, the constant temperature is not less than 4 hours, and the concrete pipe piece can be moved out of the steam curing kiln for external form removal until the difference between the surface temperature of the pipe piece and the temperature in a workshop is less than 20 ℃.
Based on the technical scheme, in the S6, the duct piece demolding treatment specifically comprises duct piece demolding, duct piece repairing and duct piece marking;
in the operation process of the duct piece demoulding, firstly, a top cover bolt is disassembled, concrete residues are removed, then a sleeve positioning rod and a grouting pipe positioning shaft are disassembled, the duct piece is cleaned and placed at a specified position, then a side mould and a bottom mould fixing bolt are disassembled, a side plate is slightly pulled out, finally, an end mould and a bottom mould connecting bolt are disassembled, an end mould plate is opened, the disassembling sequence of the mould plate is symmetrically disassembled from two sides and cannot be reversed, and the side plates are fully opened;
the duct piece repairing refers to the process of repairing and repairing a small amount of appearance defects which do not affect the use of the structure and exist on the surface of a duct piece in the production process of the duct piece;
the section of jurisdiction is repaired and is gone on at once behind the section of jurisdiction drawing of patterns, hangs the section of jurisdiction from the model with horizontal hoist or vacuum chuck, puts on dedicated repair support, and the repair personnel cleans the section of jurisdiction surface with moist cloth or cotton yarn, finds out the bubble on concrete surface and repairs with hidden bubble, and repair tools includes ash spoon, little spiller, steel brush and steel chisel, and repair materials includes primary color cement: white cement, fine sand and 101 building glue;
the section of jurisdiction mark indicates to be carved with the section of jurisdiction model on the intrados of mould man-hour according to the design requirement of section of jurisdiction, and the section of jurisdiction is pour the shaping and through repairing the back, forms permanent reference numeral on the intrados of section of jurisdiction, and the content of section of jurisdiction mark includes arrangement of reinforcement type, section of jurisdiction model, mould serial number, section of jurisdiction production line number, section of jurisdiction date of production and inspection state.
Based on the technical scheme, in S7, the underwater curing of the pipe piece means that the pipe piece is turned over by 90 degrees through a turnover machine after being demoulded and is hung into a water curing pool for curing, the water can enter the pipe piece when the temperature difference between the surface temperature of the pipe piece and water is less than 20 ℃, the pipe piece is transported to a storage field for watering curing for 7 days by a gantry crane after being cured in the water pool, and then the pipe piece is naturally cured to 28 days;
as shown in fig. 11, in S8, segment storage means that segments are transported to a storage yard for continuous maintenance and storage after being cultured in water for 7d, segment stacking yard is solid and flat, drainage is smooth, support pads are stable and reliable, segments are stacked according to lifting, mounting sequence and model during storage, a transportation channel is left between stacks and meets the requirement of a crane lifting distance, segments are placed on flexible support bars, flexible support bars are arranged between segments, the segments are separated by the flexible support bars, the positions where the support bars are placed are uniform and consistent in thickness, side-surface vertical placement or inward-cambered-surface upward stacking is adopted, pine bars of 20cm x 2m are adopted at the bottom of the flexible support, pine bars of 10cm x 2m are adopted at the upper part, layers are leveled and tamped by the support bars, the upper and lower layers of the support bars are placed on a vertical line, segments are stored with side surfaces not more than 4 layers, and the inward-cambered surfaces are horizontally stacked not more than 6 layers.
As shown in fig. 12, based on the above technical solution, in S9, a duct piece leak test refers to performing a leak test on a finished duct piece after the duct piece is naturally maintained to 28d, wherein the leak test is performed according to a designed leakage resistance pressure of 0.8MPa and a constant pressure of 2h, and a water penetration depth is 5 cm;
after the pipe piece is produced, extracting 1 pipe piece for each 50 rings of production to perform a leakage detection test, continuously and thrice reaching a detection standard, changing to extracting 1 pipe piece for each 100 rings of production, continuously and thrice reaching the detection standard, finally extracting 1 pipe piece for the leakage detection test with the detection frequency of 200 rings, if the pipe piece does not reach the standard once, recovering the initial detection frequency of extracting 1 pipe piece for each 50 rings, and performing the leakage detection test according to the requirements, wherein a test instrument comprises a pressure gauge, an electronic stopwatch and a pressure pump;
the duct piece leak detection test specifically comprises the following steps:
step 1, stably placing the duct piece on a test stand, and checking whether a sealing rubber pad is tightly attached to the outer arc surface of the duct piece;
step 2, three rubber strips are arranged on the axial line of the inner arc surface of the duct piece, the middle rubber strip is arranged, the edge of the middle rubber strip is arranged, and the distance between the duct piece sealing gasket and the edge of the duct piece is 50 mm;
step 3, pressing a fastening cross rod on the width direction of the intrados of the duct piece, connecting the fastening cross rod with the fastening cross rod on the lower supporting seat by using a bolt, and tightening the fastening cross rod from the middle to two sides;
step 4, opening an exhaust valve, then connecting a water inlet valve, injecting tap water, closing the exhaust valve after discharging water from an exhaust hole, starting a pressure pump, pressurizing to 0.2MPa at a pressurizing speed of 0.05MPa/min for 10min at constant pressure, checking the water leakage phenomenon, observing the side permeation height, and recording;
and 5, continuously pressurizing to 0.4MPa, 0.6MPa and 0.8MPa, keeping the constant pressure time of each stage for 10 minutes, observing for 2 hours at the constant pressure after the pressure reaches 0.8MPa, and ensuring that the water seepage line of each end surface of the member does not exceed 50mm, wherein the requirement that the impermeability strength grade is P12 is met.
Finally, it should be noted that: although the present invention has been described in detail with reference to the foregoing embodiments, it will be apparent to those skilled in the art that changes may be made in the embodiments and/or equivalents thereof without departing from the spirit and scope of the invention. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (10)
1. An efficient production process of a duct piece is characterized in that: comprises the following production steps:
s1, processing and assembling the die;
s2, manufacturing a reinforcement cage;
s3, stirring concrete;
s4, pouring concrete;
s5, segment collection;
s6, removing the die from the segment;
s7, maintaining the pipe piece in water;
s8, segment storage;
and S9, duct piece leak detection test.
2. The process for efficiently producing a duct piece according to claim 1, wherein: in the S1, the die processing and assembling comprises die cleaning, release agent spraying, die assembly, steel bar cage die entering and embedded part installation;
the mould cleaning means that concrete residues on a mould are required to be completely removed before the mould is produced, the concrete residues cannot be accumulated on any part of the inner surface of the cleaned mould, sponge blocks, asbestos cloth and a special plastic shovel are required to be matched for cleaning when the inner surface of the mould is cleaned, particularly, the concrete residues on a grouting hole base and a hand hole at key parts in the mould are required to be completely cleaned, when the outer surface of the mould is cleaned, the concrete residues on the side and the top surface of an end mould are particularly required to be cleaned, after the concrete residues are completely peeled off, all the impurities are timely cleaned, no residual impurities are required, the contact surfaces of the side and end moulds and the base are cleaned by using a cleaning cloth after the mould is cleaned every time, and engine oil is applied for maintenance;
the step of spraying the release agent is that after the interior of the mold is cleaned, whether concrete residues are left on the inner surface of the mold is checked before the release agent is sprayed, the release agent is sprayed after the mold is checked to be qualified, reworking cleaning is carried out if the mold is not qualified, and when the release agent is sprayed, pressure control is taken care to enable the inner surface of the mold to form a uniform release agent protective film;
the die assembly is to assemble the die, the end die plate is screwed in place by a torque wrench during die assembly, the side plate is slightly pushed in place, a positioning bolt is screwed by a hand, a connecting bolt of the end die plate and the side die plate is assembled, the end die plate and the connecting bolt of the side die plate are screwed by a hand primarily and then are screwed firmly by a special tool in a balanced and forceful manner, then fixing bolts of the side die plate and the bottom die plate are assembled, the end die plate and the side die plate are sequentially screwed by the hand from the middle position to the two ends by the special tool after being screwed by the hand, sequential operation is strictly prohibited, so that the loss of the die deformation precision is avoided, an anastomosis mark is checked after the steel die is assembled, quality inspectors visually inspect the die quality, the width of the inner arc surface of the die is measured by an inside micrometer, the inspection is not performed, and concrete is strictly poured.
3. The process for efficiently producing a duct piece according to claim 1, wherein: in the step S2, the steel bar cage manufacturing comprises bending and arc bending of steel bars, framework forming and welding;
the bending and arc bending of the steel bars are that the steel bars are bent and processed strictly according to the requirements of a design drawing, the positions of driven wheels and the diameters of mandrels are adjusted according to the specifications of the bent and curved steel bars, the steel bars are subjected to trial bending according to an operation table, and after the steel bars are qualified by checking with a standard large sample, the arc bending and bending operation is performed, the intact condition of equipment must be checked before arc bending, abnormal timely repair is found, the steel bars must be fed lightly when the arc bending operation is performed, the steel bars are kept in balance and at a constant speed when entering an arc bending machine, plane warping is prevented, cracks cannot exist on the surface after forming, the bent steel bars must be checked on a mould one by one, the steel bars can be used after being qualified, and the steel bars must be bent again when the radian is not suitable;
the framework forming and welding are that the reinforcement cage part is welded on a mould meeting the design requirements, and the reinforcement cage part is firstly bentPlacing the steel bar part at the designated position on a clamping fixture, measuring and adjusting various sizes and welding point positions, and welding by using CO2The arc welding machine spot welds stirrup and intrados owner muscle earlier, confirms the position of stirrup, penetrates the position that extrados owner muscle was marked according to the drawing in the stirrup in proper order, and it is firm to have the upper and lower owner muscle of positioning baffle one end to spot weld, and main muscle and stirrup should follow the intermediate position and weld to both ends respectively in proper order, welds the jail until the inside and outside arc owner muscle other end, marks welding waist muscle, founds muscle, end strengthening rib and hand hole strengthening rib according to position and mould in the picture at last.
4. The process for efficiently producing a duct piece according to claim 2, wherein: the steel reinforcement cage is placed into the mold by a crane matched with a special lifting appliance after the steel reinforcement cage is manufactured, the steel reinforcement cage is lifted and placed into the mold in a light lifting process, and the steel reinforcement cage is placed into the mold for inspection and correction.
The embedded part installation means that after the steel reinforcement cage is hoisted and placed, and after quality inspector inspects and approves, the embedded part is installed, during installation, a grouting pipe and a mold positioning core are assembled at first, whether the grouting pipe is tightened is inspected, and slurry leakage is prevented.
5. The process for efficiently producing a duct piece according to claim 1, wherein: in the step S3, the concrete stirring refers to stirring the concrete raw materials, the concrete raw materials are stirred by adopting a HZS120 type double-horizontal-shaft forced stirrer, river sand and cement are sequentially stirred for 20S, then a water aqua solution and water are added and reduced for stirring for 30S, finally broken stones are added, the total stirring time is controlled to be 120-180S, the stirring time in winter is prolonged by 50% compared with the specified time, and the concrete needs to be inspected after the concrete stirring is finished.
6. The process for efficiently producing a duct piece according to claim 5, wherein: in S4, the concrete pouring means that the concrete after mixing and inspection is poured into a mold, the assembled mold must be checked and accepted according to regulations before pouring, any unqualified item should be notified to the previous process for rework, and pouring can be performed after the experience collection grid;
the concrete is poured in layers, the concrete is poured in a centralized manner from the middle of the formwork by adopting pneumatic vibration, the whole formwork is filled with the concrete by utilizing the fluidity of the concrete, the vibration time is controlled by stopping or not obviously sinking the concrete surface, the concrete surface is not obviously foamed, the concrete is preferably used for pouring mortar out from the filled surface of the corner part of the formwork, the vibration time is not less than 3 minutes each time, vibration leakage or over vibration is avoided, the middle concrete is leveled, and the radian of the outer ring surface is modified after all vibration forming is finished.
7. The process for efficiently producing a duct piece according to claim 1, wherein: in the step S5, segment collection means that the top plate is opened to collect the segment in the initial setting process after the concrete is poured, when the segment is collected, channel steel is used for strickling off redundant concrete or filling the concave position, coarse grinding is carried out, and the initial collection is timely to avoid water sprinkling and dry ash;
after the surface of the concrete is polished, the concrete enters a static curing stage, static curing molding is carried out on the concrete, secondary surface collection is carried out before a mould enters a ferry vehicle, the secondary surface collection requires that the surface of the concrete is flat and smooth without the phenomena of bulging and collapse, after the concrete passes through the secondary surface collection, the surface collection is carried out for three times before the concrete enters a steam curing kiln, finger pressing can be carried out on the concrete to form finger prints, and a hand hole forming device is pulled out in time after the surface collection is finished.
After the formed concrete pipe piece is subjected to surface collection treatment and is statically maintained for not less than 1 hour, the concrete pipe piece is sent into a steam curing kiln for steam curing, the temperature rising speed is not more than 15 ℃/h, the highest temperature is not more than 55 ℃, the temperature reducing speed is not more than 20 ℃/h, the constant temperature is not less than 4 hours, and the concrete pipe piece can be moved out of the steam curing kiln for external form removal until the difference between the surface temperature of the pipe piece and the temperature in a workshop is less than 20 ℃.
8. The process for efficiently producing a duct piece according to claim 1, wherein: in the step S6, the duct piece demolding treatment specifically comprises duct piece demolding, duct piece repairing and duct piece marking;
in the operation process of the duct piece demoulding, firstly, a top cover bolt is disassembled, concrete residues are removed, then a sleeve positioning rod and a grouting pipe positioning shaft are disassembled, cleaned and placed at an appointed position, then a side mould and a bottom mould fixing bolt are disassembled, a side plate is slightly pulled out, and finally an end mould and bottom mould connecting bolt is disassembled;
the duct piece repairing refers to the process of trimming and repairing a small amount of appearance defects which do not influence the use of the structure and exist on the surface of a duct piece in the production process of the duct piece;
the duct piece repairing is carried out immediately after the duct piece is demoulded, the duct piece is lifted away from the model by a horizontal lifting appliance or a vacuum sucker and placed on a special repairing support, and a repairing person uses moist cloth or cotton yarn to wipe the surface of the duct piece to find out bubbles on the surface of concrete and hidden bubbles for repairing;
the duct piece mark means that the model of the duct piece is carved on the inner arc surface of the mold during machining according to the design requirement of the duct piece, and the duct piece is cast and molded and forms a permanent mark on the inner arc surface of the duct piece after being repaired.
9. The process for efficiently producing a duct piece according to claim 1, wherein: in the S7, the underwater curing of the pipe piece means that the pipe piece is turned over by 90 degrees through a turnover machine after being demoulded and is hung into a water curing pool for curing, the water can be fed only when the temperature difference between the surface temperature of the pipe piece and the water is less than 20 ℃ when the pipe piece is fed into the water, the pipe piece is transported to a storage field for watering curing for 7d after being cured for 7 days in a water pool by a gantry crane, and then the pipe piece is naturally cured to 28 d;
in the S8, the segment storage means that the segments are transported to a storage field after being cultured in water for 7d and are continuously maintained and stored, the segment storage field is solid and flat, the drainage is smooth, the support pad is stable and reliable, and the segments are respectively stacked according to the lifting, installation sequence and model number during storage;
the pipe piece is placed on the flexible filler strips, the flexible filler strips are arranged between the pipe piece and the pipe piece at intervals, the positions where the filler strips are placed are uniform, the thickness of the filler strips is consistent, the side faces are vertically placed or the inner arc faces are stacked upwards, the bottom of the flexible support is made of pine strips of 20cm x 2m, the upper portion of the flexible support is made of pine strips of 10cm x 2m, the layers are leveled and tamped by filler blocks, the filler blocks on the upper layer and the lower layer are arranged on a vertical line, the side faces of the pipe piece are stored and vertically placed on no more than 4 layers, and the inner arc faces upwards and horizontally stacked no more than 6 layers.
10. The process for efficiently producing a duct piece according to claim 9, wherein: in the S9, the duct piece leakage detection test means that the duct piece is naturally maintained to 28d and then a leakage detection test is carried out on a finished duct piece, the leakage detection standard is constant in pressure for 2 hours under the designed seepage resistance pressure of 0.8MPa, the seepage depth is less than or equal to 5cm, and the test instrument comprises a pressure gauge, an electronic stopwatch and a pressure pump;
the duct piece leak detection test specifically comprises the following steps:
step 1, stably placing the duct piece on a test stand, and checking whether a sealing rubber pad is tightly attached to the outer arc surface of the duct piece;
step 2, three rubber strips are arranged on the axial line of the inner arc surface of the duct piece, the middle rubber strip is arranged, the edge of the middle rubber strip is arranged, and the distance between the duct piece sealing gasket and the edge of the duct piece is 50 mm;
step 3, pressing a fastening cross rod on the width direction of the intrados of the duct piece, connecting the fastening cross rod with the fastening cross rod on the lower supporting seat by using a bolt, and tightening the fastening cross rod from the middle to two sides;
step 4, opening an exhaust valve, then connecting a water inlet valve, injecting tap water, closing the exhaust valve after discharging water from an exhaust hole, starting a pressure pump, pressurizing to 0.2MPa at a pressurizing speed of 0.05MPa/min for 10min at constant pressure, checking the water leakage phenomenon, observing the side permeation height, and recording;
and 5, continuously pressurizing to 0.4MPa, 0.6MPa and 0.8MPa, keeping the constant pressure time of each stage for 10 minutes, observing for 2 hours at the constant pressure after the pressure reaches 0.8MPa, and ensuring that the water seepage line of each end surface of the member does not exceed 50mm, wherein the requirement that the impermeability strength grade is P12 is met.
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN114856622A (en) * | 2022-05-06 | 2022-08-05 | 中煤科工集团北京华宇工程有限公司 | Shield segment |
| CN116618966A (en) * | 2023-06-06 | 2023-08-22 | 中铁二十二局集团轨道工程有限公司 | High-quality shield segment production process |
| CN116618966B (en) * | 2023-06-06 | 2025-07-18 | 中铁二十二局集团轨道工程有限公司 | High-quality shield segment production process |
| CN117140716A (en) * | 2023-06-21 | 2023-12-01 | 中铁二十二局集团轨道工程有限公司 | A concrete segment assembly line transmission prefabrication method |
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