CN114290501A - Cement balancing weight and manufacturing method thereof - Google Patents
Cement balancing weight and manufacturing method thereof Download PDFInfo
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- CN114290501A CN114290501A CN202111532812.7A CN202111532812A CN114290501A CN 114290501 A CN114290501 A CN 114290501A CN 202111532812 A CN202111532812 A CN 202111532812A CN 114290501 A CN114290501 A CN 114290501A
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Abstract
The invention provides a cement balancing weight and a manufacturing method thereof, which comprises the steps of pouring prepared concrete into a mould, forming a blank body after vibration curing, carrying out strength detection on the blank body after mould removal, and carrying out appearance inspection after the blank body is qualified; and (5) performing paint spraying treatment on the blank body qualified in appearance detection, performing appearance detection on the painted cement balancing weight, and packaging after the detection is qualified. This scheme can directly pour thoughtlessly questioning soil through the mould and need not to carry out the die filling in addition, the effectual concrete die filling that has solved is not convenient, pour long time, cause the problem of inflation to the template extrusion, pour the back through a lot of in batches and improved the effect of pouring, adopt quiet maintenance and steam maintenance to combine the effectual hardening efficiency that has improved, the setting time has been shortened, the application in-process is polished and is dried many times and is convenient for improve application effect and quality, the time of spraying has been shortened, the production efficiency of balancing weight has been improved, the manufacturing cost of balancing weight has been reduced.
Description
Technical Field
The invention relates to a counterweight block production technology, in particular to a cement counterweight block and a manufacturing method thereof.
Background
The stability is an important index of engineering machinery, and especially for heavy engineering machinery such as cranes, rotary drilling rigs and the like, the improvement of the stability of the machinery is one of important ways for reducing accidents. A counterweight is usually provided on a construction machine to balance the force applied to the machine, so as to improve the stability of the machine. Usually the balancing weight all is a balanced leveling block of weight, sets up the metal casing, and the casing intussuseption is filled with concrete or lead and is waited, but the manufacturing cost of this balancing weight is high, consequently adopts cement as the comparatively suitable selection of balancing weight.
The patent No. CN205980830U discloses a concrete balancing weight production and manufacturing method with accurately controllable specific gravity, which mainly comprises an iron ore crushing flow, an iron ore specific gravity measuring flow, a concrete balancing weight specific gravity calculating flow, a shell and mould design and manufacturing flow, a vibration pouring manufacturing flow, a curing flow and a surface treatment flow in sequence; the concrete counterweight block manufactured by the invention corresponds to the traditional cast iron counterweight, the cost is only one third of the cast iron counterweight, and the maximum specific gravity is about three fifths of the cast iron counterweight. However, this manufacturing method still works reasonably well for weights below 2T, but when the manufacturing process for producing weights above 2T has the following drawbacks: (1) the time for filling the mold is long, and the cement counterweight above 2T needs to be tied up to prevent the expansion of concrete, which causes mold expansion and product deformation; (2) the mold removing time is long, the mold can be removed from the top cover and the side surface in 1 day in winter, the mold removing needs 3-4 days or even longer, the maintenance time is longer, and the coating can be performed in 15-20 days; (3) coating is difficult, the coating needs to be hung up by a crane for coating, the surface quality of a product cannot meet the requirement, putty scraping and polishing need to be repeated, the waiting time is long, and the coating needs to be hung and dried after being sprayed; (4) the product occupies a large area and has high transportation cost; (5) there is no professional product quality detection equipment, and the factory can only judge the external quality such as appearance and installation size, and can not detect the problems such as internal crack, product strength, and the like, and the surface strength can only be determined by experience.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a cement counterweight block and a manufacturing method thereof, which are convenient to solve the problems of difficult mold filling of concrete and mold expansion and deformation of the counterweight block caused by expansion of the concrete, reduce pouring time, improve hardening efficiency, shorten solidification time, improve coating effect, reduce coating time and improve coating efficiency and counterweight block quality.
The technical scheme of the invention is as follows: a method for manufacturing a cement balancing weight, which comprises the following steps of pouring prepared concrete into a mould, vibrating and curing to form a blank body:
s1: after the mold is removed, carrying out strength detection on the blank, and carrying out appearance inspection after the strength detection is qualified;
s2: the method for painting the green body qualified in appearance detection comprises the following steps:
s2.1 base surface treatment: cleaning and polishing the surface of the blank body to ensure that the surface flatness of the blank body is below 3 mm;
s2.2 batch scraping and leveling putty and polishing: scraping the putty at least once, after the putty is completely dried, polishing and flattening the putty by using corresponding abrasive paper, and cleaning dust;
s2.3, primer construction: brushing, spraying or rolling the primer on the putty layer to form a coating film;
s2.4, constructing the real stone paint: spraying with a spray gun to control the spraying thickness at 2-8kg/m2；
S2.5, grinding: after baking and drying the stone paint, grinding particles with acute angles on the surface of the stone paint;
s2.6, construction of the dust cover finish: after the paint is completely dried, spraying at least one layer of finish paint by a spray gun uniformly, wherein the spray gun has no phenomena of floating, missing spraying, consistent gloss, flowing drop, lumps and splashed foam, and baking after spraying;
s3 detection and packaging: and (5) carrying out appearance detection on the painted cement balancing weight, and packaging after the detection is qualified.
Further, in the step S3 detection packaging process, the qualified cement counter weight blocks are packaged, and the unqualified cement counter weight blocks are returned to the step S2.2 to be polished and then are sprayed again.
Further, in step S2.3, the spraying is: adding 5-10% of clear water to dilute the coating, uniformly stirring, standing, curing for 10-15 minutes, uniformly stirring, and performing spraying construction; the brush coating comprises the following steps: the construction thickness is more than 30 mu m; the surface is smooth, flat, uniform and clean by visual inspection, and no sand holes, obvious brush marks or coating leakage is generated.
Further, in the step S2.4, selecting a spray gun with the diameter of 2-4 mm and the distance between a nozzle and the wall surface is 40-50 cm; the spraying thickness is controlled to be 4-5kg/m2Left and right, and spraying uniformly.
Further, in step S2.6, a spray gun with the pressure of more than 4kg is adopted, a muzzle is perpendicular to the wall surface and is 25-50cm away from the front surface, the spray gun is used for uniformly spraying the paint back and forth, and the finish paint is sprayed twice; firstly, a layer is sprayed uniformly and thinly, the spraying thickness is 0.1-0.125 kg/m2The dry film thickness was 30 μm.
Further, a counterweight reinforcement cage is arranged in the concrete; the processing of the reinforcement cage comprises the following steps:
step one, steel bar treatment: removing oil stain, floating skin and rust before processing the reinforcing steel bars, and cutting and blanking after removing rust;
and step two, connecting steel bars: the steel bar connection adopts mechanical connection, electric arc welding or flash butt welding;
step three, processing a steel reinforcement cage: put reinforcing bar and anchor screw on the location frock to it is fixed with the nut, steel reinforcement cage owner muscle connects and to stagger, connects quantity on each cross-section and is no longer than 50%, arranges the stirrup according to the reinforcing bar position of designing requirement, and the stirrup is connected the winding with the main muscle closely, with the stirrup spot welding on the main muscle, checks the acceptance of the steel reinforcement cage inspection after the shaping.
Furthermore, an embedded part is additionally arranged in the cement balancing weight.
Further, the concrete is poured into the mold, the concrete is poured into the divided material and is filled in three layers, each pouring layer is vibrated once, bubbles in the concrete are fully removed, the compactness of the concrete is guaranteed, and when the uppermost layer is poured, the surface is leveled after slurry is discharged from the surface.
Further, the curing comprises standing curing and steam curing; the static maintenance is to smear the surface of the formed concrete and then use an airtight film to fully cover the concrete, so as to prevent the problem of shrinkage and cracking caused by too fast surface water loss due to air drying or over high temperature during static maintenance; and steam curing, namely after the surface of the component is hardened, uncovering the film to lift the component and the die into a steam curing pool for curing, wherein when steam is introduced, a large valve is not required to be opened directly for steam feeding, steam feeding is carried out according to the principle from small to large, the temperature of 25 ℃ per hour is ensured, the temperature is raised to 70-85 ℃ for constant temperature, and the constant temperature time is less than 6 hours.
The cement counterweight block is manufactured by the method and comprises a reinforcement cage, concrete and an embedded part, wherein the reinforcement cage and the embedded part are installed in the concrete, the embedded part comprises an anchoring screw and a hoisting part, and a putty layer, a primer layer, a real stone paint layer and a finish paint layer are sprayed on the surface of the concrete.
The invention has the following characteristics: can directly pour the suspected soil of mixing through the mould and need not to carry out the die filling in addition, the effectual concrete die filling of having solved is not convenient, pour long time, to the problem that the template extrusion causes the inflation, pour the back in batches through many times, can improve the effect of pouring, adopt after pouring to halt maintenance and steam maintenance to combine effectual hardening efficiency that has improved, great shortening the setting time, polish and dry many times at the application in-process and be convenient for improve application effect and quality, the time of spraying has been shortened, the production efficiency of balancing weight has been improved, and then the production quality of balancing weight has been guaranteed, the mass production of being convenient for, the effectual manufacturing cost who reduces the balancing weight.
The detailed structure of the present invention will be further described with reference to the accompanying drawings and the detailed description.
Drawings
FIG. 1 is a schematic view of the overall structure of the weight member of the present invention;
FIG. 2-is a front view of the weight;
FIG. 3 is a test chart of the weight block;
FIG. 4-is a process flow diagram of the present invention;
FIG. 5 is a process flow diagram of a reinforcement cage processing;
FIG. 6 is a flow chart of a counterweight spraying process;
in the figure: 20-a balancing weight; 21-a groove; 22-rebar hook; 23-an anchor screw; 24-metal fasteners.
Detailed Description
Example one
As shown in the attached drawings: the utility model provides a cement balancing weight 20, includes steel reinforcement cage, concrete and built-in fitting, and steel reinforcement cage and built-in fitting are installed in the concrete, and the built-in fitting includes anchor screw 23 and hoist and mount, and the surface spraying putty layer, priming paint layer, real mineral varnish layer and finish paint layer etc. of concrete, and balancing weight 20 weight in this embodiment is 3, 4 or 5T.
The manufacturing method of the cement balancing weight 20 comprises the steps of pouring prepared concrete into a mould, forming a blank body after vibration curing, and adding an embedded part into the cement balancing weight 20; in the concrete pouring process, pouring concrete into a mould, pouring the concrete into a distribution material, loading the concrete into the mould in three layers, vibrating once every pouring layer, fully removing bubbles in the concrete and ensuring the compactness of the concrete, and when the uppermost layer is poured, finishing the surface by discharging slurry on the surface; placing a reinforcement cage in a mold before pouring concrete, wherein the processing of the reinforcement cage comprises the following steps:
step one, steel bar treatment: removing oil stain, floating skin and rust before processing the reinforcing steel bars, and cutting and blanking after removing rust; the rust removal can be carried out by adopting methods such as mechanical rust removal, sand blasting method rust removal, manual steel wire brush or grinding wheel rust removal and the like. The steel bar should be straight, have no local bending, use after should straightening to crooked reinforcing bar. Straightening can be achieved by adopting cold drawing or straightening by using a straightener, the cold drawing method is mainly used for straightening stirrups, the stirrups are slowly drawn at a constant speed when the stirrups are straightened by adopting the cold drawing method, the cold drawing rate of the I-grade steel bar is not more than 2%, and the cold drawing rate of the II-grade steel bar is not more than 1%; the main bar end is bent and cannot be straightened, and a toothless saw is adopted for cutting. Before the reinforcing bar processing, the technical staff should prepare burden the reinforcing bar according to the design drawing requirement, assigns the batching list. The processing personnel carefully check the specification, the grade and the processing quantity of the reinforcing steel bars before blanking, and blanking according to the batching list after no error. During blanking, a toothless saw or a steel bar cutting machine is adopted for cutting, so that electric and gas welding cutting is avoided. Before the reinforcing steel bar is cut off, the cutting position is marked obviously by using a pen on the reinforcing steel bar according to the blanking length marked by the batching sheet, and the mark is aligned with the cutting edge to be cut off, so that the cutting precision is improved conveniently, and the weight proportion and the weight balance of the balancing weight 20 are ensured. The bending and forming of the reinforcing steel bars are carried out by a bending machine, and the bending and the tail end hook of the reinforcing steel bars both meet the design requirements.
And step two, connecting steel bars: the steel bar connection adopts mechanical connection, electric arc welding or flash butt welding; the grade of the welding rod used by the electric arc welding is in accordance with the design requirement, and the performance of the welding rod is in accordance with the current national standard. Before formal welding of the steel bars, a trial welding test must be carried out under the same construction conditions to determine welding process, parameters and welding quality, and welding parameters and joint quality are randomly sampled after welding to ensure the welding quality. The stress bar welding joint is arranged to avoid a bending part, the distance from the bending point is not less than 10d, the same steel bar is provided with joints as few as possible, and the two welding joints on the same steel bar are within the range of 35d and not less than 500mm and do not exceed one joint. During winter construction, arc welding should be provided with snow prevention, wind prevention and heat preservation measures, and a welded joint is strictly prohibited to be immediately contacted with ice and snow.
Step three, processing a steel reinforcement cage: put reinforcing bar and anchor screw 23 on the location frock to it is fixed with the nut, steel reinforcement cage owner muscle connects and to stagger, connects quantity on each cross-section no more than 50%, arranges the stirrup according to the reinforcing bar position of design requirement, and the stirrup is connected the winding with main muscle closely, with the stirrup spot welding on main muscle, checks the acceptance of the steel reinforcement cage inspection after the shaping. The framework of the steel reinforcement cage is made of one-time integration in the processing field. Put reinforcing bar and anchor screw 23 on the location frock to it is fixed with the nut, the steel reinforcement cage owner muscle connects and to stagger, connects quantity on each cross-section and does not exceed 50%, arranges the stirrup according to the reinforcing bar position of design requirement, and the stirrup is connected the winding with the main muscle closely, with the stirrup spot welding on the main muscle. The thickness of the protective layer of the steel reinforcement cage must meet the design requirement, the thickness of the protective layer of the steel reinforcement cage can be welded with the ear cushion blocks of the steel reinforcement, the arrangement density is vertically arranged one by one at intervals of 2m, and 4 blocks are symmetrically arranged along the circumference of each path; after the formed reinforcement cage is qualified through self-inspection, the hanging plate is placed in a special place and stored by a lower cushion upper cover, so that the formed reinforcement cage is properly protected.
In an embodiment, curing includes static curing and steam curing; the static maintenance is to smear the surface of the formed concrete and then use an airtight film to fully cover the concrete, so as to prevent the problem of shrinkage and cracking caused by too fast surface water loss due to air drying or over high temperature during static maintenance; and steam curing, namely after the surface of the component is hardened, uncovering the film to lift the component and the die into a steam curing pool for curing, wherein when steam is introduced, a large valve is not required to be opened directly for steam feeding, steam feeding is carried out according to the principle from small to large, the temperature of 25 ℃ per hour is ensured, the temperature is raised to 70-85 ℃ for constant temperature, and the constant temperature time is less than 6 hours.
The weight 20 further comprises the following steps in the manufacturing process:
s1: after the mold is removed, carrying out strength detection on the blank, and carrying out appearance inspection after the strength detection is qualified; detecting the strength of the green body by using a resiliometer, continuously maintaining the green body with unqualified strength, and detecting again after the green body is completely solidified; randomly sampling and reserving a compression-resistant test piece and an anti-permeability test piece in the detection process, and detecting the shearing force, the internal force in a hoisting state, the bearing capacity, the compression strength and the like of the test piece;
s2: the method for painting the green body qualified in appearance detection comprises the following steps:
s2.1 base surface treatment: cleaning and polishing the surface of the blank body to ensure that the surface flatness of the blank body is below 3 mm; preferably, the surface flatness requires dislocation below 3mm, and has no delaminating, hollowing, no crack on the surface layer, no crack larger than 0.2mm, no obvious sand hole and other defects; the surface layer achieves high-grade plastering, namely the verticality of the produced surface is not more than 3mm, the surface flatness is less than 2mm, the verticality of the internal and external angles is less than 2mm, and the square is 2 mm; the surface is required to be flat and clean, the color is uniform, and no dust, oil stain, exposed steel bars or exposed iron wires are generated; the dust, greasy dirt and the like on the surface are removed by a steel wire brush, a synthetic detergent and the like, or are polished clean by coarse abrasive cloth, and construction can be carried out after cleaning and polishing are finished.
S2.2 batch scraping and leveling putty and polishing: scraping the putty at least once, after the putty is completely dried, polishing and flattening the putty by using corresponding abrasive paper, and cleaning dust; preferably, batch puttying should be performed using a trowel, a scraper, or a steel batch, with batch scraping from top to bottom; the putty can not be coated too thick in each time, and the excessive thickness easily causes the defects of cracking, falling off and the like; usually, the surface putty is about 0.5-1.0 mm. Preferably, the putty is batch-scraped twice, the interval time of the two putty times cannot be too short, and after the first putty is dried, the second putty is coated; when the putty is batched, the putty is not scraped repeatedly so as to prevent the phenomenon of rolling skin, falling off or extruding glue in the putty, and the sealed surface is not easy to dry; when putty is batched, attention is paid to manipulation, the forefinger presses the blade tightly, the putty is pressed into the defect with force, the putty is filled and filled, and the putty at the periphery is scraped completely, so that putty traces are reduced as much as possible; and after the putty is completely dried, polishing the putty flatly by using corresponding abrasive paper, and cleaning dust.
S2.3, primer construction: adopting alkali-resistant primer or sealing primer; brushing, spraying or rolling the primer on the putty layer to form a coating film; the spraying is as follows: adding 5-10% of clear water to dilute the coating, uniformly stirring, standing, curing for 10-15 minutes, uniformly stirring, and performing spraying construction; the brushing adopted in the embodiment specifically comprises the following steps: coating the primer on the putty layer by using a brush, wherein the construction thickness is more than 30 mu m; the surface is smooth, flat, uniform and clean by visual inspection, no sand holes, no obvious brush marks and no coating leakage are realized; a coating film is formed on the putty layer, the particle size of the emulsion is extremely small, and the emulsion can deeply penetrate into a coated base layer; the primer has the following functions: the primer can quickly permeate the inside of the base material and the putty layer to form a tight sealing isolation layer, the paint film has good flexibility, and can effectively prevent external substances such as acid, alkali, water, oil and the like from eroding the counterweight surface, so that the optimal pH value balance is achieved, the paint film is effectively prevented from falling off, whiskering and blooming, the influence on counterweight effect caused by the exosmosis of mold bred in the base material or the putty layer can be prevented, and the adhesive force of the finish paint is improved; brushing or rolling: adding clear water for dilution, stirring uniformly, and uniformly smearing on the surface of the putty layer.
S2.4, constructing the real stone paint: spraying by using a spray gun, wherein the spraying thickness is controlled to be 2-8kg/m 2; preferably, a spray gun with the diameter of 2-4 mm and the caliber is selected, and the distance between the spray nozzle and the wall surface is 40-50 cm; controlling the spraying thickness to be about 4-5kg/m2, and uniformly spraying; more preferably, the spraying thickness is 4.5kg/m 2; the real stone paint construction quality requirement is as follows: the sprayed surface is flat, and has no flowering, saltpetering and color biting; 1M front view, consistent thickness and uniform thickness; the phenomena of flow falling, lumps and splashed foam are avoided; the front view color is consistent, and no sand hole, no scratch and no leakage spray exist; the ridge is clear.
S2.5, grinding: after baking and drying the stone paint, grinding particles with acute angles on the surface of the stone paint; the sharp-angled particles can be ground to be 30-50%, so that the aesthetic feeling of the stone paint can be improved, the sharpness is reduced, and dust accumulation is avoided.
S2.6, construction of the dust cover finish: after the paint is completely dried, spraying at least one layer of finish paint by a spray gun uniformly, wherein the spray gun has no phenomena of floating, missing spraying, consistent gloss, flowing drop, lumps and splashed foam, and baking after spraying; preferably, a spray gun with the pressure of more than 4kg is adopted, a gun mouth is perpendicular to the wall surface and is 25-50cm away from the front surface, the spray gun is used for uniformly spraying the paint back and forth, and the finish paint is sprayed twice; firstly, a layer is sprayed uniformly and thinly, the spraying thickness is 0.1-0.125 kg/m2, and the dry film thickness is 30 μm.
S3 detection and packaging: carrying out appearance detection on the painted cement balancing weight 20, and packaging after the detection is qualified; and returning the unqualified cement counterweight block 20 to the step S2.2, polishing and spraying again until the cement counterweight block is qualified.
According to the invention, the mixed soil can be directly poured through the mould without additional mould filling, the problems of inconvenience in mould filling, long pouring time and expansion caused by extrusion on the template are effectively solved, the pouring effect can be improved after multiple times of pouring, the hardening efficiency is effectively improved by combining static curing and steam curing after pouring, the solidification time is greatly shortened, the coating effect and quality are improved by polishing and drying for multiple times in the coating process, the spraying time is shortened, the production efficiency of the balancing weight 20 is improved, the production quality of the balancing weight 20 is further ensured, the mass production is facilitated, and the production cost of the balancing weight 20 is effectively reduced.
Example two
As shown in the attached drawings: the utility model provides a cement balancing weight 20, includes steel reinforcement cage, concrete and built-in fitting, and steel reinforcement cage and built-in fitting are installed in the concrete, and the built-in fitting includes anchor screw 23 and hoist and mount, and the surface spraying putty layer, priming paint layer, real mineral varnish layer and finish paint layer etc. of concrete, this cement balancing weight 20's weight is 6T or 7T. Preferably, the counterweight 20 is provided with a groove 21, and the embedded part further comprises a metal fastener 24 which is hoisted to be a steel bar hook 22.
Preferably, the concrete comprises ingredients such as cement, sand, stone, additives and the like; cement, namely 425 ordinary cement is selected; the maximum cement dosage of the concrete is not more than 500kg/m 3. The quality of the cement meets the regulations in the standard, and the quality indexes comprise magnesium oxide content, sulfur trioxide content, loss on ignition, fineness, setting time, stability, compression resistance and rupture strength. Sand: the mud content of the sand is not more than 3% by weight; selecting high-quality sand; for pumping concrete, the sand is preferably medium sand, and the sand rate is preferably controlled to be 40-50%. Stone: selecting high-quality stones; the maximum particle size of the stones should not be larger than 1/4 of the cross-sectional dimension of the structure, and should not be larger than 3/4 of the minimum clear distance between the reinforcing steel bars. The maximum particle size of the concrete solid plate aggregate is not more than 1/2 of the plate thickness and not more than 50 mm; for pumping concrete, the ratio of the maximum particle size of the crushed stone to the inner diameter of the conveying pipe is preferably less than or equal to 1: preferably, the pebbles are less than or equal to 1: 2.5; the mud content of the stones is not more than 1% when the mud content is equal to or higher than that of C30 concrete by weight; below C30, not more than 2%; for concrete with frost resistance, impermeability or other special requirements, the mud content of the stones is not more than 1%; the mud content of the stones in the concrete with the weight of C10 or C10 can be properly relaxed. The content of needle and flaky particles in the pebbles is not more than 15 percent by weight; water: the drinking water meeting the national standard can be mixed with various concretes without inspection. Additive: the water reducing agent, the early strength agent, the retarding water reducing agent and the like meet the regulations of relevant standards, and the mixing amount of the water reducing agent, the early strength agent, the retarding water reducing agent and the like can be used after the mixing amount meets the requirements through tests. The main machines are as follows: the raw materials are mechanically or manually proportioned and mixed soil is uniformly stirred by a scale or an automatic metering device, a pointed spade, a flat spade, a concrete bucket, an inserted vibrator, a flat vibrator, a wood trowel, a long trowel, an iron plate, a rubber water pipe, a traveling crane and the like.
The manufacturing method of the cement counterweight block 20 comprises the following steps of pouring prepared concrete into a mould or feeding the concrete into the mould; forming a blank body after vibration curing, and additionally arranging an embedded part in the cement balancing weight 20; in the concrete pouring process, pouring concrete into a mould, pouring the concrete into a distribution material, loading the concrete into the mould in three layers, vibrating once every pouring layer, fully removing bubbles in the concrete and ensuring the compactness of the concrete, and when the uppermost layer is poured, finishing the surface by discharging slurry on the surface; placing a reinforcement cage in a mold before pouring concrete, wherein the processing of the reinforcement cage comprises the following steps:
step one, steel bar treatment: removing oil stain, floating skin and rust before processing the reinforcing steel bars, and cutting and blanking after removing rust; the rust removal can be carried out by adopting methods such as mechanical rust removal, sand blasting method rust removal, manual steel wire brush or grinding wheel rust removal and the like. The steel bar should be straight, have no local bending, use after should straightening to crooked reinforcing bar. Straightening can be achieved by adopting cold drawing or straightening by using a straightener, the cold drawing method is mainly used for straightening stirrups, the stirrups are slowly drawn at a constant speed when the stirrups are straightened by adopting the cold drawing method, the cold drawing rate of the I-grade steel bar is not more than 2%, and the cold drawing rate of the II-grade steel bar is not more than 1%; the main bar end is bent and cannot be straightened, and a toothless saw is adopted for cutting. Before the reinforcing bar processing, the technical staff should prepare burden the reinforcing bar according to the design drawing requirement, assigns the batching list. The processing personnel carefully check the specification, the grade and the processing quantity of the reinforcing steel bars before blanking, and blanking according to the batching list after no error. During blanking, a toothless saw or a steel bar cutting machine is adopted for cutting, so that electric and gas welding cutting is avoided. Before the reinforcing steel bar is cut off, the cutting position is marked obviously by using a pen on the reinforcing steel bar according to the blanking length marked by the batching sheet, and the mark is aligned with the cutting edge to be cut off, so that the cutting precision is improved conveniently, and the weight proportion and the weight balance of the balancing weight 20 are ensured. The bending and forming of the reinforcing steel bars are carried out by a bending machine, and the bending and the tail end hook of the reinforcing steel bars both meet the design requirements.
And step two, connecting steel bars: the steel bar connection adopts mechanical connection, electric arc welding or flash butt welding; the grade of the welding rod used by the electric arc welding is in accordance with the design requirement, and the performance of the welding rod is in accordance with the current national standard. Before formal welding of the steel bars, a trial welding test must be carried out under the same construction conditions to determine welding process, parameters and welding quality, and welding parameters and joint quality are randomly sampled after welding to ensure the welding quality. The stress bar welded joint is arranged to avoid a bending part, the distance from the bending point is not less than 10d, the same steel bar is provided with joints as few as possible, two welded joints on the same steel bar are within the range of 35d and are not less than 500mm, and one joint is not required to be exceeded. During winter construction, arc welding should be provided with snow prevention, wind prevention and heat preservation measures, and a welded joint is strictly prohibited to be immediately contacted with ice and snow.
Step three, processing a steel reinforcement cage: put reinforcing bar and anchor screw 23 on the location frock to it is fixed with the nut, steel reinforcement cage owner muscle connects and to stagger, connects quantity on each cross-section no more than 50%, arranges the stirrup according to the reinforcing bar position of design requirement, and the stirrup is connected the winding with main muscle closely, with the stirrup spot welding on main muscle, checks the acceptance of the steel reinforcement cage inspection after the shaping. The framework of the steel reinforcement cage is made of one-time integration in the processing field. Put reinforcing bar and anchor screw 23 on the location frock to it is fixed with the nut, the steel reinforcement cage owner muscle connects and to stagger, connects quantity on each cross-section and does not exceed 50%, arranges the stirrup according to the reinforcing bar position of design requirement, and the stirrup is connected the winding with the main muscle closely, with the stirrup spot welding on the main muscle. The thickness of the protective layer of the steel reinforcement cage must meet the design requirement, the thickness of the protective layer of the steel reinforcement cage can be welded with the ear cushion blocks of the steel reinforcement, the arrangement density is vertically arranged one by one at intervals of 2m, and 4 blocks are symmetrically arranged along the circumference of each path; after the formed reinforcement cage is qualified through self-inspection, the hanging plate is placed in a special place and stored by a lower cushion upper cover, so that the formed reinforcement cage is properly protected.
In an embodiment, curing includes static curing and steam curing; the static maintenance is to smear the surface of the formed concrete and then use an airtight film to fully cover the concrete, so as to prevent the problem of shrinkage and cracking caused by too fast surface water loss due to air drying or over high temperature during static maintenance; and steam curing is to lift the component together with the mold into a steam curing pool for curing after the surface of the component is hardened by uncovering the film, wherein when steam is introduced, a large valve is not required to be opened directly for steam feeding, the steam is fed according to the principle from small to large, the temperature rise of 25 ℃ per hour is ensured, the temperature is raised to 80 ℃ for constant temperature, and the constant temperature time is 8 hours.
The weight 20 further comprises the following steps in the manufacturing process:
s1: after the mold is removed, carrying out strength detection on the blank, and carrying out appearance inspection after the strength detection is qualified; cleaning the die after the die is removed, and coating a release agent, so that the flatness of the surface of the blank is intact when the blank is used next time; detecting the strength of the green body by using a resiliometer, continuously maintaining the green body with unqualified strength, and detecting again after the green body is completely solidified; randomly sampling and reserving a compression-resistant test piece and an anti-permeability test piece in the detection process, and detecting the shearing force, the internal force in a hoisting state, the bearing capacity, the compression strength and the like of the test piece;
s2: the blank after the appearance detection is qualified is subjected to paint spraying treatment, the blank can be hoisted before spraying, the spraying effect on the blank is convenient to improve, and the spraying comprises the following steps:
s2.1 base surface treatment: cleaning and polishing the surface of the blank body to ensure that the surface flatness of the blank body is below 3 mm; preferably, the surface flatness requires dislocation below 3mm, and has no delaminating, hollowing, no crack on the surface layer, no crack larger than 0.2mm, no obvious sand hole and other defects; the surface layer achieves high-grade plastering, namely the verticality of the produced surface is not more than 3mm, the surface flatness is less than 2mm, the verticality of the internal and external angles is less than 2mm, and the square is 2 mm; the surface is required to be flat and clean, the color is uniform, and no dust, oil stain, exposed steel bars or exposed iron wires are generated; the dust, greasy dirt and the like on the surface are removed by a steel wire brush, a synthetic detergent and the like, or are polished clean by coarse abrasive cloth, and construction can be carried out after cleaning and polishing are finished.
S2.2 batch scraping and leveling putty and polishing: scraping the putty at least once, after the putty is completely dried, polishing and flattening the putty by using corresponding abrasive paper, and cleaning dust; preferably, batch puttying should be performed using a trowel, a scraper, or a steel batch, with batch scraping from top to bottom; the putty can not be coated too thick in each time, and the excessive thickness easily causes the defects of cracking, falling off and the like; typically the surface putty is 0.8mm together. Preferably, the putty is batch-scraped twice, the interval time of the two putty times cannot be too short, and after the first putty is dried, the second putty is coated; when the putty is batched, the putty is not scraped repeatedly so as to prevent the phenomenon of rolling skin, falling off or extruding glue in the putty, and the sealed surface is not easy to dry; when putty is batched, attention is paid to manipulation, the forefinger presses the blade tightly, the putty is pressed into the defect with force, the putty is filled and filled, and the putty at the periphery is scraped completely, so that putty traces are reduced as much as possible; and after the putty is completely dried, polishing the putty flatly by using corresponding abrasive paper, and cleaning dust.
S2.3, primer construction: brushing, spraying or rolling the primer on the putty layer to form a coating film; the spraying is as follows: adding 8% of clear water to dilute the coating, standing and curing for 14 minutes after uniformly stirring, then uniformly stirring, and then performing spraying construction; the brushing adopted in the embodiment specifically comprises the following steps: coating the primer on the putty layer by using a hairbrush, wherein the construction thickness is 40, 45 or 50 mu m; the surface is smooth, flat, uniform and clean by visual inspection, no sand holes, no obvious brush marks and no coating leakage are realized; a coating film is formed on the putty layer, the particle size of the emulsion is extremely small, and the emulsion can deeply penetrate into a coated base layer; the primer has the following functions: the primer can quickly permeate the inside of the base material and the putty layer to form a tight sealing isolation layer, the paint film has good flexibility, and can effectively prevent external substances such as acid, alkali, water, oil and the like from eroding the counterweight surface, so that the optimal pH value balance is achieved, the paint film is effectively prevented from falling off, whiskering and blooming, the influence on counterweight effect caused by the exosmosis of mold bred in the base material or the putty layer can be prevented, and the adhesive force of the finish paint is improved; brushing or rolling: adding clear water for dilution, stirring uniformly, and uniformly smearing on the surface of the putty layer.
S2.4, constructing the real stone paint: spraying with a spray gun to control the spraying thickness to 3-7kg/m2(ii) a Preferably, selecting a spray gun with the diameter of 3mm and the caliber, and enabling the nozzle to be 48 cm from the wall surface; the spraying thickness is controlled to be 4-5kg/m2Left and right, and spraying uniformly; more preferably, the spray thickness is 4.5kg/m2(ii) a The real stone paint construction quality requirement is as follows: the sprayed surface is flat, and has no flowering, saltpetering and color biting; 1M front view, consistent thickness and uniform thickness; the phenomena of flow falling, lumps and splashed foam are avoided; the front view color is consistent, and no sand hole, no scratch and no leakage spray exist; the ridge is clear.
S2.5, grinding: after baking and drying the stone paint, grinding particles with acute angles on the surface of the stone paint; the sharp-angled particles can be ground to be 30-50%, so that the aesthetic feeling of the stone paint can be improved, the sharpness is reduced, and dust accumulation is avoided.
S2.6, construction of the dust cover finish: after the paint is completely dried, at least one layer of finish paint is sprayed uniformly by a spray gun without floating, leaking, consistent luster and flowingDropping, lump and splash, and baking after spraying; preferably, a spray gun with the pressure of 5kg is adopted, a gun mouth is vertical to the wall surface and is 30, 45 or 50cm away from the front surface, the paint is uniformly sprayed back and forth, and finish paint is sprayed twice; first, a thin and uniform layer of 0.12kg/m thick is applied2The dry film thickness was 30 μm.
S3 detection and packaging: carrying out appearance detection on the painted cement balancing weight 20, and packaging after the detection is qualified; and returning the unqualified cement counterweight block 20 to the step S2.2, polishing and spraying again until the cement counterweight block is qualified.
The invention can directly pour the concrete without additionally installing the mould through the mould, effectively solves the problems of inconvenient mould installation of the concrete, long pouring time and expansion caused by extrusion on a template, can improve the pouring effect after multiple times of pouring, effectively improves the hardening efficiency by combining static curing and steam curing after pouring, greatly shortens the solidification time, is convenient for improving the coating effect and quality by polishing and drying for multiple times in the coating process, shortens the spraying time, improves the production efficiency of the balancing weight 20, further ensures the production quality of the balancing weight 20, is convenient for mass production, effectively reduces the production cost of the balancing weight 20, breaks through the limit of the weight production of the balancing weight 20, can realize the processing of the balancing weight 20 with more than 2T, and solves the problem that the spraying on a coating line is not carried out because the balancing weight 20 is too large in the conventional production process, the requirement on equipment is reduced, and batch production of the cement balancing weights 20 higher than 2T is facilitated.
The above description is of the preferred embodiment of the present invention and the technical principles applied thereto, and it will be apparent to those skilled in the art that any changes and modifications based on the equivalent changes and simple substitutions of the technical solutions of the present invention are within the protection scope of the present invention without departing from the spirit and scope of the present invention.
Claims (10)
1. A cement balancing weight manufacturing method comprises the steps of pouring prepared concrete into a mould, and forming a blank body after vibration curing, and is characterized by further comprising the following steps:
s1: after the mold is removed, carrying out strength detection on the blank, and carrying out appearance inspection after the strength detection is qualified;
s2: the method for painting the green body qualified in appearance detection comprises the following steps:
s2.1 base surface treatment: cleaning and polishing the surface of the blank body to ensure that the surface flatness of the blank body is below 3 mm;
s2.2 batch scraping and leveling putty and polishing: scraping the putty at least once, after the putty is completely dried, polishing and flattening the putty by using corresponding abrasive paper, and cleaning dust;
s2.3, primer construction: brushing, spraying or rolling the primer on the putty layer to form a coating film;
s2.4, constructing the real stone paint: spraying with a spray gun to control the spraying thickness at 2-8kg/m2；
S2.5, grinding: after baking and drying the stone paint, grinding particles with acute angles on the surface of the stone paint;
s2.6, construction of the dust cover finish: after the paint is completely dried, spraying at least one layer of finish paint by a spray gun uniformly, wherein the spray gun has no phenomena of floating, missing spraying, consistent gloss, flowing drop, lumps and splashed foam, and baking after spraying;
s3 detection and packaging: and (5) carrying out appearance detection on the painted cement balancing weight, and packaging after the detection is qualified.
2. The method for manufacturing a cement counterweight according to claim 1, wherein: in the step S3, the qualified cement counter weight blocks are packaged, and the unqualified cement counter weight blocks are returned to the step S2.2 to be polished and then are sprayed again.
3. The method for manufacturing a cement counterweight according to claim 1, wherein: in step S2.3, the spraying is: adding 5-10% of clear water to dilute the coating, uniformly stirring, standing, curing for 10-15 minutes, uniformly stirring, and performing spraying construction; the brush coating comprises the following steps: the construction thickness is more than 30 mu m; the surface is smooth, flat, uniform and clean by visual inspection, and no sand holes, obvious brush marks or coating leakage is generated.
4. The method for manufacturing a cement counterweight according to claim 1, wherein: in the step S2.4, selecting a spray gun with the diameter of 2-4 mm and the distance between the spray gun and the wall surface is 40-50 cm; the spraying thickness is controlled to be 4-5kg/m2Left and right, and spraying uniformly.
5. The method for manufacturing a cement counterweight according to claim 1, wherein: step S2.6, a spray gun with the pressure of more than 4kg is adopted, a muzzle is perpendicular to the wall surface and is 25-50cm away from the front surface, the spraying is carried out back and forth uniformly, and finish paint is sprayed twice; firstly, a layer is sprayed uniformly and thinly, the spraying thickness is 0.1-0.125 kg/m2The dry film thickness was 30 μm.
6. The method for manufacturing a cement counterweight according to claim 1, wherein: a counterweight reinforcement cage is arranged in the concrete; the processing of the reinforcement cage comprises the following steps:
step one, steel bar treatment: removing oil stain, floating skin and rust before processing the reinforcing steel bars, and cutting and blanking after removing rust;
and step two, connecting steel bars: the steel bar connection adopts mechanical connection, electric arc welding or flash butt welding;
step three, processing a steel reinforcement cage: put reinforcing bar and anchor screw on the location frock to it is fixed with the nut, steel reinforcement cage owner muscle connects and to stagger, connects quantity on each cross-section and is no longer than 50%, arranges the stirrup according to the reinforcing bar position of designing requirement, and the stirrup is connected the winding with the main muscle closely, with the stirrup spot welding on the main muscle, checks the acceptance of the steel reinforcement cage inspection after the shaping.
7. The method for manufacturing a cement counterweight according to claim 1, wherein: and an embedded part is additionally arranged in the cement balancing weight.
8. The method for manufacturing a cement counterweight according to claim 1, wherein: pouring the concrete into a mould, pouring the concrete into a distribution material, loading the concrete into the mould in three layers, vibrating once every layer is poured, fully removing bubbles in the concrete and ensuring the compactness of the concrete, and when the uppermost layer is poured, finishing surface plastering after surface grout is discharged.
9. The method for manufacturing a cement counterweight according to claim 1, wherein: the curing comprises standing curing and steam curing; the static maintenance is to smear the surface of the formed concrete and then use an airtight film to fully cover the concrete, so as to prevent the problem of shrinkage and cracking caused by too fast surface water loss due to air drying or over high temperature during static maintenance; and steam curing, namely after the surface of the component is hardened, uncovering the film to lift the component and the die into a steam curing pool for curing, wherein when steam is introduced, a large valve is not required to be opened directly for steam feeding, steam feeding is carried out according to the principle from small to large, the temperature of 25 ℃ per hour is ensured, the temperature is raised to 70-85 ℃ for constant temperature, and the constant temperature time is less than 6 hours.
10. A cementitious weight made by the method of any one of claims 1 to 9, wherein: the concrete surface coating device comprises a steel reinforcement cage, concrete and embedded parts, wherein the steel reinforcement cage and the embedded parts are installed in the concrete, the embedded parts comprise anchoring screw rods and hoisting devices, and a putty layer, a primer layer, a real stone paint layer and a finish paint layer are sprayed on the surface of the concrete.
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| CN201309789Y (en) * | 2008-10-08 | 2009-09-16 | 嘉善富奥电梯配件有限公司 | Synthetic counterweight block without shells |
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