CN114319874A - Intelligent grouting construction method for large circulation of prestressed box girder - Google Patents
Intelligent grouting construction method for large circulation of prestressed box girder Download PDFInfo
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- CN114319874A CN114319874A CN202111609653.6A CN202111609653A CN114319874A CN 114319874 A CN114319874 A CN 114319874A CN 202111609653 A CN202111609653 A CN 202111609653A CN 114319874 A CN114319874 A CN 114319874A
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Abstract
The invention discloses a prestressed box girder large circulation intelligent grouting construction method, which comprises the following steps: A) preparation before construction: 1) after the steel strand is tensioned, the cutting machine is used for cutting off redundant steel strands at the end, electric arc welding cutting is strictly forbidden, the steel strand is reserved outside the anchorage device for 3cm, a shrinkage-free cement mortar seal head is adopted, a disposable grout stop valve is installed, a serial pipeline is adopted for connecting a grouting pore channel, the whole pressing system can be normally used, and preparation is made for prestressed pipeline grouting. The invention can completely eliminate the air in the pipeline, simultaneously accurately control the quality of the slurry and immediately regulate and control the pressure and the pressure stabilizing time of the slurry in the grouting process by matching the steps, and solves the problems of poor control of the water-to-glue ratio of the slurry, unstable pressure of the grouting pump and low work efficiency of single-channel grouting caused by the construction of a traditional grouting method by adopting common material mixing and manually operating a single-piston grouting pump.
Description
Technical Field
The invention relates to the technical field of grouting construction, in particular to a large-circulation intelligent grouting construction method for a prestressed box girder.
Background
The traditional grouting method adopts the construction mode of common material mixing and manual operation of a single-piston grouting pump, and has the defects of poor control of the water-to-glue ratio of the grout, unstable pressure of the grouting pump, low single-channel grouting work efficiency and the like; in the grouting construction process of the prefabricated box girder pore channel, a large-circulation intelligent grouting construction method is adopted to be matched with a construction process of a 'one-time grout stopping valve + secondary anchor sealing', intelligent tensioning equipment is adopted, a double-pore-channel external pipeline is adopted, a 'circulation' grouting new concept is introduced, air in a pipeline is completely removed in the grouting process, the quality of grout is accurately controlled, and the grouting pressure and the pressure stabilizing time are regulated and controlled in real time, so that the grouting compactness of the prestressed pipeline is ensured, a whole set of large-circulation intelligent grouting construction method is formed, and remarkable social benefits and economic benefits are obtained.
Disclosure of Invention
The invention aims to provide a large-circulation intelligent grouting construction method for a prestressed box girder, which has the advantages of completely removing air in a pipeline in the grouting process, simultaneously accurately controlling the quality of grout, and immediately regulating and controlling the grouting pressure and the pressure stabilizing time, and solves the problems of poor control of the water-to-glue ratio of the grout, unstable pressure of a grouting pump and low single-channel grouting work efficiency.
In order to achieve the purpose, the invention provides the following technical scheme: a prestressed box girder large circulation intelligent grouting construction method comprises the following steps:
A) preparation before construction:
1) after the steel strand is tensioned, cutting off redundant steel strands at the end by using a cutting machine, strictly prohibiting arc welding cutting, ensuring that the steel strands are reserved for 3cm outside an anchorage device, adopting a shrinkage-free cement mortar seal head, installing a disposable grout stop valve, adopting a serial pipeline to connect a grouting pore channel, ensuring that the whole pressing system can be normally used, and preparing for prestressed pipeline grouting;
2) after the prestressed tendons are tensioned, grouting is carried out on the pore passages as early as possible, generally the grouting is finished within 48 hours, and the working states of a pulping machine, a grouting pump, a pressure gauge, a grout storage barrel, a series pipe and connecting valve equipment are checked and confirmed before grouting, so that sufficient cement and additives are prepared;
3) data setting of the pulping and grouting integrated machine:
water-to-glue ratio: 0.28 high-speed stirring: 3min
Large circulation time in the slurry pipeline: and 3min of the slurry pressure maintaining time in the pipeline: 2min
Pressure maintaining: 0.6MPa high speed stirring motor: 1420r/min
Low-speed stirring storage motor: 40 r/min;
B) slurry mixing: stirring at a high speed to prepare slurry, stirring at a low speed to store the slurry, putting the required grouting material and water into a stirrer for high-speed stirring through an electronic weighing system, an automatic feeding system and mixing ratio calculation to prepare the slurry meeting the standard requirement, putting the prepared and stirred slurry into a low-speed stirring storage barrel, and waiting for grouting;
C) grouting: when the mixing of the grout is finished, starting a grouting process after various indexes meet the requirements, continuously operating double-hole grouting, completing primary grouting, pressing the grouting into a lower-position pore passage, flushing the grout out of the lower-position pore passage, controlling the grout inlet pressure to be 0.5-0.7 MPa, observing the grout condition after the grout flows out of a grout outlet pore passage, connecting a grout return pipe into a grout storage barrel to start circulation after the grout without water foam bubbles is discharged, maintaining the grouting pressure, closing a grout return pipe valve after the circulation is carried out for 3 minutes, maintaining the pressure for 2 minutes, and controlling the pressure to be 0.6 MPa;
D) after grouting: and closing the disposable grout stop valve after pressure relief, so that a part of grout still remains in the pipeline of the grout stop valve, cleaning waste liquid and a construction site according to regulations, and finishing the large-circulation intelligent grouting construction.
Preferably, the connection sequence of the tandem pipes of the unexpected part in the step a) 1) is performed from top to bottom according to the grouting sequence, specifically from N6 → N6 ', N5 → N5', N4 → N3, N4 '→ N3', N2 → N1, N2 '→ N1'.
Preferably, said step B) is to take care of the slurry being mixed strictly according to the mixing ratio, leaving 6 groups of test pieces with dimensions of 40mm x 160mm, and carrying out standard curing for 28 days, and carrying out the tests of compressive strength and flexural strength as the standard of quality assessment.
Preferably, before the grouting in the step C), cleaning the hole channel, and washing the concrete hollow hole channel formed by core pulling to be clean and completely wetting the hole wall; metal pipelines and plastic pipelines need to be washed to remove harmful materials when necessary; for the oil stain possibly generated in the pore channel, neutral detergent or soap solution which has no known corrosion effect on the prestressed tendon and the pipeline can be adopted, the neutral detergent or soap solution is diluted by water and then washed, and after the neutral detergent or soap solution is washed, compressed air without oil is used for blowing out all accumulated water in the pore channel.
Preferably, before the grouting in the step C), the duration from the mixing of the slurry to the grouting of the pore canal is generally within 30-45 min according to the properties of the slurry and the air temperature, the slurry should be continuously stirred before use and during the injection, the flow of the slurry in the pore canal should not be too fast, and for the cement slurry with reduced fluidity due to delayed use, the fluidity of the cement slurry should not be increased by adding water.
Preferably, during the grouting in the step C), the curve pore canal should be pressed in from the grouting hole at the lowest point, and the exhaust and bleeding are performed from the exhaust hole at the highest point, the grouting sequence is preferably to be performed by grouting the lower pore canal first, the grouting in the same pipeline should be performed continuously and once, the grouting in the concentrated and adjacent pore canals should be performed continuously as far as possible, and when the grouting cannot be performed continuously, the pore canal of the post-grouting should be flushed by pressure water before grouting.
Preferably, during grouting in the step C), a piston type grouting pump is used for grouting, compressed air cannot be used, and the maximum grouting pressure is preferably 0.5-0.7 MPa; when the pore canal is long or one-time grouting is adopted, the maximum pressure is preferably 1.0MPa, the grouting is performed until the other end of the pore canal is full and discharged and the exhaust hole discharges cement paste with the same consistency as the specified consistency, and in order to ensure that the pipeline is full of the cement paste, after the slurry outlet is closed, a pressure stabilizing period of not less than 0.5MPa is maintained, and the pressure stabilizing period is not less than 5 min.
Compared with the prior art, the invention has the following beneficial effects:
1. the invention can completely eliminate the air in the pipeline, simultaneously accurately control the slurry quality, and instantly regulate and control the pressure and the pressure stabilizing time in the grouting process by matching the steps, solves the problems of poor control of the water-to-glue ratio of the slurry, unstable pressure of the grouting pump and low work efficiency of single-channel grouting caused by the construction of a traditional grouting method by adopting common material mixing and manually operating a single-piston grouting pump, and is worthy of popularization.
Drawings
FIG. 1 is a working schematic diagram of the large-cycle intelligent grouting of the invention;
FIG. 2 is a flow chart of the construction process of the present invention.
Detailed Description
Referring to fig. 1-2, a construction method of large-circulation intelligent grouting for prestressed box girders includes the following steps:
A) preparation before construction:
1) after the steel strand is tensioned, cutting off redundant steel strands at the end by using a cutting machine, strictly prohibiting arc welding cutting, ensuring that the steel strands are reserved for 3cm outside an anchorage device, adopting a shrinkage-free cement mortar seal head, installing a disposable grout stop valve, adopting a serial pipeline to connect a grouting pore channel, ensuring that the whole pressing system can be normally used, and preparing for prestressed pipeline grouting;
2) after the prestressed tendons are tensioned, grouting is carried out on the pore passages as early as possible, generally the grouting is finished within 48 hours, and the working states of a pulping machine, a grouting pump, a pressure gauge, a grout storage barrel, a series pipe and connecting valve equipment are checked and confirmed before grouting, so that sufficient cement and additives are prepared;
3) data setting of the pulping and grouting integrated machine:
water-to-glue ratio: 0.28 high-speed stirring: 3min
Large circulation time in the slurry pipeline: and 3min of the slurry pressure maintaining time in the pipeline: 2min
Pressure maintaining: 0.6MPa high speed stirring motor: 1420r/min
Low-speed stirring storage motor: 40 r/min;
B) slurry mixing: stirring at a high speed to prepare slurry, stirring at a low speed to store the slurry, putting the required grouting material and water into a stirrer for high-speed stirring through an electronic weighing system, an automatic feeding system and mixing ratio calculation to prepare the slurry meeting the standard requirement, putting the prepared and stirred slurry into a low-speed stirring storage barrel, and waiting for grouting;
C) grouting: when the mixing of the grout is finished, starting a grouting process after various indexes meet the requirements, continuously operating double-hole grouting, completing primary grouting, pressing the grouting into a lower-position pore passage, flushing the grout out of the lower-position pore passage, controlling the grout inlet pressure to be 0.5-0.7 MPa, observing the grout condition after the grout flows out of a grout outlet pore passage, connecting a grout return pipe into a grout storage barrel to start circulation after the grout without water foam bubbles is discharged, maintaining the grouting pressure, closing a grout return pipe valve after the circulation is carried out for 3 minutes, maintaining the pressure for 2 minutes, and controlling the pressure to be 0.6 MPa;
D) after grouting: closing the disposable grout stopping valve after pressure relief, so that a part of grout still remains in the pipeline of the grout stopping valve, cleaning waste liquid and a construction site according to the specification, and finishing the large-circulation intelligent grouting construction;
the connecting sequence of the injection accident part tandem pipes in the step A) is carried out from top to bottom according to the grouting sequence, and specifically comprises N6 → N6 ', N5 → N5', N4 → N3, N4 '→ N3', N2 → N1 and N2 '→ N1';
step B), stirring the slurry strictly according to the mixing ratio, reserving 6 groups of test pieces with the size of 40mm by 160mm, performing standard maintenance for 28 days, and performing compression strength and flexural strength tests as quality evaluation standards;
before grouting, cleaning the hole channel, and washing the concrete hollow hole channel formed by core pulling to be clean and completely wetting the hole wall; metal pipelines and plastic pipelines need to be washed to remove harmful materials when necessary; for oil stains possibly occurring in the pore channel, neutral detergent or soap solution which has no known corrosion effect on the prestressed tendons and the pipeline can be adopted, the neutral detergent or soap solution is diluted by water and then washed, and after the neutral detergent or soap solution is washed, compressed air without oil is used for blowing out all accumulated water in the pore channel;
before the grouting, the duration from the mixing of the slurry to the grouting of the pore channel is generally within the range of 30-45 min according to the property and the air temperature of the slurry, the slurry is continuously stirred before use and in the process of pressure injection, the flow beam of the slurry in the pore channel is not too fast, and the fluidity of the cement slurry with reduced fluidity caused by delayed use cannot be increased by adding water;
c) when grouting, pressing in a grouting hole at the lowest point of a curve pore passage, exhausting and bleeding through an exhaust hole at the highest point, preferably pressing and injecting a lower layer pore passage in a grouting sequence, continuously grouting the same pipeline, completing the grouting once, preferably continuously grouting the concentrated and adjacent pore passages as far as possible, and flushing the pore passages subjected to post grouting with pressure water before grouting smoothly when the grouting cannot be continuously performed;
c), during grouting in the step C), a piston type grouting pump is used for grouting, compressed air cannot be used, and the maximum pressure of grouting is preferably 0.5-0.7 MPa; when the pore canal is long or one-time grouting is adopted, the maximum pressure is preferably 1.0MPa, the grouting is performed until the other end of the pore canal is full and discharged and the exhaust hole discharges cement paste with the same consistency as the specified consistency, and in order to ensure that the pipeline is full of the cement paste, after the slurry outlet is closed, a pressure stabilizing period of not less than 0.5MPa is maintained, and the pressure stabilizing period is not less than 5 min.
The large-circulation intelligent grouting system consists of a pulping system, a grouting system, a measurement and control system and a circulation loop system, wherein grout continuously circulates in a loop consisting of a prestressed pipeline, a pulping machine and a grouting pump, so that air in the pipeline is conveniently exhausted, the condition of pipeline blockage is timely found, punching is carried out by increasing pressure, impurities are discharged, and the factor causing incompact grouting is eliminated;
the method adopts a large-circulation intelligent grouting method, the grout in the pipeline is guided to a grout storage barrel from a grout outlet and then pumped into the pipeline from a grout inlet to form a large circulation loop, the grout continuously circulates in the pipeline, so that the air in the pipeline is favorably exhausted, the air in the pipeline is completely exhausted through the grout outlet and gaps between steel strand wires by adjusting the pressure and the flow, and the residual impurities in a pore channel can be brought out;
the method adopts a large-circulation intelligent grouting method and is provided with an intelligent grouting and pulping integrated machine, the pressure loss of the pipeline is automatically measured in real time, the grouting pressure value is set by the slurry outlet meeting the standard minimum pressure value, and the minimum pressure value meeting the standard requirement in the pipeline is ensured after the pressure loss along the way, so that the pipeline is filled with the slurry, the slurry is continuously supplemented into the pore channel during the pressure stabilization period, and the compactness is ensured;
a large-circulation intelligent grouting method is adopted, an intelligent grouting and pulping integrated machine is arranged, water is automatically added according to the construction mixing ratio quantity, and the water adding quantity is accurately controlled, so that the water-cement ratio is ensured to meet the requirement;
by adopting a large-circulation intelligent grouting method, because the double-hole channels are connected into an integral grouting hole channel by utilizing the external pipeline, the simultaneous grouting of the double holes is realized, the grouting is pressed in from a hole with a lower position, and the grouting is pressed out from a hole with a higher position and flows back to the grout storage barrel, thereby saving the labor force and improving the work efficiency.
In summary, the following steps: the intelligent grouting construction method for the large circulation of the prestressed box girder can completely remove air in a pipeline in the grouting process, simultaneously can accurately control the quality of grout, and can immediately regulate and control the grouting pressure and the pressure stabilizing time by matching the steps, thereby solving the problems that the traditional grouting method adopts the mode of common material mixing and manual operation of a single-piston grouting pump, the grout water-to-adhesive ratio is not tightly controlled, the pressure of the grouting pump is unstable, and the single-pore grouting work efficiency is low.
Claims (7)
1. The intelligent grouting construction method for the large circulation of the prestressed box girder is characterized by comprising the following steps of:
preparation before construction:
1) after the steel strand is tensioned, cutting off redundant steel strands at the end by using a cutting machine, strictly prohibiting arc welding cutting, ensuring that the steel strands are reserved for 3cm outside an anchorage device, adopting a shrinkage-free cement mortar seal head, installing a disposable grout stop valve, adopting a serial pipeline to connect a grouting pore channel, ensuring that the whole pressing system can be normally used, and preparing for prestressed pipeline grouting;
2) after the prestressed tendons are tensioned, grouting is carried out on the pore passages as early as possible, generally the grouting is finished within 48 hours, and the working states of a pulping machine, a grouting pump, a pressure gauge, a grout storage barrel, a series pipe and connecting valve equipment are checked and confirmed before grouting, so that sufficient cement and additives are prepared;
3) data setting of the pulping and grouting integrated machine:
water-to-glue ratio: 0.28 high-speed stirring: 3min
Large circulation time in the slurry pipeline: and 3min of the slurry pressure maintaining time in the pipeline: 2min
Pressure maintaining: 0.6MPa high speed stirring motor: 1420r/min
Low-speed stirring storage motor: 40 r/min;
slurry mixing: stirring at a high speed to prepare slurry, stirring at a low speed to store the slurry, putting the required grouting material and water into a stirrer for high-speed stirring through an electronic weighing system, an automatic feeding system and mixing ratio calculation to prepare the slurry meeting the standard requirement, putting the prepared and stirred slurry into a low-speed stirring storage barrel, and waiting for grouting;
grouting: when the mixing of the grout is finished, starting a grouting process after various indexes meet the requirements, continuously operating double-hole grouting, completing primary grouting, pressing the grouting into a lower-position pore passage, flushing the grout out of the lower-position pore passage, controlling the grout inlet pressure to be 0.5-0.7 MPa, observing the grout condition after the grout flows out of a grout outlet pore passage, connecting a grout return pipe into a grout storage barrel to start circulation after the grout without water foam bubbles is discharged, maintaining the grouting pressure, closing a grout return pipe valve after the circulation is carried out for 3 minutes, maintaining the pressure for 2 minutes, and controlling the pressure to be 0.6 MPa;
D) after grouting: and closing the disposable grout stop valve after pressure relief, so that a part of grout still remains in the pipeline of the grout stop valve, cleaning waste liquid and a construction site according to regulations, and finishing the large-circulation intelligent grouting construction.
2. The intelligent grouting construction method for the large circulation of the prestressed box girder as claimed in claim 1, wherein the grouting construction method comprises the following steps: the connection sequence of the injection accident part tandem pipes in the step A) is carried out from top to bottom according to the grouting sequence, and specifically comprises N6 → N6 ', N5 → N5', N4 → N3, N4 '→ N3', N2 → N1 and N2 '→ N1'.
3. The intelligent grouting construction method for the large circulation of the prestressed box girder as claimed in claim 1, wherein the grouting construction method comprises the following steps: and B) stirring the slurry strictly according to the mixing ratio, reserving 6 groups of test pieces with the size of 40mm by 160mm, performing standard curing for 28 days, and performing compression strength and flexural strength tests as quality evaluation standards.
4. The intelligent grouting construction method for the large circulation of the prestressed box girder as claimed in claim 1, wherein the grouting construction method comprises the following steps: before grouting in the step C), cleaning the hole channel, and washing the concrete hollow hole channel formed by core pulling to be clean and completely wetting the hole wall; metal pipelines and plastic pipelines need to be washed to remove harmful materials when necessary; for the oil stain possibly generated in the pore channel, neutral detergent or soap solution which has no known corrosion effect on the prestressed tendon and the pipeline can be adopted, the neutral detergent or soap solution is diluted by water and then washed, and after the neutral detergent or soap solution is washed, compressed air without oil is used for blowing out all accumulated water in the pore channel.
5. The intelligent grouting construction method for the large circulation of the prestressed box girder as claimed in claim 1, wherein the grouting construction method comprises the following steps: before the grouting in the step C), the duration from the mixing of the slurry to the grouting of the pore channel is generally within the range of 30-45 min according to the property and the air temperature of the slurry, the slurry is continuously stirred before use and in the process of pressure injection, the flow beam of the slurry in the pore channel is not too fast, and the fluidity of the cement slurry with reduced fluidity caused by delayed use cannot be increased by adding water.
6. The intelligent grouting construction method for the large circulation of the prestressed box girder as claimed in claim 1, wherein the grouting construction method comprises the following steps: and C) during grouting in the step C), grouting from the grouting hole at the lowest point of the curve pore passage, exhausting and bleeding from the exhaust hole at the highest point, grouting the lower layer pore passage firstly, continuously grouting the same pipeline, completing grouting once, finishing continuous grouting as far as possible in more concentrated and adjacent pore passages, and flushing the pore passages subjected to post-grouting with pressure water before grouting smoothly when continuous grouting cannot be realized.
7. The intelligent grouting construction method for the large circulation of the prestressed box girder as claimed in claim 1, wherein the grouting construction method comprises the following steps: during grouting in the step C), a piston type grouting pump is used for grouting, compressed air cannot be used, and the maximum grouting pressure is preferably 0.5-0.7 MPa; when the pore canal is long or one-time grouting is adopted, the maximum pressure is preferably 1.0MPa, the grouting is performed until the other end of the pore canal is full and discharged and the exhaust hole discharges cement paste with the same consistency as the specified consistency, and in order to ensure that the pipeline is full of the cement paste, after the slurry outlet is closed, a pressure stabilizing period of not less than 0.5MPa is maintained, and the pressure stabilizing period is not less than 5 min.
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Cited By (1)
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2021
- 2021-12-27 CN CN202111609653.6A patent/CN114319874A/en not_active Withdrawn
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Application publication date: 20220412 |