CN115401783B - Preparation process of concrete bridge deck - Google Patents
Preparation process of concrete bridge deck Download PDFInfo
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- CN115401783B CN115401783B CN202211056389.2A CN202211056389A CN115401783B CN 115401783 B CN115401783 B CN 115401783B CN 202211056389 A CN202211056389 A CN 202211056389A CN 115401783 B CN115401783 B CN 115401783B
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- 238000002360 preparation method Methods 0.000 title claims abstract description 12
- 238000012423 maintenance Methods 0.000 claims abstract description 33
- 238000000034 method Methods 0.000 claims abstract description 25
- 238000010276 construction Methods 0.000 claims abstract description 21
- 238000004519 manufacturing process Methods 0.000 claims abstract description 21
- 238000005507 spraying Methods 0.000 claims abstract description 21
- 239000002344 surface layer Substances 0.000 claims abstract description 18
- 238000000889 atomisation Methods 0.000 claims abstract description 12
- 238000012545 processing Methods 0.000 claims abstract description 8
- 230000002787 reinforcement Effects 0.000 claims abstract description 8
- 239000007921 spray Substances 0.000 claims abstract description 8
- 238000009417 prefabrication Methods 0.000 claims abstract description 7
- 238000009434 installation Methods 0.000 claims abstract description 6
- 238000005259 measurement Methods 0.000 claims abstract description 4
- 239000000463 material Substances 0.000 claims description 20
- 230000007246 mechanism Effects 0.000 claims description 18
- 230000008569 process Effects 0.000 claims description 18
- 229910000831 Steel Inorganic materials 0.000 claims description 15
- 239000010959 steel Substances 0.000 claims description 15
- 230000003068 static effect Effects 0.000 claims description 13
- 239000004744 fabric Substances 0.000 claims description 12
- 238000004381 surface treatment Methods 0.000 claims description 11
- 238000009826 distribution Methods 0.000 claims description 10
- 238000007599 discharging Methods 0.000 claims description 7
- 239000002002 slurry Substances 0.000 claims description 7
- 238000005303 weighing Methods 0.000 claims description 6
- 238000000605 extraction Methods 0.000 claims description 4
- 238000009692 water atomization Methods 0.000 claims description 4
- 239000010410 layer Substances 0.000 claims description 3
- 230000000284 resting effect Effects 0.000 claims description 3
- 238000004364 calculation method Methods 0.000 claims description 2
- 238000005266 casting Methods 0.000 claims description 2
- 239000007888 film coating Substances 0.000 claims description 2
- 238000009501 film coating Methods 0.000 claims description 2
- 239000011248 coating agent Substances 0.000 abstract description 7
- 238000000576 coating method Methods 0.000 abstract description 7
- 238000003756 stirring Methods 0.000 description 10
- 238000011161 development Methods 0.000 description 6
- 238000005516 engineering process Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 2
- 239000000835 fiber Substances 0.000 description 2
- NJPPVKZQTLUDBO-UHFFFAOYSA-N novaluron Chemical compound C1=C(Cl)C(OC(F)(F)C(OC(F)(F)F)F)=CC=C1NC(=O)NC(=O)C1=C(F)C=CC=C1F NJPPVKZQTLUDBO-UHFFFAOYSA-N 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 238000013022 venting Methods 0.000 description 2
- 238000009435 building construction Methods 0.000 description 1
- 238000005056 compaction Methods 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 230000001276 controlling effect Effects 0.000 description 1
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- 238000010586 diagram Methods 0.000 description 1
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- 238000003860 storage Methods 0.000 description 1
- 238000011079 streamline operation Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 210000002489 tectorial membrane Anatomy 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 238000009736 wetting Methods 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B15/00—General arrangement or layout of plant ; Industrial outlines or plant installations
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/04—Producing shaped prefabricated articles from the material by tamping or ramming
- B28B1/045—Producing shaped prefabricated articles from the material by tamping or ramming combined with 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
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
- B28B11/245—Curing concrete articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
- B28B13/02—Feeding the unshaped material to moulds or apparatus for producing shaped articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
- B28B13/04—Discharging the shaped articles
- B28B13/06—Removing the shaped articles from moulds
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
- B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
- B28B23/022—Means for inserting reinforcing members into the mould or for supporting them in the mould
Landscapes
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Structural Engineering (AREA)
- On-Site Construction Work That Accompanies The Preparation And Application Of Concrete (AREA)
Abstract
The invention provides a preparation process of a concrete bridge deck, which comprises a prefabrication measuring mold closing station, a framework mold entering station, a pouring flattening vibrating station, a standing atomizing curing station, a surface layer processing station, a spraying curing station and a mold removing lifting station; the method comprises the steps of at a measuring mould closing station, carrying out mould closing measurement and installation on a trolley, carrying out reinforcement cage installation on a mould of the trolley by a framework mould entering station, carrying out flattening and vibrating after pouring concrete on the mould by a pouring flattening and vibrating station, carrying out atomization maintenance on a bridge deck by a standing atomization maintenance station, exhausting air by inserting a continuous high-frequency contact pin into the surface layer of the bridge deck by a surface layer treatment station, coating the film on the bridge deck after the air exhaust, carrying out spray maintenance on the bridge deck by a spraying maintenance station, removing the mould by a mould removing and lifting station, and separating the bridge deck from the trolley; through each station modularization construction, the assembly line production of prefabricated bridge deck plates is realized, the manual operation intensity is reduced, the cost is effectively reduced, and the production efficiency is improved.
Description
Technical Field
The invention relates to the technical field of prefabricated bridge deck construction, in particular to a preparation process of a concrete bridge deck.
Background
With the development of the country, the population bonus gradually disappears, the labor gap is larger and larger, the labor cost is higher and higher, the country advocates the development of the building assembly industry, the building assembly in the building construction field is greatly developed due to the characteristics of high prefabrication assembly efficiency, low cost, stable quality and the like, but the development is slower in the traffic engineering field. Along with the development of technology, new technology and new material application, the assembly development of bridges is gradually rising. The traditional bridge deck plate is produced mostly by adopting a fixed pedestal, and has the defects of more operation points, frequent process cross operation, low production efficiency, high cost, unstable component quality, non-ideal effect and the like when the novel steel fiber concrete is adopted.
Disclosure of Invention
The invention provides a preparation process of a concrete bridge deck, which is used for solving the technical problems of complicated working procedures, low construction efficiency and unstable component quality caused by adopting fixed pedestal type production for prefabricating the bridge deck in the prior art.
The invention provides a preparation process of a concrete bridge deck, which comprises the following steps:
the prefabrication construction station comprises a measuring die closing station, a framework die entering station, a pouring flattening vibrating station, a standing atomizing maintenance station, a surface layer treatment station, a spraying maintenance station and a die removing lifting station;
closing the mold, and performing mold closing measurement and installation on the trolley at the measuring mold closing station;
the framework is put into a mold, the trolley is moved to a framework mold-putting station, and the steel reinforcement framework is installed on the mold of the trolley;
Pouring and forming, namely moving the trolley to the pouring flattening vibrating station, and flattening and vibrating the die after pouring concrete;
standing, namely moving the trolley to the standing atomization curing station, and performing atomization curing on the bridge deck;
Exhausting, namely moving the trolley to the surface treatment station, inserting a continuous high-frequency contact pin into the surface of the bridge deck to exhaust, carrying out planar vibrating slurry extraction on the bridge deck, sealing air holes, and then coating the bridge deck;
spraying, namely moving the trolley to the spraying maintenance station, and spraying and maintaining the bridge deck;
And demolding, namely moving the trolley to the demolding and lifting station, removing the mold, and separating the bridge deck from the trolley.
According to one embodiment of the invention, a traction mechanism is arranged at the pouring flattening vibration station, the standing atomization maintenance station and the surface layer treatment station, and a trolley is drawn by the traction mechanism to sequentially enter the pouring flattening vibration station, the standing atomization maintenance station and the surface layer treatment station.
According to one embodiment of the invention, a first ferrying station is arranged between the surface treatment station and the spray curing station, and the trolley is moved to the spray curing station at the first ferrying station.
According to one embodiment of the invention, a second ferrying station is arranged between the demolding and lifting station and the measuring and clamping station, and the empty trolley is moved to the measuring and clamping station at the second ferrying station.
According to one embodiment of the present invention, the step of leveling and vibrating the mold after casting the concrete includes:
an automatic material distribution step, namely arranging an automatic material distributor at the pouring flattening vibration station, wherein the automatic material distributor automatically performs concrete pouring on the die;
A flattening step, namely arranging a flattening device on one side of the automatic cloth machine, and automatically flattening the cloth by the flattening device along with the running track of the cloth machine;
And a vibrating step, namely immediately vibrating, compacting and exhausting the concrete by using a vibrating device after pouring and flattening.
According to one embodiment of the invention, in the automatic material distribution step, a dynamic weighing sensor and a material discharging star wheel are arranged in an automatic material distributor, the material discharging quantity is controlled by controlling the star wheel rotation speed through variable frequency speed regulation, and the material discharging quantity is automatically adjusted according to bridge deck parameters and the material distributor walking speed calculation processing weighing feedback value.
According to one embodiment of the present invention, in the leveling step, a vertical vibrator is installed on the leveling device, and vertical vibration is performed while performing the leveling operation.
According to one embodiment of the present invention, in the vibrating step, the vibrating is divided into vertical vibrating and planar leveling vibrating, and after pouring and leveling, high-frequency vertical vibrating is immediately performed, and a high-frequency vibrating rod is inserted into the concrete for compacting by vibrating, and then planar leveling vibrating is performed.
According to one embodiment of the invention, the static atomizing maintenance station comprises a static maintenance room, wherein the static maintenance room controls the air humidity to be 90-98% through a high-frequency water atomizing system.
According to one embodiment of the invention, in the surface treatment station, after the bridge deck plate completes pin venting, plane vibration slurry extraction is carried out on the bridge deck plate after venting, air bubbles in concrete are discharged, and surface pinholes are closed to form a flat surface.
According to the preparation process of the concrete bridge deck, a prefabricated measuring mold closing station, a framework mold entering station, a pouring flattening vibrating station, a standing atomizing curing station, a surface layer processing station, a spraying curing station and a mold removing lifting station are adopted; at a measuring mold closing station, performing mold closing measurement and installation on the trolley, performing reinforcement cage installation on a mold of the trolley by a framework mold entering station, performing leveling vibration after pouring concrete on the mold by a pouring leveling vibration station, and performing atomization maintenance on the bridge deck by a standing atomization maintenance station; the surface treatment station inserts the bridge deck surface layer through continuous high-frequency contact pins to exhaust, carries out the tectorial membrane to the bridge deck after the exhaust, sprays the maintenance station and sprays the maintenance to the bridge deck, and the mould is demolishd to the demolding handling station, separates bridge deck and platform truck, through each station modularization construction, has realized the assembly line production of prefabricated bridge deck. The whole process is completed in a production workshop, the bridge deck prefabrication processes are completed, the traditional process is optimized, the static curing and surface treatment processes for improving the quality of the prefabrication bridge deck are added, the bridge deck construction quality is improved, each process carries out pipelining operation according to the set takt time, the takt time of each construction station of the assembly line is basically consistent, the waiting time is effectively avoided, the manual operation intensity is reduced, the cost is effectively reduced, and the production efficiency is improved.
Drawings
In order to more clearly illustrate the invention or the technical solutions of the prior art, the following description will briefly explain the drawings used in the embodiments or the description of the prior art, and it is obvious that the drawings in the following description are some embodiments of the invention, and other drawings can be obtained according to the drawings without inventive effort for a person skilled in the art.
FIG. 1 is a step flow portion of a concrete deck slab preparation process provided by the present invention;
Fig. 2 is a block flow diagram of a concrete bridge deck preparation process provided by the invention.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the present invention more apparent, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings, and it is apparent that the described embodiments are some embodiments of the present invention, not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
In the description of the embodiments of the present invention, it should be noted that the terms "center", "longitudinal", "lateral", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, are merely for convenience in describing the embodiments of the present invention and simplifying the description, and do not indicate or imply that the apparatus or elements referred to must have a specific orientation, be configured and operated in a specific orientation, and thus should not be construed as limiting the embodiments of the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.
In describing embodiments of the present invention, it should be noted that, unless explicitly stated and limited otherwise, the terms "coupled," "coupled," and "connected" should be construed broadly, and may be either a fixed connection, a removable connection, or an integral connection, for example; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium. The specific meaning of the above terms in embodiments of the present invention will be understood in detail by those of ordinary skill in the art.
In embodiments of the invention, unless expressly specified and limited otherwise, a first feature "up" or "down" on a second feature may be that the first and second features are in direct contact, or that the first and second features are in indirect contact via an intervening medium. Moreover, a first feature being "above," "over" and "on" a second feature may be a first feature being directly above or obliquely above the second feature, or simply indicating that the first feature is level higher than the second feature. The first feature being "under", "below" and "beneath" the second feature may be the first feature being directly under or obliquely below the second feature, or simply indicating that the first feature is less level than the second feature.
In the description of the present specification, a description referring to terms "one embodiment," "some embodiments," "examples," "specific examples," or "some examples," etc., means that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the embodiments of the present invention. In this specification, schematic representations of the above terms are not necessarily directed to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, the different embodiments or examples described in this specification and the features of the different embodiments or examples may be combined and combined by those skilled in the art without contradiction.
Specific embodiments of the present invention are described below in conjunction with fig. 1-2:
As shown in fig. 1 and 2, an embodiment of the present invention provides a process for preparing a concrete bridge deck, including the following steps:
The first step: prefabricating a plurality of construction stations, including measuring compound die station, skeleton income mould station, pour and flatten the vibration station, keep static atomizing maintenance station, top layer processing station, spray maintenance station and form a closed loop in proper order to these stations.
In one embodiment, 16 prefabricated construction stations can be prepared firstly, namely a mold closing station, two steel reinforcement frameworks entering stations, a concrete stirring pouring flattening vibrating station, a standing atomizing maintenance station, a bridge deck surface layer treatment station, a rear ferrying station (namely a second ferrying station), 6 spraying maintenance stations, 2 demolding lifting stations and a front ferrying station (namely a first ferrying station) are respectively prepared, wherein a self-propelled trolley is used as a construction platform for circulation among the stations, and each construction process of the prefabricated bridge deck is finished on the trolley surface.
And a traction mechanism is arranged at the pouring flattening vibrating station, the standing atomizing curing station and the surface layer processing station, and a traction trolley of the traction mechanism sequentially enters the pouring flattening vibrating station, the standing atomizing curing station and the surface layer processing station. The traction mechanism can be a ground circulation servo driving mechanism, when the trolley moves to the pouring flattening vibration station, the trolley is connected with the ground circulation servo driving mechanism, and the ground circulation servo driving mechanism drives the trolley to sequentially pass through the pouring flattening vibration station, the standing atomization maintenance station and the surface layer treatment station, so that an automatic process is realized. The trolley is circulated among other stations by adopting the power of the trolley.
And a second step of: after the self-propelled trolley enters the measuring die closing station, the bottom film and the side die are assembled and fixed according to the design drawing, and the measuring is carried out after the assembling is completed.
And a third step of: and the steel reinforcement framework is put into the mould, two steel reinforcement cage manufacturing stations are arranged, and the main work comprises the placement and binding of longitudinal steel bars and longitudinal steel bars, the placement of embedded parts and the tensioning of longitudinal steel bars.
Fourth step: when the trolley reaches a concrete stirring pouring flattening and vibrating construction station, an automatic stirring system is arranged at the uppermost part of the station, feeding stirring can be carried out according to a set formula, and a material distribution system is arranged below the stirrer.
In one embodiment, the distribution system is an automatic distributor that travels along the track to effect automatic distribution of the bridge deck laterally. The cloth system is connected with the flattening system, the flattening system automatically and transversely smoothes along with the cloth system, after the cloth is finished, the vibration and the exhaust are finished by the longitudinal high-frequency vibration rod, and finally, the bridge deck is formed and compacted by the longitudinal plane vibrator, and the detailed process is as follows:
when the self-propelled trolley correctly completes the entering of the steel reinforcement framework into the mould, a waiting signal is sent, the ground and ground circulating servo driving mechanism receives the signal and then automatically butts against the trolley, and then the ground servo driving mechanism pulls the trolley to start the cloth flattening and vibrating forming work, and the method mainly comprises the following steps:
And (3) concrete stirring: the automatic stirring station is erected above a production line, the storage hopper is firstly moved to a set position of the stirring station, raw materials are discharged into the automatic stirring main machine for automatic stirring, and concrete is directly discharged into the automatic distributing machine after stirring.
Automatic material distribution: the spreader spreads transversely along the bridge deck, one strip can be completed each time, the trolley automatically walks forward one strip, and 8 strips are required to be automatically spread on one bridge deck. The automatic distributor is provided with a dynamic weighing sensor, the feeding star wheel is driven to carry out forced distribution, the star wheel rotating speed is controlled by utilizing a variable frequency speed regulating technology to control the discharge amount, and the automatic distribution is realized by calculating and processing a weighing feedback value according to bridge deck parameters and the travelling speed of the distributor and automatically adjusting the discharge amount through an automatic program.
Flattening: the flattening device automatically performs flattening operation along the running track of the material distributor after material distribution, and a longitudinal baffle plate is inserted into a steel bar net cage before the flattening operation so as to prevent steel fibers in the concrete from being distributed in the same direction due to free flowing to a non-pouring position, wherein the flattening device is provided with a horizontal servo driving device and a vertical lifting device.
The flattening device is provided with a kettle-type flattening device, and the flattening device can effectively realize the flattening operation of concrete. The vertical vibrator is arranged in the flattening device, the flattening is that vibration realizes automatic flattening operation, a flattening operation strip can be automatically completed when one cloth strip is completed, after the cloth of one strip is completed and flattening is completed, the trolley automatically walks forwards, and 8 strips are required to be completed for one strip panel.
Vibrating: the vibration is divided into vertical vibration and plane horizontal vibration, after pouring and flattening, the trolley automatically walks 1/2 strip distance, vertical high-frequency vertical vibration is carried out, the high-frequency vibration rod is adopted to automatically insert concrete along the center of the steel bar net cage for vibration compaction, air bubbles are fully discharged, then plane horizontal vibration is carried out, on one hand, the vibration ring for compacting the high-frequency vibration is filled, and on the other hand, the thickness of the bridge deck is controlled. And after continuously completing two 1/2 strips, continuously repeating the above actions to complete the construction of the rest strips until the forming process of the whole bridge deck is completed.
The steps of automatic pouring flattening and vibrating of the bridge deck slab are realized, the steps of manual pouring flattening and vibrating in bridge deck slab construction are reduced, the safety is improved, and the bridge deck slab construction efficiency is effectively improved.
Fifth step: the trolley after vibrating automatically enters a standing atomization maintenance station, and the station comprises the following steps: after the bridge deck is poured and vibrated, the bridge deck automatically flows into a static curing room, the air humidity in the static curing room is controlled to be 90-98% according to a set program through a high-frequency water atomization system, so that the bridge deck is subjected to primary curing, on one hand, air bubbles in concrete can be discharged as much as possible, and on the other hand, the surface of the bridge deck is kept not dry, water can be locked, and the next procedure is facilitated. The static curing room comprises an automatic door entering and exiting system, controls the automatic entering and exiting of the trolley, establishes a grid ultrasonic atomization point and a grid temperature and humidity sensor to automatically control the internal temperature and humidity, and achieves intelligent static curing of the bridge deck.
Sixth step: after the bridge deck is subjected to the rest work, entering a bridge deck surface treatment station, and comprising the following steps of: the continuous high-frequency contact pin is exhausted, the connecting rod mechanism is driven to act through the variable-frequency high-speed rotating mechanism, the trolley is continuously moved forward, the steel pin is quickly inserted into the surface of the bridge deck to pierce the surface layer slurry layer, and air gathered below the concrete surface layer after resting is exhausted. And (3) carrying out plane vibration, namely carrying out plane vibration slurry extraction on the bridge deck after the pin is exhausted, sealing the air holes, then carrying out film coating on the bridge deck, carrying out plane vibration, discharging air bubbles in the concrete, and closing surface pinholes to form a flat surface. And (3) wet coating, namely after the steps are finished, coating the surface of the bridge deck, and further curing the bridge deck by wetting the coating by a high-pressure spraying system while coating the coating. After the film is covered integrally, the traction mechanism is separated from the trolley, the ground circulation servo driving mechanism returns to the original point, and the trolley flows to the next station by means of the power system.
Seventh step: the trolley enters a first ferrying station, the first ferrying station adopts integral ferrying, the self-propelled trolley walks to the integral ferrying system, the ferrying system carries out line changing work, and the trolley transversely moves to a return line for maintenance.
Eighth step: the trolley enters a spraying curing station, 6 spraying curing stations can realize simultaneous spraying curing of 6 trolleys, closed curing can be adopted, open curing can also be adopted, open spraying curing can be selected according to different prefabricated bridge deck materials, and closed steam curing can also be adopted.
Ninth step: and (5) demolding and lifting, wherein after the prefabricated bridge deck is cured, the trolley flows to a demolding and lifting station. Firstly, collecting the film, then removing the side mold, stretching and releasing, then jacking up and demolding the bridge deck by the trolley, and finally transferring the bridge deck to the conveying trolley by a 25t crane.
Tenth step: the trolley enters a second ferrying station, the empty trolley is transversely moved onto the production line by a transverse moving ferrying trolley and a return line, and the automatic production is carried out by repeating the steps 2-9.
The whole process is completed in a production workshop, the decomposition of each procedure of prefabrication of the bridge deck is completed, the traditional process is optimized, the rest and surface treatment processes for improving the quality of the prefabricated bridge deck are added, the construction is completed at a specific station by adopting intelligent equipment and a standardized process, and each procedure carries out streamline operation according to set beat time; each construction work station of the assembly line is matched with equipment through process optimization, the work beat time of each work station procedure is basically consistent, waiting time is effectively avoided, and production efficiency is improved.
In the process, each working station is fixed, the condition of cross operation does not exist, different workers work at different stations, the operation skills are more and more skilled, and the construction quality is continuously improved. And the automatic program is adopted to control the construction of automatic equipment, so that the influence of random factors on the quality of the component is reduced, and the quality stability is improved.
According to the preparation process of the concrete bridge deck, the automatic equipment is adopted to replace the traditional manual operation, so that the number of workers is greatly reduced, the safety risk is also greatly reduced, and the development goal of intelligent manufacturing is realized by new equipment and process.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present invention, and are not limiting; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit and scope of the technical solutions of the embodiments of the present invention.
Claims (9)
1. A process for preparing a concrete deck, comprising:
the prefabrication construction station comprises a measuring die closing station, a framework die entering station, a pouring flattening vibrating station, a standing atomizing maintenance station, a surface layer treatment station, a spraying maintenance station and a die removing lifting station; the construction processes related to the measuring mold closing station, the framework mold entering station, the pouring flattening vibrating station, the standing atomization curing station, the surface layer treatment station and the spraying curing station are all completed on a trolley surface;
closing the mold, and performing mold closing measurement and installation on the trolley at the measuring mold closing station;
the framework is put into a mold, the trolley is moved to a framework mold-putting station, and the steel reinforcement framework is installed on the mold of the trolley;
Pouring and forming, namely moving the trolley to the pouring flattening vibrating station, and flattening and vibrating the die after pouring concrete;
Resting, remove the platform truck to the atomizing maintenance station of standing, carry out atomizing maintenance to the decking, include: after pouring and vibrating the bridge deck, automatically circulating the bridge deck into a static curing room, and controlling the air humidity in the static curing room to be 90-98% according to a set program by a high-frequency water atomization system;
The trolley is moved to the surface treatment station, the surface of the bridge deck is subjected to air discharge through the continuous high-frequency contact pins, the steel pins are quickly inserted into the surface of the bridge deck to pierce through the surface slurry layer, air collected below the concrete surface after resting is discharged, the variable-frequency high-speed rotating mechanism drives the connecting rod mechanism to act so as to realize continuous advancing of the trolley, the trolley is subjected to planar vibrating slurry lifting after the continuous advancing, air holes are closed, and then the bridge deck is subjected to film coating;
spraying, namely moving the trolley to the spraying maintenance station, and spraying and maintaining the bridge deck;
Demolding, namely moving the trolley to the demolding and lifting station, removing the mold, and separating the bridge deck from the trolley;
A traction mechanism is arranged at the pouring flattening vibrating station, the standing atomizing maintenance station and the surface layer treatment station, and a trolley is pulled by the traction mechanism to sequentially enter the pouring flattening vibrating station, the standing atomizing maintenance station and the surface layer treatment station;
the device comprises a measuring mold closing station, a framework mold entering station, a pouring flattening and vibrating station, a surface treatment station, a spraying maintenance station and a mold removing and lifting station, wherein the measuring mold closing station and the framework mold entering station, the framework mold entering station and the pouring flattening and vibrating station, the surface treatment station and the spraying maintenance station, and the spraying maintenance station and the mold removing and lifting station are powered by a trolley.
2. The concrete bridge deck preparation process of claim 1, further comprising providing a first ferrying station between the skin treatment station and the spray curing station, and moving a trolley change line to the spray curing station at the first ferrying station.
3. The concrete deck preparation process of claim 2, further comprising providing a second ferrying station between the stripping and lifting station and the measuring and closing station, and moving the empty trolley to the measuring and closing station at the second ferrying station.
4. The process for preparing a concrete bridge deck according to claim 1, wherein the step of leveling and vibrating the mold after pouring the concrete comprises:
an automatic material distribution step, namely arranging an automatic material distributor at the pouring flattening vibration station, wherein the automatic material distributor automatically performs concrete pouring on the die;
A flattening step, namely arranging a flattening device on one side of the automatic cloth machine, and automatically flattening the cloth by the flattening device along with the running track of the cloth machine;
And a vibrating step, namely immediately vibrating, compacting and exhausting the concrete by using a vibrating device after pouring and flattening.
5. The process for preparing a concrete bridge deck according to claim 4, wherein in the step of automatically distributing, a dynamic weighing sensor and a discharging star wheel are arranged in the automatic distributing machine, the rotation speed of the star wheel is controlled by utilizing variable frequency speed regulation to control the discharging amount, and the discharging amount is automatically adjusted according to bridge deck parameters and a travelling speed calculation processing weighing feedback value of the distributing machine to realize automatic distributing.
6. The process for preparing a concrete bridge deck according to claim 4, wherein in the leveling step, a vertical vibrator is installed on the leveling device, and vertical vibration is performed while the leveling operation.
7. The process for preparing a concrete bridge deck according to claim 6, wherein in the vibrating step, the vibrating is divided into vertical vibrating and plane leveling vibrating, the high-frequency vertical vibrating is immediately performed after the casting leveling, the high-frequency vibrating rod is inserted into the concrete for compacting by vibrating, and then the plane leveling vibrating is performed.
8. The process for preparing a concrete bridge deck according to any one of claims 1 to 7, wherein the static atomizing curing station comprises a static curing chamber which controls the air humidity to 90 to 98% by a high frequency water atomizing system.
9. The process according to any one of claims 1 to 7, wherein in the surface treatment station, after the bridge deck is completed with pin removal, the bridge deck is subjected to planar vibrating and slurry extraction to remove air bubbles in the concrete and close surface pinholes to form a flat surface.
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| CN202211056389.2A CN115401783B (en) | 2022-08-31 | 2022-08-31 | Preparation process of concrete bridge deck |
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Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN207888889U (en) * | 2018-02-08 | 2018-09-21 | 建华建材（中国）有限公司 | Prefabricated components integrated production line |
| CN111203972A (en) * | 2020-01-19 | 2020-05-29 | 安徽省交通控股集团有限公司 | Automatic production line for pile plate type structural bridge deck |
| CN111702942A (en) * | 2020-06-29 | 2020-09-25 | 中铁十二局集团有限公司 | Railway bridge deck auxiliary structure integral prefabrication production line and production process thereof |
| CN113585017A (en) * | 2021-08-25 | 2021-11-02 | 中冶南方城市建设工程技术有限公司 | Road cement concrete distributing, vibrating and paving integrated equipment and using method thereof |
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Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN207888889U (en) * | 2018-02-08 | 2018-09-21 | 建华建材（中国）有限公司 | Prefabricated components integrated production line |
| CN111203972A (en) * | 2020-01-19 | 2020-05-29 | 安徽省交通控股集团有限公司 | Automatic production line for pile plate type structural bridge deck |
| CN111702942A (en) * | 2020-06-29 | 2020-09-25 | 中铁十二局集团有限公司 | Railway bridge deck auxiliary structure integral prefabrication production line and production process thereof |
| CN113585017A (en) * | 2021-08-25 | 2021-11-02 | 中冶南方城市建设工程技术有限公司 | Road cement concrete distributing, vibrating and paving integrated equipment and using method thereof |
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