CN115431402A - Automatic prefabrication production process for light T-shaped beam - Google Patents
Automatic prefabrication production process for light T-shaped beam Download PDFInfo
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- CN115431402A CN115431402A CN202211130046.6A CN202211130046A CN115431402A CN 115431402 A CN115431402 A CN 115431402A CN 202211130046 A CN202211130046 A CN 202211130046A CN 115431402 A CN115431402 A CN 115431402A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 29
- 238000009417 prefabrication Methods 0.000 title claims abstract description 11
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 62
- 239000010959 steel Substances 0.000 claims abstract description 62
- 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 claims abstract description 27
- 230000002787 reinforcement Effects 0.000 claims abstract description 11
- 238000003466 welding Methods 0.000 claims abstract description 11
- 238000005520 cutting process Methods 0.000 claims abstract description 8
- 230000007246 mechanism Effects 0.000 claims abstract description 5
- 238000005507 spraying Methods 0.000 claims abstract description 4
- 239000000463 material Substances 0.000 claims description 32
- 210000002435 tendon Anatomy 0.000 claims description 27
- 238000000034 method Methods 0.000 claims description 25
- 238000012360 testing method Methods 0.000 claims description 21
- 238000009826 distribution Methods 0.000 claims description 18
- 230000001276 controlling effect Effects 0.000 claims description 14
- 230000008569 process Effects 0.000 claims description 14
- 239000002002 slurry Substances 0.000 claims description 12
- 238000004873 anchoring Methods 0.000 claims description 6
- 238000005452 bending Methods 0.000 claims description 6
- 239000004568 cement Substances 0.000 claims description 6
- 238000013461 design Methods 0.000 claims description 6
- 238000012423 maintenance Methods 0.000 claims description 6
- 239000007921 spray Substances 0.000 claims description 6
- 229910001294 Reinforcing steel Inorganic materials 0.000 claims description 5
- 238000009739 binding Methods 0.000 claims description 5
- 238000012544 monitoring process Methods 0.000 claims description 5
- 230000002035 prolonged effect Effects 0.000 claims description 4
- 244000126211 Hericium coralloides Species 0.000 claims description 3
- 238000013459 approach Methods 0.000 claims description 3
- 230000001680 brushing effect Effects 0.000 claims description 3
- 239000011083 cement mortar Substances 0.000 claims description 3
- 239000011248 coating agent Substances 0.000 claims description 3
- 238000000576 coating method Methods 0.000 claims description 3
- 238000000151 deposition Methods 0.000 claims description 3
- 238000001514 detection method Methods 0.000 claims description 3
- 239000011268 mixed slurry Substances 0.000 claims description 3
- 239000011148 porous material Substances 0.000 claims description 3
- 238000012545 processing Methods 0.000 claims description 3
- 230000001105 regulatory effect Effects 0.000 claims description 3
- 230000000087 stabilizing effect Effects 0.000 claims description 3
- 239000012528 membrane Substances 0.000 claims description 2
- 239000004570 mortar (masonry) Substances 0.000 claims description 2
- 238000003825 pressing Methods 0.000 claims description 2
- 241000221535 Pucciniales Species 0.000 claims 1
- 239000004744 fabric Substances 0.000 abstract description 6
- 230000009467 reduction Effects 0.000 abstract description 2
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- 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
- B28B23/04—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 the elements being stressed
-
- 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
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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
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/08—Producing shaped prefabricated articles from the material by vibrating or jolting
- B28B1/093—Producing shaped prefabricated articles from the material by vibrating or jolting by means directly acting on the material, e.g. by cores wholly or partly immersed in the material or elements acting on the upper surface of the material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
- B28B11/245—Curing concrete articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
- B28B13/02—Feeding the unshaped material to moulds or apparatus for producing shaped articles
- B28B13/0215—Feeding the moulding material in measured quantities from a container or silo
-
- 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
- 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
- B28B23/04—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 the elements being stressed
- B28B23/043—Wire anchoring or tensioning means for the reinforcements
-
- 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
- B28B23/04—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 the elements being stressed
- B28B23/046—Post treatment to obtain pre-stressed articles
Landscapes
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Structural Engineering (AREA)
- Manufacturing Of Tubular Articles Or Embedded Moulded Articles (AREA)
Abstract
The invention relates to the technical field of road and bridge engineering, and discloses an automatic prefabrication production process of a light T-beam, which comprises the following steps: manufacturing and assembling a template; manufacturing a steel bar, and transferring a steel bar framework; closing the pedestal and the side template; stirring and transferring concrete; vibrating; detecting strength and demolding; steam curing the precast beam; stretching the steel strand; grouting; spraying and preserving health; storing; this scheme, through adopting automation equipment to carry out the cutting of reinforcing bar, the welding, the ligature, promote the fashioned speed of framework of steel reinforcement, with separation between pedestal and the side form board, make same producing on the line can be to there being a plurality of precast beams simultaneously, the side form board utilizes hydraulic pressure mechanism to carry out the whole transmission, the convenience of compound die and drawing of patterns has been promoted, the reduction of erection time, through the setting to the cloth machine, make the cloth segmentation go on, thereby cloth and vibration can go on in step, when guaranteeing curing time, the quality that the concrete was laid has been guaranteed, promote precast beam's intensity.
Description
Technical Field
The invention relates to the field of road and bridge engineering, in particular to an automatic prefabricating production process for a light T-shaped beam.
Background
T-shaped beam: refers to a beam with a T-shaped cross section; the parts of the two sides are called flanges, the middle part is called a beam rib (or a web plate), and the parts are formed by excavating the concrete in the tension area of the rectangular beam, which does not work in resisting bending strength, and the bending strength is completely the same as the original rectangular bending strength, so that the concrete can be saved, the self weight of the member is reduced, and the spanning capability is improved; in the process of bridge construction, in order to accelerate the construction progress, the T-shaped beam is usually prefabricated, and the T-shaped beam can be put into use when being transported to a construction site.
Every prefabricated one of traditional T roof beam prefabrication all need carry out assembling and demolising of template, and the process is comparatively loaded down with trivial details, and the preparation of T roof beam is comparatively slow, leads to the time limit for a project to be prolonged, simultaneously at the concrete placement in-process, the vibration of concrete is mostly gone on through the manual work, and the level of pouring is obvious inadequately, leads to the T roof beam to produce the difference of certain degree in curing process, and then causes the intensity reduction of T roof beam.
With respect to the related art among the above, the inventors consider that the above-described drawbacks exist.
Disclosure of Invention
In order to solve the problems, the invention provides an automatic prefabricating production process of a light T-shaped beam.
The invention provides an automatic prefabricating production process of a light T-beam, which adopts the following technical scheme:
an automatic prefabricating production process of a light T-shaped beam comprises the following steps:
the method comprises the following steps: template manufacturing and assembling, including manufacturing of a pedestal and assembling of a hydraulic side template;
step two: manufacturing a steel bar, wherein the manufacturing comprises cutting, bending, welding and binding of the steel bar, and supporting into a T-shaped steel bar framework;
step three: transferring the steel reinforcement framework, and hoisting the steel reinforcement framework to a pedestal by using a truss crane;
step four: the pedestal and the side templates are closed, the pedestal moves to a position between the side templates, and the hydraulic structure on the outer sides of the side templates drives the side templates to approach to the two sides of the pedestal and close the mold;
step five: mounting top plate steel bars and comb tooth steel bars;
step six: concrete is stirred and transferred, the stirred concrete is conveyed into a distributing machine mechanism by a torpedo tank, and the material is distributed between the templates by a distributing machine; the material distribution of the material distributor is carried out in four layers, the laying thickness of each layer from first to last is 32cm, 50cm, 45cm and 33cm, the length of the concrete material laid at a single time is 3.114m, the material distribution time of each section of the first layer is 4min, the total time of the material distribution of the first layer is 12min, the total time of each section of the material distribution of the second and third sections is 1min, the total time is 28min, and the material distribution time of the top plate of the fourth layer is 30min;
step seven: vibrating, namely, vibrating by using a vibrator on a side die and additionally manually assisting in vibrating, wherein the interval between vibrating and distributing is two distributing time sections, namely, distributing to a third section, starting vibrating at the first section, vibrating for 40s at the first layer for 2 times, vibrating for 40s at the bottom and the web plate at the second layer, vibrating for 40s at the web plate for matching with insert vibrating, vibrating for 40s at the web plate at the third layer for matching with insert vibrating for 2 times, and vibrating for the fourth layer by adopting insert vibrating;
step eight: performing strength detection, demolding and concrete pouring, and manufacturing 7 groups of test blocks, wherein the strength of the concrete is detected when one group of the same-nutrient test blocks is demolded, the strength is detected when one group of the same-nutrient test blocks is moved by a trolley, the strength of the concrete is detected after the three groups of the same-nutrient test blocks are steamed, and the strength is detected in two groups of standard culture rooms for 28 days; when the concrete strength reaches 2.5Mpa, the side die is removed, when the concrete strength reaches 10Mpa, the trolley is moved to a steam curing room, and when the concrete strength reaches 90%, the mortar is tensioned and pressed;
step nine: steam curing the precast beam, and transferring the pedestal to steam curing equipment for steam curing;
step ten: tensioning the steel strand, namely tensioning by adopting intelligent equipment, automatically controlling the tensioning stress, the loading rate, the stop point and the load holding time, and automatically collecting and checking the elongation value error;
step eleven: grouting, namely accurately controlling a water-to-rubber ratio, a grouting direction, automatically adjusting pressure and flow, automatically recording grouting data and continuously and circularly exhausting air in slurry by adopting intelligent equipment, adopting a mode that a grouting machine has no pressure fluctuation and continuously works, judging the filling condition of pipeline grouting by monitoring the pressure difference of a slurry outlet, monitoring the pressure loss of the pipeline in real time by grouting, and filling the pipeline grouting when the pressure difference of an outlet tends to a constant value;
step twelve: spraying and maintaining, wherein one spray nozzle is arranged at each 3m of the web plate, and one spray nozzle is arranged at each 5m of the top plate;
step thirteen: deposit, transport to depositing the district through the portal crane, deposit the district and set up 24.2m interval ridges, put things in good order according to two layers of classification, both sides adopt the steel pipe to support the web.
Preferably, after the template assembly in the first step is completed, the position of the joint is checked, and the surface of the steel template is polished until the surface is smooth and free of holes and rusty spots.
Preferably, the steel bars in the second step are cut and bent by an MEP digital steel bar processing robot, the steel bars of the bottom web plate and the top plate are bound on the tire mold, and the welding between the steel bars is carried out by a gantry type numerical control welding robot.
Preferably, in the fourth step, the verticality, the height and the horizontal position are adjusted through the driving of an oil cylinder, when the hydraulic system is close to a beam-making pedestal by about 2cm, a bottom pull rod and an upper pull rod are installed, templates on two sides are tensioned through the pull rods and are close to the beam-making pedestal, and two ends of each pull rod are locked through double nuts to prevent looseness in the concrete vibrating process; after the pull rod is installed, the bottom support and the inclined strut of the template are installed again, the template is supported on a concrete terrace, and then the vertical oil cylinder is slightly retracted for a little stroke, so that the walking trolley and the hydraulic system are not influenced by the vibration force in the whole concrete pouring vibration process, and the service life of the hydraulic system is prolonged.
Preferably, in the ninth step, the steam temperature is controlled, the temperature is gradually increased from low temperature to high temperature, the constant temperature is kept for 10 hours after the temperature is increased, the temperature increasing speed is controlled at 15 ℃/hour, the temperature decreasing speed is controlled at 10 ℃/hour, the maximum temperature is controlled at 60 ℃, the device is kept at the constant temperature when the temperature is increased to the maximum temperature, and the temperature difference between the surface temperature of the concrete and the external environment temperature is not more than 15 ℃ when the temperature is decreased.
Preferably, in the step ten, (1) when the steel strand is pulled, a pulling machine is used for pulling, the exposed working lengths on the two sides are kept close, before tensioning, a jack and an oil pressure gauge are calibrated in a matched manner, the reading of the corresponding oil gauge is calculated according to a regression equation, and when the test block strength and the site resilience strength under the same pressure test condition are more than or equal to 90% of the design strength value, tensioning is carried out;
(2) The prestress tension design is symmetrically and sequentially carried out; tensioning the steel strand: 0 → initial stress (0.15 δ k) → 0.3 δ k → 1.0 δ k (5 min load holding anchoring); the initial stress virtual elongation of the steel strand 0 → 0.15 delta k is calculated by the reading difference of the actually measured elongations of adjacent stages 0.15 delta k → 0.3 delta k;
(3) The camber of the T beam is obtained by calculating the difference value before and after tensioning; after tensioning, arranging observation point positions on the central axis of the beam from midspan to the longitudinal distance of every 2m of two sides, and detecting by using a clearance gauge;
(4) The rated tension force of the tensioning jack is 1.2-1.5 times of the required tension force, and the tensioning machine equipment is matched with an anchorage device product for use;
(5) When the prestressed tendon is tensioned by adopting a stress control method, the elongation value is checked, the difference value between the actual elongation value and the theoretical elongation value is controlled within +/-6%, otherwise tensioning is suspended;
the calculation formula of the theoretical elongation of the prestressed reinforcement is as follows:
ΔL＝PpL/(ApEp)
in the formula: pp is the average tensile force of the prestressed tendon, and the linear tendon takes the tensile force (N) of the tensile end;
l is the length (mm) of the prestressed tendon;
ap-the cross-sectional area of the tendon (mm 2);
ep-modulus of elasticity (MPa) of the tendon.
When the prestressed tendon is tensioned, the initial stress sigma should be adjusted, the initial stress is preferably 10% -25% of the tensioning control stress sigma com, the elongation value should be measured from the initial stress, and the actual elongation value delta Ls (mm) of the prestressed tendon tensioning is calculated by the formula:
△Ls＝△L1+△L2
Δ L1 — measured elongation (mm) from initial stress to maximum tensile stress;
DeltaL 2, the calculated elongation (mm) below the initial stress, the elongation of adjacent stages can be used.
(6) The anchoring of the prestressed tendon should be performed under the condition that the tension control stress is in a stable state.
Preferably, in the eleventh step, (1) grouting adopts an intelligent grouting large circulation system, and pore grouting materials are prepared by grouting; the intelligent grouting system can completely remove air in the pipeline, accurately control the water-cement ratio and accurately control the slurry quality; the grouting pressure and the pressure stabilizing time are regulated and controlled in real time; the once-mixed slurry ensures that the grouting of a single pipeline is continuously completed at one time; grouting is carried out in sequence from bottom to top, and 3 groups of 40-160 test pieces are manufactured on site; (2) Coating and protecting the end of the exposed steel strand after the mud jacking and cutting by cement mortar, and manually brushing all exposed steel bars by using cement paste for protection treatment; (3) And arranging end-capping reinforcing steel bars, erecting end-capping templates, checking the length and the verticality of the beam, and pouring end-capping concrete after reinforcement.
In summary, the invention includes at least one of the following beneficial technical effects:
the automatic equipment is adopted for cutting, welding and binding the reinforcing steel bars, the forming speed of the reinforcing steel bar framework is improved, and the pedestal and the side templates are separated, so that a plurality of prefabricated beams can be simultaneously arranged on the same production line, and the side templates are integrally transmitted by using a hydraulic mechanism, so that the convenience of die assembly and demolding is improved, the manufacturing convenience of the prefabricated beams is improved, and the construction period is shortened; through the setting to the cloth machine, make the cloth segmentation go on to cloth and vibration can go on in step, when guaranteeing curing time, have guaranteed the quality that the concrete was laid, effectively promote precast beam's intensity.
Detailed Description
The embodiment of the invention discloses an automatic prefabricating production process of a light T-shaped beam. An automatic prefabricating production process of a light T-shaped beam comprises the following steps:
the method comprises the following steps: the method comprises the steps of template manufacturing and assembling, including the manufacturing of a pedestal and the assembling of a hydraulic side template, after the template assembling is completed, the position of a seam is checked, and the surface of a steel template is polished until the surface is smooth and free of holes and rusty spots;
step two: manufacturing the steel bars, wherein the manufacturing comprises cutting, bending, welding and binding of the steel bars, a T-shaped steel bar framework is supported, the steel bars are cut and bent by adopting an MEP digital steel bar processing robot, the binding of the steel bars of the bottom web plate and the top plate is carried out on a tire membrane, and the welding between the steel bars is carried out by a gantry type numerical control welding robot;
step three: transferring the steel reinforcement framework, and hoisting the steel reinforcement framework to a pedestal by using a truss crane;
step four: the pedestal and the side templates are closed, the pedestal moves between the side templates, a hydraulic structure on the outer side of the side template drives the side templates to approach and close the two sides of the pedestal, the verticality, the height and the horizontal position are adjusted through the driving of an oil cylinder, when the side templates are close to the beam-making pedestal by about 2cm, the use of a hydraulic system is stopped, a bottom pull rod and an upper pull rod are started to be installed, the templates on the two sides are tensioned through the pull rods and are close to the beam-making pedestal, and the two ends of each pull rod are locked by double nuts, so that the looseness in the concrete vibrating process is prevented; after the pull rod is installed, a bottom support and an inclined strut of the template are installed and supported on a concrete floor, and then the vertical oil cylinder is slightly retracted by a stroke, so that the walking trolley and the hydraulic system are not influenced by vibration force in the whole concrete pouring vibration process, and the service life of the hydraulic system is prolonged;
step five: mounting top plate steel bars and comb tooth steel bars;
step six: concrete is stirred and transferred, the stirred concrete is transmitted to a distributing machine mechanism by a torpedo tank, and the material is distributed between the templates by the distributing machine; the material distribution of the material distributor is carried out in four layers, the laying thickness of each layer from first to last is 32cm, 50cm, 45cm and 33cm, the length of the concrete material laid at a single time is 3.114m, the material distribution time of each section of the first layer is 4min, the total time of the material distribution of the first layer is 12min, the total time of each section of the material distribution of the second and third sections is 1min, the total time is 28min, and the material distribution time of the top plate of the fourth layer is 30min;
step seven: vibrating, namely, vibrating by using a vibrator on a side die and additionally performing manual auxiliary vibration, wherein the interval between the vibration and the material distribution is two-section material distribution time, namely, the material distribution time is from the third section, the vibration is started in the first section, the vibration is performed for 40s in the first layer for 2 times, the vibration is performed for 40s in the bottom and the web plates of the second layer, the vibration is performed for 40s in the web plates in a matched inserted mode, the vibration is performed for 40s in the web plates of the third layer for 2 times in a matched inserted mode, and the vibration is performed for the fourth layer in an inserted mode;
step eight: during strength detection, demolding and concrete pouring, 7 groups of test blocks are manufactured, wherein the strength of the concrete is detected when one group of the same-maintenance test blocks are demolded, the strength is detected when one group of the same-maintenance test blocks are moved by a trolley, the strength of the concrete is detected after the three groups of the same-maintenance test blocks are steamed, and the strength is detected in two groups of standard curing rooms for 28 days; when the concrete strength reaches 2.5Mpa, the side mold is disassembled, when the concrete strength reaches 10Mpa, the trolley is moved to a steam curing room, and when the concrete strength reaches 90 percent, the slurry is tensioned and pressed;
step nine: steam curing the precast beam, transferring the pedestal to steam curing equipment for steam curing, controlling the steam temperature, gradually raising the temperature from low temperature to high temperature, keeping the temperature constant for 10 hours after the temperature is raised, controlling the temperature raising speed to be 15 ℃/hour, controlling the temperature lowering speed to be 10 ℃/hour, controlling the highest temperature to be 60 ℃, keeping the temperature of the device constant when the temperature is raised to the highest temperature, and keeping the temperature difference between the surface temperature of the concrete and the external environment temperature to be not more than 15 ℃ when the temperature is lowered;
step ten: tensioning the steel strand, namely tensioning by adopting intelligent equipment, automatically controlling the tensioning stress, the loading rate, the stop point and the load holding time, and automatically collecting and checking the elongation value error;
(1) When the steel strand is pulled, a pulling machine is used for pulling, the exposed working lengths on two sides are kept close, before tensioning, a jack and an oil pressure gauge are calibrated in a matched mode, corresponding oil gauge reading is calculated according to a regression equation, and tensioning is carried out when the test block strength and the site resilience strength under the same pressure test condition are more than or equal to 90% of design strength values;
(2) The prestress tension design is symmetrically and sequentially carried out; and (3) tensioning the steel strand: 0 → initial stress (0.15 δ k) → 0.3 δ k → 1.0 δ k (5 min load holding anchoring); the initial stress virtual elongation of the steel strand 0 → 0.15 delta k is calculated by the reading difference of the actually measured elongations of adjacent stages 0.15 delta k → 0.3 delta k;
(3) The camber of the T-shaped beam is obtained by calculating the difference value before and after tensioning; after tensioning, arranging observation point positions on the central axis of the beam from midspan to the longitudinal distance of every 2m of two sides, and detecting by using a clearance gauge;
(4) The rated tension force of the tensioning jack is 1.2-1.5 times of the required tension force, and the tensioning machine equipment is matched with an anchorage device product for use;
(5) When the prestressed tendon is tensioned by adopting a stress control method, the elongation value is checked, the difference value between the actual elongation value and the theoretical elongation value is controlled within +/-6%, otherwise, tensioning is suspended;
the calculation formula of the theoretical elongation of the prestressed reinforcement is as follows:
ΔL＝PpL/(ApEp)
in the formula: pp is the average tensile force of the prestressed tendon, and the linear tendon takes the tensile force (N) of the tensile end;
l is the length (mm) of the prestressed tendon;
ap-the cross-sectional area of the tendon (mm 2);
ep-modulus of elasticity (MPa) of the tendon.
When the prestressed tendon is tensioned, the initial stress sigma should be adjusted, the initial stress is preferably 10% -25% of the tensioning control stress sigma com, the elongation value should be measured from the initial stress, and the actual elongation value delta Ls (mm) of the prestressed tendon tensioning is calculated by the formula:
△Ls＝△L1+△L2
Δ L1 — the measured elongation (mm) from initial stress to maximum tensile stress;
delta L2, the calculated elongation (mm) below the initial stress, and the elongation of adjacent stages can be used.
(6) Anchoring the prestressed tendon should be carried out when the tension control stress is in a stable state;
step eleven: grouting, namely accurately controlling a water-to-glue ratio, a grouting direction, automatically adjusting pressure and flow, automatically recording grouting data, and continuously and circularly exhausting air in slurry by adopting intelligent equipment, wherein a grouting machine is operated in a continuous working mode without pressure fluctuation, the grouting filling condition of a pipeline is judged by monitoring the pressure difference of a slurry outlet, the pressure loss of the pipeline is monitored in real time by grouting, and when the pressure difference of an outlet tends to a constant value, the pipeline grouting is filled;
(1) Grouting by adopting an intelligent grouting large circulation system, wherein the pore grouting material is prepared by adopting grouting material; the intelligent grouting system can completely remove air in the pipeline, accurately control the water-cement ratio and accurately control the slurry quality; the grouting pressure and the pressure stabilizing time are regulated and controlled in real time; the once-mixed slurry ensures that the grouting of a single pipeline is continuously completed at one time; pressing slurry is carried out in sequence from bottom to top, and 3 groups of 40-160 test pieces are manufactured on site; (2) Coating and protecting the end of the exposed steel strand after the mud jacking and cutting by cement mortar, and manually brushing all exposed steel bars by using cement paste for protection treatment; (3) Arranging end-capped reinforcing steel bars, erecting end-capped templates, checking the length and the verticality of the beam, and pouring end-capped concrete after reinforcement;
step twelve: spraying and maintaining, wherein one spray nozzle is arranged at each 3m of the web plate, and one spray nozzle is arranged at each 5m of the top plate;
step thirteen: deposit, transport to depositing the district through the portal crane, deposit the district and set up 24.2m interval ridges, put things in good order according to two layers of classification, both sides adopt the steel pipe to support the web.
It should be noted that, in this document, terms such as "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (7)
1. The automatic prefabrication production process of the light T-shaped beam is characterized in that: the method comprises the following steps:
the method comprises the following steps: template manufacturing and assembling, including manufacturing of a pedestal and assembling of a hydraulic side template;
step two: manufacturing a steel bar, namely cutting, bending, welding and binding the steel bar, and supporting the steel bar into a T-shaped steel bar framework;
step three: transferring the steel bar framework, and hoisting the steel bar framework to the pedestal by using a truss crane;
step four: the pedestal and the side templates are closed, the pedestal moves between the side templates, and the hydraulic structure on the outer side of the side templates drives the side templates to approach to the two sides of the pedestal and close the mold;
step five: mounting top plate steel bars and comb tooth steel bars;
step six: concrete is stirred and transferred, the stirred concrete is transmitted to a distributing machine mechanism by a torpedo tank, and the material is distributed between the templates by the distributing machine; the material distribution of the material distributor is carried out in four layers, the laying thickness of each layer from first to last is 32cm, 50cm, 45cm and 33cm, the length of the concrete material laid at a single time is 3.114m, the material distribution time of each section of the first layer is 4min, the total time of the material distribution of the first layer is 12min, the total time of each section of the material distribution of the second and third sections is 1min, the total time is 28min, and the material distribution time of the top plate of the fourth layer is 30min;
step seven: vibrating, namely, vibrating by using a vibrator on a side die and additionally manually assisting in vibrating, wherein the interval between vibrating and distributing is two distributing time sections, namely, distributing to a third section, starting vibrating at the first section, vibrating for 40s at the first layer for 2 times, vibrating for 40s at the bottom and the web plate at the second layer, vibrating for 40s at the web plate for matching with insert vibrating, vibrating for 40s at the web plate at the third layer for matching with insert vibrating for 2 times, and vibrating for the fourth layer by adopting insert vibrating;
step eight: during strength detection, demolding and concrete pouring, 7 groups of test blocks are manufactured, wherein the strength of the concrete is detected when one group of the same-maintenance test blocks are demolded, the strength is detected when one group of the same-maintenance test blocks are moved by a trolley, the strength of the concrete is detected after the three groups of the same-maintenance test blocks are steamed, and the strength is detected in two groups of standard curing rooms for 28 days; when the concrete strength reaches 2.5Mpa, the side die is removed, when the concrete strength reaches 10Mpa, the trolley is moved to a steam curing room, and when the concrete strength reaches 90%, the mortar is tensioned and pressed;
step nine: steam curing the precast beam, and transferring the pedestal to steam curing equipment for steam curing;
step ten: tensioning the steel strand, namely tensioning by adopting intelligent equipment, automatically controlling the tensioning stress, the loading rate, the stop point and the load holding time, and automatically collecting and checking the elongation value error;
step eleven: grouting, namely accurately controlling a water-to-rubber ratio, a grouting direction, automatically adjusting pressure and flow, automatically recording grouting data and continuously and circularly exhausting air in slurry by adopting intelligent equipment, adopting a mode that a grouting machine has no pressure fluctuation and continuously works, judging the filling condition of pipeline grouting by monitoring the pressure difference of a slurry outlet, monitoring the pressure loss of the pipeline in real time by grouting, and filling the pipeline grouting when the pressure difference of an outlet tends to a constant value;
step twelve: spraying and maintaining, wherein one spray nozzle is arranged at each 3m position of the web plate, and one spray nozzle is arranged at each 5m position of the top plate;
step thirteen: deposit, transport to depositing the district through the portal crane, deposit the district and set up 24.2m interval ridges, put things in good order according to two layers of classification, both sides adopt the steel pipe to support the web.
2. The automatic prefabrication production process of the light T-shaped beam as claimed in claim 1, wherein: and after the template assembly in the first step is completed, the seam position is checked, and the surface of the steel template is polished until the surface is smooth and free of holes and rusts.
3. The automatic prefabrication process of a light T-beam according to claim 1, wherein: and in the second step, the steel bars are cut and bent by adopting an MEP digital steel bar processing robot, the steel bars of the bottom web plate and the top plate are bound on the tire membrane, and the welding between the steel bars is carried out by a gantry type numerical control welding robot.
4. The automatic prefabrication process of a light T-beam according to claim 1, wherein: in the fourth step, the verticality, the height and the horizontal position are adjusted through the driving of an oil cylinder, when the hydraulic system is close to a beam-making pedestal by about 2cm, a bottom pull rod and an upper pull rod are installed, the templates on two sides are tensioned through the pull rods and are close to the beam-making pedestal, and two ends of the pull rods are locked by double nuts to prevent the looseness in the concrete vibrating process; after the pull rod is installed, the bottom support and the inclined strut of the template are installed again, the template is supported on a concrete terrace, and then the vertical oil cylinder is slightly retracted for a little stroke, so that the walking trolley and the hydraulic system are not influenced by the vibration force in the whole concrete pouring vibration process, and the service life of the hydraulic system is prolonged.
5. The automatic prefabrication process of a light T-beam according to claim 1, wherein: and step nine, controlling the steam temperature, gradually raising the temperature from low temperature to high temperature, keeping the constant temperature for 10 hours after the temperature is raised, controlling the temperature raising speed at 15 ℃/hour, controlling the temperature lowering speed at 10 ℃/hour, controlling the highest temperature at 60 ℃, keeping the device at the constant temperature when the temperature is raised to the highest temperature, and keeping the temperature difference between the surface temperature of the concrete and the external environment temperature not to exceed 15 ℃ when the temperature is lowered.
6. The automatic prefabrication production process of the light T-shaped beam as claimed in claim 1, wherein: in the step ten, (1) when the steel strand is pulled, a pulling machine is adopted for pulling, the exposed working lengths of the two sides are kept to be close, before tensioning operation, a jack and an oil pressure gauge are matched and calibrated, corresponding oil gauge reading is calculated according to a regression equation, and tensioning is carried out when the test block strength and the site resilience strength under the same pressure test condition are more than or equal to 90% of the design strength value;
(2) The prestress tension design sequence is symmetrically and sequentially carried out; and (3) tensioning the steel strand: 0 → initial stress (0.15 δ k) → 0.3 δ k → 1.0 δ k (holding load for 5min anchoring); the initial stress virtual elongation of the steel strand 0 → 0.15 delta k is calculated by the reading difference of the actually measured elongations of adjacent stages 0.15 delta k → 0.3 delta k;
(3) The camber of the T beam is obtained by calculating the difference value before and after tensioning; after tensioning, arranging observation point positions on the central axis of the beam from midspan to the longitudinal distance of every 2m of two sides, and detecting by using a clearance gauge;
(4) The rated tension force of the tensioning jack is 1.2-1.5 times of the required tension force, and the tensioning machine equipment is matched with an anchorage device product for use;
(5) When the prestressed tendon is tensioned by adopting a stress control method, the elongation value is checked, the difference value between the actual elongation value and the theoretical elongation value is controlled within +/-6%, otherwise, tensioning is suspended;
the calculation formula of the theoretical elongation of the prestressed reinforcement is as follows:
ΔL＝PpL/(ApEp)
in the formula: pp is the average tension of the prestressed tendon, and the tension (N) of the tension end is taken by the linear tendon;
l is the length (mm) of the prestressed tendon;
ap-the cross-sectional area of the tendon (mm 2);
ep-modulus of elasticity (MPa) of the tendon.
When the prestressed tendon is tensioned, the initial stress sigma is adjusted, the initial stress sigma is preferably 10% -25% of the tensioning control stress sigma com, the elongation value is measured from the initial stress, and the actual elongation value delta Ls (mm) of the prestressed tendon tensioning is calculated by the formula:
△Ls＝△L1+△L2
Δ L1 — the measured elongation (mm) from initial stress to maximum tensile stress;
DeltaL 2, the calculated elongation (mm) below the initial stress, the elongation of adjacent stages can be used.
(6) The anchoring of the prestressed tendon should be performed under the condition that the tension control stress is in a stable state.
7. The automatic prefabrication production process of the light T-shaped beam as claimed in claim 1, wherein: in the eleventh step, the intelligent grouting large circulation system is adopted for grouting, and grouting materials of the pore channels are prepared by grouting materials; the intelligent grouting system can completely remove air in the pipeline, accurately control the water-cement ratio and accurately control the slurry quality; the grouting pressure and the pressure stabilizing time are regulated and controlled in real time; the once-mixed slurry ensures that the grouting of a single pipeline is continuously completed at one time; pressing slurry is carried out in sequence from bottom to top, and 3 groups of 40-160 test pieces are manufactured on site; (2) Coating and protecting the end of the exposed steel strand after the mud jacking and cutting by cement mortar, and manually brushing all exposed steel bars by using cement paste for protection treatment; (3) And arranging end-capped reinforcing steel bars, erecting end-capped templates, checking the length and the verticality of the beam, and pouring end-capped concrete after reinforcement.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117655241A (en) * | 2024-01-17 | 2024-03-08 | 中铁七局集团郑州工程有限公司 | Automatic assembling process for prefabricated beam reinforcement cage |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR1509678A (en) * | 1967-01-30 | 1968-01-12 | Prestressed concrete bridge with two main beams and method for the construction of such a bridge | |
| CN113752379A (en) * | 2021-09-15 | 2021-12-07 | 浙江交工集团股份有限公司 | Concrete T-beam prefabricating method adopting secondary tensioning process and movable pedestal |
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2022
- 2022-09-16 CN CN202211130046.6A patent/CN115431402A/en active Pending
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR1509678A (en) * | 1967-01-30 | 1968-01-12 | Prestressed concrete bridge with two main beams and method for the construction of such a bridge | |
| CN113752379A (en) * | 2021-09-15 | 2021-12-07 | 浙江交工集团股份有限公司 | Concrete T-beam prefabricating method adopting secondary tensioning process and movable pedestal |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117655241A (en) * | 2024-01-17 | 2024-03-08 | 中铁七局集团郑州工程有限公司 | Automatic assembling process for prefabricated beam reinforcement cage |
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