WO2024001685A1 - 一种公路市政预应力混凝土预制箱梁预应力施工的方法 - Google Patents

一种公路市政预应力混凝土预制箱梁预应力施工的方法 Download PDF

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WO2024001685A1
WO2024001685A1 PCT/CN2023/098477 CN2023098477W WO2024001685A1 WO 2024001685 A1 WO2024001685 A1 WO 2024001685A1 CN 2023098477 W CN2023098477 W CN 2023098477W WO 2024001685 A1 WO2024001685 A1 WO 2024001685A1
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prestressed
box
tensioning
concrete
construction
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PCT/CN2023/098477
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English (en)
French (fr)
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张春飞
黄森涌
佟冠中
赖少华
付金龙
刘波
公培志
黄振杨
袁瑞希
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中交(南京)建设有限公司
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Publication of WO2024001685A1 publication Critical patent/WO2024001685A1/zh

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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
    • 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
    • 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

Definitions

  • the invention relates to the technical field of highway and urban bridge construction, and specifically relates to a method for prestressed construction of highway municipal prestressed concrete prefabricated box beams.
  • prefabricated small box girders Due to the advantages of mature technology, economical cost, and convenient construction, prefabricated small box girders have become a commonly used prefabricated bridge structure for new urban viaduct bridges.
  • the construction period is short and the time is tight.
  • the prestressed steel bars can only be stretched 7 days after the concrete is cured (the concrete strength reaches more than 90% of the design strength).
  • the main factor is that tensioning is performed when the concrete strength is low, and the box beams are easy to arch after being arched. Causes concrete cracking at the beam end.
  • the beam moving operation can be carried out only after the tensioning is completed, which increases the turnover period of the beam making platform.
  • the construction scale of the prefabricated beam field needs to be large enough.
  • the invention provides a method for prestressed construction of highway municipal prestressed concrete prefabricated box beams, which includes the following steps:
  • a hoisting hole reserved box is installed on the box girder side formwork, and the reserved box is connected to the steel side formwork through bolts; at the same time, a 20mm thick hard plastic plate is set at the end of the beam making pedestal, and the end of the box girder is pressed on on hard plastic board;
  • the box beam moves from the beam making pedestal to the beam storage pedestal;
  • the second secondary tension After the concrete strength and elastic modulus of the box girder body reach the standard design value and the age is not less than 7 days, the second secondary tension;
  • Figure 1 is a schematic diagram of the beam-making pedestal in the construction method of the present invention; in the figure, 1 represents a prefabricated box beam, 2 represents a stainless steel bottom form, 3 represents a settlement joint, 4 represents a 10cm thick gravel cushion, and 5 represents a 30cm thick C30 reinforced concrete pedestal. ; 6 represents the embedded steel plate of the support, 7 represents the 30cm thick C30 reinforced concrete expanded foundation, 8 represents the 10cm thick C15 concrete cushion, 9 represents the lifting hole, and 10 represents the hard plastic plate;
  • FIG. 2 is a schematic diagram of the installation position of the hoisting hole reserved box in step (1) of the present invention; in the figure Represents the hoisting hole reserved box, stands for bolt, Represents precast box girder steel side forms;
  • Figure 3 is a schematic diagram of beam-moving hoisting according to the present invention.
  • a method for prestressed construction of highway municipal prestressed concrete prefabricated box beams which is characterized by: including the following steps:
  • a hoisting hole reserved box is installed on the box beam side formwork, and the reserved box is connected to the steel side formwork through bolts; at the same time, a 20mm thick hard plastic plate is set at the end of the beam making pedestal, and the end of the box beam is pressed on On the hard plastic board, as shown in Figure 1; the beam end can be displaced downward during tensioning.
  • the maintenance method is determined based on the ambient temperature and the rate at which the strength of the concrete increases. In order to carry out initial tensioning as early as possible, it generally takes 3 days for the concrete strength of precast box beams to reach more than 60% of the design value. Establish dedicated maintenance and maintenance file cards to facilitate management and control.
  • the detailed maintenance control methods for prefabricated box beams are: 1 When the ambient temperature is above 10°C and the concrete strength is greater than 60% of the design strength in 3 days, sprinkler maintenance is used. Immediately after the concrete is poured, cover it with geotextile and sprinkle it in time. For water curing, avoid exposure to the sun. First remove the inner mold for curing from the inside, and then remove the outer mold. This not only accelerates the improvement of concrete strength, but also cools the concrete components from the inside.
  • the first tensioning is performed; during the first tensioning, the tensile stress of a single prestressed tendon on the box girder is the first tensile stress value;
  • the box beam moves from the beam making pedestal to the beam storage pedestal;
  • the present invention optimizes the beam moving process.
  • a hoisting hole reserved box is installed on the steel side formwork of the prefabricated box girder, and the reserved box is connected to the steel side formwork through bolts.
  • a hoisting reserved hole is formed on the roof above the web of the precast beam.
  • the position and angle of the reserved hole should ensure that the sling comes up from the bottom of the beam and is close to the web concrete. After the sling passes through the reserved hole, it is connected upward with the spreader along the direction of the web, and then the gantry crane moves the beam.
  • Prestressed construction adopts dual control of tension and elongation values.
  • the friction loss between the steel tendon and the anchor ring mouth must also be considered.
  • the specific value of the friction loss at the anchor ring should be determined based on tests, or the data accumulated by the manufacturer and construction unit over the years should be used. Any time the anchor is stretched outside The control stress shall not exceed 0.8fpk.
  • the elongation at both ends should be kept basically the same, and the difference in elongation at both ends should not be greater than 5%.
  • the tension of the prestressed steel tendons reaches the design tension, the error between the actual elongation value and the theoretical elongation value should be controlled within ⁇ 6%.
  • the actual elongation value should be deducted from the influence of inelastic deformation of the steel tendons.
  • the tunnel should be grouted as soon as possible, and generally the grouting should be completed within 48 hours.
  • the grouting sequence of the tunnel should be down first and then up.
  • the steel bars are tied and the end formwork is installed, and the box beam end-capping concrete is poured.
  • the box beam end-capping concrete is poured.
  • rinse the area around the beam end with water after grouting chisel the concrete at the beam end, check to confirm that there are no leaking pipes, and remove the mortar on the surface of the pressure-bearing plate and the mortar on the outside of the anchors. , perform rust-proof treatment on the anchors, and then set up a steel mesh to pour the end-capping concrete.
  • the end-capping concrete should be non-shrinkage concrete, and its strength should not be lower than the concrete strength of the box beam.
  • the length of the beam body after pouring the end-capping concrete must be strictly controlled.
  • the anchor sealing concrete can be poured at the same time as the inner end beam and head concrete of the box.
  • Table 1 shows the lower edge stress of the mid-span section of the prefabricated box girder
  • Table 2 shows the displacement of the beam body after tensioning. It can be seen from these two tables that the compressive stress and displacement of the beam body are both equal in the second tensioning compared with the primary tensioning. Smaller, indicating that the adverse effects caused by shrinkage and creep are smaller.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Structural Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Bridges Or Land Bridges (AREA)

Abstract

本发明提出了一种公路市政预应力混凝土预制箱梁预应力施工的方法，在小箱梁预制时进行初张拉和终张拉，由于采取两次分级张拉，小箱梁初张拉后就可以吊离预制台座，这使得混凝土在预制台座上的时间仅为传统一次张拉所需时间的一半，大大提高预制箱梁制梁台座的周转效率，进而大大提高了单位时间内预制箱梁制作数量。

Description

一种公路市政预应力混凝土预制箱梁预应力施工的方法 技术领域
本发明涉及公路城市桥梁施工技术领域，具体是一种公路市政预应力混凝土预制箱梁预应力施工的方法。
背景技术
预制小箱梁由于工艺成熟、造价经济、施工方便等优势，目前已经成为城市新建高架梁桥较多采用的一种常规施工的预制桥梁结构形式。
城市桥梁施工中，为避免影响城市交通的正常运营，面临工期短，时间紧的情况。小箱梁在预制时，需在混凝土养护后7天(混凝土强度达到设计强度的90％以上)才能进行张拉预应力钢筋，主要因素是混凝土强度低时进行张拉，箱梁上拱后容易造成梁端混凝土开裂。张拉结束后方可进行移梁作业，这增加了制梁台座周转周期。为满足工程进度的需要预制梁场建设规模需要足够大，但是随着国家对环境保护力度的持续加大，临时用地的征用越来越困难。因此，如何缩短制梁台座周转周期，以减少预制场用地，成为技术人员急需解决的问题。
发明内容
本发明提供一种公路市政预应力混凝土预制箱梁预应力施工的方法，包括如下步骤：
(1)箱梁预制
箱梁预制时在箱梁侧模上安装吊装孔预留盒，预留盒与钢侧模通过螺栓连接；同时，在制梁台座端头设置20mm厚硬塑板，箱梁的端部压在硬塑板上；
(2)混凝土养护
(3)钢绞线下料及安装、锚具准备及安装；
(4)第一次张拉
在箱梁梁体混凝土强度达到规范设计值60％后，进行第一次张拉；
(5)移梁
第一次张拉完成后，箱梁从制梁台座上移动到存梁台座上；
(6)第二次张拉
在箱梁梁体混凝土强度及弹性模量达到规范设计值后且龄期不少于7天时进行第二 次张拉；
(7)压浆、封锚。
发明的一种公路市政预应力混凝土预制箱梁预应力施工的方法，在小箱梁预制时进行初张拉和终张拉，由于采取两次分级张拉，小箱梁初张拉后就可以吊离预制台座，这使得混凝土在预制台座上的时间仅为传统一次张拉所需时间的一半，大大提高预制箱梁制梁台座的周转效率，进而大大提高了单位时间内预制箱梁制作数量。
通过该方法，使得在相同产能下，制梁台座需求数量减半，进而制梁区占地面积将减半。减少预制梁场的整体占地面积，节资源投入，产生良好的经济效益。
附图说明
图1为本发明施工方法中的制梁台座示意图；图中①代表预制箱梁，②代表不锈钢底模，③代表沉降缝，④代表10cm厚碎石垫层，⑤代表30cm厚C30钢筋混凝土台座；⑥代表支座预埋钢板，⑦代表30cm厚C30钢筋混凝土扩大基础，⑧代表10cm厚C15混凝土垫层，⑨代表吊装孔，⑩代表硬塑板；
图2为本发明步骤(1)中吊装孔预留盒的安装位置示意图；图中代表吊装孔预留盒，代表螺栓，代表预制箱梁钢侧模；
图3为本发明移梁吊装示意图；图中代表吊具，代表吊带，代表吊装预留孔。
具体实施方式
下面结合附图和实施例对本发明做进一步详细描述，需要指出的是，以下所述实施例旨在便于对本发明的理解，而对其不起任何限定作用。
一种公路市政预应力混凝土预制箱梁预应力施工的方法，其特征在于：包括如下步骤：
(1)箱梁预制
箱梁预制时在箱梁侧模上安装吊装孔预留盒，预留盒与钢侧模通过螺栓连接；同时，在制梁台座端头设置20mm厚硬塑板，箱梁的端部压在硬塑板上，如图1所示；张拉时梁端可向下位移，这种设计可解决预制梁混凝土强度不足梁端开裂问题。
(2)混凝土养护
根据环境温度以及混凝土强度上升的速度确定养护方式。为了尽早进行初张拉，一般需要预制箱梁3天混凝土强度达到设计值的60％以上。建立专人养护以及养护档案卡，便于管理控制，详细箱梁预制养生控制方法为：①环境温度在10以上，3天混凝土强度大于设计强度的60％时，采用洒水养护方式。混凝土浇筑后立即用土工布覆盖并适时洒 水养护，避免曝晒，先脱内模从内养护，而后再脱外模，即加快提高混凝土强度，又使混凝土构件从内冷却。前3天在制梁台座上养护，移梁后到存梁台座上继续养护。做到前7天坚持洒水保持湿润，经常连续养护，并坚持按时段加强养护，后7天内做到间断养生的三段养护法。使结构逐渐干燥，这样可以利用混凝土的徐变性能，对温度及干缩应力起到"卸荷"作用，避免裂缝的发生。②环境温度在10以下或3天混凝土强度小于设计值的60％时，采用蒸汽养护方式。使用蒸养将箱梁包裹，使用蒸汽发生装置给预制箱梁持续蒸养，使混凝土强度3天大于设计强度的60％。移梁以后在存梁区选择继续蒸养或包裹养护。
(3)钢绞线下料及安装、锚具准备及安装；
(4)第一次张拉
在箱梁梁体混凝土强度达到规范设计值60％后，进行第一次张拉；第一次张拉时，箱梁上单根预应力筋的张拉应力为第一张拉应力值；第一张拉应力值为σ1＝0.55fpk，按照该应力值张拉后，箱梁即可从制梁台座上移出。
(5)移梁
第一次张拉完成后，箱梁从制梁台座上移动到存梁台座上；
具体的，移梁时，应先进行试吊，观察过梁体变形情况，确认无误后方可移出制梁台座。传统公路、市政预制箱梁通常在混凝土强度达到设计强度的90％以上时才进行预应力张拉作业，有一个因素是混凝土强度低时进行移梁，容易造成吊装位置梁体受损。如图2所示，本发明在移梁工艺上进行优化，箱梁预制时在预制箱梁钢侧模上安装吊装孔预留盒，预留盒与钢侧模通过螺栓连接。拆模后，如图3所示，在预制梁腹板上方的顶板上形成吊装预留孔，预留孔的位置和角度要保证吊带从梁底上来后紧贴腹板混凝土。吊带穿出预留孔后沿腹板方向向上与吊具连接，再由龙门吊进行移梁。
(6)第二次张拉(终张拉)
在箱梁梁体混凝土强度及弹性模量达到规范设计值后且龄期不少于7天时进行第二次张拉；第二张拉应力值为σ2＝0.75fpk。
预应力施工采用张拉力与伸长值双控。预应力张拉时还需考虑钢束与锚圈口之间的摩擦损失，锚口摩阻损失的具体数值应根据试验确定，或采用厂家及施工单位常年积累的数据，任何时候锚外张拉控制应力不得超过0.8fpk。预应力施工过程中，应保持两端的伸长量基本一致，两端伸长量之差不宜大于5％。当预应力钢束张拉达到设计张拉力时，实际伸长量值与理论伸长值的误差应控制在±6％以内。实际伸长值应扣除钢束的非弹性变形影响。
(7)压浆
第二次张拉(终张拉)完成后，孔道应尽早压浆，一般应在48小时内灌浆完毕。压浆前，先用水将管道清洗干净，然后采用空压机将孔道吹干。对孔道内可能发生的油污等，可采用已知对预应力筋和管道无腐蚀作用的中性洗涤剂或皂液，用水稀释后进行冲洗。孔道压浆顺序应先下后上。
(8)封锚
在箱梁灌浆强度达到要求后，进行钢筋的绑扎和安装端模，浇筑箱梁封端砼。梁端封端砼浇筑前，压浆后应先将梁端周围用水冲干净，对梁端混凝土凿毛，检查确认无漏压的管道，铲除承压板表面的粘浆和锚具外部的灰浆，对锚具进行防锈处理，然后设置钢筋网浇筑封端砼。封端砼应采用无收缩混凝土，强度不低于箱梁混凝土强度，同时必须严格控制浇筑封端砼后的梁体长度。封锚混凝土可与箱内端横梁及封头混凝土同时浇筑。
对预制箱梁进行应力、位移监控，测得数据与正常张拉方法做出比较，得出小箱梁张拉后的应力、位移均能满足要求，可有效缩短工期。以下为一次张拉、分次张拉应力位移对比表。
表1跨中截面下缘应力对比表(单位:MPa)
表2位移对比表(单位:m)

表1表示预制箱梁跨中截面的下缘应力，表2表示张拉后梁体的位移，从这两个表格可以看出，二次张拉相对于一次张拉，梁体压应力和位移均较小，说明收缩徐变引起的不利效应较小。
以上所述，仅是本发明的较佳实施例而已，并非对本发明作任何形式上的限制，虽然本发明已以较佳实施例揭示如上，然而并非用以限定本发明，任何本领域技术人员，在不脱离本发明技术方案范围内，当可利用上述揭示的技术内容做出些许更动或修饰为等同变化的等效实施例，但凡是未脱离本发明技术方案内容，依据本发明的技术实质对以上实施例所作的任何简介修改、等同变化与修饰，均仍属于本发明技术方案的范围内。

Claims (10)

  1. 一种公路市政预应力混凝土预制箱梁预应力施工的方法，其特征在于：包括如下步骤：
    (1)箱梁预制
    箱梁预制时在箱梁侧模上安装吊装孔预留盒，预留盒与钢侧模通过螺栓连接；同时，在制梁台座端头设置20mm厚硬塑板，箱梁的端部压在硬塑板上；
    (2)混凝土养护
    (3)钢绞线下料及安装、锚具准备及安装；
    (4)第一次张拉
    在箱梁梁体混凝土强度达到规范设计值60％后，进行第一次张拉；
    (5)移梁
    第一次张拉完成后，箱梁从制梁台座上移动到存梁台座上；
    (6)第二次张拉
    在箱梁梁体混凝土强度及弹性模量达到规范设计值后且龄期不少于7天时进行第二次张拉；
    (7)压浆、封锚。
  2. 根据权利要求1所述的公路市政预应力混凝土预制箱梁预应力施工的方法，其特征在于：
    第一次张拉时，箱梁上单根预应力筋的张拉应力为第一张拉应力值；第一张拉应力值为σ1＝0.55fpk，按照该应力值张拉后，箱梁即可从制梁台座上移出。
  3. 根据权利要求1所述的公路市政预应力混凝土预制箱梁预应力施工的方法，其特征在于：
    第二次张拉时，箱梁上单根预应力筋的张拉应力为第二张拉应力值；第二张拉应力值为σ2＝0.75fpk。
  4. 根据权利要求1所述的公路市政预应力混凝土预制箱梁预应力施工的方法，其特征在于：
    混凝土养护时，若环境温度在10℃以上或3天混凝土强度大于设计强度的60％时，采用洒水养护方式；
    若环境温度在10以下或3天混凝土强度小于设计值的60％时，采用蒸汽养护方式。
  5. 根据权利要求4所述的公路市政预应力混凝土预制箱梁预应力施工的方法，其特征在于：移梁后，混凝土继续养护；若之前采用的是洒水养护方式，则移梁后到存梁 台座上后继续洒水养护；若之前采用的是蒸汽养护方式，则移梁后在存梁台座上继续蒸汽养护或包裹养护。
  6. 根据权利要求1所述的公路市政预应力混凝土预制箱梁预应力施工的方法，其特征在于：第二次张拉后尽早压浆，48小时内灌浆完毕。
  7. 根据权利要求1所述的公路市政预应力混凝土预制箱梁预应力施工的方法，其特征在于：在箱梁灌浆强度达到要求后，进行钢筋的绑扎和安装端模，浇筑箱梁封端混凝土进行封锚。
  8. 根据权利要求7所述的公路市政预应力混凝土预制箱梁预应力施工的方法，其特征在于：
    封锚前，先将梁端周围用水冲干净，对梁端混凝土凿毛，检查确认无漏压的管道，铲除承压板表面的粘浆和锚具外部的灰浆，对锚具进行防锈处理。
  9. 根据权利要求3所述的公路市政预应力混凝土预制箱梁预应力施工的方法，其特征在于：
    第二次张拉时采用张拉力与伸长值双控的方法；预应力施工过程中，保持两端的伸长量基本一致，两端伸长量之差不宜大于5％。
  10. 根据权利要求9所述的公路市政预应力混凝土预制箱梁预应力施工的方法，其特征在于：
    当预应力钢束张拉达到设计张拉力时，实际伸长量值与理论伸长值的误差应控制在±6％以内。
PCT/CN2023/098477 2022-06-27 2023-06-06 一种公路市政预应力混凝土预制箱梁预应力施工的方法 WO2024001685A1 (zh)

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