Construction method of synchronous pouring type precast concrete fragmented bent cap and component mold and component manufacturing method of synchronous pouring type precast concrete fragmented bent cap

Abstract

The invention discloses a construction method of a synchronous pouring type precast concrete split cover beam, a component mold of the synchronous pouring type precast concrete split cover beam and a component manufacturing method.The combined component mold is composed of a bottom mold, a side mold, a first side mold and a second side mold, and a baffle is arranged in a pouring area of the component mold; a plurality of components can be synchronously manufactured at a time through the mold, then the multiple components are spliced on site and cast in situ to form the component-piece-type prefabricated concrete cover beam, manufacturing of the large-cantilever prefabricated cover beam under the special working conditions that the construction site is narrow, the distance between supporting stand columns is small, cantilevers on the two sides are large, and the stress requirement is high can be achieved, and due to the fact that the prefabricated concrete cover beam is heavy, manufacturing cost is low. The prefabricated concrete cover beam is simple in structure and high in transportation difficulty, the transportation and hoisting difficulty is reduced by manufacturing the multiple components in a split mode, the manufacturing difficulty of the prefabricated concrete cover beam is reduced, meanwhile, manufacturing of the prefabricated concrete cover beam with the larger size and weight can be achieved, and the requirements for the prefabricated concrete cover beam in different projects are effectively met.

Description

Technical Field

[0001] The invention relates to the technical field of urban elevated cap beam manufacturing, and in particular to a construction method of a synchronously cast precast concrete segmented cap beam, a component mold and a component manufacturing method. Background Art

[0002] With the rapid development of urban elevated prefabrication technology, urban elevated roads are mostly prefabricated in factories and then assembled on site, which can effectively improve the construction speed of urban elevated roads and the level of on-site construction civilization. However, with the increasing complexity of construction conditions, traditional integral or segmented prefabricated cap beam technology cannot meet the actual needs of some specific projects. The segmented cap beam can effectively meet the overall force needs of the large cantilevers at both ends of the cap beam, but its related efficient production and manufacturing technology is still lacking. Summary of the invention

[0003] In view of this, the present invention provides a construction method of a synchronously cast precast concrete segmented cap beam and its component mold and component manufacturing method, so as to solve the problems existing in the above-mentioned background technology.

[0004] A synchronous casting type precast concrete segmented cap beam component mold, the precast concrete segmented cap beam includes multiple components and a post-cast strip formed in a casting cavity between the multiple components, the component mold includes a bottom mold, end molds arranged at both ends of the bottom mold, and a first side mold and a second side mold arranged on both sides of the bottom mold, a baffle is arranged in the casting area surrounded by the bottom mold, the end mold, the first side mold and the second side mold, the baffle is arranged in the longitudinal direction to divide the casting area into multiple areas in the transverse direction so that multiple independent components can be cast synchronously, the bottom of the baffle is fixed on the bottom mold, and the top is fixed to the first side mold and the second side mold by multiple baffle hangers, and the baffle is provided with a positioning hole for passing transverse prestressed tendons.

[0005] Preferably, the baffle includes a partition plate and end baffles obliquely fixed at both ends of the partition plate, the partition plate is longitudinally arranged in the casting area and its plate surface is perpendicular to the bottom template of the bottom mold, the bottom of the partition plate is embedded in the bottom template of the bottom mold, and the top of the partition plate is connected to multiple baffle hangers.

[0006] Preferably, the partition plate is provided with one, which divides the casting area into two parts so that two components can be cast simultaneously, and the two ends of the partition plate are provided with oblique notches, and the end baffles are obliquely fixed on the hypotenuse of the oblique notches.

[0007] Preferably, two partition plates are provided, and the two partition plates are parallel to divide the casting area into three parts so that three components can be cast simultaneously. Both ends of the two partition plates are provided with angled notches, and the end baffles are respectively fixed obliquely on the hypotenuse of the angled notches at the two ends of the two partition plates.

[0008] Preferably, the baffle hanger includes a transverse hanger spanning the casting area, hangers arranged at both ends of the transverse hanger, and a hanger connecting rod. The upper end of the hanger is mounted on the first side mold or the second side mold, and the lower end is fixed to the transverse hanger. The hanger connecting rod vertically passes through the transverse hanger and is locked and fixed to the transverse hanger by fasteners, and the lower end of the hanger connecting rod is connected to the top of the partition plate.

[0009] Preferably, a plurality of protrusions are extended upward from the top of the partition plate, and the lower end of the sling connecting rod is fixed on the protrusions.

[0010] Preferably, the bottom mold includes a bottom mold plate and a plurality of bottom mold brackets fixed to the bottom of the bottom mold plate. The shape of the bottom mold plate matches the bottom surface shape of the component, and the upper surface of the bottom mold plate is provided with at least one slot along its length.

[0011] Preferably, the structure of the first side form is the same as that of the second side form, both of which are steel frame structures, and the shape of the steel frame and the shape of the template inside the steel frame match the shape of the outer side surface of the component.

[0012] Preferably, the end mold is a U-shaped steel frame structure, and the end mold is tilted and fixed on the bottom mold.

[0013] A method for manufacturing a synchronously cast precast concrete segmented cap beam component using the component mold described above specifically comprises the following steps:

[0014] S1, placing the bottom mold on a flat ground, setting a positioning plate at the center of the bottom mold, setting a grouting sleeve on the positioning plate, and fixing a baffle on the upper surface of the bottom mold;

[0015] S2, hoisting and fixing the tied steel cages in each area separated by the baffle, and inserting the longitudinal prestressed corrugated pipe, the transverse prestressed corrugated pipe and the reserved ribs in each steel cage, wherein the transverse prestressed corrugated pipe is arranged at the lower part of the steel cage and is aligned with each positioning hole on the baffle, and the reserved ribs are arranged at the upper part of the steel cage;

[0016] S3, setting the first side mold and the second side mold on both sides of the bottom mold, and setting the end mold at both ends of the bottom mold, the bottom mold and the end mold, the first side mold and the second side mold together form a casting area, and the casting area is divided into a plurality of independent areas in the horizontal direction by the baffle plate;

[0017] S4, fixing a plurality of baffle plate hangers on the top of the baffle plate, and connecting two ends of each baffle plate hanger to the first side mold (3) and the second side mold respectively;

[0018] S5, pouring ultra-high performance concrete in the pouring area, and performing maintenance treatment on the formed components after the concrete solidifies;

[0019] S6, prestressed steel strands are inserted into longitudinal and transverse prestressed corrugated pipes;

[0020] S7, demoulding of the component.

[0021] A construction method for a synchronously cast precast concrete segmented cap beam specifically comprises the following steps:

[0022] S1, using the above method to produce multiple components at one time;

[0023] The manufactured multiple components all have longitudinal prestressed steel strands, transverse prestressed steel strands and reserved reinforcements.

[0024] After the components are manufactured, the first batch of longitudinal prestressed steel strands on each component are tensioned;

[0025] S2, hoisting each component onto the pier column and aligning the transverse prestressed steel strands of each component;

[0026] S3, connect the reserved reinforcement of each component through the joint reinforcement, then pour the ultra-high performance concrete into the casting cavity surrounded by the components, and complete the post-casting concrete of the support pad stone and the block at the same time;

[0027] S4, after the strength of the ultra-high performance concrete poured in the pouring cavity surrounded by the components reaches 100% of the design strength, tensioning the second batch of longitudinal prestressed steel strands on each component;

[0028] S5, tensioning the transverse prestressed steel strands on each component, then installing the prefabricated box beam and tensioning the third batch of longitudinal prestressed steel strands on each component;

[0029] S6, bridge deck construction, completed bridge.

[0030] Preferably, the specific steps of hoisting each component on the pier column in step S2 are:

[0031] Pre-assemble all components first;

[0032] Then, all the components are transported to the viaduct construction site and hoisted onto the pier columns, and the transverse prestressed steel strands of each component are aligned;

[0033] Then, grouting is injected into the grouting sleeve of each component to connect each component with the pier column.

[0034] Preferably, the specific steps of pre-assembling all components are:

[0035] Fix one of the components, then lift the other component to make it fit with the fixed component;

[0036] When another component is moved to be in contact with the fixed component, one end of the other component is first fixed on the ground and the other end is slowly lowered. During the process of the other end of the other component slowly lowering to touch the ground steadily, observe whether the transverse prestressed steel strands or reserved bars of the component will collide or interfere with the transverse prestressed steel strands or reserved bars on the fixed component. If no collision or interference occurs, the pre-assembly of the components is completed, otherwise the transverse prestressed steel strands on the components are adjusted.

[0037] Preferably, each time the prestressed steel strands are tensioned, they are tensioned symmetrically, and initial stress is applied first, and then the tensioning force is gradually increased to the design value and maintained for a set time before grouting and anchor sealing.

[0038] The beneficial effects of the present invention are:

[0039] 1. The present invention forms a combined component mold through a bottom mold, a side mold, a first side mold and a second side mold, and a baffle is arranged in the casting area of ​​the component mold. A plurality of components can be simultaneously manufactured at one time by using the mold, and then the plurality of components are assembled on site and cast in situ into piece-type precast concrete cap beams. The manufacture of large cantilever precast cap beams under special working conditions such as narrow construction sites, small support column spacing, large cantilevers on both sides, and high force requirements can be realized. Moreover, since the precast concrete cap beam is heavy and difficult to transport, the difficulty of transportation and hoisting is reduced by manufacturing a plurality of components in pieces, and the difficulty of manufacturing the precast concrete cap beam is reduced. At the same time, the manufacture of precast concrete cap beams of larger size and weight can also be realized, effectively meeting the requirements for precast concrete cap beams in different projects.

[0040] 2. The construction method of the precast concrete cap beam of the present invention can effectively improve the production efficiency and production accuracy of the components, and can be assembled on the ground or at low altitude, reducing the time of high-altitude operations. At the same time, the construction method of the segmented cap beam can save a large amount of auxiliary materials such as formwork and scaffolding, thereby reducing construction costs and reducing construction risks.

[0041] 3. The segmented cap beam can flexibly adapt to different terrains and construction conditions, especially in sites with complex terrain or limited space, the construction of the segmented cap beam is more convenient. At the same time, the construction process of the segmented cap beam reduces the noise, dust, wastewater and other pollutants generated during on-site pouring and maintenance, which helps to reduce the negative impact of construction on the surrounding environment and residents, and is in line with the concept of modern green buildings.

[0042] 4. The precast concrete cap beam of the present invention is divided into three or four parts in the longitudinal direction, which are two or three components and a post-cast strip. Multiple components can be manufactured simultaneously, and the manufactured multiple components are structurally independent of each other and prestressed tendons are reserved. After the multiple components are assembled on site, they are connected and displaced by cast-in-place concrete. Compared with the segmented precast concrete cap beam, it can achieve greater cantilever stress and has a wider range of usage scenarios.

[0043] 5. The structures of the first side form and the second side form used in the component are the same, both of which are composed of a steel frame structure. The steel frame structure can support the overall shape of the component, and the positioning holes on the baffle can realize the precise positioning of the exposed transverse prestressed tendons. The exposed reserved tendons on each component are all L-shaped steel bars, which can greatly reduce the difficulty of post-penetration of the longitudinally laid joint steel bars in the middle cast-in-place post-cast zone. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0045] Figure 1 It is a structural schematic diagram of a two-piece precast concrete cap beam.

[0046] Figure 2 It is a side view of a two-piece precast concrete cap beam.

[0047] Figure 3 It is a structural schematic diagram of a component mold for a two-piece precast concrete cap beam (with the first side mold deleted).

[0048] Figure 4 It is a schematic diagram of the structure of the components on the component mold (the first side mold is deleted) of the two-piece precast concrete cap beam.

[0049] Figure 5 It is a structural schematic diagram of a three-piece precast concrete cap beam.

[0050] Figure 6 It is a side view of a three-piece precast concrete cap beam.

[0051] Figure 7 It is a schematic diagram of the structure of the component mold of the three-piece precast concrete cap beam (the first side mold is deleted).

[0052] Figure 8 It is a schematic diagram of the structure of the components on the component mold (the first side mold is deleted) of the three-piece precast concrete cap beam.

[0053] Fig. 9It is a schematic diagram of the structure of a baffle used for making a two-piece precast concrete cap beam.

[0054] Fig.10 It is a schematic diagram of the structure of the baffle used for making the three-piece precast concrete cap beam.

[0055] Fig.11 It is a structural diagram of the baffle hanger.

[0056] Fig.12 It is a structural diagram of the end mold.

[0057] Fig.13 It is a structural diagram of the bottom mold.

[0058] Fig.14 It is a structural schematic diagram of a mold for a precast concrete segmented cap beam component.

[0059] The meanings of the numbers in the figure are:

[0060] 1 is a bottom mold, 11 is a bottom mold plate, 12 is a bottom mold bracket, 13 is a slot,

[0061] 2 is the end mold,

[0062] 3 is the first side mold,

[0063] 4 is the second side mold,

[0064] 5 is the pouring area,

[0065] 6 is a baffle, 61 is a partition plate, 62 is an end baffle, 63 is an angled notch, 64 is a protrusion, 65 is a positioning hole,

[0066] 7 is a baffle hanger, 71 is a transverse hanger, 72 is a hanger, 73 is a hanger connecting rod,

[0067] 8 is the post-casting belt,

[0068] 9 is a component, 91 is a transverse prestressed steel strand, 92 is a reserved reinforcement, and 93 is a joint reinforcement. DETAILED DESCRIPTION

[0069] In order to make the purpose, technical scheme and advantages of the present invention clearer, the present invention is described below by the specific embodiments shown in the accompanying drawings. However, it should be understood that these descriptions are only exemplary and are not intended to limit the scope of the present invention. In addition, in the following description, the description of well-known structures and technologies is omitted to avoid unnecessary confusion of the concept of the present invention.

[0070] The terms used in this disclosure are for the purpose of describing specific embodiments only and are not intended to limit the disclosure. The singular forms of "a", "said" and "the" used in this disclosure and the appended claims are also intended to include plural forms unless the context clearly indicates otherwise. It should also be understood that the term "and / or" used herein refers to and includes any or all possible combinations of one or more associated listed items.

[0071] In the description of the present invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship are based on the orientation or position relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0072] In the description of the present invention, unless otherwise specified and limited, it should be noted that the terms "installed", "connected" and "connected" should be understood in a broad sense. For example, it can be a mechanical connection or an electrical connection, or it can be the internal connection between two components. It can be a direct connection or an indirect connection through an intermediate medium. For ordinary technicians in this field, the specific meanings of the above terms can be understood according to the specific circumstances.

[0073] In order to better understand the technical solution of the present invention, the present invention is described in detail below with reference to the accompanying drawings.

[0074] The present invention provides a synchronous casting type precast concrete segmented cap beam component mold, including a bottom mold 1, end molds 2 arranged at both ends of the bottom mold 1, and a first side mold 3 and a second side mold 4 arranged on both sides of the bottom mold 2. The bottom mold 1, the end mold 2, the first side mold 3 and the second side mold 4 together enclose a casting area 5.

[0075] The casting area 5 is provided with a baffle 6, which is arranged longitudinally to divide the casting area 5 into a plurality of areas in the transverse direction so that a plurality of independent components can be cast synchronously.

[0076] Specifically, in one embodiment, as shown in the figure, the baffle 6 includes a partition plate 61 and two end baffles 62 fixed obliquely at both ends of the partition plate 61. The partition plate 61 is longitudinally arranged in the middle position of the casting area 5, that is, the partition plate 61 divides the casting area 5 into two independent casting areas, so that when pouring concrete into the area, two components can be poured out simultaneously at one time. Since the two components are separated by the partition plate 61, the two components are independent of each other and are not connected. The partition plate 61 is vertically arranged and its plate surface is perpendicular to the bottom template of the bottom mold 1. The bottom of the partition plate 61 is embedded in the bottom template of the bottom mold 1, and the top is connected to a plurality of baffle hangers 7. The two ends of each baffle hanger 7 are connected to the first side mold 3 and the second side mold 4. The bottom edge shape of the partition plate 61 matches the shape of the bottom mold 1, and the shape of the bottom mold 1 is the same as the bottom plate shape of the component to be cast (that is, the bottom plate shape of the cap beam). The two ends of the partition plate 61 are provided with oblique notches 63, and the end baffles 62 are fixed obliquely on the oblique sides of the oblique notches 63. The lower part of the partition plate 61 is provided with a plurality of positioning holes for passing transverse prestressed tendons, and the plurality of positioning holes are evenly spaced.

[0077] As shown in the figure, in another embodiment, the baffle 6 includes two partition plates 61 and two end baffle plates 62 fixed obliquely at the two ends of the two partition plates 61. The two partition plates 61 are parallel to each other to divide the casting area 5 into three independent casting areas. In this way, when pouring concrete into the area, three components can be cast synchronously at one time. Since the three components are separated by the two baffle plates 6, the three components are independent of each other and are not connected. The two partition plates 61 are both vertically arranged and their plate surfaces are perpendicular to the bottom template of the bottom mold 1. The bottoms of the two partition plates 61 are embedded in the bottom template of the bottom mold 1, and the tops are connected to a plurality of baffle hangers 7. The two ends of each baffle hanger 7 are connected to the first side mold 3 and the second side mold 4. The bottom edge shape of the two partition plates 61 matches the shape of the bottom mold 1, and the shape of the bottom mold 1 is the same as the bottom plate shape of the component to be cast (i.e., the bottom plate shape of the cap beam). Both ends of the two partition plates 61 are provided with oblique notches 63, and the end baffles 62 are respectively fixed on the oblique sides of the oblique notches 63 of the two partition plates 61. The lower part of each partition plate 61 is provided with a plurality of positioning holes for passing transverse prestressed tendons, and the plurality of positioning holes are evenly spaced.

[0078] Of course, in other embodiments, according to actual needs, the baffle 6 can also be set to other shapes and structures.

[0079] The bottom of the baffle plate 6 is embedded in the bottom mold plate of the bottom mold 1 , and the top is fixed to the first side mold 3 and the second side mold 4 through a plurality of baffle plate hangers 7 .

[0080] The structures of all baffle hangers 7 on the top of the baffle 6 are the same. Each baffle hanger 7 includes a transverse hanger 71 spanning the casting area 5, hangers 72 arranged at both ends of the transverse hanger 71, and a hanger connecting rod 73. The upper end of the hanger 72 is mounted on the first side mold 3 or the second side mold 4, and the lower end is fixed to the transverse hanger 71. The hanger connecting rod 73 vertically passes through the transverse hanger 71 and is locked and fixed to the transverse hanger 71 by fasteners, and the lower end of the hanger connecting rod 73 is connected to the top of the partition plate 61. As shown in the figure, the transverse hanger 71 is made of square steel, and the hanger 72 is an inverted L-shaped steel frame. The hanger 72 is hooked on the first side mold or the second side mold so that its horizontal section is in contact with the top surface of the first side mold or the second side mold, and the vertical section is in contact with the inner side surface of the first side mold or the second side mold. The lower ends of the left and right hangers 72 are respectively fixed to the left and right ends of the transverse hanger 71 by bolts; the hanger connecting rod 73 is a screw rod, the lower end of which is fixed to the top of the baffle 6, and the upper end vertically passes through the transverse hanger 71 upward, and is fixed to the transverse hanger 71 by a nut.

[0081] Preferably, a plurality of protrusions 64 are extended upward from the top of the partition plate 61, and the lower end of the sling connecting rod 73 is fixed on the protrusion 64. Specifically, the lower end of the sling connecting rod 73 is directly welded and fixed on the protrusion 64, or other connecting parts and fasteners can be fixed to the protrusion 64. In this embodiment, the protrusion 64 is a rectangular protrusion.

[0082] The bottom mold 1 includes a bottom mold plate 11 and a plurality of bottom mold brackets 12 fixed to the bottom of the bottom mold plate 11. The shape of the bottom mold plate 11 matches the bottom surface shape of the component to be cast. The upper surface of the bottom mold plate 11 is provided with at least one card groove 13 along its length direction. When installing the above-mentioned baffle 6, the bottom of the partition plate 61 of the baffle 6 is clamped in the card groove.

[0083] The structure of the first side mold 3 is the same as that of the second side mold 4, both of which are steel frame structures, and the shape of the steel frame and the shape of the template inside the steel frame match the shape of the outer side surface of the component.

[0084] The end mold 2 is a U-shaped steel frame structure, and the end mold 2 is tilted and fixed on the bottom mold 1.

[0085] When the bottom mold 1, the end mold 2, the first side mold 3 and the second side mold 4 are assembled together, and the baffle 6 is fixed on the upper surface of the bottom mold 1, the casting area 5 surrounded by the bottom mold 1, the end mold 2, the first side mold 3 and the second side mold 4 is divided into multiple areas by the baffle 6, and when pouring concrete into the casting area 5, multiple components can be cast synchronously at one time. When making the precast concrete segmented cap beam, all the cast components are spliced ​​and combined together, and a casting cavity is formed between the multiple components. The cast-in-place concrete in the casting cavity can form a post-casting strip 8.

[0086] The present invention also provides a method for manufacturing a synchronously cast precast concrete segmented cap beam component by using the component mold described above, which specifically comprises the following steps:

[0087] S1, place the bottom form 1 on a flat ground. The bottom form 1 needs to be fixed flat and firmly to avoid movement or structural deformation during the subsequent installation of the steel cage and pouring. The bottom form will not be moved during the subsequent installation of the steel cage and mold closing. After the bottom form 1 is installed, clean the bottom form 1, set a positioning plate at the center of the bottom form 1, and set a grouting sleeve on the positioning plate.

[0088] After the bottom mold 1 is fixed, the baffle 6 is fixed on the upper surface of the bottom mold 1. If the baffle 6 adopts the structure shown in the figure, it divides the casting area 5 into two parts. When the baffle 6 adopts the structure shown in the figure, it divides the casting area 5 into three parts.

[0089] S2, hoisting and fixing the tied steel cages in each area separated by the baffle 6, and inserting longitudinal prestressed corrugated pipes, transverse prestressed corrugated pipes and reserved ribs in each steel cage, wherein the transverse prestressed corrugated pipes are arranged at the lower part of the steel cage and aligned with the positioning holes on the baffle 6, and the reserved ribs are arranged at the upper part of the steel cage.

[0090] The steel cages at various positions should be tied firmly as designed. The welding length of double-sided welding on the skeleton steel bars is 5d, and the welding length of single-sided welding is 10d. The thickness of the net protective layer of the steel bars is not less than 25 mm. A 135° hook is provided at the end of the steel bars. The stirrup joints of adjacent steel bars are staggered longitudinally to avoid looseness or deformation during subsequent pouring of concrete.

[0091] The positions of each steel cage, longitudinal prestressed corrugated pipe and transverse prestressed corrugated pipe should be ensured to be accurate to avoid collision with the mold or other components during subsequent mold closing.

[0092] S3, the first side mold 3 and the second side mold 4 are arranged on both sides of the bottom mold 1, and the end mold 2 is arranged at both ends of the bottom mold 1. The bottom mold 1 and the end mold 2, the first side mold 3 and the second side mold 4 together form a casting area 7, and the casting area 7 is divided into multiple independent areas in the horizontal direction by the baffle 6.

[0093] S4, fixing a plurality of baffle hangers 7 on the top of the baffle 6, and connecting the two ends of each baffle hanger 7 to the first side mold 3 and the second side mold 4 respectively.

[0094] When installing the baffle hanger 7, the hanger 72 can be first hung on the first side mold 3 and the second side mold 4 from the inner side of the first side mold 3 and the second side mold 4, and at the same time, the hanger connecting rod 73 is fixed to the same position on the top of the partition plate 61 of the baffle 6 by welding or other means, and then, the through hole on the transverse hanger 71 is aligned with the hanger connecting rod 73, so that the hanger connecting rod 73 passes through the transverse hanger 71, and after the two ends of the transverse hanger 71 are fixed to the left and right hangers 72, a nut is put on the hanger connecting rod 73, and the nut is screwed down until the nut is tight against the transverse hanger 71.

[0095] S5, pouring ultra-high performance concrete in the pouring area 7, after the concrete solidifies, a plurality of components can be obtained, and then the formed components are cured.

[0096] S6, when the component is cured until its structural strength reaches 100%, prestressed steel strands are inserted into the longitudinal and transverse prestressed corrugated pipes;

[0097] S7, demoulding of the component.

[0098] A construction method for a synchronously cast precast concrete segmented cap beam specifically comprises the following steps:

[0099] S1, using the above method to produce multiple components at one time;

[0100] The manufactured multiple components all have longitudinal prestressed steel strands, transverse prestressed steel strands and reserved reinforcements.

[0101] After the components are manufactured, the first batch of longitudinal prestressed steel strands on each component are tensioned. When tensioning the prestressed steel strands, they should be tensioned symmetrically, and the initial stress should be applied first, and then the tensioning force should be gradually increased to the design value and maintained for a set time before grouting and anchoring. In this embodiment, the first batch of 4 N3 prestressed steel strands are tensioned, and the 4 N3 prestressed steel strands are tensioned symmetrically using double control. First, the initial stress is applied to the 4 N3 prestressed steel strands, and then the tensioning force is gradually increased to the design value, and then anchored after a period of time. After tensioning, the vacuum grouting process is used for grouting and anchoring. The grouting cement strength is not less than 60MPa, and a vacuum grouting agent is used for grouting.

[0102] S2, hoist each component onto the pier column and align the transverse prestressed steel strands of each component.

[0103] Specifically, all components are pre-assembled first: one of the components is fixed first, and then the other component is lifted to fit with the fixed component; when the other component is moved to fit with the fixed component, one end of the other component is first fixed on the ground, and the other end is slowly lowered, and in the process of the other end of the other component slowly lowering to stably touch the ground, observe whether the transverse prestressed steel strands or reserved bars of the component collide or interfere with the transverse prestressed steel strands or reserved bars on the fixed component. If no collision or interference occurs, the pre-assembly of the components is completed, otherwise the transverse prestressed steel strands on the components are adjusted;

[0104] Then, all the components are transported to the viaduct construction site and hoisted onto the pier columns, and the transverse prestressed steel strands of each component are aligned;

[0105] Then, grouting is injected into the grouting sleeve of each component to connect each component with the pier column.

[0106] S3, connect the reserved bars on each component together through the joint steel bars, then pour the ultra-high performance concrete into the casting cavity surrounded by the components, and at the same time complete the post-casting concrete of the support pad stone and the block.

[0107] S4, after the strength of the ultra-high performance concrete poured in the pouring cavity surrounded by the components reaches 100% of the design strength, the second batch of longitudinal prestressed steel strands on each component are tensioned. In this embodiment, the second batch of 2 N2 and 4 N4 prestressed steel strands are tensioned, and the 2 N2 and 4 N4 prestressed steel strands are also tensioned symmetrically by double control. The initial stress is first applied to the 6 prestressed steel strands, and then the tension force is gradually increased to the design value, and anchored after a period of time. After tensioning, the vacuum grouting process is used for grouting and anchoring. The grouting cement strength is not less than 60MPa, and a vacuum grouting agent is used for grouting.

[0108] S5, tension the transverse prestressed steel strands on each component, then install the prefabricated box beam and tension the third batch of longitudinal prestressed steel strands on each component. In this embodiment, the third batch tensions 2 N2 and 4 N1 prestressed steel strands, and still adopts double-controlled symmetrical tensioning. Initial stress is first applied to the 6 prestressed steel strands, and then the tensioning force is gradually increased to the design value, and anchored after a period of time. After tensioning, the vacuum grouting process is used for grouting and anchor sealing. The grouting cement strength is not less than 60MPa, and a vacuum grouting agent is used for grouting.

[0109] S6, bridge deck construction, completed bridge.

[0110] It should be clear that the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

Claims

1. A synchronous casting type precast concrete segmented cap beam component mold, the precast concrete segmented cap beam comprising a plurality of components (9) and a post-cast strip (8) formed in a casting cavity between the plurality of components, characterized in that: The component mold comprises a bottom mold (1), end molds (2) arranged at both ends of the bottom mold (1), and a first side mold (3) and a second side mold (4) arranged on both sides of the bottom mold (2); a baffle (6) is arranged in a casting area (5) enclosed by the bottom mold (1), the end mold (2), the first side mold (3) and the second side mold (4); the baffle (6) is arranged longitudinally to divide the casting area (5) into a plurality of areas in the transverse direction so that a plurality of independent components can be cast synchronously; the bottom of the baffle (6) is fixed on the bottom mold (1), and the top is fixed to the first side mold (3) and the second side mold (4) through a plurality of baffle hangers (7); and a positioning hole (65) for passing a transverse prestressed tendon is provided on the baffle (6).

2. The synchronous casting precast concrete segmented cap beam component mold according to claim 1 is characterized in that: The baffle (6) comprises a partition plate (61) and end baffles (62) fixed obliquely at both ends of the partition plate (61); the partition plate (61) is longitudinally arranged in the casting area (5) and its plate surface is perpendicular to the bottom template of the bottom mold (1); the bottom of the partition plate (61) is embedded in the bottom template of the bottom mold (1); and the top of the partition plate (61) is connected to a plurality of baffle hangers (7).

3. The synchronous casting precast concrete segmented cap beam component mold according to claim 2 is characterized in that: The partition plate (61) is provided with one partition plate (61) which divides the casting area (5) into two parts so that two components can be cast simultaneously. The two ends of the partition plate are provided with oblique notches (63), and the end baffles (62) are obliquely fixed on the oblique sides of the oblique notches (63).

4. The synchronous casting precast concrete segmented cap beam component mold according to claim 2 is characterized in that: Two partition plates (61) are provided, and the two partition plates (61) are parallel to each other so as to divide the casting area (5) into three parts so as to simultaneously cast three components. Both ends of the two partition plates (61) are provided with oblique notches (63), and the end baffles (62) are respectively fixed obliquely on the oblique sides of the oblique notches (63) at the two ends of the two partition plates (61).

5. The synchronous casting precast concrete segmented cap beam component mold according to claim 1 or 2, characterized in that: The baffle hanger (7) comprises a transverse hanger (71) spanning the casting area (5), hangers (72) arranged at both ends of the transverse hanger (71), and a hanger connecting rod (73); the upper end of the hanger (72) is mounted on the first side mold (3) or the second side mold (4), and the lower end is fixed to the transverse hanger (71); the hanger connecting rod (73) vertically passes through the transverse hanger (71) and is locked and fixed to the transverse hanger (71) by fasteners, and the lower end of the hanger connecting rod (73) is connected to the top of the partition plate (61).

6. The synchronous casting precast concrete segmented cap beam component mold according to claim 5 is characterized in that: A plurality of protrusions (64) are also extended upward from the top of the partition plate (61), and the lower end of the hanger connecting rod (73) is fixed on the protrusion (64).

7. The synchronous casting precast concrete segmented cap beam component mold according to claim 1 is characterized in that: The bottom mold (1) comprises a bottom mold plate (11) and a plurality of bottom mold brackets (12) fixed to the bottom of the bottom mold plate (11). The shape of the bottom mold plate (11) matches the shape of the bottom surface of the component. The upper surface of the bottom mold plate (11) is provided with at least one clamping groove (13) along its length direction.

8. The synchronous casting precast concrete segmented cap beam component mold according to claim 1 is characterized in that: The structure of the first side mold (3) is the same as that of the second side mold (4), both of which are steel frame structures, and the shape of the steel frame and the shape of the template inside the steel frame match the shape of the outer side surface of the component.

9. The synchronous casting precast concrete segmented cap beam component mold according to claim 1, characterized in that: The end mold (2) is a U-shaped steel frame structure, and the end mold (2) is tilted and fixed on the bottom mold (1).

10. A method for manufacturing a synchronously cast precast concrete segmented cap beam component using the component mold according to any one of claims 1 to 9, characterized in that: The specific steps include: S1, placing the bottom mold (1) on a flat ground, setting a positioning plate at the center of the bottom mold (1), setting a grouting sleeve on the positioning plate, and fixing a baffle (6) on the upper surface of the bottom mold (1); S2, hoisting and fixing the tied steel cages in each area separated by the baffle (6), and inserting longitudinal prestressed corrugated pipes, transverse prestressed corrugated pipes and reserved ribs in each steel cage, wherein the transverse prestressed corrugated pipes are arranged at the lower part of the steel cage and aligned with each positioning hole on the baffle (6), and the reserved ribs are arranged at the upper part of the steel cage; S3, arranging the first side mold (3) and the second side mold (4) on both sides of the bottom mold (1), arranging the end mold (2) at both ends of the bottom mold (1), the bottom mold (1) and the end mold (2), the first side mold (3) and the second side mold (4) together enclose a casting area (7), and the casting area (7) is divided into a plurality of mutually independent areas in the transverse direction by the baffle plate (6); S4, fixing a plurality of baffle hangers (7) on the top of the baffle (6), and connecting two ends of each baffle hanger (7) to the first side mold (3) and the second side mold (4) respectively; S5, pouring ultra-high performance concrete in the pouring area (7), and performing a curing treatment on the formed components after the concrete solidifies; S6, prestressed steel strands are inserted into longitudinal and transverse prestressed corrugated pipes; S7, demoulding of the component.

11. A construction method for synchronously casting precast concrete segmented cap beams, characterized in that: The specific steps include: S1, using the method of claim 10 to manufacture a plurality of components at one time; The manufactured multiple components all have longitudinal prestressed steel strands, transverse prestressed steel strands and reserved reinforcements. After the components are manufactured, the first batch of longitudinal prestressed steel strands on each component are tensioned; S2, hoisting each component onto the pier column and aligning the transverse prestressed steel strands of each component; S3, connect the reserved reinforcement of each component through the joint reinforcement, then pour the ultra-high performance concrete into the casting cavity surrounded by the components, and complete the post-casting concrete of the support pad stone and the block at the same time; S4, after the strength of the ultra-high performance concrete poured in the pouring cavity surrounded by the components reaches 100% of the design strength, tensioning the second batch of longitudinal prestressed steel strands on each component; S5, tensioning the transverse prestressed steel strands on each component, then installing the prefabricated box beam and tensioning the third batch of longitudinal prestressed steel strands on each component; S6, bridge deck construction, completed bridge.

12. The construction method of synchronous casting precast concrete segmented cap beam according to claim 11, characterized in that: The specific steps of hoisting each component on the pier column in step S2 are: Pre-assemble all components first; Then, all the components are transported to the viaduct construction site and hoisted onto the pier columns, and the transverse prestressed steel strands of each component are aligned; Then, grouting is injected into the grouting sleeve of each component to connect each component with the pier column.

13. The construction method of synchronous casting precast concrete segmented cap beam according to claim 11, characterized in that: The specific steps for pre-assembling all components are as follows: Fix one of the components, then lift the other component to make it fit with the fixed component; When another component is moved to be in contact with the fixed component, one end of the other component is first fixed on the ground and the other end is slowly lowered. During the process of the other end of the other component slowly lowering to touch the ground steadily, observe whether the transverse prestressed steel strands or reserved bars of the component will collide or interfere with the transverse prestressed steel strands or reserved bars on the fixed component. If no collision or interference occurs, the pre-assembly of the components is completed, otherwise the transverse prestressed steel strands on the components are adjusted.

14. The construction method of synchronous casting precast concrete segmented cap beam according to claim 11, characterized in that: Each time the prestressed steel strands are tensioned, they are tensioned symmetrically, and initial stress is applied first. The tensioning force is then gradually increased to the design value and maintained for a set time before grouting and anchoring.

Images