Prefabricated box girder production line and production line construction method using beam transport vehicle to transfer box girders

Abstract

The present invention discloses a prefabricated box girder production line and a production line construction method for transporting box girders using a beam transport vehicle. The prefabricated box girder production line includes a box girder production line unit and a circulating line unit. The box girder production line unit includes a template installation and pouring station, an inner mold insertion and removal station, a curing and pre-tensioning station, a steam curing station, an initial tensioning and reinforcement cage insertion station, and a beam transport vehicle transverse movement area, which are sequentially arranged. The construction method includes installation of the bottom and side mold combination system, reinforcement cage installation, inner mold insertion, end mold installation, concrete pouring, pre-tensioning strength steam curing, strand bundle threading and pre-tensioning, inner mold demolding, initial tensioning strength steam curing, and initial tensioning. The present invention rationally optimizes the production line station layout and combines it with a suitable construction method to significantly improve the production efficiency of the box girder prefabrication production line.

Description

Technical Field

[0001] The invention relates to the technical field of box girder prefabrication, in particular to a prefabricated box girder production line and a production line construction method for transferring the box girder using a beam transport vehicle. Background Art

[0002] Box girders are a key structure in highway and railway bridge construction. Initially, they were cast in-situ, a method associated with long construction periods, significant traffic impacts, high overall energy consumption, numerous on-site construction personnel, and high labor intensity. Later, the concept of prefabricated bridge construction emerged. Box girders are prefabricated in a standardized, centralized manner, constructed simultaneously with the bridge substructure. They are then transported to designated locations by girder transporters and erected by bridge erection machines. This prefabricated bridge construction method significantly improves construction efficiency. With the advancement of construction techniques and technologies, centralized prefabrication of box girders at beam fabrication sites has become mainstream, gradually evolving from traditional fixed-position prefabrication to production lines.

[0003] Traditional prefabricated box girders are prefabricated on a fixed platform. From placing the steel cage into the mold, closing the formwork, pouring to completing the initial tensioning, all are completed on one platform. At present, the technology of this prefabrication method is mature, but it has obvious disadvantages. The main problems are as follows: high construction cost, low degree of automation of mechanical equipment, low production efficiency, low steaming efficiency, and when multiple platforms are poured at the same time, concrete needs to be transported from the mixing station to the pouring site by tank trucks, which is inefficient and consumes a lot of fuel.

[0004] The currently developed production line production method is divided into a bottom mold insertion station, a mold closing and pouring station, an inner mold insertion and exit station, a maintenance and pre-tensioning station, and an initial tensioning station. To a certain extent, it also has the problem of insufficient production efficiency. Specifically, in order to save space in the precast beam yard, multiple processes still need to be completed at one station at the same time. In particular, the mold closing and pouring station needs to complete the bottom mold insertion, side mold closing and grinding, coating agent application, steel cage insertion, inner mold insertion, end mold closing, embedded parts installation, concrete pouring and final setting. The box beam strength development reaches the strength required for the load-bearing formwork to be removed and the formwork is completed before entering the next station. This process takes up too much time in the production line and cannot give full play to the production capacity advantage of the production line. Therefore, it is very necessary to study how to improve the production efficiency of the precast box beam production line. Summary of the Invention

[0005] The present invention discloses a prefabricated box girder production line and a production line construction method using a beam transporter to transport box girders. The production line's workstation layout is rationally optimized, and combined with a suitable construction method, it is beneficial to significantly improve the production efficiency of the box girder prefabrication production line.

[0006] To achieve the above object, the technical solution of the present invention is:

[0007] A prefabricated box girder production line comprises a box girder production line unit and a circulation line unit, wherein:

[0008] The box girder production line unit includes a template installation and pouring station, an inner mold entry and exit station, a maintenance and pre-tensioning station, a steam maintenance station, an initial tensioning and reinforcement cage entry station and a beam transport vehicle transverse movement area, which are arranged in sequence. An inner mold avoidance platform is provided on the outside of the inner mold entry and exit station; the template installation and pouring station is used to complete the installation of the inner mold and the end mold, concrete pouring and final setting, and end mold removal in the bottom mold and side mold combination system with the reinforcement cage installed; the inner mold entry and exit station is used to cooperate with the demoulding and insertion of the inner mold, and provide space for the bottom mold and side mold combination system to return to the template installation and pouring station; the maintenance and pre-tensioning station is used to transfer the inner mold and the end mold to the bottom mold and side mold combination system. The box beam transferred from the formwork installation and casting station is subjected to steam curing for pre-tensioning strength, threading and pre-tensioning of prestressed steel strands, and demolding of the inner mold; the steam curing station is used to steam curing the box beam transferred from the curing and pre-tensioning station for initial tensioning strength; the initial tensioning and reinforcement cage mold insertion station is used to perform initial tensioning on the box beam transferred from the steam curing station, and after the box beam is demolded and transferred, the reinforcement cage is installed in the bottom mold and side mold combination system; the inner mold avoidance station is used to temporarily store the inner mold of the box beam; the beam transport vehicle transverse movement area is used to realize the transfer of the bottom mold and side mold combination system from the box beam production line unit to the circulation line unit;

[0009] The circulating line unit is arranged on one side of the box girder production line unit or between two box girder production line units, extending from the transverse movement area of ​​the beam transport vehicle to the inner mold entry and exit station, and is used to provide space for the beam transport vehicle to move, and transfer the bottom mold and side mold combination system from the initial tensioning and reinforcement cage entry station back to the inner mold entry and exit station;

[0010] The bottom formwork and side formwork combination system is transferred between the box beam production line unit and the circulation line unit through a beam transport vehicle.

[0011] A production line construction method using a beam transport vehicle to transport box beams, wherein the box beams are prefabricated on the above-mentioned production line;

[0012] The construction method includes the following steps:

[0013] S1. Installation of the base and side formwork system and the reinforcement cage: Place the base and side formwork system on the beam transport vehicle and position it at the initial tensioning and reinforcement cage placement station. Apply a release agent and install the reinforcement cage in the designed position. Alternatively, place the base and side formwork system on the beam transport vehicle and position it at the formwork installation and pouring station. Apply a release agent and install the reinforcement cage in the designed position.

[0014] S2. Inner formwork placement and end formwork installation: After the base and side formwork system for the rebar cage is installed, the end and inner formwork are installed at the formwork installation and pouring station. If the base and side formwork system is currently in the initial tensioning and rebar cage placement station, the base and side formwork system is carried by a beam transporter and transferred via the circulating line unit to the formwork installation and pouring station.

[0015] S3. Concrete pouring: After pouring concrete and waiting for the concrete to set, remove the end formwork.

[0016] S4. Pre-tensioning strength steam curing, strand bundle through the bundle and pre-tensioning: The beam transport vehicle carrying the bottom and side formwork combination system and the box girder is transferred to the curing pre-tensioning station, in the steam curing room of the curing pre-tensioning station for automatic steam curing. After the pre-tensioning strength steam curing is completed, the prestressed strand bundle is passed through the bundle and pre-tensioned;

[0017] S5. Inner mold demolding: The inner mold is demolded from the pre-tensioned box girder and returned to the inner mold transfer station on the inner mold entry and exit station; when the next box girder needs to pass through the inner mold entry and exit station, the inner mold is transferred to the inner mold avoidance station to temporarily avoid;

[0018] S6 initial tensioning strength steam curing: After removing the inner mold box girder from the curing pre-tensioning station, with the bottom mold and side mold combination system, under the load of the beam transport vehicle moving, transferred to the steam curing station for initial tensioning strength steam curing;

[0019] S7. Initial tensioning: The box girder after the initial tensioning strength steam curing is completed, with the bottom and side formwork combination system, moved under the load of the beam transport vehicle, transferred to the initial tensioning and reinforcement cage mold station, the initial tensioning, after the completion of the initial tensioning box girder removal bottom and side formwork combination system, into the storage final tensioning area;

[0020] S8. Rebar Cage Installation: Clean the bottom and side formwork systems of the box girder, apply release agent, and install the rebar cage in the designed position.

[0021] The operations of steps S2-S8 are repeated in a cycle; the formwork installation and pouring station, the inner mold insertion and extraction station, the curing and pre-tensioning station, the steam curing station, the initial tensioning and reinforcement cage insertion station simultaneously prefabricate the box beam.

[0022] Furthermore, the formwork installation and pouring station, the curing and pre-tensioning station, the steam curing station, and the initial tensioning and reinforcement cage mold insertion station are provided with at least two strip foundations to support the bottom formwork and side formwork combination system after the beam transport vehicle transfers the bottom formwork and side formwork combination system into place;

[0023] The beam transport vehicle is provided with a beam transport vehicle jack;

[0024] When the beam transport vehicle is transferred into position, the jack of the beam transport vehicle retracts, causing the bottom formwork and side formwork combination system to fall onto the strip foundation, and then the corresponding construction work is carried out; when the construction work of a work station is completed, the jack of the beam transport vehicle is lifted, causing the bottom formwork and side formwork combination system to separate from the strip foundation, and the beam transport vehicle moves to realize the transfer of the bottom formwork and side formwork combination system.

[0025] Furthermore, the bottom formwork and side formwork combination system includes a formwork combination body and a formwork support system;

[0026] The template assembly body includes a bottom mold, a side mold and a bottom mold longitudinal connecting piece. The bottom mold is provided with a bottom mold longitudinal connecting plate protruding downward on both sides, and a plurality of bottom mold longitudinal connecting holes are provided on the bottom mold longitudinal connecting plate at intervals; the lower side of the side mold is provided with a side mold longitudinal connecting plate protruding downward, and a plurality of side mold longitudinal connecting holes are provided on the side mold longitudinal connecting plate at intervals; the bottom mold longitudinal connecting piece passes through the bottom mold longitudinal connecting hole and the side mold longitudinal connecting hole and is fastened to fix the side molds on both sides of the bottom mold;

[0027] The template support system is arranged below and outside the template assembly body, and a hydraulic support system that can be raised and lowered is arranged at the bottom;

[0028] When the bottom formwork and side formwork combination system falls onto the strip foundation, the liftable hydraulic support system adjusts its height to support the ground foundation, so that the hydraulic support system and the strip foundation jointly support the bottom formwork and side formwork combination system.

[0029] Furthermore, the bottom mold includes a bottom mold panel, and bottom mold supporting longitudinal beams are fixed at intervals below the bottom mold panel, and the bottom mold supporting longitudinal beams extend along the length direction of the bottom mold panel, and the length matches the length of the bottom mold panel; the side mold includes a side mold panel, and side mold supporting longitudinal beams are fixed at intervals on the outer side of the side mold panel, and the side mold supporting longitudinal beams extend along the length direction of the side mold panel, and the length matches the length of the side mold panel.

[0030] Furthermore, the bottom form support longitudinal beam is made of I-beam; the side form support longitudinal beam includes a first side form support longitudinal beam and a second side form support longitudinal beam, the first side form support longitudinal beam is fixed to the middle of the web plate of the side form panel and the middle of the upper flange plate of the side form panel, and the second side form support longitudinal beam is fixed at intervals on both sides, the first side form support longitudinal beam is made of I-beam, and the second side form support longitudinal beam is made of channel steel.

[0031] Furthermore, the formwork support system includes a formwork support beam, a back rib support structure, a formwork support beam adjustment assembly, a side formwork support structure and a side formwork hydraulic support mechanism, wherein: the formwork support beam is detachably fixed at equal intervals in the horizontal direction below the bottom formwork and extends outward; the back rib support structure is arranged at intervals outside the side formwork, has a shape matching the side formwork, and one end is fixed on the formwork support beam; the formwork support beam adjustment assembly is fixed below the formwork support beam and is located below the connection position between the back rib support structure and the formwork support beam, and includes a lifting member for adjusting the lifting of the formwork support beam; the side formwork support structure is supported on the outside and below the back rib support structure, and the lower part includes a bottom transverse bracket connected to the formwork support beam adjustment assembly and supports the outer end of the formwork support beam; the side formwork hydraulic support mechanism is arranged below the outer end of the bottom transverse bracket for adjusting the lifting of the formwork support beam;

[0032] The hydraulic support system includes the template support beam adjustment assembly and the side template hydraulic support mechanism.

[0033] Furthermore, the side form support structure includes multiple groups of first vertical supports, second vertical supports, third vertical supports, upper transverse supports, bottom transverse supports and reinforcement connection units, one end of the upper transverse support is fixed to the upper part of the back rib support structure located on the outside of the side form web portion, and the other end is connected to the first vertical support; the upper end of the first vertical support is connected to the lower outer end of the back rib support structure located on the outside of the upper flange plate portion of the side form, and the lower end is connected to the upper outer end of the bottom transverse support; the upper end of the second vertical support is connected to the lower middle part of the upper transverse support, and the lower end is connected to the upper outer end of the formwork supporting beam; the upper end of the third vertical support is connected to the lower outer end of the formwork supporting beam, and the lower end is connected to the bottom transverse support , and is located below the second vertical support; the inner end of the bottom horizontal support is connected to the fixed part of the lifting member; the connections between the multiple first vertical supports and the upper horizontal support and the bottom horizontal support are respectively connected with bracket connecting longitudinal beams; between the back rib support structure and the second vertical support, between the first vertical support and the second vertical support, between adjacent first vertical supports, between adjacent upper horizontal supports, and between adjacent bottom horizontal supports, there are detachably fixed reinforcement connection units, and the reinforcement connection units are single inclined rod support structures or X-shaped support structures or herringbone support structures; vertical supports are spaced apart and connected between the back rib support structure and the upper horizontal support located on the outside of the upper flange plate part of the side form.

[0034] Furthermore, the beam transport vehicle includes a beam transport vehicle frame, beam transport vehicle rollers and beam transport vehicle jacks. The beam transport vehicle frame matches the length of the bottom form and side form combination system, and multiple beam transport vehicle rollers are connected in a rolling manner below, and multiple rows of beam transport vehicle jacks are arranged at intervals above.

[0035] Furthermore, the bottom formwork and side formwork combination system is transferred from the initial tensioning and reinforcement cage mold insertion station to the formwork installation and pouring station through the beam transport vehicle. Specifically, the bottom formwork and side formwork combination system is carried by the beam transport vehicle from the initial tensioning and reinforcement cage mold insertion station, through the circulation line unit, back to the inner mold entry and exit station, and then transferred to the formwork installation and pouring station.

[0036] The above-mentioned prefabricated box girder production line and construction method have the following advantages:

[0037] (1) The present invention rationally optimizes the workstation layout and, in combination with appropriate construction methods, completes the steel cage mold-in process at the initial tensioning and steel cage mold-in process stations. This can reduce the operating procedures of the template installation and pouring stations, reduce the time occupied by the template installation and pouring stations, and improve the prefabrication efficiency of the entire production line.

[0038] (2) The use of beam transport vehicles to transfer box girder prefabrication stations has higher efficiency. The beam transport vehicles move within the prefabrication yard, which makes the process distribution more dispersed and the time difference between each station is smaller, which fully releases the production line capacity.

[0039] (3) The bottom formwork and the side formwork are designed as an integrated whole. The bottom formwork and the side formwork are not separated during the entire prefabrication process. Therefore, there is no need to close or demould the side formwork during the prefabrication process. This simplifies the box girder prefabrication construction process, reduces the operation process of template installation and casting stations, and thus reduces the time occupied by the closing and casting stations, thus reducing the labor cost of construction workers to a certain extent.

[0040] (4) The use of this production line for box girder prefabrication improves the prefabrication efficiency of the box girder, thereby reducing the construction time of construction workers to a certain extent and effectively reducing the cost of box girder prefabrication. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Figure 1 It is a structural schematic diagram of the box girder production line unit and the circulation line unit of the present invention.

[0042] Figure 2 It is a schematic diagram of the main structure of the beam transport vehicle.

[0043] Figure 3 yes Figure 2 Schematic diagram of the top view structure.

[0044] Figure 4 yes Figure 2Schematic diagram of the left side structure (omitted the beam transport vehicle control room).

[0045] Figure 5 It is a structural diagram of the longitudinal connection between the bottom formwork and the side formwork in the formwork assembly body.

[0046] Figure 6 It is a structural diagram of the horizontal connection between the bottom formwork and the side formwork in the formwork assembly body.

[0047] Figure 7 It is a structural diagram of the formwork support system.

[0048] Figure 8 yes Figure 7 Schematic diagram of the right side structure (showing the outer part of one of the dorsal ribs supporting the structure).

[0049] Figure 9 It is a structural diagram of the bottom formwork and side formwork combined system supporting the box girder forming.

[0050] Figure 10 It is a structural diagram of the layout of the formwork support system, strip foundation, beam transporter, bottom formwork and side formwork combination system.

[0051] Figure 11 yes Figure 10 Schematic diagram of the left view structure.

[0052] In the figure, the box girder production line unit 1, the formwork installation and pouring station 101, the end form avoidance station 102, the inner form avoidance station 103, the inner form entry and exit station 104, the curing and pre-tensioning station 105, the steam curing station 106, the initial tensioning and reinforcement cage mold entry station 107, the beam transporter transverse movement area 108, the feeding track 109, the concrete mixing station 110, the circulation line unit 2, the beam transporter 3, the beam transporter control room 301, the beam transporter jack 302, the beam transporter frame 303, the beam transporter roller 304, the box girder 4, the side form 5, the side form panel 501, the side form supporting longitudinal beam 502, the first side form supporting longitudinal beam 502a, the second side form supporting longitudinal beam 502b, and the side form longitudinal connecting plate 503 , baffle formwork 504, bottom formwork 6, bottom formwork panel 601, bottom formwork supporting longitudinal beam 602, bottom formwork longitudinal connecting plate 603, formwork support system 7, first reinforcement connection unit 701, back rib support structure 702, vertical support 703, second reinforcement connection unit 704, upper horizontal bracket 705, third reinforcement connection unit 706, fourth reinforcement connection unit 707, second vertical bracket 708, formwork supporting beam 709, first vertical bracket 710, third vertical bracket 711, bottom horizontal bracket 712, formwork support mechanism adjustment assembly 713, side formwork hydraulic support mechanism 714, bracket connecting longitudinal beam 715, fifth reinforcement connection unit 716, strip foundation 8, working ladder 9. DETAILED DESCRIPTION

[0053] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only some of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts shall fall within the scope of protection of the present invention.

[0054] In the description of the present invention, it should be noted that the terms "upper" and "lower" etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, or are the orientations or positional relationships in which the inventive product is usually placed when in use. These are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, they should not be understood as limitations on the present invention.

[0055] In this application, unless otherwise expressly specified or limited, terms such as "mounted," "connected," "connect," and "fixed" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integration; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal connections between two components or interactions between two components. Those skilled in the art will understand the specific meanings of these terms in this application based on specific circumstances.

[0056] A prefabricated box girder production line, such as Figure 1As shown, it includes: a box girder production line unit 1 and a circulation line unit 2. Among them: the box girder production line unit 1 includes a template installation and casting station 101, an inner mold entry and exit station 104, a maintenance and pre-tensioning station 105, a steam curing station 106, an initial tensioning and steel cage entry station 107 and a beam transport vehicle transverse movement area 108, which are arranged in sequence. An inner mold avoidance platform 103 is provided on the outside of the inner mold entry and exit station 104. Among them: the template installation and casting station 101 is used to complete the installation of the inner mold, end mold, and some embedded parts, concrete pouring and final setting, and end mold removal in the bottom mold and side mold combination system with the steel cage installed, wherein the installation of some embedded parts includes the installation of embedded parts such as ventilation holes, drain holes, and lifting holes. The inner mold entry and exit station 104 is used to cooperate with the demolding and insertion of the inner mold, and provide space for the bottom mold and side mold combination system to return to the template installation and casting station 101. The inner mold avoidance position 103 is used to temporarily store the inner mold to avoid the box girder 4. Specifically, when entering the mold, the inner mold is transferred from the inner mold entry and exit station 104 to the template installation and casting station 101 to complete the inner mold entry. When unmolding, the inner mold is unmolded from the curing and pre-tensioning station 105 to the inner mold entry and exit station 104. The inner mold avoidance position 103 is set. When the box girder 4 of the template installation and casting station 101 is transferred to the curing and pre-tensioning station 105, the inner mold entry and exit station 104 waits for the next beam to be produced and enters the inner mold avoidance position 103 temporarily. After completing the transfer of the box girder 4 to the curing and pre-tensioning station 105, the inner mold is transferred back to the inner mold entry and exit station 104 to wait for entering the mold. The transfer of the inner mold can be completed by using an inner mold transfer trolley. The curing and pre-stressing station 105 is used to steam-cure the box girder 4 transferred from the formwork installation and casting station 101 for pre-stressing strength, thread and pre-stressing the prestressed steel strand bundles, and remove the inner mold; the steam curing station 106 is used to steam-cure the box girder 4 transferred from the curing and pre-stressing station 105 for initial tensioning strength; both the curing and pre-stressing station 105 and the steam curing station 106 perform closed steaming, which is beneficial to improving heat utilization efficiency, and the use of steam curing can greatly shorten the curing time, shorten the prefabrication process time, and improve the prefabrication efficiency. In addition, the occupancy time of the inner mold can be reduced in the curing and pre-stressing station 105, the turnover application efficiency of the inner mold can be improved, and the cost of tooling use can be reduced. The initial tensioning and reinforcement cage mold-in-place station 107 is used to perform initial tensioning on the box girder 4 transferred from the steam curing station 106, and after the box girder 4 is demolded and transferred, the reinforcement cage is installed in the bottom mold and side mold combination system. After the finished box girder 4 is tensioned, the beam is lifted out of the box girder production line unit 1 by the beam lifting machine. At this time, the production of the finished box girder 4 is completed, and the prefabrication of the next box girder 4 is started. That is, the template is polished and cleaned, the release agent is applied, the support plate and the anti-fall beam embedded parts are installed, and then the reinforcement cage is installed.This embodiment always maintains an integrated design of the bottom formwork 6 and the side formwork 5, that is, forming a combined system of the bottom formwork and the side formwork, which reduces the time for dismantling the side formwork. At the same time, the installation steps of the steel cage are reasonably adjusted and completed at the initial tensioning and steel cage mold-entering station 107. This can reduce the operating procedures of the template installation and pouring station 101, reduce the time occupied by the template installation and pouring station 101, and greatly improve the efficiency of box girder prefabrication.

[0057] The circulation line unit 2 is arranged on one side of the box girder production line unit 1, extending from the transverse movement area 108 of the beam transport vehicle to the inner mold entry and exit station 104, and is used to provide space for the movement of the beam transport vehicle 3, and transfer the bottom mold and side mold combination system from the initial tensioning and reinforcement cage mold entry station 107 back to the inner mold entry and exit station 104; the transfer of the bottom mold and side mold combination system in the box girder production line unit 1 and the circulation line unit 2 is achieved by the beam transport vehicle. For the beam transport vehicle 3 to transfer the bottom mold and side mold combination system from the initial tensioning and reinforcement cage mold entry station 107 back to the inner mold entry and exit station 104, specifically, the beam transport vehicle 3 first moves the bottom mold and side mold combination system and the reinforcement cage to the transverse movement area 108 of the beam transport vehicle, and then moves them horizontally to the circulation line unit 2, such as Figure 1 As shown by the arrows in the figure, the beam transport vehicle 3 passes through the space of the circulating line unit 2, moves the bottom and side formwork assembly system and the steel cage to the side of the inner mold insertion and extraction station 104, then moves horizontally back to the inner mold insertion and extraction station 104, and finally returns to the formwork installation and pouring station 101 from the inner mold insertion and extraction station 104. Since the circulating line unit 2 occupies a shorter time, in order to make more rational use of space, a circulating line unit 2 can also be set between two box girder production line units 1.

[0058] The production line construction method adopts the beam transport vehicle 3 to transport the box beam 4, and the box beam 4 is prefabricated on the above-mentioned production line; the construction method includes the following steps:

[0059] S1. Installation of the Bottom and Side Formwork System and the Rebar Cage: The bottom and side formwork system is placed on the beam transport vehicle and placed at the initial tensioning and rebar cage insertion station 107. A release agent is applied, and embedded components, including support plates and anti-drop beams, are installed. The rebar cage is then installed to the designed location. Alternatively, the bottom and side formwork system is placed on the beam transport vehicle and placed at the formwork installation and pouring station 101. A release agent is applied, and embedded components, including support plates and anti-drop beams, are installed. The rebar cage is then installed to the designed location. That is, at the initial start of the production line, installation of the bottom and side formwork system and the rebar cage can be performed at either the initial tensioning and rebar cage insertion station 107 or the formwork installation and pouring station 101.

[0060] S2. Inserting the inner formwork and installing the end formwork: After the bottom formwork and side formwork combination system for the reinforcement cage installation is completed, the end formwork, inner formwork, and embedded parts including ventilation holes, drain holes, and lifting holes are installed at the formwork installation and pouring station 101. If the bottom formwork and side formwork combination system was previously in the initial tensioning and reinforcement cage insertion station 107 after the reinforcement cage installation was completed, the bottom formwork and side formwork combination system is carried by the beam transporter and transferred to the formwork installation and pouring station 101 via the circulation line unit. That is, if the bottom formwork and side formwork combination system completes the reinforcement cage installation at the initial tensioning and reinforcement cage insertion station 107 during the initial installation, it is necessary to transfer the bottom formwork and side formwork combination system to the formwork installation and pouring station 101 and then proceed with the steps of installing the end formwork and inner formwork. If the bottom formwork and side formwork combination system completes the reinforcement cage installation at the formwork installation and pouring station 101 during the initial installation, it is not necessary to transfer the system and the steps of installing the end formwork and inner formwork can be directly carried out after the reinforcement cage installation is completed.

[0061] S3. Concrete pouring: After pouring concrete, wait for the concrete to set and then remove the end formwork.

[0062] S4. Prestressing Strength Steaming, Strand Threading, and Prestressing: The beam transport vehicle carries the combined bottom and side formwork system and box girder to the prestressing station 105. Automatic steam curing is performed in the steam curing room of prestressing station 105. After prestressing strength steaming is completed, prestressing strand threading and prestressing are performed.

[0063] S5. Inner mold demolding: The inner mold is demolded from the pre-tensioned box girder 4 and returned to the inner mold transfer platform on the inner mold insertion and extraction station 104. When the next box girder needs to pass through the inner mold insertion and extraction station 104, the inner mold is transferred to the inner mold avoidance station 103 for temporary avoidance.

[0064] S6. Initial Tension Strength Steam Curing: After removing the inner mold, the box girder 4 moves from the curing and pre-tensioning station 105 along with the bottom mold and side mold combination system under the load of the beam transport vehicle and is transferred to the steam curing station 106 for initial tension strength steam curing.

[0065] S7. Initial Tensioning: After initial tensioning strength curing, the box girder, along with the bottom and side formwork system, is moved under the load of the beam transport vehicle to the initial tensioning and reinforcement cage placement station 107 for initial tensioning. After initial tensioning is completed, the box girder 4 is removed from the bottom and side formwork system and placed in the final tensioning storage area. A beam hoist can be used to operate the box girder 4 in the final tensioning storage area.

[0066] S8. Installation of reinforcement cage: Clean the bottom formwork and side formwork system of the box girder 4, apply release agent, install embedded parts including support plates and anti-drop beams, and install the reinforcement cage to the designed position.

[0067] The operations of steps S2-S8 are repeated repeatedly. Each station in a production line can simultaneously perform its corresponding steps. That is, multiple box girders 4 on the production line are simultaneously undergoing different prefabrication steps. For example, one box girder 4 is being poured with concrete at the formwork installation and pouring station 101, another box girder 4 is being steam-cured for pre-tensioning strength at the curing and pre-tensioning station 105, another box girder 4 is being steam-cured for initial tensioning strength at the steam curing station 106, and the reinforcement cage is being installed at the initial tensioning and reinforcement cage mold placement station 107.

[0068] In addition, to facilitate the casting of the box girder 4, a concrete mixing station 110 can be set outside the formwork installation and casting station 101, and a feeding track 109 is set between the concrete mixing station 110 and the formwork installation and casting station 101. The concrete mixing station 10 can directly send the mixed concrete to the formwork installation and casting station 101 through the feeding track 9 for box girder casting, thereby reducing the repeated transfer of the concrete mixer truck and reducing construction costs.

[0069] Preferably, at least two strip foundations 8 are provided at the formwork installation and pouring station 101, the curing and pre-stressing station 105, the steam curing station 106 and the initial tensioning and steel cage mold-entry station 107, which are used to support the bottom formwork and side formwork combination system after the beam transport vehicle 3 transfers the bottom formwork and side formwork combination system into place. The two strip foundations can symmetrically support the bottom formwork and side formwork combination system with the longitudinal center line of the bottom formwork and side formwork combination system as the center. The strip foundation 8 is for concrete pouring, and the concrete structure support can ensure that the box beam 4 will not shift or sink during the prefabrication process, and the construction safety is higher. A beam transport vehicle jack 302 is provided on the beam transport vehicle 3; when the beam transport vehicle 3 is transferred into position, the beam transport vehicle jack 302 retracts, causing the bottom formwork and side formwork combination system to fall onto the strip foundation 8, and then the corresponding construction work is carried out; when the construction work of a work station is completed, the beam transport vehicle jack 302 is lifted, causing the bottom formwork and side formwork combination system to separate from the strip foundation 8, and the beam transport vehicle 3 moves to realize the transfer of the bottom formwork and side formwork combination system. In addition, since the formwork installation and casting station 101 is provided with a strip foundation 8, when the bottom formwork and side formwork combination system is transferred from the initial tensioning and reinforcement cage mold entry station 107 to the formwork installation and casting station 101 through the beam transport vehicle 3, it is not convenient for the beam transport vehicle 3 to directly move horizontally from the circulation line unit 2 back to the formwork installation and casting station 101. Specifically, the bottom formwork and side formwork combination system is carried by the beam transport vehicle 3 from the initial tensioning and reinforcement cage mold entry station 107, through the circulation line unit 2, back to the inner mold entry and exit station 104, and then transferred to the formwork installation and casting station 101.

[0070] Furthermore, this embodiment also provides a bottom mold and side mold combination system, combined with Figure 9 As shown, the bottom formwork and side formwork combination system includes a template combination body and a template support system 7, as shown in FIG. Figure 5As shown, the template assembly body includes a bottom mold 6, a side mold 5 and a bottom mold longitudinal connector, wherein: the bottom mold 6 is provided with a bottom mold longitudinal connecting plate 603 protruding downward on both sides, the bottom mold longitudinal connecting plate 603 is arranged along the longitudinal direction, and a plurality of bottom mold longitudinal connecting holes are arranged at intervals; the lower side of the side mold 5 is provided with a side mold longitudinal connecting plate 503 protruding downward, the side mold longitudinal connecting plate 503 is also arranged along the longitudinal direction, and a plurality of side mold longitudinal connecting holes are arranged at intervals; the side mold longitudinal connecting plate 503 and the bottom mold longitudinal connecting plate 603 are both arranged along the longitudinal direction. Figure 5 The longitudinal connection pieces of the bottom formwork are arranged in the front-to-back direction as shown in . The longitudinal connection pieces of the bottom formwork pass through the longitudinal connection holes of the bottom formwork and the longitudinal connection holes of the side formwork and are tightened to fix the side formwork 5 on both sides of the bottom formwork 6. Of course, the longitudinal connection plates 503 of the side formwork and the longitudinal connection plates 603 of the bottom formwork must fit together to stably fix the side formwork 5 and the bottom formwork 6 together. For the longitudinal connection pieces of the bottom formwork, a combination of bolts and nuts commonly used in engineering is used. The bolts pass through the longitudinal connection holes of the bottom formwork and the longitudinal connection holes of the side formwork, and the other ends are tightened with nuts. This combination of the bottom formwork and the side formwork is fixed together throughout the prefabrication process of the box girder 4. When transportation or replacement is required, the longitudinal connection pieces of the bottom formwork are removed to separate the bottom formwork 6 and the side formwork 5. The formwork support system 7 is arranged below and outside the formwork assembly body, with a hydraulic support system installed at the bottom. When the base and side formwork assembly system drops onto the strip foundation 8, the hydraulic support system adjusts its height to support it above the ground foundation, so that the hydraulic support system and strip foundation 8 jointly support the base and side formwork assembly system. The strip foundation 8 is primarily supported below the base form 6, and the hydraulic support system is primarily supported below the side form 5 and the formwork support system 7. The hydraulic support system ensures that after the workstation is transferred, the formwork support system 7 outside the strip foundation 8 is supported on the ground foundation, preventing partial structural overhang, which could cause deformation and damage to some areas of the formwork structure and result in the internal prefabricated box girder 4 not meeting structural requirements.

[0071] In addition, a baffle formwork 504 is fixed on the outer side of the side formwork 5 to fix the shape of the outer side surface of the upper flange plate of the box beam 4. This is existing technology and will not be described in detail.

[0072] Preferably, since the bottom formwork 6 and the side formwork 5 need to carry the box girder 4 for transfer, in order to prevent the box girder 4 from deforming, the present embodiment optimizes the structure of the bottom formwork 6 and the side formwork 5. The bottom formwork 6 includes a bottom formwork panel 601, which is a conventional structure. Below the bottom formwork panel 601, bottom formwork supporting longitudinal beams 602 are fixed at intervals. The bottom formwork supporting longitudinal beams 602 extend along the length of the bottom formwork panel 601 and their lengths match the length of the bottom formwork panel 601. The bottom formwork supporting longitudinal beams 602 are parallel to each other and are preferably arranged at equal distances. The side formwork 5 includes a side formwork panel 501. Side formwork supporting longitudinal beams 502 are fixed at intervals on the outer side of the side formwork panel 501. The side formwork supporting longitudinal beams 502 extend along the length of the side formwork panel 501 and their lengths match the length of the side formwork panel 501. The side formwork supporting longitudinal beams 502 are also parallel to each other. The bottom formwork supporting longitudinal beams 602 and the side formwork supporting longitudinal beams 502 can ensure the strength of the bottom formwork and side formwork combination system, and better ensure that the box girder will not have quality problems such as cracks and deformation during the casting and transfer process. Preferably, this embodiment provides a material for a bottom formwork supporting longitudinal beam 602 and a side formwork supporting longitudinal beam 502. The bottom formwork supporting longitudinal beam 602 is made of I-beams. Since the bottom formwork 6 bears a large load, the use of I-beams can better ensure the support strength. The side formwork supporting longitudinal beams 502 include a first side formwork supporting longitudinal beam 502a and a second side formwork supporting longitudinal beam 502b. The first side formwork supporting longitudinal beam 502a is fixed to the middle of the web plate of the side formwork panel 501 and the middle of the upper flange plate of the side formwork panel 501. Second side formwork supporting longitudinal beams 502b are fixed on both sides at intervals. The first side formwork supporting longitudinal beam 502a is made of I-beams, and the second side formwork supporting longitudinal beam 502b is made of channel steel. I-beams are fixed to the locations where the side formwork 5 bears a large load for reinforcement, and channel steels can be used for reinforcement at other locations. The bottom formwork supporting longitudinal beam 602 and the side formwork supporting longitudinal beam 502 are respectively connected to the bottom formwork panel 601 and the side formwork panel 501 by welding.

[0073] In addition, due to the large length of the box beam, in order to facilitate transportation and storage, the bottom mold 6 includes a plurality of bottom mold segments connected together along the length direction (ie, along the longitudinal direction), combined with Figure 6 As shown, the front and rear sides of the bottom mold segment are provided with bottom mold transverse connecting plates 204 protruding downwards; the bottom mold transverse connecting plates 204 are arranged transversely, i.e. Figure 6In the left and right directions shown in the figure, the bottom mold transverse connecting plates 204 of adjacent bottom mold segments are pasted together and fixed by the bottom mold transverse connecting pieces, and are spliced ​​to form the bottom mold 6. For the convenience of installation, the bottom mold 6 can be divided into multiple bottom mold segments of equal length, so that there is no need to limit the splicing order; similarly, the side mold 5 includes multiple side mold segments connected together along the length direction, and the front and rear sides of the side mold segments are provided with downwardly protruding side mold transverse connecting plates 105; the side mold transverse connecting plates 105 of adjacent side mold segments are pasted together and fixed by the side mold transverse connecting pieces, and are spliced ​​to form the side mold 5. The bottom formwork transverse connectors utilize a combination of bolts and nuts commonly used in engineering. The bottom formwork transverse connecting plates 204 are intermittently perforated with bottom formwork transverse connecting holes 205. Bolts are inserted through the bottom formwork transverse connecting holes 205 of the two bottom formwork transverse connecting plates 204 and tightened with nuts at the other ends to achieve the front-to-back connection of the bottom formwork 6. The same is true for the front-to-back connection of the side formwork 5. The side formwork transverse connecting plates 105 are intermittently perforated with side formwork transverse connecting holes 106, which are also used to connect the side formwork segments. Preferably, the bottom formwork segments and the side formwork segments have the same longitudinal length to facilitate the longitudinal connection between the bottom formwork and side formwork segments after each bottom formwork segment is connected to the side formwork segment in the transverse direction.

[0074] Preferably, a template support system 7 is provided below and outside the template assembly body, and the template support system 7 supports the template assembly body. Figure 7-8As shown, this embodiment provides a structure of one of the formwork support systems 7, which includes a formwork support beam 709, a back rib support structure 702, a formwork support beam adjustment assembly 713, a side formwork support structure and a side formwork hydraulic support mechanism 714; the formwork support beam 709 is detachably fixed at intervals laterally below the bottom formwork 6 and extends outward, and in this embodiment is perpendicular to the bottom formwork support longitudinal beam 602. Specifically, the formwork support beam 709 is arranged laterally and spaced apart along the longitudinal direction (i.e., the length direction) below the bottom formwork 6 to support the bottom formwork 6. When the workstation is transferred, it bears the structural deadweight of the protruding suspended part of the bottom formwork and side formwork combination system on the beam transport vehicle 3; the back rib support structure 702 is arranged at intervals laterally outside the side formwork 5, and its shape matches the side formwork 5, forming an up and down direction for the side formwork 5 The support has one end fixed on the formwork support beam 709, which is vertically connected to the side formwork support longitudinal beam 502. The connection method can be welding. The spacing between the back rib support structures 702 matches the spacing of the formwork support beams 709; the formwork support beam adjustment assembly 713 is fixed under the formwork support beam 709 and is located below the connection position between the back rib support structure 702 and the formwork support beam 709, and includes a lifting part for adjusting the lifting of the formwork support beam; the side formwork support structure is supported on the outside and below the back rib support structure 702, and the lower part includes a bottom horizontal bracket 712 connected to the formwork support beam adjustment assembly, and supports the outer end of the formwork support beam 709; the side formwork hydraulic support mechanism 714 is arranged below the outer end of the bottom horizontal bracket 712, and is used to adjust the lifting of the formwork support beam. The side formwork support structure supports the side formwork 5, and the formwork support beam adjustment component 713 and the side formwork hydraulic support mechanism 714 jointly support the bottom formwork 6 and the side formwork support structure, forming a hydraulic support system that can be raised and lowered for the formwork support system 7. The two simultaneously lift or retract to adjust the rise and fall of the inside and outside of the bottom formwork 6 and the side formwork support structure. After the bottom formwork and side formwork combination system is transferred to the workstation, the formwork support beam adjustment component 713 and the side formwork hydraulic support mechanism 714 are lifted and supported on the ground foundation. In combination with each construction workstation, a strip foundation 8 is provided to transfer the deadweight load of the box beam 4 and the formwork, as well as the construction operation load, to the ground foundation to ensure the safety of the box beam 4 construction and the product quality. Of course, by Figure 7 It is obvious that the formwork support system 7 has two groups, one for each side form 5, and is symmetrical with respect to the longitudinal center line of the bottom form 6. Figure 10As shown, the process of the beam transport vehicle 3 carrying the bottom formwork and side formwork combination system to transfer between different workstations is as follows: during the prefabrication process of the box beam 4, the beam transport vehicle 3 carries the bottom formwork and side formwork combination system to transfer between different workstations. After the transfer is in place, the beam transport vehicle jack 302 on the beam transport vehicle 3 retracts, causing the bottom formwork and side formwork combination system to fall to the position of the strip foundation 8 of the workstation. At this time, the hydraulic support system at the bottom of the formwork support system 7 also rises downward to support the formwork support system 7. The box beam 4 and the formwork self-weight load, and the construction operation load are transmitted to the ground foundation through the strip foundation 8 and the hydraulic support system; when the operation of one workstation is completed and the bottom formwork and side formwork combination system needs to be transferred to the next workstation, the hydraulic support system retracts, and the beam transport vehicle jack 302 rises, causing the bottom formwork and side formwork combination system to separate from the strip foundation 8, and the bottom formwork and side formwork combination system can be transferred by the beam transport vehicle 3.

[0075] Preferably, the side form support structure includes multiple groups of first vertical supports 710, second vertical supports 708, third vertical supports 711, upper transverse supports 705, bottom transverse supports 712 and reinforced connection units, one end of the upper transverse support 705 is fixed to the upper part of the back rib support structure 702 located on the outside of the web portion of the side form 5, and the other end is connected to the first vertical support 710; the upper end of the first vertical support 710 is connected to the lower outer end of the back rib support structure 702 located on the outside of the upper flange plate portion of the side form 5, and the lower end is connected to the upper outer end of the bottom transverse support 712; the upper end of the second vertical support 708 is connected to the lower middle part of the upper transverse support 705, and the lower end is connected to the upper outer end of the template support beam 709. When the workstation is transferred, the template support beam adjustment assembly 713 and the side form hydraulic support mechanism 714 are not supported on the ground, and the bottom form and The weight of the structure of the overhanging suspended part of the side form assembly system on the beam transport vehicle 3 is transferred to the formwork support beam 709, which provides support and guarantee; the first vertical bracket 710 supports the outer end of the side form 5, and the second vertical bracket 708 supports the part of the side form 5 close to the web, so that the side form 5 can ensure the partial quality stability of the flange plate of the box girder 4; the upper end of the third vertical bracket 711 is connected to the lower side of the outer end of the formwork support beam, and the lower end is connected to the upper side of the bottom horizontal bracket 712, and is located below the second vertical bracket 708. The third vertical bracket 711 enables the formwork support beam 709 and other components of the side form support structure to be connected as one; the inner end of the bottom horizontal bracket 712 is connected to the fixed part of the lifting member, that is, when the formwork support beam adjustment assembly 713 is lifted or retracted, the bottom horizontal bracket 712 will not hinder its movement; combined with Figure 8As shown, a first vertical support 710, a second vertical support 708, a third vertical support 711, an upper horizontal support 705, a bottom horizontal support 712, and a formwork support beam 709 constitute a horizontal side formwork support structure unit. The horizontal side formwork support structure units are equidistantly arranged to avoid structural damage caused by excessive local loads; the connection points of the multiple first vertical supports 710 and the upper horizontal support 705 and the bottom horizontal support 712 are respectively connected with support connecting longitudinal beams 715, and the side formwork support structure units in the entire length direction of the formwork can be connected as a whole through the support connecting longitudinal beams 715; combined with Figure 10 and Figure 11 As shown, there are detachably fixed reinforcement connection units between the back rib support structure 702 and the second vertical bracket 708, between the first vertical bracket 710 and the second vertical bracket 708, between adjacent first vertical brackets 710, between adjacent upper horizontal brackets 705, and between adjacent bottom horizontal brackets 712. The reinforcement connection units can improve the integrity of the side form support structure and the stability of the support. The connections between the various components of the side form support structure can be connected by bolts. The reinforcement connection unit is a single diagonal rod support structure or an X-shaped support structure or a herringbone support structure, but this embodiment provides a more preferred reinforcement connection unit structure combination, combined with Figure 7 As shown, a third reinforcement connection unit 706 is provided between adjacent first vertical brackets 710. It is an X-shaped connection rod structure, with the upper end provided at the connection between the first vertical bracket 710 and the bracket connecting longitudinal beam 715 located above, and the lower end provided at the connection between the first vertical bracket 710 and the bracket connecting longitudinal beam 715 located below, forming a structure similar to a scissors brace. The third reinforcement connection unit 706 can be made of angle steel. Figure 7As shown, a second reinforcement connection unit 704 is also provided between adjacent upper horizontal brackets 705, which is also an X-shaped connection rod structure. The connecting rod of the second reinforcement connection unit 704 can be seen in the figure, but there is no top view, and the X-shaped structure cannot be seen. The two ends of each rod are respectively arranged at the connection between the upper horizontal bracket 705 and the first vertical bracket 710 and the diagonally opposite second vertical bracket 708 (the second vertical bracket 708 of the adjacent other side mold support structure unit), and the materials can refer to the third reinforcement connection unit 706; a fifth reinforcement connection unit 716 is also provided between adjacent bottom horizontal brackets 712, and the two ends of each rod are respectively arranged at the connection between the bottom horizontal bracket 712 and the diagonally opposite second vertical bracket 708 (the second vertical bracket 708 of the adjacent other side mold support structure unit), and the materials can refer to the second reinforcement connection unit 704. The reinforcement connection unit between the back rib support structure 702 and the second vertical bracket 708, namely the first reinforcement connection unit 701, is a diagonal support rod connecting the diagonals, one end of which is connected to the connection position of the back rib support structure 702 and the formwork support beam 709, and the other end is connected to the connection position of the second vertical bracket 708 and the upper horizontal bracket 705. Angle steel can be used, and corresponding connecting plates are set to form a bolt connection; the reinforcement connection unit between the first vertical bracket 710 and the second vertical bracket 708 forms a triangular reinforcement structure with the second vertical bracket 708, namely the fourth reinforcement connection unit 707 shown in the figure. The vertex of the triangular reinforcement structure is on the first vertical bracket 710, so that the load of the side form is evenly transferred to the ground foundation through the first vertical bracket 710 and the formwork support beam 709. Vertical supports 703 are spaced apart between the back rib support structure 702 and the upper transverse support 705 located on the outside of the upper flange plate portion of the side form 5 to form more load transfer points on the outside of the side form 5, thereby preventing the upper flange plate portion of the box girder 4 from being locally deformed due to the side form 5 and affecting product quality.

[0076] In addition, a working platform can be set on the outside of the outer surface of the side form 5 and the top surface of the back rib support structure 702. In addition, a working ladder 9 can be set on the formwork support system 7, so that people can climb from the ground foundation to the working platform.

[0077] Preferably, the lifting parts of the template support beam adjustment assembly 713 and the side template hydraulic support mechanism 714 are hydraulic jacks. Hydraulic jacks are easy to operate and control and are the preferred lifting structure.

[0078] More preferably, this embodiment provides a structure of a beam transport vehicle 3, combined with Figure 2-4As shown, the beam transport vehicle 3 includes a beam transport vehicle frame 303, beam transport vehicle rollers 304, and beam transport vehicle jacks 302. The beam transport vehicle frame 303 matches the length of the bottom formwork and side formwork combination system to match and support the bottom formwork and side formwork combination system and transfer it. The beam transport vehicle frame 303 is connected to a plurality of beam transport vehicle rollers 304 for rolling connection below, and a plurality of rows of beam transport vehicle jacks 302 are arranged at intervals above. When the beam transport vehicle 3 needs to transfer the bottom formwork and side formwork combination system, the beam transport vehicle jacks 302 are lifted to lift the bottom formwork and side formwork combination system so that it is no longer supported by the strip foundation 8. The beam transport vehicle 3 then moves to transfer the bottom formwork and side formwork combination system to a suitable workstation. After the transfer is in place, the beam transport vehicle jacks 302 retract so that the bottom formwork and side formwork combination system is supported by the strip foundation 8. A beam transport vehicle control room 301 is provided at the front or rear end of the beam transport vehicle frame 303, which can separately control the front and rear beam transport vehicle rollers 304 to realize the front diagonal or rear diagonal movement adjustment of the beam transport vehicle, as well as the overall lateral movement. The overall lateral movement can be achieved by walking in a W-shaped route.

[0079] In addition, this embodiment provides a specific solution for the installation and removal of end forms. To facilitate storage, an end form avoidance platform 102 can be provided at the end of the formwork installation and pouring station 101 away from the inner form entry and exit station 104. An end form avoidance platform 102 is also provided at the end of the inner form avoidance platform 103 closer to the formwork installation and pouring station 101. Each set of box girder formwork is matched with two sets of end forms, one at the front and rear ends. Before installation, the end forms are placed in the end form avoidance platform 102. When installation is required, the end forms at one end of the inner form avoidance platform 103 are transferred to the front end of the formwork installation and pouring station 101 for installation. The transfer of the end forms can be achieved by using an end form installation platform. Figure 1 As shown in , with the direction of the box girder 4 moving forward as the front, there is a box girder production line unit 1 on each side of the circulation line unit 2. In the schematic diagram of the box girder production line unit 1 on the right, the end mold has been transferred to the front end of the template installation and pouring station 101. In the schematic diagram of the box girder production line unit 1 on the left, the end mold is still located at the inner mold avoidance position 103 close to one end of the template installation and pouring station 101. In addition, an additional explanation is given here on the coordinated transfer of the inner mold. In the schematic diagram of the box girder production line unit 1 on the right, the inner mold transfer trolley is located in the inner mold entry and exit station 104. At this time, the installation of the inner mold has been completed, and then the end mold is moved to the front end of the template installation and pouring station 101. In the schematic diagram of the box girder production line unit 1 on the left, the inner mold transfer trolley avoids in the inner mold avoidance position 103.

Claims

1. A prefabricated box girder production line, characterized by: It includes box girder production line unit and circulation line unit, including: The box girder production line unit includes a template installation and pouring station, an inner mold entry and exit station, a maintenance and pre-tensioning station, a steam maintenance station, an initial tensioning and reinforcement cage entry station and a beam transport vehicle transverse movement area, which are arranged in sequence. An inner mold avoidance platform is provided on the outside of the inner mold entry and exit station; the template installation and pouring station is used to complete the installation of the inner mold and the end mold, concrete pouring and final setting, and end mold removal in the bottom mold and side mold combination system with the reinforcement cage installed; the inner mold entry and exit station is used to cooperate with the demoulding and insertion of the inner mold, and provide space for the bottom mold and side mold combination system to return to the template installation and pouring station; the maintenance and pre-tensioning station is used to transfer the inner mold and the end mold to the bottom mold and side mold combination system. The box beam transferred from the formwork installation and casting station is subjected to steam curing for pre-tensioning strength, threading and pre-tensioning of prestressed steel strands, and demolding of the inner mold; the steam curing station is used to steam curing the box beam transferred from the curing and pre-tensioning station for initial tensioning strength; the initial tensioning and reinforcement cage mold insertion station is used to perform initial tensioning on the box beam transferred from the steam curing station, and after the box beam is demolded and transferred, the reinforcement cage is installed in the bottom mold and side mold combination system; the inner mold avoidance station is used to temporarily store the inner mold of the box beam; the beam transport vehicle transverse movement area is used to realize the transfer of the bottom mold and side mold combination system from the box beam production line unit to the circulation line unit; The circulating line unit is arranged on one side of the box girder production line unit or between two box girder production line units, extending from the transverse movement area of ​​the beam transport vehicle to the inner mold entry and exit station, and is used to provide space for the beam transport vehicle to move, and transfer the bottom mold and side mold combination system from the initial tensioning and reinforcement cage entry station back to the inner mold entry and exit station; The bottom formwork and side formwork combination system is transferred between the box beam production line unit and the circulation line unit through a beam transport vehicle.

2. A production line construction method using a beam transport vehicle to transport box beams, characterized in that: The box beam is prefabricated on the production line described in claim 1; The construction method includes the following steps: S1. Installation of the base and side formwork system and the reinforcement cage: Place the base and side formwork system on the beam transport vehicle and position it at the initial tensioning and reinforcement cage placement station. Apply a release agent and install the reinforcement cage in the designed position. Alternatively, place the base and side formwork system on the beam transport vehicle and position it at the formwork installation and pouring station. Apply a release agent and install the reinforcement cage in the designed position. S2. Inner formwork placement and end formwork installation: After the base and side formwork system for the rebar cage is installed, the end and inner formwork are installed at the formwork installation and pouring station. If the base and side formwork system is currently in the initial tensioning and rebar cage placement station, the base and side formwork system is carried by a beam transporter and transferred via the circulating line unit to the formwork installation and pouring station. S3. Concrete pouring: After pouring concrete and waiting for the concrete to set, remove the end formwork. S4. Pre-tensioning strength steam curing, strand bundle through the bundle and pre-tensioning: The beam transport vehicle carrying the bottom and side formwork combination system and the box girder is transferred to the curing pre-tensioning station, in the steam curing room of the curing pre-tensioning station for automatic steam curing. After the pre-tensioning strength steam curing is completed, the prestressed strand bundle is passed through the bundle and pre-tensioned; S5. Inner mold demolding: The inner mold is demolded from the pre-tensioned box girder and returned to the inner mold transfer station on the inner mold entry and exit station; when the next box girder needs to pass through the inner mold entry and exit station, the inner mold is transferred to the inner mold avoidance station to temporarily avoid; S6 initial tensioning strength steam curing: After removing the inner mold box girder from the curing pre-tensioning station, with the bottom mold and side mold combination system, under the load of the beam transport vehicle moving, transferred to the steam curing station for initial tensioning strength steam curing; S7. Initial tensioning: The box girder after the initial tensioning strength steam curing is completed, with the bottom and side formwork combination system, moved under the load of the beam transport vehicle, transferred to the initial tensioning and reinforcement cage mold station, the initial tensioning, after the completion of the initial tensioning box girder removal bottom and side formwork combination system, into the storage final tensioning area; S8. Rebar Cage Installation: Clean the bottom and side formwork systems of the box girder, apply release agent, and install the rebar cage in the designed position. The operations of steps S2-S8 are repeated in a cycle; the formwork installation and pouring station, the inner mold insertion and extraction station, the curing and pre-tensioning station, the steam curing station, the initial tensioning and reinforcement cage insertion station simultaneously prefabricate the box beam.

3. The production line construction method according to claim 2, characterized in that: The formwork installation and pouring station, the curing and pre-tensioning station, the steam curing station, and the initial tensioning and reinforcement cage mold insertion station are provided with at least two strip foundations to support the bottom formwork and side formwork combination system after the beam transport vehicle transfers the bottom formwork and side formwork combination system into place; The beam transport vehicle is provided with a beam transport vehicle jack; When the beam transport vehicle is transferred into position, the jack of the beam transport vehicle retracts, causing the bottom formwork and side formwork combination system to fall onto the strip foundation, and then the corresponding construction work is carried out; when the construction work of a work station is completed, the jack of the beam transport vehicle is lifted, causing the bottom formwork and side formwork combination system to separate from the strip foundation, and the beam transport vehicle moves to realize the transfer of the bottom formwork and side formwork combination system.

4. The production line construction method according to claim 3, characterized in that: The bottom formwork and side formwork combination system includes a template combination body and a template support system; The template assembly body includes a bottom mold, a side mold and a bottom mold longitudinal connecting piece. The bottom mold is provided with a bottom mold longitudinal connecting plate protruding downward on both sides, and a plurality of bottom mold longitudinal connecting holes are provided on the bottom mold longitudinal connecting plate at intervals; the lower side of the side mold is provided with a side mold longitudinal connecting plate protruding downward, and a plurality of side mold longitudinal connecting holes are provided on the side mold longitudinal connecting plate at intervals; the bottom mold longitudinal connecting piece passes through the bottom mold longitudinal connecting hole and the side mold longitudinal connecting hole and is fastened to fix the side molds on both sides of the bottom mold; The template support system is arranged below and outside the template assembly body, and a hydraulic support system that can be raised and lowered is arranged at the bottom; When the bottom formwork and side formwork combination system falls onto the strip foundation, the liftable hydraulic support system adjusts its height to support the ground foundation, so that the hydraulic support system and the strip foundation jointly support the bottom formwork and side formwork combination system.

5. The production line construction method according to claim 4, characterized in that: The bottom mold includes a bottom mold panel, and bottom mold supporting longitudinal beams are fixed at intervals below the bottom mold panel. The bottom mold supporting longitudinal beams extend along the length direction of the bottom mold panel, and the length matches the length of the bottom mold panel; the side mold includes a side mold panel, and side mold supporting longitudinal beams are fixed at intervals on the outer side of the side mold panel. The side mold supporting longitudinal beams extend along the length direction of the side mold panel, and the length matches the length of the side mold panel.

6. The production line construction method according to claim 5, characterized in that: The bottom formwork supporting longitudinal beam is made of I-beam; the side formwork supporting longitudinal beam includes a first side formwork supporting longitudinal beam and a second side formwork supporting longitudinal beam, the first side formwork supporting longitudinal beam is fixed to the middle part of the web plate of the side formwork panel and the middle part of the upper flange plate of the side formwork panel, and the second side formwork supporting longitudinal beam is fixed at intervals on both sides, the first side formwork supporting longitudinal beam is made of I-beam, and the second side formwork supporting longitudinal beam is made of channel steel.

7. The production line construction method according to any one of claims 4 to 6, characterized in that: The formwork support system includes a formwork support beam, a back rib support structure, a formwork support beam adjustment assembly, a side formwork support structure and a side formwork hydraulic support mechanism, wherein: the formwork support beam is detachably fixed at equal intervals laterally below the bottom formwork and extends outward; the back rib support structure is arranged at intervals outside the side formwork, has a shape matching the side formwork, and one end is fixed on the formwork support beam; the formwork support beam adjustment assembly is fixed below the formwork support beam and is located below the connection position between the back rib support structure and the formwork support beam, and includes a lifting member for adjusting the lifting of the formwork support beam; the side formwork support structure is supported on the outside and below the back rib support structure, and the lower part includes a bottom transverse bracket connected to the formwork support beam adjustment assembly and supports the outer end of the formwork support beam; the side formwork hydraulic support mechanism is arranged below the outer end of the bottom transverse bracket, and is used to adjust the lifting of the formwork support beam; The hydraulic support system includes the template support beam adjustment assembly and the side template hydraulic support mechanism.

8. The production line construction method according to claim 7, characterized in that: The side form support structure includes multiple groups of first vertical supports, second vertical supports, third vertical supports, upper transverse supports, bottom transverse supports and reinforcement connection units, one end of the upper transverse support is fixed to the upper part of the back rib support structure located on the outside of the side form web portion, and the other end is connected to the first vertical support; the upper end of the first vertical support is connected to the lower outer end of the back rib support structure located on the outside of the upper flange plate portion of the side form, and the lower end is connected to the upper outer end of the bottom transverse support; the upper end of the second vertical support is connected to the lower middle part of the upper transverse support, and the lower end is connected to the upper outer end of the formwork supporting beam; the upper end of the third vertical support is connected to the lower outer end of the formwork supporting beam, and the lower end is connected to the upper outer end of the bottom transverse support The cam is connected to the upper and lower horizontal supports and is located below the second vertical support; the inner end of the bottom horizontal support is connected to the fixed part of the lifting member; the connection points of multiple first vertical supports and the upper and lower horizontal supports are respectively connected with support connecting longitudinal beams; between the back rib support structure and the second vertical support, between the first vertical support and the second vertical support, between adjacent first vertical supports, between adjacent upper and lower horizontal supports, and between adjacent bottom and upper horizontal supports, a reinforcing connection unit is detachably fixed, and the reinforcing connection unit is a single inclined rod support structure or an X-shaped support structure or a herringbone support structure; vertical supports are spaced apart and connected between the back rib support structure and the upper horizontal support located on the outside of the upper flange plate portion of the side form.

9. The production line construction method according to any one of claims 2 to 5, characterized in that: The beam transport vehicle includes a beam transport vehicle frame, beam transport vehicle rollers and beam transport vehicle jacks. The beam transport vehicle frame matches the length of the bottom form and side form combination system. Multiple beam transport vehicle rollers are connected in a rolling manner below, and multiple rows of beam transport vehicle jacks are arranged at intervals above.

10. The production line construction method according to claim 3, characterized in that: The bottom formwork and side formwork combination system is transferred from the initial tensioning and reinforcement cage mold insertion station to the formwork installation and pouring station by the beam transport vehicle. Specifically, the bottom formwork and side formwork combination system is carried by the beam transport vehicle from the initial tensioning and reinforcement cage mold insertion station, through the circulation line unit, back to the inner mold entry and exit station, and then transferred to the formwork installation and pouring station.

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