Prefabricated single-cabin pipe gallery production process

Abstract

The invention provides a production process for a prefabricated single-cabin pipe gallery. The production process comprises the following operation steps of S1, designing and manufacturing a pipe joint mold, S2, transporting the pipe joint mold, S3, assembling and adjusting the mold, S4, putting a reinforcement cage into the mold and installing an embedded part, S5, pouring and vibrating concrete, and stirring and transporting the concrete before pouring and vibrating the concrete. S7, pipe joint demolding; S8, pipe joint spraying protection; S9, pipe joint inspection and repairing; S10, pipe joint final testing and inspection; according to the pipe joint, the customized high-precision steel die is adopted for vertical vibration forming (the steel bellmouth faces downwards), the die is novel in structure, good in rigidity and high in precision, the inner die is tightened, positioned and loosened to be disassembled through tightening screws at the four corners of the inner die, die disassembly and assembly are fast, operation is extremely convenient, the pipe joint machining difficulty is small, positioning is accurate, and production and machining of the prefabricated single-cabin pipe gallery are facilitated.

Description

Technical Field

[0001] The invention relates to the field of single-cabin pipe gallery production, and in particular to a production process for a prefabricated single-cabin pipe gallery. Background Art

[0002] The pipe gallery is an underground urban pipeline integrated corridor. That is, a tunnel space is built underground in the city, which integrates various engineering pipelines such as electricity, communications, gas, heating, water supply and drainage, and is equipped with special inspection ports, lifting ports and monitoring systems. It implements unified planning, unified design, unified construction and management. It is an important infrastructure and "lifeline" to ensure the operation of the city. The pipe gallery is an important part of urban infrastructure. It is not only used to accommodate pipelines of various urban lifeline projects, but also provides convenience for the inspection and capacity expansion of pipelines. A single-cabin pipe gallery usually has only one independent corridor to accommodate all pipelines. This design is simple and the construction speed is fast. It is suitable for engineering projects with fewer types of pipelines and smaller scale.

[0003] In the existing single-cabin pipe gallery production process, the cross-section of the pipe segment is large, especially the length and width span is large, the wall is thick, and it needs to be assembled with inner and outer molds. The dimensional error is difficult to control, and the mold processing accuracy is high, especially the verticality and curvature of the four corners are difficult to control. In addition, the steel plate is thick, the manufacturing process is complicated, and the processing is difficult. At the same time, the positioning of the lifting holes of the embedded parts of the pipe segment is not accurate enough, which can easily cause deflection or inability to lift the top pipe during lifting, directly affecting the displacement, flipping, and loading of the pipe segment. When going down the well, if the pipe body tilts due to incorrect hole position, it will also cause the pipes to be unable to align, resulting in more serious problems such as displacement of the top axis, affecting the production of prefabricated single-cabin pipe gallery. Summary of the invention

[0004] The technical problem to be solved by the present invention is to overcome the defects in the prior art that pipe segment processing is difficult and positioning is not accurate enough, which affects the production of prefabricated single-cabin pipe corridors, and to provide a production process for prefabricated single-cabin pipe corridors.

[0005] The present invention solves the above technical problems through the following technical solutions:

[0006] The present invention provides a production process for a prefabricated single-cabin pipe gallery, and the production process comprises the following operating steps:

[0007] S1. Design and manufacture of pipe segment molds. Design the pipe segment structure construction design according to the needs, and then design and manufacture the pipe segment mold according to the pipe segment structure construction drawing;

[0008] S2, transporting the pipe segment mold, transporting the pipe segment mold obtained in step S1 to the pipe segment manufacturing site;

[0009] S3, mold assembly and adjustment. Before mold assembly and adjustment, pipe joint construction site preparation is required;

[0010] S4, steel cage mold placement, embedded parts installation, before the steel cage mold placement, embedded parts installation, the steel cage and socket production;

[0011] S5, concrete pouring and vibration, before concrete pouring and vibration, concrete mixing and transportation are required;

[0012] S6, concrete finishing and steam curing. After step S5, the concrete at the pipe joint and the wound surface are smoothed and then steam curing is performed on the concrete using steam equipment;

[0013] S7, demoulding the pipe segment. When demoulding, first open the joint of the inner and outer molds to completely separate the inner and outer molds from the pipe segment. Move the outer mold plate to a safe position, retract the inner mold with a bidirectional screw, and gently lift the pipe segment away.

[0014] S8, pipe segment spray protection, transporting the pipe segment after demoulding in step S7 to the spray area for spray curing;

[0015] S9. Inspection and repair of pipe joints: inspect the size and appearance quality of pipe joints and repair any broken parts;

[0016] S10, final test and inspection of the pipe segment, conduct concrete strength test and horizontal assembly inspection of the pipe segment after inspection and repair in step S9;

[0017] S11, stacking of finished pipe segment products. The pipe segments inspected in step S10 are divided into unqualified pipe segment products and qualified pipe segment products. Unqualified pipe segment products are marked and isolated in time, and qualified pipe segment products are stacked and stored. Then, the qualified pipe segment finished products are used to assemble a single-cabin pipe gallery.

[0018] In this technical solution, the pipe segment is formed by vertical vibration using a customized high-precision steel mold (with the steel socket facing downward). The mold has a novel structure, good rigidity, and high precision. Many parts and components are finely processed. The inner and outer molds are composed of four side molds. A central support frame is provided to support the inner mold. The inner mold does not need to be shifted. The inner mold is tightened and positioned and loosened for demolding by tightening screws at the four corners of the inner mold. Therefore, the mold can be disassembled and assembled quickly, and the operation is extremely convenient. The product appearance can be perfect and intact, and the diagonal dimensions of the rectangular frame and the verticality and curvature of the side surfaces of the components have extremely small errors, which is convenient for the production and processing of prefabricated single-cabin pipe galleries.

[0019] Preferably, in the step S1, when designing the pipe segment mold, it is necessary to fully consider whether the mold has sufficient rigidity and durability;

[0020] Strengthen supervision during the manufacturing of pipe joint molds to ensure the rigidity of the molds.

[0021] In this technical solution, the standards for designing and processing pipe segment molds are determined.

[0022] Preferably, in step S3, before the pipe segment mold is brought into the site, a foundation is prepared according to the weight of the pipe segment, the weight of the mold and other loads in the construction.

[0023] Preferably, the specific operation steps of mold assembly and adjustment in step S3 are:

[0024] A1. Bottom mold positioning;

[0025] A2, support and fixation;

[0026] A3, corner mould and inner mould are in place;

[0027] A4. The steel bar skeleton is hoisted into the steel formwork as a whole;

[0028] A5. Embedded parts positioning;

[0029] A6, outer mold in place;

[0030] A7. Adjustment of internal and external template dimensions;

[0031] A8. Inspection of concrete cover;

[0032] A9. Mould assembly inspection.

[0033] In this technical solution, the specific operation steps of mold assembly and adjustment are determined.

[0034] Preferably, the manufacturing process of the steel cage in step S4 is:

[0035] B1. Inspection of steel bar raw materials;

[0036] B2, straightening and cutting;

[0037] B3, arc and bend;

[0038] B4. Component inspection;

[0039] B5. Component welding;

[0040] B6, steel frame forming and welding;

[0041] B7. Inspection of steel cage.

[0042] In this technical solution, the manufacturing steps of the steel cage are determined.

[0043] Preferably, the specific operation steps of inserting the steel cage into the mold and installing the embedded parts in step S4 are:

[0044] C1, bottom mold and inner mold are in place;

[0045] C2, socket steel ring into the mold;

[0046] C3. The steel bar skeleton is hoisted into the mold as a whole;

[0047] C4, positioning of embedded parts of socket grouting holes and lifting holes;

[0048] C5. Check the positioning and fixing of the template;

[0049] C6. Preparation for pouring.

[0050] In this technical solution, the specific operation steps of inserting the steel cage into the mold and installing the embedded parts are determined.

[0051] Preferably, in step S5, the slump of the concrete is controlled at 180-200 mm, and the upper end surface of the pipe segment is compacted and smoothed after vibration molding.

[0052] In this technical solution, the quality standard of concrete is determined.

[0053] Preferably, the steam curing of concrete in step S6 is divided into four stages: static stop, heating, constant temperature and cooling.

[0054] In this technical solution, the stages of steam curing of concrete are determined.

[0055] Preferably, in the step S7, after the concrete is cooled, the concrete test blocks under the same conditions are sent to the laboratory for pressure testing. After the strength reaches 75% of the design strength grade, the concrete test blocks can be demoulded and hoisted, and demoulding begins after receiving notification from the laboratory;

[0056] During demoulding, the difference between the pipe joint temperature and the ambient temperature shall not exceed 20°C.

[0057] In this technical solution, the demoulding standard of the pipe fitting is determined.

[0058] Preferably, in step S9, the size inspection of the pipe segment is to measure the width and thickness of the pipe segment respectively with a vernier caliper;

[0059] The appearance quality inspection requirements for pipe joints are that the surface of the pipe joints is smooth and flat, without honeycombs, exposed reinforcement, cracks, or missing corners.

[0060] In this technical solution, the direction and standard of pipe segment size detection and appearance quality inspection are determined.

[0061] On the basis of being in accordance with the common sense in the art, the above-mentioned preferred conditions can be arbitrarily combined to obtain the preferred embodiments of the present invention.

[0062] The positive and progressive effects of the present invention are:

[0063] The pipe joint of the present invention is formed by vertical vibration by using a customized high-precision steel mold (with the steel socket facing downward). The mold has a novel structure, good rigidity, high precision, and many parts are finely processed. The inner and outer molds are assembled by four side molds. A central support frame is provided to support the inner mold. The inner mold does not need to be shifted. The inner mold is tightened and positioned and loosened and demolded by tightening screws at the four corners of the inner mold. Therefore, the mold can be disassembled and assembled quickly, and the operation is extremely convenient. The appearance of the product can be perfect and intact, and the diagonal size of the rectangular frame and the verticality and curvature of each side of the component are extremely small.

[0064] The present invention is a mechanical device for bending thick steel plates such as socket steel rings. The four corners of the 10mm thick socket steel ring are bent into semi-finished products with a radius of 200mm. All the steel rings are then shaped and welded through a factory-made steel ring combination steel flat mouth. The embedded steel ring reinforcement is also welded here, so that the steel ring size error is small, the installation deformation is small, and the embedded reinforcement is firmly welded.

[0065] The present invention ensures that the installation dimensions of all embedded parts of each pipe section are accurate and can be installed quickly by making positioning holes on the mold. The positioning measure of the lifting hole is to position the lifting hole formed steel pipe by engraving lines on the inner mold and a movable vertical positioning frame, and then weld the steel pipe to the main reinforcement of the pipe body with embedded reinforcement, so that the position of the lifting hole can be ensured to be accurate and vertical, and sufficient embedded reinforcement can be ensured to weld the steel pipe of the lifting hole firmly (the lifting hole is positioned by drilling holes in the outer mold to avoid the displacement of the embedded parts during the concrete vibration process);

[0066] The present invention is provided with four lifting points, namely, two center holes (for demoulding and lifting) and two eccentric holes (for flipping). The center holes are lifted when the component is demoulded; after demoulding, the component is horizontally placed on the ground, the eccentric holes are replaced, and the auxiliary hook of the gantry crane hooks the grouting hole. The component is still slowly lifted horizontally. When the component is lifted to a certain height, the auxiliary hook is slowly dropped to realize the aerial flipping of the component. BRIEF DESCRIPTION OF THE DRAWINGS

[0067] Figure 1 The present invention is a schematic diagram of the overall process of the prefabricated single-cabin pipe gallery production process according to an embodiment of the present invention.

[0068] Figure 2 for Figure 1 The schematic diagram of the operational flow of mold assembly and adjustment in the prefabricated single-cabin tunnel production process is shown.

[0069] Figure 3 for Figure 1 The schematic diagram of the production process of the steel cage of the prefabricated single-cabin pipe gallery is shown.

[0070] Figure 4 for Figure 1 The diagram shows the operational flow of inserting the steel cage into the mold and installing the embedded parts in the production process of the prefabricated single-cabin pipe gallery. DETAILED DESCRIPTION

[0071] The present invention is further described below by way of examples, but the present invention is not limited to the scope of the examples.

[0072] Figures 1 to 4 The structure diagram of an embodiment of the prefabricated single-cabin pipe gallery production process of the present invention is shown. The prefabricated single-cabin pipe gallery production process includes the following steps:

[0073] S1. Design and manufacture of pipe segment molds. Design the pipe segment structure construction design according to the needs, and then design and manufacture the pipe segment mold according to the pipe segment structure construction drawing;

[0074] S2, transporting the pipe segment mold, transporting the pipe segment mold obtained in step S1 to the pipe segment manufacturing site;

[0075] S3, mold assembly and adjustment. Before mold assembly and adjustment, pipe joint construction site preparation is required;

[0076] S4, steel cage mold placement, embedded parts installation, before the steel cage mold placement, embedded parts installation, the steel cage and socket production;

[0077] S5, concrete pouring and vibration, before concrete pouring and vibration, concrete mixing and transportation are required;

[0078] S6, concrete finishing and steam curing. After step S5, the concrete at the pipe joint and the wound surface are smoothed and then steam curing is performed on the concrete using steam equipment;

[0079] S7, demoulding the pipe segment. When demoulding, first open the joint of the inner and outer molds to completely separate the inner and outer molds from the pipe segment. Move the outer mold plate to a safe position, retract the inner mold with a bidirectional screw, and gently lift the pipe segment away.

[0080] S8, pipe segment spray protection, transporting the pipe segment after demoulding in step S7 to the spray area for spray curing;

[0081] S9. Inspection and repair of pipe joints: inspect the size and appearance quality of pipe joints and repair any broken parts;

[0082] The allowable error values ​​for pipe joint inspection are shown in the following table:

[0083]

[0084] S10, final test and inspection of the pipe segment, conduct concrete strength test and horizontal assembly inspection of the pipe segment after inspection and repair in step S9;

[0085] In order to ensure good mechanical performance of the prefabricated structure and provide conditions that meet the calculation assumptions, 3 rings of segments shall be randomly inspected for horizontal assembly inspection for every 30 rings of segments produced. The allowable error of the horizontal assembly of 3 rings shall meet the requirements of the following table:

[0086]

[0087] S11, stacking of finished pipe segment products. The pipe segments inspected in step S10 are divided into unqualified pipe segment products and qualified pipe segment products. Unqualified pipe segment products are marked and isolated in time, and qualified pipe segment products are stacked and stored. Then, the qualified pipe segment finished products are used to assemble a single-cabin pipe gallery.

[0088] In this technical solution, the pipe segment is formed by vertical vibration using a customized high-precision steel mold (with the steel socket facing downward). The mold has a novel structure, good rigidity, and high precision. Many parts and components are finely processed. The inner and outer molds are composed of four side molds. A central support frame is provided to support the inner mold. The inner mold does not need to be shifted. The inner mold is tightened and positioned and loosened for demolding by tightening screws at the four corners of the inner mold. Therefore, the mold can be disassembled and assembled quickly, and the operation is extremely convenient. The product appearance can be perfect and intact, and the diagonal dimensions of the rectangular frame and the verticality and curvature of the side surfaces of the components have extremely small errors, which is convenient for the production and processing of prefabricated single-cabin pipe galleries.

[0089] In the step S1, when designing the pipe segment mold, it is necessary to fully consider whether the mold has sufficient rigidity and durability;

[0090] Strengthen supervision during the manufacturing of pipe joint molds to ensure the rigidity of the molds.

[0091] In this technical solution, the standards for designing and processing pipe segment molds are determined.

[0092] In the present application, the pipe segment mold can be processed by a professional mold manufacturer and transported to the pipe segment manufacturing site by a transport vehicle.

[0093] In the step S3, before the pipe segment mold is brought into the site, a foundation is prepared according to the weight of the pipe segment, the weight of the mold and other loads in the construction.

[0094] The pipe segment production site needs to meet the requirements of pipe segment production and stacking. All pipe segment production construction must be completed before the pipe jacking construction. After the pipe segment is demoulded, it should be turned vertically using a turning platform and stored vertically, with sleepers or concrete strip foundations underneath.

[0095] The specific steps of mold assembly and adjustment in step S3 are as follows:

[0096] A1. Bottom mold positioning;

[0097] A2, support and fixation;

[0098] A3, corner mould and inner mould are in place;

[0099] A4. The steel bar skeleton is hoisted into the steel formwork as a whole;

[0100] A5. Embedded parts positioning;

[0101] A6, outer mold in place;

[0102] A7. Adjustment of internal and external template dimensions;

[0103] A8. Inspection of concrete cover;

[0104] A9. Mould assembly inspection.

[0105] In this technical solution, the specific operation steps of mold assembly and adjustment are determined.

[0106] Before the steel structure mold is brought to the site, the foundation should be prepared according to the weight of the pipe section, the weight of the mold and other loads during construction. It is required that the base of the mold should not be deformed during use, especially the long sides should not be concave.

[0107] The inspection items of the mold include the net inner and outer length dimensions of the socket; the net inner and outer width dimensions of the socket; the net inner and outer length dimensions of the plug; the net inner and outer width dimensions and height of the plug.

[0108] The positioning and flatness of the mold base directly affect the molding quality of the pipe segment. The positioning of the bottom mold is the decisive factor in ensuring the flatness of the end face of the pipe segment.

[0109] After the base mold is installed in place, the elevation must be measured with a level. At least 8 points (the key points of the 4 corners and 4 sides) should be taken, and the elevation difference should be controlled within 1mm. After adjustment, electric welding can be performed to ensure that the base mold is level.

[0110] The manufacturing process of the steel cage in step S4 is as follows:

[0111] B1. Inspection of steel bar raw materials;

[0112] B2, straightening and cutting;

[0113] B3, arc and bend;

[0114] B4. Component inspection;

[0115] B5. Component welding;

[0116] B6, steel frame forming and welding;

[0117] B7. Inspection of steel cage.

[0118] In this technical solution, the manufacturing steps of the steel cage are determined.

[0119] When making steel cages, the quality of the raw materials of the steel bars needs to be strictly controlled, and steel bars that have not been inspected and tested and passed will not be used;

[0120] The straightening, cutting, bending and curving of steel bars are all completed manually with the help of steel bar processing machinery. Then the parts are inspected and the unqualified steel bar parts are cleared out. The qualified parts can be used for steel cage processing.

[0121] The steel bars are first welded into pieces on a small model frame, and then the pieces are placed on the steel cage processing model and welded into shape;

[0122] After forming, the inspector will check the steel bar diameter, quantity, spacing, welding firmness, welding burns, and mark them after inspection. Unqualified steel cages will be scrapped and not used in pipe segment production;

[0123] After the steel cage has passed the inspection, the steel cage is placed in the storage area by a crane. When in use, the steel cage is directly loaded into the pipe segment mold by a crane.

[0124] It is worth noting that anti-rust and anti-corrosion measures need to be taken when storing steel cages.

[0125] The processing of steel cages should meet the following requirements:

[0126] Steel bars should be manufactured strictly according to the design drawings and should not be changed at will;

[0127] The steel bar should be kept balanced when entering the bending machine to prevent the plane from warping, and there should be no cracks on the surface after forming;

[0128] When the steel bar skeleton is welded and formed, it must be made on a template that meets the design requirements;

[0129] The skeleton must first be installed on the mold, and after measuring, adjusting and checking that all dimensions meet the requirements, it can be cut into fixed sizes and bent into shape;

[0130] When welding the steel frame, the welding position should be accurate, the welding quality of the steel frame should be strictly controlled, and the steel welding current should be controlled between 100 and 140A; the steel bars should not be burned during welding, and any main reinforcement with a burn depth exceeding 1mm will be treated as scrap; no pores or slag inclusions are allowed on the weld surface, and the oxide scale and welding slag must be cleaned up in time after welding;

[0131] Select welding rods correctly, and the welding rod model should meet the requirements of the design drawings.

[0132] After the steel cage is made, the interface ring needs to be made. The arc part of the interface steel ring is stamped and formed. The arc length part must be close to the steel mold without leakage. The socket steel ring is generally spliced ​​in 4 sections.

[0133] In this application, the raw materials of the steel sleeve ring can be processed in the factory and transported to the construction site for welding and assembly;

[0134] After the socket welding is completed, anti-rust treatment is carried out. Before anti-rust treatment, rust, oil stains, dust and other debris on the surface and corners behind the socket are removed.

[0135] The specific operation steps of inserting the steel cage into the mold and installing the embedded parts in step S4 are as follows:

[0136] C1, bottom mold and inner mold are in place;

[0137] C2, socket steel ring into the mold;

[0138] C3. The steel bar skeleton is hoisted into the mold as a whole;

[0139] C4, positioning of embedded parts of socket grouting holes and lifting holes;

[0140] C5. Check the positioning and fixing of the template;

[0141] C6. Preparation for pouring.

[0142] In this technical solution, the specific operation steps of inserting the steel cage into the mold and installing the embedded parts are determined.

[0143] The pipe segment steel mold should be cleaned after each demoulding and the release agent should be evenly applied;

[0144] The socket steel ring, embedded grouting holes and lifting holes should be close to the formwork and welded to the steel cage to ensure that there is no leakage or displacement during the production process;

[0145] The embedded water stop strips at the socket should be installed before pouring concrete. Before pouring, ensure that the surface of the water stop strips is dry and does not expand;

[0146] Before the steel frame is put into the mold, the protective layer pads must be fixed on the outer ring main reinforcement. The spacing of the protective layer pads is one per meter. The steel frame must be hoisted with special hoists to ensure the integrity of the steel frame after entering the mold.

[0147] When entering the mold, the steel mold must be cleaned thoroughly, and then the mold release oil should be applied evenly without oil accumulation or oil dripping;

[0148] Before closing the steel mold, check whether the mold bottom and the contact surface between the inner and outer molds are clean;

[0149] After the steel mold is closed, the inner diameter separation card must be used to check the net cross-sectional dimensions of the steel mold. There must be more than three points and they must be recorded in the self-check table. If the error dimension is exceeded, the mold must be re-adjusted until it meets the requirements.

[0150] The steel skeleton should be placed in the middle of the steel formwork plane, and pads should be installed on the four peripheries and the bottom surface. The thickness of the pads should meet the thickness of the concrete protective layer specified in the design.

[0151] The steel bar skeleton must not contact the bolt hole mold core, and the bolt core rod must be in place without any looseness;

[0152] The bottom surface of embedded parts such as lifting holes and injection holes must be installed flat and closely attached to the side formwork; all embedded parts must be accurately positioned as per design requirements and should be securely fixed to prevent displacement during vibration.

[0153] When welding workpieces such as steel cages and sockets:

[0154] For welding personnel, welding personnel include welding technicians, welders, welding inspectors, metal laboratory welding inspectors and welding heat treatment personnel;

[0155] All types of welding personnel should have corresponding professional and technical knowledge and on-site practical experience, and pass professional training and examinations before they can take up their posts with a certificate.

[0156] For welding materials, welding rods, welding wires and other welding materials should be properly labeled and managed;

[0157] The distribution of welding materials should be recorded in a ledger to make the use of materials traceable;

[0158] Welding rods should be placed in a special welding rod insulation barrel, connected to the power supply when arriving at the site, and taken out as needed to prevent them from getting damp.

[0159] The control requirements for welding process are as follows: welding technicians are responsible for the formulation and control of welding process;

[0160] Welding technicians should compile welding technical measures in accordance with the requirements of the project department's construction technical measures catalog, based on drawings, materials, regulations, specifications, etc.;

[0161] Before the welding project starts, welding technicians should prepare welding operation instructions and process cards for each project based on the welding process assessment, and guide the construction after review and approval by the dedicated engineer;

[0162] When welders receive welding materials, they must hold a receipt issued by a welding technician;

[0163] Welding should strictly follow the welding operation instructions and process cards. If the actual working conditions do not conform to the instructions, they must be reported to the technician for verification and processing;

[0164] After welding, welders should clean up, self-check, mark and submit self-check records in time;

[0165] Welding quality inspectors must master the welding quality of each project on site, work together with technicians to supervise the process, and inspect, evaluate and report completed projects in a timely manner;

[0166] Welding technicians or quality inspectors should commission heat treatment, spectrum inspection and flaw detection inspection in a timely manner according to the requirements of the specifications, and analyze and study the quality problems that arise and find countermeasures to ensure continuous improvement of quality;

[0167] Welding technical records should be timely, accurate and standardized.

[0168] After welding is completed, inspection is required. The welding inspection requirements are as follows: There are many embedded parts in the pipe joints. Before construction, professional technicians are arranged to be responsible for the installation and inspection and acceptance of the embedded parts;

[0169] The technicians will count the embedded pipe parts one by one in the form of a table. After the statistics are completed, they will be checked and inspected by the technical person in charge. After the technical person in charge signs and confirms, they can be used to guide the construction.

[0170] Guide on-site installation and construction according to the embedded parts statistics table, requiring the embedded parts model, size and position to meet the design requirements;

[0171] During the installation of embedded parts, they must be fixed in place. The reinforcement must be firm and stable, and must not damage the embedded parts.

[0172] Before concrete construction, arrange personnel to protect the embedded parts by means of blocking, covering, etc., and notify the supervising engineer for acceptance. Only after qualified acceptance can the next process be entered.

[0173] In the step S5, the slump of the concrete is controlled at 180-200 mm, and the upper end surface of the pipe segment is compacted and smoothed after being vibrated and formed.

[0174] In this technical solution, the quality standard of concrete is determined.

[0175] Before pouring concrete, the following contents must be strictly checked: concealed works, protective layer, embedded parts position, mold quality and geometric dimensions of components. Only after confirmation can pouring be carried out;

[0176] The concrete is self-mixed concrete, which is transported to the construction site by concrete trucks and distributed in mobile hoppers;

[0177] The pipe segment concrete adopts the vertical (socket) vibration forming process. When pouring concrete, it can be divided into three layers according to the height direction of the pipe segment; after the first layer is laid, the inserted vibrator must be inserted to a place about 10cm from the bottom, and the longitudinal insertion point spacing of the vibrator should not be greater than 30cm (using a 70 vibrator), and it is advisable to vibrate and compact it in a cross-biased front vibration manner; when vibrating the second and third layers of concrete, the vibrator must penetrate the surface of the lower layer to combine the upper and lower layers into one. During the vibration process, the flat vibrator is mainly used, and the vibrator is supplemented;

[0178] Avoid collision with steel bars during vibration. Vibrate more frequently and shorten the distance between insertion points in areas with dense steel bars such as embedded parts and steel molds to avoid missed vibrations and loose compaction.

[0179] To ensure the compaction quality of concrete, the viscosity and slump of concrete should be properly controlled. The slump should be controlled at 180-200mm. The upper end surface of the pipe section after vibration forming should be compacted and smoothed. The number of smoothing times should not be less than three times. The end surface must be smooth and flat.

[0180] In step S6, the steam curing of concrete is divided into four stages: static stop, heating, constant temperature and cooling.

[0181] In this technical solution, the stages of steam curing of concrete are determined.

[0182] After the concrete is poured and the upper surface of the pipe joint is smoothed, it should be covered with plastic film in time, and then a tight and airtight canvas cover should be placed on the outside of the mold, and steam boiler should be used for steam curing.

[0183] Steam curing of concrete can be divided into four stages: static, heating, constant temperature, and cooling. Steam curing of concrete should comply with the following regulations:

[0184] The ambient temperature should be kept at no less than 5°C during the static period, and the temperature can be raised only after 4 to 6 hours of pouring and final setting of the concrete;

[0185] The heating rate should not be greater than 20℃ / h;

[0186] During the constant temperature period, the internal temperature of the concrete should not exceed 60°C, and the maximum should not exceed 65°C. The constant temperature curing time should be determined through experiments based on the demoulding strength requirements of the components, the concrete mix ratio, and environmental conditions;

[0187] The cooling rate should not be greater than 20℃ / h.

[0188] At the same time, the concrete test blocks and pipe segments are cured under the same conditions, and the strength of the test blocks is tested. When the concrete strength reaches 75% of the design strength, it can be used as the basis and standard for demoulding the pipe segments.

[0189] In the step S7, after the concrete is cooled, the concrete test blocks under the same conditions are sent to the laboratory for pressure testing. After the strength reaches 75% of the design strength grade, they can be demoulded and hoisted, and demoulding begins after receiving notification from the laboratory;

[0190] During demoulding, the difference between the pipe joint temperature and the ambient temperature should not exceed 20°C to prevent temperature difference cracks.

[0191] In this technical solution, the demoulding standard of the pipe fitting is determined.

[0192] Special lifting equipment must be used for demoulding, and four people must cooperate in ground operation to connect the lifting equipment with the lifting embedded parts of the pipe segment. A special person will send a lifting signal to the crane driver to gently lift the pipe segment to avoid collision between the steel mold and the pipe segment.

[0193] During the demoulding process, rough operations such as hammering and knocking are strictly prohibited.

[0194] After demoulding, clean the inner and outer surfaces and corners of the pipe section in time. Clean the contact surface between the mold and concrete with a brush and cotton wool.

[0195] In step S8, after the demoulding of the pipe segment is completed, an 80T gantry crane and a special pipe segment hoist are used to slowly lift the pipe segment using a two-point lifting method;

[0196] Since the steel socket of the prefabricated pipe segment faces downward, the steel socket must be turned upward when the pipe segment is stacked. After the pipe segment is lifted, fixed ropes are used to manually turn the pipe segment over. After the pipe segment is turned over, it is hoisted to the pipe segment stacking site by a special hoist.

[0197] After the pipe section is turned over, an 80T gantry crane is used to transport the pipe section to the spray curing area of ​​the temporary storage yard;

[0198] The pipe joints should be lifted and placed gently during transportation to prevent damage to the edges and corners of the pipe joints. During spray maintenance, a dedicated person should be assigned to spray regularly to avoid dryness and waterlessness on the surface of the pipe joints.

[0199] The requirements for pipe segment concrete spray protection are that embedded parts such as grouting holes and lifting holes cannot be damaged and the installation position must be correct;

[0200] Before pouring, the assembled mold must be inspected and accepted according to the specified items. If any unqualified items are found, the previous process should be notified to rework;

[0201] The mold can be placed in the steel cage, embedded parts can be installed and the protective layer can be checked only after it passes the inspection;

[0202] Concrete pouring is allowed only after the assembled mold has passed the inspection;

[0203] Only concrete that is confirmed to have a slump within the required range and meets the design gradation requirements can be used for pipe segment production;

[0204] After finishing, cover with sealed canvas cover and steam cure;

[0205] Strictly control the steaming time, heating and cooling rates, constant temperature time and humidity. The steaming of pipe sections must meet the requirements. The concrete strength must reach 75% of the specified strength before demolding and lifting can be carried out. The lifted pipe sections should be measured and marked, and then spray-cured after demolding. The curing time is 7 days in summer and 14 days in winter.

[0206] In the step S9, the size inspection of the pipe segment is to measure the width and thickness of the pipe segment respectively with a vernier caliper;

[0207] The appearance quality inspection requirements for pipe joints are that the surface of the pipe joints is smooth and flat, without honeycombs, exposed reinforcement, cracks, or missing corners.

[0208] In this technical solution, the direction and standard of pipe segment size detection and appearance quality inspection are determined.

[0209] The pipe segment size inspection uses a vernier caliper to measure the width and thickness of the pipe segment respectively; each ring of pipe segment is inspected for appearance quality, and the surface of the pipe segment should be smooth and flat, without honeycombs, exposed ribs, cracks, or missing corners;

[0210] Minor defects will be modified, no defects are allowed near the water stop, and the grouting holes should be complete and free of cement slurry and other debris.

[0211] When repairing the product, bubbles and blister holes with a depth greater than 2mm and a diameter greater than 3mm, and surface shrinkage cracks with a width of no more than 0.2mm should be filled with adhesive and water in a ratio of 1:1 to 1:4, and then added with an appropriate amount of cement and fine sand, and the surface should be ground to achieve a smooth and flat surface. If the damage depth is no more than 20mm and the width is no more than 10mm, it should be repaired with epoxy resin mortar, and then the surface should be filled and ground with super glue cement mortar.

[0212] The requirements for pipe joint inspection are that the strength of the pipe joint must reach the design strength after testing and the anti-seepage performance must meet the design requirements before it can be used; the pipe joint must have no missing corners or edges, no rough surfaces or exposed reinforcement; the embedded parts of the pipe joint must be intact and correctly positioned; the dimensions of the pipe joint must comply with the design and relevant specifications; the markings on the pipe joint model and production date must be eye-catching and accurate.

[0213] In step S11, when the pipe segments are stacked, the manufacturing number, production date, etc. are marked in a conspicuous place on the end face of the socket of the pipe segment;

[0214] When stacking and transporting pipe sections, there should be a dedicated person to direct them to prevent collision and damage;

[0215] The ground of the pipe joint site should be solid and flat, and abnormal stress and deformation caused by uneven sinking of the storage site or deformation of the pads due to the dead weight of the pipe joints must be avoided;

[0216] The pipe sections are stacked upright in the order of production, with the stacking height not exceeding two pieces.

[0217] Although the specific embodiments of the present invention are described above, it should be understood by those skilled in the art that this is only for illustration and the protection scope of the present invention is defined by the appended claims. Those skilled in the art may make various changes or modifications to these embodiments without departing from the principles and essence of the present invention, but these changes and modifications all fall within the protection scope of the present invention.

Claims

1. The production process of prefabricated single-cabin pipe gallery is characterized by: The production process comprises the following steps: S1. Design and manufacture of pipe segment molds. Design the pipe segment structure construction design according to the needs, and then design and manufacture the pipe segment mold according to the pipe segment structure construction drawing; S2, transporting the pipe segment mold, transporting the pipe segment mold obtained in step S1 to the pipe segment manufacturing site; S3, mold assembly and adjustment. Before mold assembly and adjustment, pipe joint construction site preparation is required; S4, steel cage mold placement, embedded parts installation, before the steel cage mold placement, embedded parts installation, the steel cage and socket need to be made; S5, concrete pouring and vibration, before concrete pouring and vibration, concrete mixing and transportation are required; S6, concrete finishing and steam curing. After step S5, the concrete at the pipe joint and the wound surface are smoothed and then steam curing is performed on the concrete using steam equipment; S7, demoulding the pipe segment. When demoulding, first open the joint of the inner and outer molds to completely separate the inner and outer molds from the pipe segment. Move the outer mold plate to a safe position, retract the inner mold with a bidirectional screw, and gently lift the pipe segment away. S8, pipe segment spray protection, transporting the pipe segment after demoulding in step S7 to the spray area for spray curing; S9. Inspection and repair of pipe joints: inspect the size and appearance quality of pipe joints and repair any broken parts; S10, final test and inspection of the pipe segment, conduct concrete strength test and horizontal assembly inspection of the pipe segment after inspection and repair in step S9; S11, stacking of finished pipe segment products. The pipe segments inspected in step S10 are divided into unqualified pipe segment products and qualified pipe segment products. Unqualified pipe segment products are marked and isolated in time, and qualified pipe segment products are stacked and stored. Then, the qualified pipe segment finished products are used to assemble a single-cabin pipe gallery.

2. The prefabricated single-cabin pipe gallery production process according to claim 1, characterized in that: In the step S1, when designing the pipe segment mold, it is necessary to fully consider whether the mold has sufficient rigidity and durability; Strengthen supervision during the manufacturing of pipe joint molds to ensure the rigidity of the molds.

3. The prefabricated single-cabin pipe gallery production process according to claim 1, characterized in that: In the step S3, before the pipe segment mold is brought into the site, a foundation is prepared according to the weight of the pipe segment, the weight of the mold and other loads in the construction.

4. The prefabricated single-cabin pipe gallery production process according to claim 1, characterized in that: The specific steps of mold assembly and adjustment in step S3 are as follows: A1. Bottom mold positioning; A2, support and fixation; A3, corner mould and inner mould are in place; A4. The steel bar skeleton is hoisted into the steel formwork as a whole; A5. Embedded parts positioning; A6, outer mold in place; A7. Adjustment of internal and external template dimensions; A8. Inspection of concrete cover; A9. Mould assembly inspection.

5. The prefabricated single-cabin pipe gallery production process according to claim 1, characterized in that: The manufacturing process of the steel cage in step S4 is as follows: B1. Inspection of steel bar raw materials; B2, straightening and cutting; B3, arc and bend; B4. Component inspection; B5. Component welding; B6, steel frame forming and welding; B7. Inspection of steel cage.

6. The prefabricated single-cabin pipe gallery production process according to claim 1, characterized in that: The specific operation steps of inserting the steel cage into the mold and installing the embedded parts in step S4 are: C1, bottom mold and inner mold are in place; C2, socket steel ring into the mold; C3. The steel bar skeleton is hoisted into the mold as a whole; C4, positioning of embedded parts of socket grouting holes and lifting holes; C5. Check the positioning and fixing of the template; C6. Preparation for pouring.

7. The prefabricated single-cabin pipe gallery production process according to claim 1, characterized in that: In the step S5, the slump of the concrete is controlled at 180-200 mm, and the upper end surface of the pipe segment is compacted and smoothed after being vibrated and formed.

8. The prefabricated single-cabin pipe gallery production process according to claim 1, characterized in that: In step S6, the steam curing of concrete is divided into four stages: static stop, heating, constant temperature and cooling.

9. The prefabricated single-cabin pipe gallery production process according to claim 1, characterized in that: In the step S7, after the concrete is cooled, the concrete test blocks under the same conditions are sent to the laboratory for pressure testing. After the strength reaches 75% of the design strength grade, they can be demoulded and hoisted, and demoulding begins after receiving notification from the laboratory; During demoulding, the difference between the pipe joint temperature and the ambient temperature shall not exceed 20°C.

10. The prefabricated single-cabin pipe gallery production process according to claim 1, characterized in that: In the step S9, the size inspection of the pipe segment is to measure the width and thickness of the pipe segment respectively with a vernier caliper; The appearance quality inspection requirements for pipe joints are that the surface of the pipe joints is smooth and flat, without honeycombs, exposed reinforcement, cracks, or missing corners.

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