Prefabricated double-cabin pipe gallery production process

Abstract

The invention discloses a production process of a prefabricated double-cabin pipe gallery. The production process of the prefabricated double-cabin pipe gallery comprises the following steps: (1) manufacturing a semi-finished reinforcing steel bar; (2) welding a steel reinforcement framework; (3) mold cleaning; (4) brushing a release agent; (5) hoisting the reinforcement cage; (6) assembling the mold; (7) carrying out concealed acceptance; (8) pouring concrete; (9) maintaining the components; (10) demolding and hoisting; (11) repairing a finished product; (12) inspecting and marking finished products; according to the technical scheme, prefabrication production is effectively conducted on the double-cabin pipe gallery, the production efficiency can be remarkably improved, the production period can be shortened, the requirement for large-scale construction can be met through the standardized production process and refined labor division, each production step has the clear quality standard and inspection process, and the production efficiency is improved. And it can be ensured that the produced pipe gallery component meets design requirements and standards, and the quality reliability of products is improved.

Description

Technical Field

[0001] The present application relates to the technical field of double-compartment pipe gallery production, and in particular to a prefabricated double-compartment pipe gallery production process. Background Art

[0002] The double-warehouse pipeline corridor, as an advanced urban infrastructure, refers to a pipeline corridor structure with two independent compartments (or "warehouses"); this design is usually used to accommodate and protect various urban pipelines, such as cables, communication lines, water pipes, gas pipelines, etc., to ensure their safe operation and easy maintenance.

[0003] Ordinary double-storehouse pipe corridors are usually constructed by on-site pouring, which requires a large number of auxiliary facilities such as formwork, support and scaffolding, has a long construction period and relatively low production efficiency. The on-site poured double-storehouse pipe corridor is affected by many factors such as construction environment, personnel skills, material quality, etc., and quality control is difficult. On-site pouring requires more labor and materials, and waste is easily generated during the construction process, resulting in high costs;

[0004] That is, the prior art has the following technical problems: the ordinary double-compartment pipe gallery construction process has a long construction period and relatively low production efficiency. Therefore, a prefabricated double-compartment pipe gallery production process is proposed to address the above problems. Summary of the invention

[0005] In this embodiment, a prefabricated double-compartment pipe gallery production process is provided to solve the problems of long construction period and relatively low production efficiency of the double-compartment pipe gallery construction process in the prior art.

[0006] According to one aspect of the present application, a prefabricated double-compartment pipe gallery production process is provided, and the prefabricated double-compartment pipe gallery production process comprises the following steps:

[0007] (1) Production of semi-finished steel bars;

[0008] (2) Steel bar skeleton welding;

[0009] (3) Mold cleaning;

[0010] (4) Apply release agent;

[0011] (5) Hanging the steel reinforcement frame;

[0012] (6) Mold assembly;

[0013] (7) Hidden acceptance;

[0014] (8) Concrete pouring;

[0015] (9) Component maintenance;

[0016] (10) Demoulding and hoisting;

[0017] (11) Finished product repair;

[0018] (12) Inspection and labeling of finished products.

[0019] Furthermore, in the step (1), the semi-finished steel bar product includes: main bars, vertical bars, corner bars and hooks, and the equipment used in making the semi-finished steel bar product includes: a steel bar cutting machine, a steel bar bending machine and a steel bar bending machine;

[0020] The steel bars are inspected before use, and the inspection includes the following steps:

[0021] a. Check the factory certificate and retest report of the steel bars;

[0022] b. Re-inspection of the appearance dimensions and mechanical properties of the steel bars;

[0023] c. Review drawings before cutting steel bars;

[0024] d. After cutting, the semi-finished steel bars are stored in piles according to brand specifications and marked;

[0025] In the step (1), the following points should be noted: 1. The length and external dimensions of the semi-finished steel bars meet the requirements; 2. The steel bars are cut using a cutting machine or a grinding wheel saw. In the step (1), the technical requirements are: the length dimension error of the main bar is ±10 mm.

[0026] Furthermore, in step (2), the welding sequence of the steel frame body includes the following steps:

[0027] a. Steel frame welding: first arrange the welded steel mesh in the steel frame mold, adjust the spacing and position of the steel mesh, and fix it with the frame tooling;

[0028] b. Insert the transverse distribution steel bars and fix them by welding;

[0029] c. Arrange hook bars and socket stirrups, and connect the hooks with the main bars by electric welding to ensure the spacing between the upper and lower layers of the steel skeleton;

[0030] d. Check the steel bar welding points and re-weld and adjust the leaking positions;

[0031] e. The transverse and vertical reinforcements of the steel skeleton are kept vertical, and all intersections are welded;

[0032] During the welding, the welding equipment used includes: an electric welder and a bridge crane;

[0033] In the step (2), the tools and materials include: semi-finished steel bars, transverse bars, stirrups, hooks, protective layer pads, oblique tie bars, reinforcing bars, electric welders, welding rods, measuring tapes, mesh membranes and steel cage membranes. In the step (2), the steel mesh is overlapped. To ensure that the steel mesh is firm, a welding connection method is used. The operation is carried out on the mesh frame, and the size is strictly controlled. It must not be tilted or twisted to ensure the thickness of the protective layer.

[0034] In the step (2), the technical requirements include: 1. The outer protective layer is 50 mm, the inner protective layer is 35 mm, and the error is ±5 mm; 2. The allowable deviation of the steel bar spacing is ±10 mm.

[0035] Furthermore, in the step (3), the mold cleaning includes: cleaning the inner mold and cleaning the outer mold. In the step (3), the tools and materials used include: a shovel, a putty knife, a broom, double-sided tape, glass glue, a wheelbarrow, an angle grinder, a wire wheel, and a wire brush;

[0036] In the step (3), the mold cleaning comprises the following steps:

[0037] a. Use a putty knife to remove the residue on the surface of the steel formwork, and then use an angle grinder with a torque wire wheel to clean the small concrete residue on the surface of the formwork;

[0038] b. Use a putty knife to clean the concrete residue on the wooden formwork, and tap it lightly with a small hammer to vibrate the concrete off;

[0039] c. Clean the socket surface template, inner mold top surface template, and socket rubber strip groove position of the double-cabin pipe gallery;

[0040] d. During the cleaning process, check the stop glue strips and replace the damaged glue strips and the glass glue at the inner corners of the mold;

[0041] e. After cleaning, the waste residues and waste materials shall be cleaned up and piled in a unified location;

[0042] In the step (4), a mold release agent is applied. Before the application, check whether the mold is cleaned thoroughly to ensure that there is no residue and that the mold meets the use requirements. The application tools include: a sprayer, a mold release agent and a roller brush. The application of the mold release agent includes the following steps:

[0043] a. Select a release agent, and use a water-based release agent;

[0044] b. Use a sprayer to spray the release agent. After spraying, use a clean roller brush to roll evenly to ensure that there is no dripping or accumulation of liquid;

[0045] c. After painting, pay attention to protection to avoid contamination by other impurities, which may affect the effect of the release agent;

[0046] In the step (3), a spray dust suppressor is used to prevent pollution and dust during the cleaning process;

[0047] In the step (4), the release agent must be applied evenly, and certain protective measures must be taken after the application is completed.

[0048] Furthermore, in step (5), the process of placing the steel bar skeleton comprises: lifting, mold placement and correction, the tools used for placing the steel bar skeleton comprise: steel wire rope, round steel and work frame, and the process of placing the steel bar skeleton comprises the following steps:

[0049] a. Mobile steel cage and tire frame fixing tooling;

[0050] b. Use a crane to lift the steel frame, set up 6 lifting points, and pass 50 cm round steel through the lifting points. The round steel is located at the lower mesh layer below the upper steel bars of the steel frame;

[0051] c. Before lifting the steel frame, a trial lifting is required. Only after the trial lifting is safe can the lifting be carried out;

[0052] d. When the steel bar skeleton is put into the mold, it needs to be lowered slowly and the position of the skeleton and the end mold should be adjusted;

[0053] In the step (5), the safety requirements include: 1. When hoisting the steel frame, a trial lift must be carried out, and the lowering should be slow and steady; 2. During the hoisting of the steel frame, it is strictly forbidden to stand below. In the step (5), the precautions include: 1. The safety of the slings must be checked during hoisting; 2. Before the steel frame is hoisted into the mold, the steel protection layer pads need to be arranged on the bottom mold in advance.

[0054] Furthermore, in step (6), the mold assembly tool includes: a steel pipe, a rubber hose, a separate groove forming tool, a double-sided tape, a release agent and a screw;

[0055] In step (6), the mold assembly includes the following steps:

[0056] a. After the steel cage is put into the mold, close the socket side mold first, and clamp the two side molds with the fixed end mold and the bottom mold;

[0057] b. After the two side molds are closed, lift the movable end mold, and after the end mold is in place, fasten it with the buckle;

[0058] c. After the outer mold is assembled, the length, width and height of the mold are reviewed to ensure that the outer mold dimensions meet the requirements;

[0059] d. Insert the inner mold by forklift. The speed of inserting the inner mold should be slow and the position should be accurate to avoid collision between the inner mold and the outer mold and damage to the mold.

[0060] e. After the inner and outer molds are closed, check whether the template joints are tight, whether the buckles are tight, and whether the ejector pins are in place;

[0061] f. After 10 minutes of pouring and vibrating the bottom slab concrete, cover the bottom slab formwork and fasten it with buckles;

[0062] In step (7), the concealed inspection tools include: a square and a measuring tape; the concealed inspection includes the following steps:

[0063] a. Check the firmness, flatness and inner finish of the mold. There should be no gaps and whether the release agent is evenly applied;

[0064] b. Check whether the model, quantity and position of the steel bars and embedded parts meet the requirements, and whether the steel bar protection layer meets the requirements;

[0065] c. Check whether the hole-forming and groove-forming tooling is firmly fixed and the position is accurate;

[0066] d. Check the position and verticality of the hanging nails to see if they are firmly fixed;

[0067] In the step (6), the mold is self-checked after assembly, and the self-check includes the following steps:

[0068] a. Review the mold length, width, height, and end face height difference to ensure they meet the requirements of the drawing;

[0069] b. Check whether the mold is tightly assembled and whether sealing measures are taken to check whether there is a hidden danger of leakage;

[0070] In the step (7), the matters needing attention include: before laying the materials, the quality inspector shall make a final inspection according to the drawings, and the materials can only be laid after they are qualified.

[0071] Furthermore, in step (8), pouring concrete includes:

[0072] a. Concrete pouring and mold closing are carried out alternately; the order is: 1. pouring bottom plate concrete, 2. closing bottom plate cover mold, 3. pouring side wall concrete, 4. pouring side wall top concrete, 5. finishing;

[0073] b. According to the planned volume of concrete of this specification, the slump of the bottom slab concrete is controlled between 160 and 180 mm, the slump of the side wall concrete is controlled between 180 and 200 mm, and the slump of the top of the side wall concrete is controlled between 180 and 200 mm;

[0074] c. After pouring each layer, use a flat vibrator to vibrate, and the vibration time should not exceed 10s. Use an inserted vibrator to vibrate and compact. When vibrating the upper layer, insert it into the lower concrete for about 5cm and vibrate together. The vibration interval is 20-30cm. The vibration time is controlled at 20-30s at each point, and insert quickly and pull out slowly.

[0075] d. For the concrete leveling of the bottom plate, first use rectangular tubes or channel steel for preliminary leveling, and then perform manual surface leveling;

[0076] e. Use a 30mm vibrating rod to vibrate the socket, focusing on the inclined surface of the socket;

[0077] f. Pour the side slab concrete to the height of the axilla corner and vibrate once. Vibrate the remaining side slabs every 50 cm.

[0078] g. The concrete is evenly distributed and a chute is set for the bottom plate distribution;

[0079] h. After the top surface concrete is poured, vibrate it once. After the vibration is completed, use a scraper to finish the surface. After the concrete is initially set, it is calendered for the second time. After the finishing is completed, cover it with plastic film;

[0080] i. Three groups of test blocks with the same conditions and one group of standard curing test blocks are retained for each production component every day;

[0081] In the step (8), the safety requirements include: when using a vibrating rod to compact, it is strictly forbidden to allow the vibrating rod to touch personnel; in the step (8), the precautions include: 1. During pouring, be careful not to let the vibrating rod touch the embedded parts; 2. When the base plate is finished for the first time, only leveling and mold closing are required, and the vibration time of the flat vibrator shall not exceed 10 seconds.

[0082] Furthermore, in step (9), the component maintenance is steam maintenance, and the steam maintenance tools include: a maintenance shed, a temperature gauge, a steam generator and a hot air gun;

[0083] The component maintenance comprises the following steps:

[0084] a. Steam curing measures are adopted for component curing;

[0085] b. Use steam curing shed to carry out steam curing in situ;

[0086] c. Carry out steam maintenance;

[0087] d. After steam curing, ventilation should be stopped first, so that the temperature difference between inside and outside does not exceed 20℃, then open the steam curing shed and demould;

[0088] In the step (9), the precautions include: 1. It is strictly forbidden to use a hot air gun to directly blow the surface of the component; 2. After the steam curing is completed, it is not allowed to directly open the steam curing shed for demoulding to avoid excessive temperature difference and cracking of the component.

[0089] Furthermore, in step (10), demoulding and hoisting include the following steps:

[0090] a. Test the compressive strength of concrete. It can be lifted only when it reaches 75% of the design strength;

[0091] b. Remove the tension hole tooling;

[0092] c. Loosen the inner mold buckle, loosen the inner mold ejector rod, and use a forklift to remove the inner mold;

[0093] d. Loosen the side mold buckle and remove the side mold;

[0094] e. Use the crane to dismantle the movable end mold;

[0095] f. Loosen the side mold buckle and remove the side mold;

[0096] g. Lift the components after demoulding to the yard and use square timber to raise them to avoid rigid contact;

[0097] In the step (10), the safety requirements include: the U-shaped ring and the wire rope of the hanger must be checked before use to ensure that they are in good condition; in the step (10), the precautions include: 1. Before lifting, it must be ensured that the strength of the concrete reaches the design demoulding and lifting requirements before lifting; 2. When removing the side form, the force points must be controlled and the side form must be kept parallel to the outside as much as possible to reduce damage to the components.

[0098] Furthermore, in step (11), the finished product repair tools include: a shovel, a broom, repair materials, a wheelbarrow and a spatula. In step (11), the finished product repair includes the following steps:

[0099] a. For the exposed steel bars that are bent due to demoulding, adjust them to be straight;

[0100] b. Repair the appearance defects of pollution, honeycomb, pockmarks, bubbles and cracks on the prefabricated integrated pipe gallery;

[0101] c. After repair, the repaired component shall be repaired with a color paste that is consistent with the surface and color of the component;

[0102] d. Repair the socket corner collapse and air holes. After the repair is completed, remove the residue in the waterproof groove;

[0103] In the step (12), the finished product inspection and identification tool comprises: a hollow steel plate and a spray paint. In the step (12), the finished product inspection and identification tool comprises the following steps:

[0104] a. Check for exposed reinforcement, honeycombs, rough surfaces, corner drops, and cracks;

[0105] b. Measure the length, width, height, surface flatness of the components, the position of embedded parts and dowels, and the exposed length of dowels and embedded bolts;

[0106] c. Qualified components are stamped with "qualified" stamps, and unqualified components are labeled with "unqualified" and the unqualified items are recorded;

[0107] d. For qualified components, the information of component name, specification model and production date shall be marked;

[0108] e. After the components are inspected and qualified, they are wrapped with plastic film for maintenance;

[0109] f. After storage in the yard, cover with geotextile and maintain watering continuously.

[0110] Through the above technical solution, the double-compartment pipe gallery can be effectively prefabricated. Through standardized production processes and refined division of labor, the production efficiency can be significantly improved, the production cycle can be shortened, and the needs of large-scale construction can be met. Each production step has clear quality standards and inspection processes to ensure that the produced pipe gallery components meet the design requirements and standards, thereby improving the quality reliability of the product. BRIEF DESCRIPTION OF THE DRAWINGS

[0111] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0112] Figure 1 A flowchart of an embodiment of the present application is shown in FIG. DETAILED DESCRIPTION

[0113] In order to enable those skilled in the art to better understand the solution of the present application, the technical solution in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of the present application.

[0114] It should be noted that the terms "first", "second", etc. in the specification and claims of the present application and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequential order. It should be understood that the data used in this way can be interchanged where appropriate, so that the embodiments of the present application described here. In addition, the terms "including" and "having" and any of their variations are intended to cover non-exclusive inclusions, for example, a process, method, system, product or device comprising a series of steps or units is not necessarily limited to those steps or units clearly listed, but may include other steps or units that are not clearly listed or inherent to these processes, methods, products or devices.

[0115] In the present application, the terms "upper", "lower", "left", "right", "front", "back", "top", "bottom", "inner", "outer", "middle", "vertical", "horizontal", "lateral", "longitudinal" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the drawings. These terms are mainly used to better describe the present application and its embodiments, and are not used to limit the indicated devices, elements or components to have a specific orientation, or to be constructed and operated in a specific orientation.

[0116] In addition, some of the above terms may be used to express other meanings in addition to indicating orientation or positional relationship. For example, the term "on" may also be used to express a certain dependency or connection relationship in some cases. For those of ordinary skill in the art, the specific meanings of these terms in this application can be understood according to specific circumstances.

[0117] In addition, the terms "installed", "set", "provided with", "connected", "connected", and "socketed" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral structure; it can be a mechanical connection, or an electrical connection; it can be a direct connection, or an indirect connection through an intermediate medium, or it can be an internal connection between two devices, elements, or components. For those of ordinary skill in the art, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0118] See also Figure 1 As shown, the production process of the prefabricated double-cabin pipe gallery includes the following steps:

[0119] (1) Production of semi-finished steel bars;

[0120] (2) Steel bar skeleton welding;

[0121] (3) Mold cleaning;

[0122] (4) Apply release agent;

[0123] (5) Hanging the steel reinforcement frame;

[0124] (6) Mold assembly;

[0125] (7) Hidden acceptance;

[0126] (8) Concrete pouring;

[0127] (9) Component maintenance;

[0128] (10) Demoulding and hoisting;

[0129] (11) Finished product repair;

[0130] (12) Inspection and labeling of finished products.

[0131] Furthermore, in the step (1), the semi-finished steel bar product includes: main bars, vertical bars, corner bars and hooks, and the equipment used in making the semi-finished steel bar product includes: a steel bar cutting machine, a steel bar bending machine and a steel bar bending machine;

[0132] The steel bars are inspected before use, and the inspection includes the following steps:

[0133] c. Check the factory certificate and retest report of the steel bars;

[0134] d. Re-inspection of the appearance dimensions and mechanical properties of the steel bars;

[0135] c. Review drawings before cutting steel bars;

[0136] d. After cutting, the semi-finished steel bars are stored in piles according to brand specifications and marked;

[0137] In the step (1), the following points should be noted: 1. The length and external dimensions of the semi-finished steel bars meet the requirements; 2. The steel bars are cut using a cutting machine or a grinding wheel saw. In the step (1), the technical requirements are: the length dimension error of the main bar is ±10 mm.

[0138] Furthermore, in step (2), the welding sequence of the steel frame body includes the following steps:

[0139] a. Steel frame welding: first arrange the welded steel mesh in the steel frame mold, adjust the spacing and position of the steel mesh, and fix it with the frame tooling;

[0140] b. Insert the transverse distribution steel bars and fix them by welding;

[0141] c. Arrange hook bars and socket stirrups, and connect the hooks with the main bars by electric welding to ensure the spacing between the upper and lower layers of the steel skeleton;

[0142] d. Check the steel bar welding points and re-weld and adjust the leaking positions;

[0143] e. The transverse and vertical reinforcements of the steel skeleton are kept vertical, and all intersections are welded;

[0144] During the welding, the welding equipment used includes: an electric welder and a bridge crane;

[0145] In the step (2), the tools and materials include: semi-finished steel bars, transverse bars, stirrups, hooks, protective layer pads, oblique tie bars, reinforcing bars, electric welders, welding rods, measuring tapes, mesh membranes and steel cage membranes. In the step (2), the steel mesh is overlapped. To ensure that the steel mesh is firm, a welding connection method is used. The operation is carried out on the mesh frame, and the size is strictly controlled. It must not be tilted or twisted to ensure the thickness of the protective layer.

[0146] In the step (2), the technical requirements include: 1. The outer protective layer is 50 mm, the inner protective layer is 35 mm, and the error is ±5 mm; 2. The allowable deviation of the steel bar spacing is ±10 mm.

[0147] Furthermore, in the step (3), the mold cleaning includes: cleaning the inner mold and cleaning the outer mold. In the step (3), the tools and materials used include: a shovel, a putty knife, a broom, double-sided tape, glass glue, a wheelbarrow, an angle grinder, a wire wheel, and a wire brush;

[0148] In the step (3), the mold cleaning comprises the following steps:

[0149] a. Use a putty knife to remove the residue on the surface of the steel formwork, and then use an angle grinder with a torque wire wheel to clean the small concrete residue on the surface of the formwork;

[0150] b. Use a putty knife to clean the concrete residue on the wooden formwork, and tap it lightly with a small hammer to vibrate the concrete off;

[0151] c. Clean the socket surface template, inner mold top surface template, and socket rubber strip groove position of the double-cabin pipe gallery;

[0152] d. During the cleaning process, check the stop glue strips and replace the damaged glue strips and the glass glue at the inner corners of the mold;

[0153] e. After cleaning, the waste residues and waste materials shall be cleaned up and piled in a unified location;

[0154] In the step (4), a mold release agent is applied. Before the application, check whether the mold is cleaned thoroughly to ensure that there is no residue and that the mold meets the use requirements. The application tools include: a sprayer, a mold release agent and a roller brush. The application of the mold release agent includes the following steps:

[0155] a. Select a release agent, and use a water-based release agent;

[0156] b. Use a sprayer to spray the release agent. After spraying, use a clean roller brush to roll evenly to ensure that there is no dripping or accumulation of liquid;

[0157] c. After painting, pay attention to protection to avoid contamination by other impurities, which may affect the effect of the release agent;

[0158] In the step (3), a spray dust suppressor is used to prevent pollution and dust during the cleaning process;

[0159] In the step (4), the release agent must be applied evenly, and certain protective measures must be taken after the application is completed.

[0160] Furthermore, in step (5), the process of placing the steel bar skeleton comprises: lifting, mold placement and correction, the tools used for placing the steel bar skeleton comprise: steel wire rope, round steel and work frame, and the process of placing the steel bar skeleton comprises the following steps:

[0161] a. Mobile steel cage and tire frame fixing tooling;

[0162] b. Use a crane to lift the steel frame, set up 6 lifting points, and pass 50 cm round steel through the lifting points. The round steel is located at the lower mesh layer below the upper steel bars of the steel frame;

[0163] c. Before lifting the steel frame, a trial lifting is required. Only after the trial lifting is safe can the lifting be carried out;

[0164] d. When the steel bar skeleton is put into the mold, it needs to be lowered slowly and the position of the skeleton and the end mold should be adjusted;

[0165] In the step (5), the safety requirements include: 1. When hoisting the steel frame, a trial lift must be carried out, and the lowering should be slow and steady; 2. During the hoisting of the steel frame, it is strictly forbidden to stand below. In the step (5), the precautions include: 1. The safety of the slings must be checked during hoisting; 2. Before the steel frame is hoisted into the mold, the steel protection layer pads need to be arranged on the bottom mold in advance.

[0166] Furthermore, in step (6), the mold assembly tool includes: a steel pipe, a rubber hose, a separate groove forming tool, a double-sided tape, a release agent and a screw;

[0167] In step (6), the mold assembly includes the following steps:

[0168] a. After the steel cage is put into the mold, close the socket side mold first, and clamp the two side molds with the fixed end mold and the bottom mold;

[0169] b. After the two side molds are closed, lift the movable end mold, and after the end mold is in place, fasten it with the buckle;

[0170] c. After the outer mold is assembled, the length, width and height of the mold are reviewed to ensure that the outer mold dimensions meet the requirements;

[0171] d. Insert the inner mold by forklift. The speed of inserting the inner mold should be slow and the position should be accurate to avoid collision between the inner mold and the outer mold and damage to the mold.

[0172] e. After the inner and outer molds are closed, check whether the template joints are tight, whether the buckles are tight, and whether the ejector pins are in place;

[0173] f. After 10 minutes of pouring and vibrating the bottom slab concrete, cover the bottom slab formwork and fasten it with buckles;

[0174] In step (7), the concealed inspection tools include: a square and a measuring tape; the concealed inspection includes the following steps:

[0175] a. Check the firmness, flatness and inner finish of the mold. There should be no gaps and whether the release agent is evenly applied;

[0176] b. Check whether the model, quantity and position of the steel bars and embedded parts meet the requirements, and whether the steel bar protection layer meets the requirements;

[0177] c. Check whether the hole-forming and groove-forming tooling is firmly fixed and the position is accurate;

[0178] d. Check the position and verticality of the hanging nails to see if they are firmly fixed;

[0179] In the step (6), the mold is self-checked after assembly, and the self-check includes the following steps:

[0180] b. Review the mold length, width, height, and end face height difference to ensure they meet the requirements of the drawing;

[0181] b. Check whether the mold is tightly assembled and whether sealing measures are taken to check whether there is a hidden danger of leakage;

[0182] In the step (7), the matters needing attention include: before laying the materials, the quality inspector shall make a final inspection according to the drawings, and the materials can only be laid after they are qualified.

[0183] Furthermore, in step (8), pouring concrete includes:

[0184] a. Concrete pouring and mold closing are carried out alternately; the order is: 1. pouring bottom plate concrete, 2. closing bottom plate cover mold, 3. pouring side wall concrete, 4. pouring side wall top concrete, 5. finishing;

[0185] b. According to the planned volume of concrete of this specification, the slump of the bottom slab concrete is controlled between 160 and 180 mm, the slump of the side wall concrete is controlled between 180 and 200 mm, and the slump of the top of the side wall concrete is controlled between 180 and 200 mm;

[0186] c. After pouring each layer, use a flat vibrator to vibrate, and the vibration time should not exceed 10s. Use an inserted vibrator to vibrate and compact. When vibrating the upper layer, insert it into the lower concrete for about 5cm and vibrate together. The vibration interval is 20-30cm. The vibration time is controlled at 20-30s at each point, and insert quickly and pull out slowly.

[0187] d. For the concrete leveling of the bottom plate, first use rectangular tubes or channel steel for preliminary leveling, and then perform manual surface leveling;

[0188] e. Use a 30mm vibrating rod to vibrate the socket, focusing on the inclined surface of the socket;

[0189] f. Pour the side slab concrete to the height of the axilla corner and vibrate once. Vibrate the remaining side slabs every 50 cm.

[0190] g. The concrete is evenly distributed and a chute is set for the bottom plate distribution;

[0191] h. After the top surface concrete is poured, vibrate it once. After the vibration is completed, use a scraper to finish the surface. After the concrete is initially set, it is calendered for the second time. After the finishing is completed, cover it with plastic film;

[0192] i. Three groups of test blocks with the same conditions and one group of standard curing test blocks are retained for each production component every day;

[0193] In the step (8), the safety requirements include: when using a vibrating rod to compact, it is strictly forbidden to allow the vibrating rod to touch personnel; in the step (8), the precautions include: 1. During pouring, be careful not to let the vibrating rod touch the embedded parts; 2. When the base plate is finished for the first time, only leveling and mold closing are required, and the vibration time of the flat vibrator shall not exceed 10 seconds.

[0194] Furthermore, in step (9), the component maintenance is steam maintenance, and the steam maintenance tools include: a maintenance shed, a temperature gauge, a steam generator and a hot air gun;

[0195] The component maintenance comprises the following steps:

[0196] a. Steam curing measures are adopted for component curing;

[0197] b. Use steam curing shed to carry out steam curing in situ;

[0198] c. Carry out steam maintenance;

[0199] d. After steam curing, ventilation should be stopped first, so that the temperature difference between inside and outside does not exceed 20℃, then open the steam curing shed and demould;

[0200] In the step (9), the precautions include: 1. It is strictly forbidden to use a hot air gun to directly blow the surface of the component; 2. After the steam curing is completed, it is not allowed to directly open the steam curing shed for demoulding to avoid excessive temperature difference and cracking of the component.

[0201] Furthermore, in step (10), demoulding and hoisting include the following steps:

[0202] a. Test the compressive strength of concrete. It can be lifted only when it reaches 75% of the design strength;

[0203] b. Remove the tension hole tooling;

[0204] c. Loosen the inner mold buckle, loosen the inner mold ejector rod, and use a forklift to remove the inner mold;

[0205] d. Loosen the side mold buckle and remove the side mold;

[0206] e. Use the crane to dismantle the movable end mold;

[0207] f. Loosen the side mold buckle and remove the side mold;

[0208] g. Lift the components after demoulding to the yard and use square timber to raise them to avoid rigid contact;

[0209] In the step (10), the safety requirements include: the U-shaped ring and the wire rope of the hanger must be checked before use to ensure that they are in good condition; in the step (10), the precautions include: 1. Before lifting, it must be ensured that the strength of the concrete reaches the design demoulding and lifting requirements before lifting; 2. When removing the side form, the force points must be controlled and the side form must be kept parallel to the outside as much as possible to reduce damage to the components.

[0210] Furthermore, in step (11), the finished product repair tools include: a shovel, a broom, repair materials, a wheelbarrow and a spatula. In step (11), the finished product repair includes the following steps:

[0211] a. For the exposed steel bars that are bent due to demoulding, adjust them to be straight;

[0212] b. Repair the appearance defects of pollution, honeycomb, pockmarks, bubbles and cracks on the prefabricated integrated pipe gallery;

[0213] c. After repair, the repaired component shall be repaired with a color paste that is consistent with the surface and color of the component;

[0214] d. Repair the socket corner collapse and air holes. After the repair is completed, remove the residue in the waterproof groove;

[0215] In the step (12), the finished product inspection and identification tool comprises: a hollow steel plate and a spray paint. In the step (12), the finished product inspection and identification tool comprises the following steps:

[0216] a. Check for exposed reinforcement, honeycombs, rough surfaces, corner drops, and cracks;

[0217] b. Measure the length, width, height, surface flatness of the components, the position of embedded parts and dowels, and the exposed length of dowels and embedded bolts;

[0218] c. Qualified components are stamped with "qualified" stamps, and unqualified components are labeled with "unqualified" and the unqualified items are recorded;

[0219] d. For qualified components, the information of component name, specification model and production date shall be marked;

[0220] e. After the components are inspected and qualified, they are wrapped with plastic film for maintenance;

[0221] f. After storage in the yard, cover with geotextile and maintain watering continuously.

[0222] Through the above technical solution, the double-compartment pipe gallery can be effectively prefabricated. Through standardized production processes and refined division of labor, the production efficiency can be significantly improved, the production cycle can be shortened, and the needs of large-scale construction can be met. Each production step has clear quality standards and inspection processes to ensure that the produced pipe gallery components meet the design requirements and standards, thereby improving the quality reliability of the product.

[0223] The above description is only the preferred embodiment of the present application and is not intended to limit the present application. For those skilled in the art, the present application may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. The production process of prefabricated double-compartment pipe gallery is characterized by: The prefabricated double-compartment pipe gallery production process comprises the following steps: (1) Production of semi-finished steel bars; (2) Steel bar skeleton welding; (3) Mold cleaning; (4) Apply release agent; (5) Hanging the steel reinforcement frame; (6) Mold assembly; (7) Hidden acceptance; (8) Concrete pouring; (9) Component maintenance; (10) Demoulding and hoisting; (11) Finished product repair; (12) Inspection and labeling of finished products.

2. The prefabricated double-compartment pipe gallery production process according to claim 1 is characterized in that: In the step (1), the semi-finished steel bars include: main bars, vertical bars, corner bars and hooks. The equipment used in making the semi-finished steel bars include: a steel bar cutting machine, a steel bar bending machine and a steel bar bending machine; The steel bars are inspected before use, and the inspection includes the following steps: a. Check the factory certificate and retest report of the steel bars; b. Re-inspection of the appearance dimensions and mechanical properties of the steel bars; c. Review drawings before cutting steel bars; d. After cutting, the semi-finished steel bars are stored in piles according to brand specifications and labeled.

3. The prefabricated double-compartment pipe gallery production process according to claim 1 is characterized in that: In the step (2), the welding sequence of the steel frame body includes the following steps: a. Steel frame welding: first arrange the welded steel mesh in the steel frame mold, adjust the spacing and position of the steel mesh, and fix it with the frame tooling; b. Insert the transverse distribution steel bars and fix them by welding; c. Arrange hook bars and socket stirrups, and connect the hooks with the main bars by electric welding to ensure the spacing between the upper and lower layers of the steel skeleton; d. Check the steel bar welding points and re-weld and adjust the leaking positions; e. The transverse and vertical reinforcements of the steel frame remain vertical, and all intersections are welded.

4. The prefabricated double-compartment pipe gallery production process according to claim 1 is characterized in that: In the step (3), the mold cleaning includes: cleaning the inner mold and cleaning the outer mold. In the step (3), the tools and materials used include: a shovel, a putty knife, a broom, double-sided tape, glass glue, a wheelbarrow, an angle grinder, a wire wheel, and a wire brush; In the step (3), the mold cleaning comprises the following steps: a. Use a putty knife to remove the residue on the surface of the steel formwork, and then use an angle grinder with a torque wire wheel to clean the small concrete residue on the surface of the formwork; b. Use a putty knife to clean the concrete residue on the wooden formwork, and tap it lightly with a small hammer to vibrate the concrete off; c. Clean the socket surface template, inner mold top surface template, and socket rubber strip groove position of the double-cabin pipe gallery; d. During the cleaning process, check the stop glue strips and replace the damaged glue strips and the glass glue at the inner corners of the mold; e. After cleaning, the waste residues and waste materials shall be cleaned up and piled in a unified location; In the step (4), a mold release agent is applied. Before the application, check whether the mold is cleaned thoroughly to ensure that there is no residue. The application tool includes: a sprayer, a mold release agent and a roller brush. The application of the mold release agent includes the following steps: a. Select a release agent, and use a water-based release agent; b. Use a sprayer to spray the release agent. After spraying, use a clean roller brush to roll evenly to ensure that there is no dripping or accumulation of liquid; c. Protect after painting to avoid contamination from other impurities.

5. The prefabricated double-compartment pipe gallery production process according to claim 1 is characterized in that: In the step (5), the process of placing the steel bar skeleton includes: lifting, placing in a mold and calibrating. The tools used for placing the steel bar skeleton include: steel wire rope, round steel and work frame. The process of placing the steel bar skeleton includes the following steps: a. Mobile steel cage and tire frame fixing tooling; b. Use a crane to lift the steel frame, set up 6 lifting points, and pass 50 cm round steel through the lifting points. The round steel is located at the lower mesh layer below the upper steel bars of the steel frame; c. Before lifting the steel frame, a trial lifting is required. Only after the trial lifting is safe can the lifting be carried out; d. When the steel bar skeleton is put into the mold, it needs to be lowered slowly and the position of the skeleton and the end mold must be adjusted.

6. The prefabricated double-compartment pipe gallery production process according to claim 1 is characterized in that: In the step (6), the mold assembly tool includes: a steel pipe, a rubber hose, a separate groove forming tool, a double-sided tape, a release agent and a screw; In step (6), the mold assembly includes the following steps: a. After the steel cage is put into the mold, close the socket side mold first, and clamp the two side molds with the fixed end mold and the bottom mold; b. After the two side molds are closed, lift the movable end mold, and after the end mold is in place, fasten it with the buckle; c. After the outer mold is assembled, the length, width and height of the mold are reviewed to ensure that the outer mold dimensions meet the requirements; d. Insert the inner mold by forklift. The speed of inserting the inner mold should be slow and the position should be accurate to avoid collision between the inner mold and the outer mold and damage to the mold. e. After the inner and outer molds are closed, check whether the template joints are tight, whether the buckles are tight, and whether the ejector pins are in place; f. After 10 minutes of pouring and vibrating the bottom slab concrete, cover the bottom slab formwork and fasten it with buckles; In step (7), the concealed inspection tools include: a square and a measuring tape; the concealed inspection includes the following steps: a. Check the firmness, flatness and inner finish of the mold. There should be no gaps and whether the release agent is evenly applied; b. Check whether the model, quantity and position of the steel bars and embedded parts meet the requirements, and whether the steel bar protection layer meets the requirements; c. Check whether the hole-forming and groove-forming tooling is firmly fixed and the position is accurate; d. Check the position and verticality of the hanging nails to see if they are firmly fixed.

7. The prefabricated double-compartment pipe gallery production process according to claim 1 is characterized in that: In the step (8), pouring concrete includes: a. Concrete pouring and mold closing are carried out alternately; the order is:

1. pouring bottom plate concrete, 2. closing bottom plate cover mold, 3. pouring side wall concrete, 4. pouring side wall top concrete, 5. finishing; b. According to the planned volume of concrete of this specification, the slump of the bottom slab concrete is controlled between 160 and 180 mm, the slump of the side wall concrete is controlled between 180 and 200 mm, and the slump of the top of the side wall concrete is controlled between 180 and 200 mm; c. After pouring each layer, use a flat vibrator to vibrate, and the vibration time should not exceed 10s. Use an inserted vibrator to vibrate and compact. When vibrating the upper layer, insert it into the lower concrete for about 5cm and vibrate together. The vibration interval is 20-30cm. The vibration time is controlled at 20-30s at each point, and insert quickly and pull out slowly. d. For the concrete leveling of the bottom plate, first use rectangular tubes or channel steel for preliminary leveling, and then perform manual surface leveling; e. Use a 30mm vibrating rod to vibrate the socket, focusing on the inclined surface of the socket; f. Pour the side slab concrete to the height of the axilla corner and vibrate once. Vibrate the remaining side slabs every 50 cm. g. The concrete is evenly distributed and a chute is set for the bottom plate distribution; h. After the top surface concrete is poured, vibrate it once. After the vibration is completed, use a scraper to finish the surface. After the concrete is initially set, it is calendered for the second time. After the finishing is completed, cover it with plastic film; i. Every day, three groups of test blocks under the same conditions and one group of standard curing test blocks are retained for the production components.

8. The prefabricated double-compartment pipe gallery production process according to claim 1 is characterized in that: In the step (9), the component maintenance is steam maintenance, and the steam maintenance tools include: a maintenance shed, a temperature gauge, a steam generator and a hot air gun; The component maintenance comprises the following steps: a. Steam curing measures are adopted for component curing; b. Use steam curing shed; c. Carry out steam maintenance; d. After steam curing, stop ventilation first, so that the temperature difference between inside and outside does not exceed 20℃, then open the steaming shed and demoulding.

9. The prefabricated double-compartment pipe gallery production process according to claim 1, characterized in that: In the step (10), demoulding and hoisting include the following steps: a. Test the compressive strength of concrete. It can be lifted only when it reaches 75% of the design strength; b. Remove the tension hole tooling; c. Loosen the inner mold buckle, loosen the inner mold ejector rod, and use a forklift to remove the inner mold; d. Loosen the side mold buckle and remove the side mold; e. Use the crane to dismantle the movable end mold; f. Loosen the side mold buckle and remove the side mold; g. Lift the components after demoulding to the yard and raise them with square timber to avoid rigid contact.

10. The prefabricated double-compartment pipe gallery production process according to claim 1, characterized in that: In the step (11), the finished product repair tools include: a shovel, a broom, repair materials, a wheelbarrow and a spatula. In the step (11), the finished product repair includes the following steps: a. For the exposed steel bars that are bent due to demoulding, adjust them to be straight; b. Repair the appearance defects of pollution, honeycomb, pockmarks, bubbles and cracks on the prefabricated integrated pipe gallery; c. After repair, the repaired component shall be repaired with a color paste that is consistent with the surface and color of the component; d. Repair the socket corner collapse and air holes. After the repair is completed, remove the residue in the waterproof groove; In the step (12), the finished product inspection and identification tool comprises: a hollow steel plate and a spray paint. In the step (12), the finished product inspection and identification tool comprises the following steps: a. Check for exposed reinforcement, honeycombs, rough surfaces, corner drops, and cracks; b. Measure the length, width, height, surface flatness of the components, the position of embedded parts and dowels, and the exposed length of dowels and embedded bolts; c. Qualified components are stamped with "qualified" stamps, and unqualified components are labeled with "unqualified" labels and the unqualified items are recorded; d. For qualified components, the information of component name, specification model and production date shall be marked; e. After the components are inspected and qualified, they are wrapped with plastic film for maintenance; f. After storage in the yard, cover with geotextile and maintain watering continuously.

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