Prefabricated box girder reinforcement cage binding construction technology

Abstract

The invention aims to provide a prefabricated box girder reinforcement cage binding construction process, which comprises the following steps of: splitting a girder reinforcement cage into a plurality of reinforcement meshes and steel belt meshes, directly processing the reinforcement meshes into required shapes, directly placing the reinforcement meshes on a binding mold table in place, and manually carrying out post-repair binding; for an oversized mesh and a special-shaped mesh, a single steel bar is firstly machined and then placed in place in a steel belt net mode, and then cloth laying and binding of full-length steel bars are completed through the steel belt net. According to the process, a box girder is divided into a plurality of reinforcing meshes and a plurality of steel belt meshes, the reinforcing meshes and the steel belt meshes are machined respectively and then spliced integrally, steel is fed, conveyed, sized, sheared and welded to be subjected to mesh bending forming, numerical control integrated equipment can be integrated on an assembly line, a single mesh can be mechanically machined, the overall automation rate is greatly increased, and the production efficiency is improved. Manual operation links are reduced, manpower is saved, the quality is stable, and the efficiency is greatly improved.

Description

Technical Field

[0001] The invention relates to the technical field of railway engineering, and in particular to a construction process for binding a reinforcement skeleton of a prefabricated box girder. Background Art

[0002] The prefabrication of high-speed railway box girders includes the main processes of steel bar production and installation, template grinding, concrete pouring, prestressing, channel grouting, beam body concrete maintenance, anchor hole roughening and anchor sealing, beam end waterproof coating spraying, etc. Except for steel bar production and installation, other processes have achieved breakthroughs in intelligent construction. Traditional box girder steel bars are of many types, large quantities, and require a lot of labor. Taking a 32m box girder as an example, the steel bars include 6 diameters, 103 patterns, and a total weight of 52t. There are as many as 70,000 connection nodes between steel bars. The connection forms are complex and diverse, and the process is primitive, the quality is unstable, and the efficiency is low. Summary of the invention

[0003] The purpose of the present invention is to provide a prefabricated box girder reinforcement skeleton binding construction process, which reduces manual operation links, saves manpower, and has stable quality and greatly improved efficiency by dividing the box girder into several reinforcement meshes and steel belt meshes, processing them separately and then assembling them as a whole.

[0004] Based on the above purpose, the present invention adopts the following technical solutions:

[0005] A prefabricated box girder reinforcement skeleton binding construction process, wherein the girder body reinforcement skeleton is split into a plurality of reinforcement meshes and steel belt meshes, wherein the reinforcement meshes are directly processed into a desired shape, and then the reinforcement meshes are directly placed in place on a binding die table, and are manually bound afterwards; for oversized meshes and special-shaped meshes, a single piece of reinforcement is first processed and placed in place in the form of a steel belt mesh, and then the laying and binding of the full-length reinforcement is completed through the steel belt mesh.

[0006] Preferably, the assembly steps of the steel mesh and the steel strip mesh are as follows:

[0007] Step 1: The bottom plate N12 steel bars are delivered to the binding die table one by one and placed in place;

[0008] Step 2, laying out the bottom plate steel belt mesh;

[0009] Step 3, laying out the steel belt mesh on one side of the web;

[0010] Step 4, laying out the steel belt mesh on the other side of the abdomen;

[0011] Step 5, the bottom plate mesh is put into place;

[0012] Step 6, the web mesh is put into place;

[0013] Step 7, top plate reinforcement is put into place;

[0014] Step 8, after the steel mesh at the bottom of the top plate is put into the mold, the steel strip mesh is placed;

[0015] Step 9: prefabricate the top steel bar wire under the top plate into a mesh and then put it into the mold;

[0016] Step 10: Put the mesh panels on both sides of the top plate into place.

[0017] Preferably, the steel mesh welding process is as follows:

[0018] Step 1, transporting the steel bar raw materials from the storage area to the wire rod steel bar straightening and feeding area, and performing steel bar pulling, buffering, straightening, sizing, and shearing;

[0019] Step 2, conveying the transverse ribs to the transverse rib feeding area, and chain-type transverse ribs are dropped;

[0020] Step 3, then transporting to the welding area, resistance welding forming;

[0021] Step 4: After forming, bend the steel mesh one by one on both sides in the online bending area.

[0022] Preferably, the bending direction is upward.

[0023] Preferably, the steel belt mesh processing method is:

[0024] Step 1: The longitudinal reinforcement (transverse reinforcement) required for the prefabricated box girder is straightened and prepared online through the data setting of the CNC steel bar straightening mechanism, and straightened and transported one by one according to the set step spacing;

[0025] Step 2, cross-lap and weld the full-length steel bars and steel strips into a mesh;

[0026] Step 3: After welding is completed, the mesh is fed forward and curled in the cross-sectional direction of the steel strip for automatic winding, and the finished steel strip mesh roll is automatically transported to the pallet.

[0027] Preferably, the hook of the inner stirrup N15 of the web is a 90° straight hook, which is convenient for welding / binding it to the transverse steel bars at the bottom of the top plate.

[0028] Preferably, a hook is provided at the end of the upper layer of steel bars N35 of the bottom plate, and the hook is 135° or 90°; or, an anchor plate is provided at the end of N35.

[0029] Preferably, the N14 steel bars of the bottom layer of the top plate are welded / tied to N15, and an anchor plate is provided at the end of the N14 steel bars.

[0030] Compared with the prior art, the present invention has the following beneficial effects:

[0031] The construction process of the present invention divides the box girder skeleton into several steel meshes and steel belt meshes, processes them separately and then assembles them as a whole. Steel material is fed, conveyed, sizing, sheared, welded to mesh bending and forming. Assembly line integrated CNC integrated equipment such as welding machines, shearing lines and bending centers can be used. Single mesh is easier to achieve mechanized processing. Some steel bars are manually inserted, and the overall automation rate is greatly improved, reducing manual operation links, saving manpower, and the quality is stable and the efficiency is greatly improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 Provide a flow chart for mesh assembly;

[0033] Figure 2 This is the steel mesh layout diagram;

[0034] Figure 3 This is a schematic diagram of the inner stirrup hook of the web;

[0035] Figure 4 This is a schematic diagram of the bent hook at the anchorage end of the N35 steel bar on the upper layer of the bottom plate;

[0036] Figure 5 This is a schematic diagram of the end anchor plate of the upper reinforcement N35 on the bottom plate;

[0037] Figure 6 Schematic diagram of the bent hook at the anchorage end of the N35 steel bar on the upper layer of the bottom plate. DETAILED DESCRIPTION

[0038] Refer to the following Figures 1 to 6 To describe a prefabricated box girder reinforcement skeleton binding construction process of an embodiment of the present invention. In the description of this embodiment, it should be understood that the terms "first" and "second" are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features, that is, include one or more of the features. In the description of the present invention, the meaning of "multiple" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined. When a feature "includes or contains" one or some of the features it covers, unless otherwise specifically described, this indicates that other features are not excluded and may further include other features.

[0039] In the description of the present embodiment, the description with reference to the terms "one embodiment", "some embodiments", "illustrative embodiments", "examples", "specific examples", or "some examples" means that the specific features, structures, materials, or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described may be combined in any one or more embodiments or examples in a suitable manner.

[0040] like Figures 1 to 6 As shown, a prefabricated box girder reinforcement skeleton binding construction process of the present invention, the construction process splits the beam body reinforcement skeleton into a plurality of reinforcement meshes and steel belt meshes, wherein the reinforcement meshes are directly processed into the required shape, and then the reinforcement meshes are directly placed in place on the binding mold table, and manually supplemented with binding; for extra-large meshes and special-shaped meshes, the single steel bar is first placed in place after processing in the form of a steel belt mesh, and then the steel belt mesh is used to complete the laying and binding of the full-length steel bars.

[0041] Preferably, the assembly steps of the steel mesh and the steel strip mesh are as follows:

[0042] Step 1: The bottom plate N12 steel bars are delivered to the binding die table one by one and placed in place;

[0043] Step 2, laying out the bottom plate steel belt mesh;

[0044] Step 3, laying out the steel belt mesh on one side of the web;

[0045] Step 4, laying out the steel belt mesh on the other side of the abdomen;

[0046] Step 5, the bottom plate mesh is put into place;

[0047] Step 6, the web mesh is put into place;

[0048] Step 7, top plate reinforcement is put into place;

[0049] Step 8, after the steel mesh at the bottom of the top plate is put into the mold, the steel strip mesh is placed;

[0050] Step 9: prefabricate the top steel bar wire under the top plate into a mesh and then put it into the mold;

[0051] Step 10: Put the mesh panels on both sides of the top plate into place.

[0052] Preferably, the steel mesh welding process is as follows:

[0053] Step 1, transporting the steel bar raw materials from the storage area to the wire rod steel bar straightening and feeding area, and performing steel bar pulling, buffering, straightening, sizing, and shearing;

[0054] Step 2, conveying the transverse ribs to the transverse rib feeding area, and chain-type transverse ribs are dropped;

[0055] Step 3, then transporting to the welding area, resistance welding forming;

[0056] Step 4: After forming, bend the steel mesh one by one on both sides in the online bending area.

[0057] Preferably, the bending direction is upward.

[0058] Preferably, the steel belt mesh processing method is:

[0059] Step 1: The longitudinal reinforcement (transverse reinforcement) required for the prefabricated box girder is straightened and prepared online through the data setting of the CNC steel bar straightening mechanism, and straightened and transported one by one according to the set step spacing;

[0060] Step 2, cross-lap and weld the full-length steel bars and steel strips into a mesh;

[0061] Step 3: After welding is completed, the mesh is fed forward and curled in the cross-sectional direction of the steel strip for automatic winding, and the finished steel strip mesh roll is automatically transported to the pallet.

[0062] Preferably, the hook of the inner stirrup N15 of the web is a 90° straight hook, which is convenient for welding / binding it to the transverse steel bars at the bottom of the top plate.

[0063] Preferably, a hook is provided at the end of the upper layer of steel bars N35 of the bottom plate, and the hook is 135° or 90°; or, an anchor plate is provided at the end of N35.

[0064] Preferably, the N14 steel bars of the bottom layer of the top plate are welded / tied to N15, and an anchor plate is provided at the end of the N14 steel bars.

[0065] In order to make the purpose, technical scheme and advantages of the present invention clearer, the technical scheme of the present invention is described in detail below, but the following embodiments are only part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other implementation methods obtained by those skilled in the art without making creative work belong to the scope of protection of the present invention.

[0066] Example 1

[0067] A prefabricated box girder reinforcement skeleton binding construction process, the construction process splits the beam body reinforcement skeleton into a plurality of reinforcement meshes and steel belt meshes, wherein the reinforcement mesh is directly processed into a required shape, and then, workers operate a crane and a hoist to place the reinforcement mesh directly on a binding mold platform. Due to interference during mesh assembly, some 32-meter-long reinforcements cannot be directly welded to the mesh, and need to be manually placed in place in advance. After the mesh is placed in the mold, manual supplementary binding is performed. For super-large meshes (width exceeding 6 meters) and special-shaped meshes (N12 large U-shaped reinforcement meshes), which cannot be processed in the form of reinforcement mesh, they are processed in the form of steel belt mesh, that is, N12 and other single pieces are first processed and placed in place, and then the steel belt mesh is used to complete the laying of the full-length reinforcement.

[0068] Taking a simply supported beam as an example, the entire beam reinforcement skeleton is split into 14 meshes, including 10 steel meshes and 4 steel strip meshes, and then assembled and welded. The specific steps are as follows:

[0069] Step 1: The bottom plate N12 steel bars are delivered to the binding die table one by one and placed in place;

[0070] Step 2, laying out the bottom plate steel belt mesh;

[0071] Step 3, laying out the steel belt mesh on one side of the web 1;

[0072] Step 4, laying out the steel belt mesh on the other side of the abdomen 2;

[0073] Step 5, the bottom plate mesh is put into place;

[0074] Step 6, the web mesh is put into place;

[0075] Step 7, top plate reinforcement is put into place;

[0076] Step 8, after the steel mesh at the bottom of the top plate is put into the mold, the steel strip mesh is placed;

[0077] Step 9: prefabricate the top steel bar wire under the top plate into a mesh and then put it into the mold;

[0078] Step 10: Put the mesh panels on both sides of the top plate into place.

[0079] Among them, the steel mesh welding process is as follows:

[0080] Step 1, transporting the steel bar raw materials from the storage area to the wire rod steel bar straightening and feeding area, and performing steel bar pulling, buffering, straightening, sizing, and shearing;

[0081] Step 2, conveying the transverse ribs to the transverse rib feeding area, and chain-type transverse ribs are dropped;

[0082] Step 3, then transporting to the welding area, resistance welding forming;

[0083] Step 4, after forming, bend the steel mesh one by one on both sides of the online bending area; because the mesh needs to be conveyed by the roller device after bending, the longitudinal reinforcement moves forward according to the set grid spacing, and the transverse reinforcement is welded after being positioned one by one. Therefore, the bending direction is upward, otherwise the hook will interfere with the conveying roller, resulting in failure to transport. Therefore, there will be a single piece of steel bar (transverse reinforcement) located both above and below the full-length steel bar, so a single piece of steel bar needs to take into account the above two feeding methods.

[0084] The steel belt mesh processing method is:

[0085] First, the longitudinal reinforcement (transverse reinforcement) required for the prefabricated box girder is straightened and prepared online through the data setting of the CNC steel bar straightening mechanism, and then straightened and transported one by one according to the set step spacing, and then the full-length steel bars and steel strips are cross-lapped and welded into a mesh. After welding is completed, the mesh is fed forward and curled in the cross-sectional direction of the steel strip for automatic winding, and the finished steel strip mesh roll is automatically transported to the pallet. The steel strip mesh welding equipment is mainly composed of automatic straightening, automatic feeding, automatic sizing, automatic winding and other devices, which can realize the fully automated process of steel strip mesh welding.

[0086] The process flow of the steel strip mesh welding equipment is as follows: raw material straightening, lengthening and cutting → longitudinal reinforcement step loading → longitudinal reinforcement blanking → steel strip loading → main machine welding → winding → finished steel strip mesh hoisting.

[0087] The processing process of U-shaped steel bars in the prefabricated box girder is as follows: automatic loading of raw materials → cutting to a fixed length and aligning the blanking → bending and forming the large U-shaped bars → transferring the large U-shaped bars to the positioning device → hoisting the finished products to the assembly jig.

[0088] The hook of the inner stirrup N15 of the web is changed from a 135° hook to a flat hook, which is convenient for welding / binding the flat hook of N15 with the transverse steel bars of the top and bottom plates to form an integral steel bar skeleton.

[0089] A hook is provided at the end of the upper layer of the bottom plate steel bar N35, the hook is 135°, and the steel bar length is reduced by 320mm to avoid interference with the outer side steel bars of the web.

[0090] The N14 steel bars at the bottom layer of the top plate are welded / tied to N15, and the end hooks are removed and anchor plates are provided to facilitate construction.

[0091] The construction process adopted in this embodiment, in which the steel mesh processing method has the following advantages: ① high processing accuracy and standardized finished products; ② robot loading to improve work efficiency; ③ convenient modification and low operating failure rate; ④ reduced labor and reduced labor intensity. Work efficiency improvement: the working hours of a single beam are reduced by 20%, the number of operators is reduced from 4 to 2, and the labor cost is reduced by 440 yuan.

[0092] The steel belt mesh welding has the following advantages: ① subverting the traditional process, laying is convenient and fast; ② high work efficiency and low labor intensity; ③ short production cycle and high economic benefits; ④ human-machine interaction and low failure rate. Work efficiency improvement: the working hours of a single beam are reduced by 20%, the number of operators is reduced from 4 to 2, and the labor cost is reduced by 440 yuan.

[0093] The U-shaped steel bar processing technology has the following advantages: ① simple operation, safe and reliable, high production efficiency; ② large U-shaped steel bar bending and bending process is formed in one step; ③ orderly material arrangement and precise positioning; ④ fully automated process flow, reducing the labor intensity of workers. Work efficiency improvement: the working hours of a single beam are reduced by 80%, the number of operators is reduced from 6 to 1, and the labor cost is reduced by 1,087.5 yuan.

[0094] Example 2

[0095] A prefabricated box girder reinforcement skeleton binding construction process, wherein a hook is provided at the end of the upper layer of the bottom plate reinforcement N35, the hook is 90 degrees, and the reinforcement length is reduced by 320mm to avoid interference with the reinforcement outside the web. The rest is the same as in Example 1.

[0096] Example 3

[0097] A prefabricated box girder reinforcement skeleton binding construction process, wherein an anchor plate is provided at the end of the upper layer of the bottom plate reinforcement N35, and the reinforcement length is reduced by 320 mm to avoid interference with the outer reinforcement of the web. The rest is the same as in Example 1.

[0098] The above is only a specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art can easily think of changes or substitutions within the technical scope disclosed by the present invention, which should be included in the protection scope of the present invention. Therefore, the protection scope of the present invention should be based on the protection scope of the claims.

Claims

1. A prefabricated box girder reinforcement skeleton binding construction process, characterized in that: The construction process splits the steel skeleton of the beam into several steel meshes and steel belt meshes, wherein the steel meshes are directly processed into the required shape, and then the steel meshes are directly placed in place on the binding formwork, and manually tied afterwards; for extra-large meshes and special-shaped meshes, the single steel bars are first processed and placed in place in the form of steel belt meshes, and then the steel belt meshes are used to complete the laying and binding of the full-length steel bars.

2. The prefabricated box girder reinforcement skeleton binding construction process according to claim 1 is characterized in that: The assembly steps of the steel mesh and the steel strip mesh are as follows: Step 1: The bottom plate N12 steel bars are delivered to the binding die table one by one and placed in place; Step 2, laying out the bottom plate steel belt mesh; Step 3, laying out the steel belt mesh on one side of the web; Step 4, laying out the steel belt mesh on the other side of the abdomen; Step 5, the bottom plate mesh is put into place; Step 6, the web mesh is put into place; Step 7, top plate reinforcement is put into place; Step 8, after the steel mesh at the bottom of the top plate is put into the mold, the steel strip mesh is placed; Step 9: prefabricate the top steel bar wire under the top plate into a mesh and then put it into the mold; Step 10: Put the mesh panels on both sides of the top plate into place.

3. The prefabricated box girder reinforcement skeleton binding construction process according to claim 1 is characterized in that: The steel mesh welding process is as follows: Step 1, transporting the steel bar raw materials from the storage area to the wire rod steel bar straightening and feeding area, and performing steel bar pulling, buffering, straightening, sizing, and shearing; Step 2, conveying the transverse ribs to the transverse rib feeding area, and chain-type transverse ribs are dropped; Step 3, then transporting to the welding area, resistance welding forming; Step 4: After forming, bend the steel mesh one by one on both sides in the online bending area.

4. The prefabricated box girder reinforcement skeleton binding construction process according to claim 3 is characterized in that: The bending direction is upward.

5. The prefabricated box girder reinforcement skeleton binding construction process according to claim 1 is characterized in that: The steel belt mesh processing method is: Step 1: The longitudinal reinforcement (transverse reinforcement) required for the prefabricated box girder is straightened and prepared online through the data setting of the CNC steel bar straightening mechanism, and straightened and transported one by one according to the set step spacing; Step 2, cross-lap and weld the full-length steel bars and steel strips into a mesh; Step 3: After welding is completed, the mesh is fed forward and curled in the cross-sectional direction of the steel strip for automatic winding, and the finished steel strip mesh roll is automatically transported to the pallet.

6. The prefabricated box girder reinforcement skeleton binding construction process according to claim 2 is characterized in that: The N15 hook of the inner stirrup of the web is a 90° straight hook, which is convenient for welding / binding it with the transverse steel bars at the bottom of the top plate.

7. The prefabricated box beam reinforcement skeleton binding construction process according to claim 2 is characterized in that: A hook is provided at the end of the upper layer of steel bars N35 of the bottom plate, and the angle of the hook is 135° or 90°; or, an anchor plate is provided at the end of N35.

8. The prefabricated box beam reinforcement skeleton binding construction process according to claim 2 is characterized in that: The N14 steel bars at the bottom layer of the top plate are welded / tied to N15, and an anchor plate is provided at the end of the N14 steel bar.

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