Prefabricated beam yard layout structure and method

Abstract

The invention relates to the technical field of precast beam fields, and discloses a precast beam field layout structure and method. Comprising a mixing station, a stock bin located beside the mixing station, an office area opposite to the mixing station, a test room beside the stock bin, an intelligent reinforcing steel bar machining center and a material reserve center on the side edge of the test room, a reinforcing steel bar binding area on the side edge of the intelligent reinforcing steel bar machining center, and a beam manufacturing area and a beam storage area on the side edge of the reinforcing steel bar binding area. All functional areas are intensively arranged according to the production process, streamlined operation is formed, construction connection between procedures is enhanced, labor division is clear, cross construction of all the areas is reduced, logistics organization pressure is reduced, construction management is facilitated, a steel bar factory and a steel bar binding area are designed to be communicated, and therefore the defects that the beam field expansion distance, the steel bar cage hoisting distance and the beam lifting distance are too long, and construction efficiency is low are overcome. The problems that functional areas of an existing prefabricated beam field layout structure are scattered, and zoning is not clear are solved.

Description

Technical Field

[0001] The present invention relates to the technical field of prefabricated beam yards, and specifically to a prefabricated beam yard layout structure and method. Background Art

[0002] Precast beams are prefabricated in factories and then transported to the construction site for installation and fixation in the position required by the design. They are usually made of reinforced concrete or prestressed concrete. They have the advantages of high production efficiency, stable quality, energy saving and environmental protection. Precast beams can be customized in different sizes and shapes as needed to meet the needs of different buildings and projects, involving various fields such as roads, bridges, houses, and large equipment.

[0003] The box girder prefabrication site generally adopts two layout forms, vertical or horizontal, depending on the site terrain, equipment configuration, design scale, monthly design production capacity, etc. The disadvantages of the traditional layout are: first, the functional areas are scattered, the functional area division is not clear, and intensive management cannot be achieved; second, it is greatly affected by the land acquisition terrain, and each functional area needs to adjust its position and layout according to the terrain; third, the steel bar factory and the steel bar binding area are not connected, and the transportation of steel bars is inconvenient. Summary of the invention

[0004] In order to solve the problem that the functional areas of the existing precast beam yard layout structure are dispersed and the zoning is unclear, the present invention provides a precast beam yard layout structure and method to solve the above problems.

[0005] To achieve the above object, the present invention provides the following technical solutions:

[0006] A prefabricated beam yard layout structure and method, including a mixing station, a silo located next to the mixing station, an office area opposite the mixing station, a laboratory next to the silo, a steel bar intelligent processing center and a material storage center on the side of the laboratory, a steel bar binding area on the side of the steel bar intelligent processing center, a beam manufacturing area on the side of the steel bar binding area, and a beam storage area;

[0007] The office area between the mixing station and the silo forms the main road line, the beam storage area and its beam lifting and turning area are located on both sides of the beam manufacturing area, and the steel bar intelligent processing center and material storage center are located at the end of the feed port of the beam manufacturing area, forming a mirror-image longitudinal layout.

[0008] Preferably, the mixing station is equipped with an intelligent weighing scale system for weighing and generating a receipt, and also includes a tank truck Internet of Things technology system for real-time statistics of the tank truck's monthly and cumulative transportation volume, assigning tasks and sending text messages to idle tank truck drivers. A tank truck parking area is provided on the side of the mixing station.

[0009] Preferably, the mixing station, silo, office area, laboratory, intelligent steel processing center, material storage center, steel bar binding area, beam manufacturing area and beam storage area are all provided with eight-meter-wide transportation passages between each other.

[0010] Preferably, the silo includes several gravel silos, sand silos and steel support beams for storing 5-10 mm gravel, and the test laboratory includes a glue room, a chemical room, a durability room, a high temperature room, an aggregate room, a sample room, a prestressed concrete room, a data room, a metering room, an office and several grouting standard curing rooms.

[0011] Preferably, the steel bar intelligent processing center is equipped with a steel bar shearing production line, a steel bar bending production line, a steel bar shearing and bending integrated production line and a positioning net welding production line, and also includes a box girder positioning net welding robot and a beam yard U-shaped bar handling and discharging system.

[0012] Preferably, the steel bar binding area includes a number of assembled steel bar binding jigs, intelligent segmented self-propelled steel bar binding inner support frames, box girder steel bar binding welding robots and retractable canopies, and the steel bar binding area is connected to the truss crane track of the steel bar distribution center.

[0013] Preferably, the beam-making area includes a plurality of single-line beam-making pedestals and double-line beam-making pedestals, and a gantry is provided between every two adjacent beam-making pedestals.

[0014] Preferably, beam loading areas are provided on both sides of the beam storage area, tire-type transporters are provided in the beam loading areas, beam lifting and turning areas are provided on the sides of the beam loading areas, beam lifting and turning areas are provided with beam transport channels extending to the construction site, and the beam transport channels extending to the construction site are provided with gantry cranes.

[0015] Preferably, the beam storage area is equipped with a total of 146 beam storage pedestals, including 42 maintenance pedestals, with a maximum beam storage capacity of 292 beams, including 98 double-line beam storage pedestals, of which 61 are 32m special beam storage pedestals, 37 are 24m / 32m double-line universal beam storage pedestals, and 32 are single-line beam storage pedestals, including 16 32m special beam storage pedestals, 16 are 24m / 32m universal beam storage pedestals, and 16 are single and double shared pedestals. The height of the beam storage pier is 60cm, and the bottom of the beam is hardened, and the hardened height is the same as the beam storage pedestal.

[0016] Preferably, a precast beam yard layout method comprises the following steps:

[0017] Step A, stacking the steel bar raw materials, sand, gravel and gel materials required for concrete inside the silo;

[0018] Step A1, pile 5-10 mm crushed stones in the crushed stone bin, pile sand in the sand bin, and arrange and pile steel bars on the steel bar bracket beam, and classify and mark them, and record the inventory of crushed stones, sand and steel bars in the bin;

[0019] Step A2, a conveyor belt is provided at the silo inlet. When storing materials, crushed stone, sand and steel bars are transported into the silo through the conveyor belt, and then transported to the crushed stone silo, sand silo and steel bar bracket beam. When used, they are then transported out through the conveyor belt.

[0020] Step B, preparing steel bars and concrete;

[0021] Step B1, transporting the steel bars to the steel bar binding area via the truss crane track;

[0022] Step B2, by using assembled steel bar binding jigs, intelligent segmented self-propelled steel bar binding inner support frames, box girder steel bar binding welding robots and other tools, in conjunction with retractable canopies, all-weather intelligent steel bar binding operations can be achieved.

[0023] Step B3, adding raw materials into the mixing station according to the proportion, mixing in the mixing station, loading the fresh concrete into the tank by loading the materials in the mixing station, and then transporting it to the beam making area.

[0024] Step C, preparing a prefabricated beam;

[0025] Step C1, the steel cage skeleton is transferred to the beam-making pedestal through the steel cage hanger, and the mixed concrete is poured. The concrete pouring adopts a concrete placing machine, a slurry raising and leveling machine, and a concrete pouring vehicle dispatching system. After pouring, it is left to stand for forming and demoulding;

[0026] Step C2, after the prefabricated beam is formed and demoulded, the outer mold is polished and sprayed with a chemical polishing and spraying integrated machine, and the inner mold is installed with a chemical walking system, which cooperates with an intelligent cutting and roughening robot to cut the steel bars inside the anchor hole of the prefabricated beam, and polish the side wall of the anchor hole port, and then spray paint for protection after polishing;

[0027] Step C3: After the grinding and spraying is completed, the intelligent concrete curing system and AI process recognition realize the concrete curing of the box beam. The curing agent is sprayed on the outer surface of the precast beam by the intelligent robot. After spraying, the curing agent is covered with a protective film for curing;

[0028] Step D, transporting the prefabricated beams to the construction site;

[0029] Step D1, transporting the prefabricated beams to a beam transport vehicle by a tire transporter, and the beam transport vehicle transports the beams to the vicinity of the construction site;

[0030] Step D2, after arriving at the construction site, the prefabricated beams on the beam transport vehicle are unloaded by the gantry crane and assembled, and the beam transport vehicle returns through the beam transport channel to continue transporting beams.

[0031] Compared with the prior art, the present invention has the following beneficial effects:

[0032] In the present invention, through the mirror-image longitudinal layout, each functional area is intensively arranged according to the production process to form a streamlined operation, strengthen the construction connection between processes, clearly divide the work, reduce the cross-construction of each interval, reduce the pressure of logistics organization, and facilitate construction management. The rebar factory and the rebar binding area are designed to be connected to optimize the rebar transfer process. The mirror-image longitudinal layout also has the disadvantages of the beam yard being expanded due to the offline construction period, the lifting distance of the rebar cage and the lifting and moving of the beam are too long, and the construction efficiency is low. It solves the problem of the existing prefabricated beam yard layout structure with scattered functional areas and unclear divisions. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] 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.

[0034] Figure 1 It is a schematic diagram of the layout structure of a precast beam yard according to an embodiment of the present application.

[0035] The meanings of the reference numbers in the figure are: 1. Mixing station; 2. Silo; 3. Office area; 4. Laboratory; 5. Prefabricated beam yard layout structure; 6. Material storage center; 7. Rebar binding area; 8. Beam manufacturing area; 9. Beam storage area. DETAILED DESCRIPTION

[0036] In order to make the purpose, features, and advantages of the present application more obvious and easy to understand, the technical solutions 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 embodiments described below 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 are within the scope of protection of this application.

[0037] Reference Figure 1 A prefabricated beam yard layout structure and method, including a mixing station 1, a silo 2 located next to the mixing station 1, an office area 3 opposite the mixing station, a laboratory 4 next to the silo 2, a steel bar intelligent processing center 5 and a material storage center 6 on the side of the laboratory 4, a steel bar binding area 7 on the side of the steel bar intelligent processing center 5, a beam making area 8 on the side of the steel bar binding area 7, and a beam storage area 9. The office area 3 forms a main road line between the mixing station 1 and the silo 2, the beam storage area 9 and its beam lifting and turning area are located on both sides of the beam making area 8, and the steel bar intelligent processing center 5 and the material storage center 6 are located at the end of the feed inlet of the beam making area 8, forming a mirror image longitudinal layout.

[0038] Clarify the regional division. According to the precast beam production process, it is divided into mixing station 1, steel bar processing center 6, steel bar binding area 7, beam making area 8, beam storage area 9, and office area 3, to realize the streamlined operation of box girder steel bar processing, binding, mold putting, and concrete pouring, and solidify the production process at the same time. After the steel bar raw materials enter the site, they are processed by intelligent equipment and transferred to the steel bar binding jig. The template grinding adopts a chemical grinding and spraying all-in-one machine, the inner mold installation adopts a chemical walking system, and the concrete pouring adopts a slurry raising and leveling all-in-one machine, to realize the streamlined operation of box girder steel bar processing, binding, mold putting, and concrete pouring. Finally, strengthen the connection between processes, promote AI process recognition system and process APP reporting system, identify the start time of processes such as steel bar binding and concrete pouring, timely push production instructions such as process acceptance, and generate electronic construction logs and inspection batches.

[0039] Mixing Station 1 is equipped with an intelligent floor scale system for weighing and generating receipts. It also includes a tank truck Internet of Things technology system, which can real-time count the tank truck's monthly and cumulative transportation volume, assign tasks and send text messages to idle tank truck drivers. A tank truck parking area is set up on the side of Mixing Station 1.

[0040] Mixing station 1, silo 2, office area 3, laboratory 4, intelligent steel bar processing center 5, material reserve center 6, steel bar binding area 7, beam manufacturing area 8 and beam storage area 9 are all equipped with eight-meter-wide transportation passages for personnel activities, material transportation and tank truck driving; silo 2 includes several gravel silos, sand silos and steel support beams for storing 5-10mm gravel, and laboratory 4 includes glue room, chemical room, durability room, high temperature room, aggregate room, sample retention room, prestressed concrete room, data room, metering room, office and several grouting standard curing rooms.

[0041] The intelligent steel bar processing center 5 is equipped with a steel bar shearing production line, a steel bar bending production line, an integrated steel bar shearing and bending production line and a positioning net welding production line, and also includes a box girder positioning net welding robot and a beam yard U-shaped bar handling and discharging system; the steel bar binding area 6 includes a number of assembled steel bar binding jigs, intelligent segmented self-propelled steel bar binding internal support frames, box girder steel bar binding welding robots and a retractable canopy, and the steel bar binding area 6 is connected to the truss crane track of the steel bar distribution center.

[0042] The beam making area 8 includes a number of single-line beam making pedestals and double-line beam making pedestals, and a gantry is arranged between every two adjacent beam making pedestals for the transportation of formed prefabricated beams; beam loading areas are arranged on both sides of the beam storage area 9, and tire-type transporters are arranged in the beam loading areas. A beam lifting and turning area is arranged on the side of the beam loading area, and a beam transport channel extending to the construction site is arranged in the beam lifting and turning area, and a gantry crane is arranged in the beam transport channel extending to the construction site.

[0043] A total of 146 beam storage pedestals are set up in beam storage area 9, including 42 maintenance pedestals, with a maximum storage capacity of 292 beams, including 98 double-line beam storage pedestals, of which 61 are special 32m beam storage pedestals, 37 are 24m / 32m double-line universal beam storage pedestals, and 32 are single-line beam storage pedestals, including 16 special 32m beam storage pedestals, 16 are 24m / 32m universal beam storage pedestals, and 16 are shared by single and double lines. The height of the beam pier is 60cm, and the bottom of the beam is hardened, and the hardened height is the same as the beam cap.

[0044] A precast beam yard layout method, the layout method comprising the following steps:

[0045] Step A: stacking steel bar raw materials, sand, gravel and gel materials required for concrete inside the silo 2;

[0046] Step A1, pile 5-10 mm crushed stones in the crushed stone bin, pile sand in the sand bin, and arrange and pile steel bars on the steel bar bracket beam, and classify and mark them, and record the inventory of crushed stones, sand and steel bars in the silo 2;

[0047] Step A2, a conveyor belt is provided at the inlet of the silo 2. When storing materials, the crushed stone, sand and steel bars are transported to the inside of the silo 2 through the conveyor belt, and then transported to the crushed stone silo, sand silo and steel bar bracket beam. When in use, they are then transported out through the conveyor belt.

[0048] Step B, preparing steel bars and concrete;

[0049] Step B1, transporting the steel bars to the steel bar binding area 6 via the truss crane track;

[0050] Step B2: By using assembled steel bar tying jigs, intelligent segmented self-propelled steel bar tying inner braces, box girder steel bar tying welding robots and other tools, in conjunction with retractable canopies, intelligent steel bar tying operations can be achieved around the clock.

[0051] Step B3, add the raw materials into the mixing station 1 according to the proportion, mix them in the mixing station 1, load the fresh concrete into the tank by charging the materials in the mixing station, and then transport it to the beam making area 8.

[0052] Step C, preparing prefabricated beams;

[0053] Step C1, the steel cage skeleton is transferred to the beam-making pedestal through the steel cage hanger, and the mixed concrete is poured. The concrete pouring adopts a placing machine, a slurry raising and leveling machine, and a concrete pouring vehicle dispatching system. After pouring, it is left to stand for forming and demoulding;

[0054] Step C2, after the prefabricated beam is formed and demoulded, the outer mold is polished and sprayed by a chemical polishing and spraying integrated machine, and the inner mold is installed by a chemical walking system, and the steel bars inside the anchor hole of the prefabricated beam are cut in cooperation with an intelligent cutting and roughening robot, and the side wall of the anchor hole port is polished, and then sprayed with paint for protection;

[0055] Step C3: After the grinding and spraying are completed, the intelligent concrete curing system and AI process recognition realize the concrete curing of the box beam. The curing agent is sprayed on the outer surface of the precast beam by the intelligent robot. After spraying, the curing agent is covered with a protective film for curing;

[0056] Step D: transporting the prefabricated beams to the construction site;

[0057] Step D1, transporting the prefabricated beams to a beam transport vehicle by a tire transporter, and the beam transport vehicle transports the beams to the vicinity of the construction site;

[0058] Step D2: After arriving at the construction site, the prefabricated beams on the beam transport vehicle are unloaded by the gantry crane and assembled. The beam transport vehicle returns through the beam transport channel to continue transporting beams.

[0059] It will be apparent to those skilled in the art that the present application is not limited to the details of the exemplary embodiments described above, and that the present application can be implemented in other specific forms without departing from the spirit or essential features of the present application. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the present application is defined by the appended claims rather than the above description, and it is intended that all changes within the meaning and scope of the equivalent elements of the claims be included in the present application. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

[0060] As described above, the above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit them. Although the present application has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present application.

Claims

1. A prefabricated beam yard layout structure, characterized in that: It includes the mixing station, the silo next to the mixing station, the office area opposite the mixing station, the laboratory next to the silo, the steel bar intelligent processing center and material storage center next to the laboratory, the steel bar binding area next to the steel bar intelligent processing center, the beam manufacturing area next to the steel bar binding area, and the beam storage area; The office area between the mixing station and the silo forms the main road line, the beam storage area and its beam lifting and turning area are located on both sides of the beam manufacturing area, and the steel bar intelligent processing center and material storage center are located at the end of the feed port of the beam manufacturing area, forming a mirror-image longitudinal layout.

2. The precast beam yard layout structure according to claim 1 is characterized in that: The mixing station is equipped with an intelligent floor scale system for weighing and generating material receipts. It also includes a tank truck Internet of Things technology system, which can real-time count the tank truck's monthly and cumulative transportation volume, assign tasks and send text messages to idle tank truck drivers. A tank truck parking area is set on the side of the mixing station.

3. The precast beam yard layout structure according to claim 1 is characterized in that: The mixing station, silo, office area, laboratory, intelligent steel bar processing center, material storage center, steel bar binding area, beam manufacturing area and beam storage area are all equipped with eight-meter-wide transportation passages.

4. The precast beam yard layout structure according to claim 1 is characterized in that: The silo includes several gravel silos, sand silos and steel support beams for storing 5-10mm gravel. The test laboratory includes a glue room, a chemical room, a durability room, a high temperature room, an aggregate room, a sample room, a prestressed concrete room, a data room, a metering room, an office and several grouting standard curing rooms.

5. The precast beam yard layout structure according to claim 1 is characterized in that: The intelligent steel bar processing center is equipped with a steel bar shearing production line, a steel bar bending production line, a steel bar shearing and bending integrated production line and a positioning net welding production line, and also includes a box girder positioning net welding robot and a beam yard U-shaped bar handling and discharging system.

6. The precast beam yard layout structure according to claim 1, characterized in that: The steel bar binding area includes a number of assembled steel bar binding jigs, intelligent segmented self-propelled steel bar binding inner support frames, box girder steel bar binding welding robots and retractable canopies. The steel bar binding area is connected to the truss crane track of the steel bar distribution center.

7. The precast beam yard layout structure according to claim 1 is characterized in that: The beam making area includes a plurality of single-line beam making pedestals and double-line beam making pedestals, and a gantry is arranged between every two adjacent beam making pedestals.

8. The precast beam yard layout structure according to claim 1 is characterized in that: Beam loading areas are arranged on both sides of the beam storage area, tire-type transporters are arranged in the beam loading areas, beam lifting and turning areas are arranged on the sides of the beam loading areas, beam lifting and turning areas are arranged with beam transport channels extending to the construction site, and the beam transport channels extending to the construction site are arranged with gantry cranes.

9. The precast beam yard layout structure according to claim 1, characterized in that: A total of 146 beam storage pedestals are set up in the beam storage area, including 42 maintenance pedestals, with a maximum storage capacity of 292 beams, including 98 double-line beam storage pedestals, of which 61 are special 32m beam storage pedestals, 37 are 24m / 32m double-line universal beam storage pedestals, and 32 are single-line beam storage pedestals, including 16 special 32m beam storage pedestals, 16 are 24m / 32m universal beam storage pedestals, and 16 are shared by single and double pedestals. The height of the beam storage pier is 60cm, and the bottom of the beam is hardened, and the hardened height is the same as the beam storage pedestal.

10. A precast beam yard layout method is obtained according to any one of the precast beam yard layout structures of claims 1 to 9, characterized in that: The layout method comprises the following steps: Step A, stacking the steel bar raw materials, sand, gravel and gel materials required for concrete inside the silo; Step A1, pile 5-10 mm crushed stones in the crushed stone bin, pile sand in the sand bin, and arrange and pile steel bars on the steel bar bracket beam, and classify and mark them, and record the inventory of crushed stones, sand and steel bars in the bin; Step A2, a conveyor belt is provided at the silo inlet. When storing materials, crushed stone, sand and steel bars are transported into the silo through the conveyor belt, and then transported to the crushed stone silo, sand silo and steel bar bracket beam. When used, they are then transported out through the conveyor belt. Step B, preparing steel bars and concrete; Step B1, transporting the steel bars to the steel bar binding area via the truss crane track; Step B2, by using assembled steel bar binding jigs, intelligent segmented self-propelled steel bar binding inner support frames, box girder steel bar binding welding robots and other tools, in conjunction with retractable canopies, all-weather intelligent steel bar binding operations can be achieved. Step B3, adding raw materials into the mixing station according to the proportion, mixing in the mixing station, loading the fresh concrete into the tank by loading the materials in the mixing station, and then transporting it to the beam making area. Step C, preparing a prefabricated beam; Step C1, the steel cage skeleton is transferred to the beam-making pedestal through the steel cage hanger, and the mixed concrete is poured. The concrete pouring adopts a concrete placing machine, a slurry raising and leveling machine, and a concrete pouring vehicle dispatching system. After pouring, it is left to stand for forming and demoulding; Step C2, after the prefabricated beam is formed and demoulded, the outer mold is polished and sprayed with a chemical polishing and spraying integrated machine, and the inner mold is installed with a chemical walking system, which cooperates with an intelligent cutting and roughening robot to cut the steel bars inside the anchor hole of the prefabricated beam, and polish the side wall of the anchor hole port, and then spray paint for protection after polishing; Step C3: After the grinding and spraying is completed, the intelligent concrete curing system and AI process recognition realize the concrete curing of the box beam. The curing agent is sprayed on the outer surface of the precast beam by the intelligent robot. After spraying, the curing agent is covered with a protective film for curing; Step D, transporting the prefabricated beams to the construction site; Step D1, transporting the prefabricated beams to a beam transport vehicle by a tire transporter, and the beam transport vehicle transports the beams to the vicinity of the construction site; Step D2, after arriving at the construction site, the prefabricated beams on the beam transport vehicle are unloaded by the gantry crane and assembled, and the beam transport vehicle returns through the beam transport channel to continue transporting beams.

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