Shaping rack binding construction method for bent cap steel reinforcement framework

Abstract

The invention relates to the technical field of construction of bent cap steel reinforcement frameworks, in particular to a binding construction method of a shaping rack for the bent cap steel reinforcement frameworks, all components of the rack are designed in a modular mode, and positioning clamping grooves of all models can be disassembled and replaced at will, so that the bent cap steel reinforcement frameworks of different types are manufactured and assembled on the same base; the construction scale is greatly reduced, the efficiency is improved, and the cost is reduced; the steel bar positioning clamping grooves are formed in the bottom of the rack, and accurate positioning of the distance between steel bar framework pieces of the bent cap is achieved; positioning cross rods are arranged at the end parts to ensure that the end parts of the framework sheets are aligned; the vertical rods are arranged on the side faces and used for fixing the framework pieces and controlling perpendicularity, inclination of the framework pieces is avoided, all the positioning modules are effectively combined, and accurate control over the overall size of the framework is guaranteed; the whole rack is about 1m higher than the ground, so that an operator can conveniently install stirrups on the side face and the bottom at the same time, the working efficiency is obviously improved, and meanwhile the safety coefficient is greatly increased.

Description

Technical Field

[0001] The invention relates to the technical field of cap beam reinforcement frame construction, and in particular to a method for binding a cap beam reinforcement frame with a forming stand. Background Art

[0002] At present, in the process of tying the steel bar skeleton of the cap beam of highway bridges in my country, scaffolding or simple support frames with steel bars are usually used for assembly. The positioning of the steel bars of the cap beam is completely controlled manually, which requires a large number of people and has high labor intensity. In addition, the assembly operation is difficult and inefficient, the finished cap beam skeleton is not accurate, and it is easy to tilt and collapse, resulting in safety accidents. By developing a tying stand with simple production, wide application range, high reuse rate, and modular design of each main positioning device, the tying quality is improved, while the construction progress is accelerated, costs are saved, and construction safety risks are reduced.

[0003] During the construction of Tanggaang Bridge in the LH13 contract section of Linhe Expressway and Xiguoyuan Bridge in the seventh contract section of Lanzhou Ring Expressway, Gansu Road and Bridge Construction Group Co., Ltd. carried out research on the processing and manufacturing construction technology of the cap beam skeleton in order to improve the construction quality of the cap beam reinforcement skeleton, increase the qualified rate of the concrete protective layer thickness, enhance the durability of concrete, speed up the construction progress, save costs, and reduce construction safety risks. Through independent innovation, a cap beam reinforcement skeleton binding rig was designed. The above problems were effectively solved, the overall quality of the bridge project was guaranteed, and the construction period requirements were met. Summary of the invention

[0004] The purpose of the present invention is to overcome the above-mentioned shortcomings and provide a method for supporting formwork for transverse construction joints of cement-stabilized structural layers of highway pavements. The method utilizes formwork and longitudinal and transverse roller climbing devices to treat the transverse construction joints of cement-stabilized structural layers, thereby significantly improving the construction quality of the cement-stabilized pavement structural layers and reducing material waste.

[0005] In order to achieve the above purpose, the technical solutions provided are as follows:

[0006] A construction method for binding a cap beam reinforcement frame with a shaped stand, characterized in that it comprises the following steps:

[0007] Step 1: Construction preparation and site planning

[0008] Before construction, the design drawings of the cap beams shall be comprehensively and carefully reviewed, analyzed and studied. The scale and layout of the skeleton processing site shall be determined according to the size and quantity of different types of cap beams. The processing and production site shall be flat and well-planned, and all kinds of auxiliary supporting facilities shall be fully equipped.

[0009] Step 2: Make the rack, including the following steps:

[0010] Step (1): Bracket arrangement and quantity

[0011] The position of the bracket is planned uniformly according to the steel bar processing plant. The general principle is to reduce the transportation distance, avoid the impact of cross-operation, and facilitate the lifting of finished products. The number of scaffolding produced is determined by the type of cap beam, construction schedule and quantity. Under normal circumstances, a set of standardized scaffolding can produce one cap beam steel bar skeleton every day (10 hours).

[0012] Step (2): Bracket fabrication

[0013] The bracket is divided into the main bracket and the auxiliary operation platform bracket. The legs are designed as 6 and the crossbeams are designed as 3. The longitudinal spacing is 5m and the transverse spacing is 3m (which can be adjusted according to the designed cap beam size). They are all made of I22 I-beams. The auxiliary operation platform bracket is located at the end of the main bracket (the side part can use the main bracket). The legs are set 0.5m outside the main bracket and are made of 4*8 square steel, which is convenient for operators to stand and operate.

[0014] Step (3) Module production

[0015] ① The bottom slot is made of 5*5 angle steel, and the length and slot spacing are cut according to the design width of the drawing and the spacing of the skeleton steel bars; each stand is equipped with two slots, located on the upper part of the main beam, and it is appropriate to control the 1 / 3 position at both ends of the stand. The slot is connected to the main beam with bolts, and 3 bolt holes are reserved for a single slot, and the hole spacing is divided equally according to the length of the slot;

[0016] ②The end crossbar is made of Φ42 round tube and is designed to be pull-out. It is installed by drilling holes in the end vertical pole and will be removed when the end stirrups are tied.

[0017] ③ The side movable buckle is made of Φ28 steel bar and is set on the inner side of the side upright. The length is processed according to the distance from the outermost frame piece to the stand upright. The position should be in the same section as the bottom plate slot to facilitate the precise positioning and control of the frame piece.

[0018] ④ The top fixing buckles are made of [50 channel steel. The buckles are installed row by row when the skeleton is hoisted, with one buckle set every 2 meters, staggered, and removed in sequence when the stirrups are tied;

[0019] Step 3: Steel bar processing and skeleton sheet production

[0020] The steel bars used in the cap beam frame are processed in a CNC bending machine according to the design requirements. The steel bar processing accuracy is strictly controlled during processing. After processing, they are placed in the welding positioning groove according to the number for welding to ensure that the size of the skeleton piece after welding meets the requirements. When welding the skeleton piece, all skeleton steel bars are double-sided welded, and the main reinforcement joints must be coaxial butt welded, and the welding joints of the same section of the main reinforcement cannot exceed 50%; the position of the overlapped part of the bent steel bar must be accurately positioned to facilitate the binding of stirrups and on-site hoisting;

[0021] Step 3: hoisting and tying of skeleton pieces, including the following steps:

[0022] Step 1: Skeleton hoisting

[0023] ① After the skeleton pieces are processed and manufactured, they are hoisted into the bottom slots of the platform by the gantry crane in sequence. Hoisting equipment is used to prevent deformation caused by uneven force on the lifting points during the hoisting process;

[0024] ② During hoisting, ensure that the ends of the frame pieces are aligned with the end beams, the side uprights fix the outermost frame pieces with their bayonet holes, and the top plate movable bayonet holes fix the frame pieces in sequence to prevent overturning or deformation of the steel bar spacing;

[0025] Step 2: Binding of skeleton pieces

[0026] ① When tying stirrups, proceed from the other side of the end in sequence, remove the movable buckles of the top plate in sequence, complete the vertical stirrup tying, remove the side pole buckles after all are completed, and tie the horizontal stirrups;

[0027] ②Rebar binding has the advantage of large operating space and can be tied into shape in one go without the need for flipping and lifting. However, the upper and lower parts should not be operated at the same time, and a certain safe construction distance should be reserved.

[0028] The principle of the present invention is to use a stand space combination device to form a "multi-point" fixation on the cap beam steel bar skeleton piece. By setting steel bar positioning slots, end cross bars, side vertical bars, and top buckles, the three-dimensional positioning of the plane position and elevation of the cap beam steel bar skeleton piece is achieved, effectively controlling the spacing of the cap beam steel bar skeleton, the installation height difference between each piece, and the thickness of the steel bar protective layer, thereby improving the installation quality of the cap beam steel bars.

[0029] The beneficial effects of the present invention are:

[0030] 1. The components of the rack of the present invention adopt modular design, and the positioning slots of various models can be disassembled and replaced at will, so that different types of cap beam steel bar skeletons can be assembled on the same base, which greatly reduces the construction scale, improves the efficiency and reduces the cost;

[0031] 2. The bottom of the stand of the present invention is provided with a steel bar positioning slot to achieve accurate positioning of the spacing between the steel bar skeleton pieces of the cap beam; a positioning cross bar is provided at the end to ensure that the ends of the skeleton pieces are aligned; a vertical bar is provided on the side to fix the skeleton pieces and control the verticality to avoid the skeleton pieces from tilting. The positioning modules are effectively combined to ensure that the overall size of the skeleton is accurately controlled;

[0032] 3. The overall platform of the present invention is about 1m above the ground, which is convenient for operators to install stirrups on the side and bottom at the same time. While the work efficiency is significantly improved, the safety factor is greatly increased.

[0033] Instruction Manual

[0034] Figure 1 It is a main cross-sectional view of the main body of the platform in the present invention;

[0035] Figure 2 It is a side sectional view of the main body of the platform in the present invention;

[0036] Figure 3 It is an application diagram in an embodiment of the present invention;

[0037] Figure 4 It is a flow chart of the construction method of the present invention. DETAILED DESCRIPTION

[0038] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0039] Example 1

[0040] A construction method for binding a cap beam reinforcement frame with a shaped stand, comprising the following steps:

[0041] Step 1: Construction preparation and site planning

[0042] Before construction, the design drawings of the cap beams shall be comprehensively and carefully reviewed, analyzed and studied. The scale and layout of the skeleton processing site shall be determined according to the size and quantity of different types of cap beams. The processing and production site shall be flat and well-planned, and all kinds of auxiliary supporting facilities shall be fully equipped.

[0043] Step 2: Make the rack, including the following steps:

[0044] Step (1): Bracket arrangement and quantity

[0045] The position of the bracket is planned uniformly according to the steel bar processing plant. The general principle is to reduce the transportation distance, avoid the impact of cross-operation, and facilitate the lifting of finished products. The number of scaffolding produced is determined by the type of cap beam, construction schedule and quantity. Under normal circumstances, a set of standardized scaffolding can produce one cap beam steel bar skeleton every day (10 hours).

[0046] Step (2): Bracket fabrication

[0047] The bracket is divided into the main bracket and the auxiliary operation platform bracket. The legs are designed as 6 and the crossbeams are designed as 3. The longitudinal spacing is 5m and the transverse spacing is 3m (which can be adjusted according to the designed cap beam size). They are all made of I22 I-beams. The auxiliary operation platform bracket is located at the end of the main bracket (the side part can use the main bracket). The legs are set 0.5m outside the main bracket and are made of 4*8 square steel, which is convenient for operators to stand and operate.

[0048] Step (3) Module production

[0049] ① The bottom slot is made of 5*5 angle steel, and the length and slot spacing are cut according to the design width of the drawing and the spacing of the skeleton steel bars; each stand is equipped with two slots, located on the upper part of the main beam, and it is appropriate to control the 1 / 3 position at both ends of the stand. The slot is connected to the main beam with bolts, and 3 bolt holes are reserved for a single slot, and the hole spacing is divided equally according to the length of the slot;

[0050] ②The end crossbar is made of Φ42 round tube and is designed to be pull-out. It is installed by drilling holes in the end vertical pole and will be removed when the end stirrups are tied.

[0051] ③ The side movable buckle is made of Φ28 steel bar and is set on the inner side of the side upright. The length is processed according to the distance from the outermost frame piece to the stand upright. The position should be in the same section as the bottom plate slot to facilitate the precise positioning and control of the frame piece.

[0052] ④ The top fixing buckles are made of [50 channel steel. The buckles are installed row by row when the skeleton is hoisted, with one buckle set every 2 meters, staggered and removed in sequence when the stirrups are tied;

[0053] Step 3: Steel bar processing and skeleton sheet production

[0054] The steel bars used in the cap beam frame are processed in a CNC bending machine according to the design requirements. The steel bar processing accuracy is strictly controlled during processing. After processing, they are placed in the welding positioning groove according to the number for welding to ensure that the size of the skeleton piece after welding meets the requirements. When welding the skeleton piece, all skeleton steel bars are double-sided welded, and the main reinforcement joints must be coaxial butt welded, and the welding joints of the same section of the main reinforcement cannot exceed 50%; the position of the overlapped part of the bent steel bar must be accurately positioned to facilitate the binding of stirrups and on-site hoisting;

[0055] Step 3: hoisting and tying of skeleton pieces, including the following steps:

[0056] Step 1: Skeleton hoisting

[0057] ① After the skeleton pieces are processed and manufactured, they are hoisted into the bottom slots of the platform by the gantry crane in sequence. Hoisting equipment is used to prevent deformation caused by uneven force on the lifting points during the hoisting process;

[0058] ② During hoisting, ensure that the ends of the frame pieces are aligned with the end beams, the side uprights fix the outermost frame pieces with their bayonet holes, and the top plate movable bayonet holes fix the frame pieces in sequence to prevent overturning or deformation of the steel bar spacing;

[0059] Step 2: Binding of skeleton pieces

[0060] ① When tying stirrups, proceed from the other side of the end in sequence, remove the movable buckles of the top plate in sequence, complete the vertical stirrup tying, remove the side pole buckles after all are completed, and tie the horizontal stirrups;

[0061] ②Rebar binding has the advantage of large operating space and can be tied into shape in one go without the need for flipping and lifting. However, the upper and lower parts should not be operated at the same time, and a certain safe construction distance should be reserved.

[0062] Example 2 Benefit Analysis

[0063] 1. Economic benefits

[0064] A method for binding the steel bar skeleton of the cap beam using a standardized gantry has been successfully applied in the Tanggaang Bridge of the LH13 contract section of the Linhe Expressway and the Xiguoyuan Bridge of the seventh contract section of the Lanzhou Ring Expressway. The construction of the cap beam skeleton has achieved precise positioning and safe construction, shortened the binding operation time of each skeleton piece, ensured the construction quality, saved 717 yuan per piece, and saved a total of 40,200 yuan. The use of the overall binding gantry reduces the labor intensity of the operators, improves the binding efficiency, reduces the use time of the gantry crane, saves electricity, and no safety accidents occurred during the construction period, with good economic benefits. A comparison with the traditional anti-collision guardrail construction method in terms of quality, construction period and economic benefits is shown in Table 1

[0065] Table 1 Comparison of quality, construction period and economic benefits with traditional anti-collision guardrail construction methods

[0066]

[0067] (1) Cost of making the stand

[0068] The "cap beam reinforcement frame shaping gantry binding construction technology" was used for construction. Compared with the traditional simple support method, this technology added a binding gantry during construction. According to the actual use on site, one gantry can produce 1 bridge cap beam per day. The cost is shown in Table 2.

[0069] Table 2: Cost of making a rack

[0070]

[0071]

[0072] (2) Accelerate the construction progress

[0073] The "cap beam reinforcement frame shaping scaffolding binding construction method" was used for construction, which effectively solved the common problem of the traditional simple bracket manually controlling the reinforcement frame piece installation, saved a lot of manpower, accelerated the construction speed, and improved production efficiency. At the same time, it fundamentally improved the installation quality of the reinforcement and ensured the safety of the operators. The construction period calculation for each cap beam frame production is shown in Table 3.

[0074] Table 3 Calculation of the construction period for producing one cap beam frame

[0075]

[0076] (3) Save labor

[0077] The "cap beam reinforcement frame shaping rig binding construction method" is adopted to accurately control the spacing of the cap beam frame pieces, avoid the uneven installation spacing of the frame pieces in traditional construction, and the difficulty in installing stirrups caused by the misalignment of the frame pieces, effectively ensuring the overall binding accuracy control of the frame pieces. At the same time, the binding rig has a large working space, reduces labor intensity, and requires fewer operators. The number of operators can be reduced from 10 in the traditional binding method to 7, saving about 600 yuan.

[0078] In summary, the cost savings for every 100 cap beam frames using this technology is:

[0079] [100×240 yuan (saving of overhead costs during working hours) + 100×600 yuan (saving of labor) - 12,314 yuan (making the stand) = 71,686 yuan.

[0080] 2. Social Benefits

[0081] The overall binding stand for the cap beam has the advantages of being economical and practical, having good stability, good safety, simple structure, and quick and convenient binding. By using the binding stand, the processing quality of the cap beam skeleton is stable, the qualified rate of the concrete protective layer thickness is significantly improved, and the durability of the concrete is effectively guaranteed. At the same time, the labor intensity of the operators is reduced, the safety factor of the operation is improved, the qualified rate of the project quality is 100%, and no safety accidents occur during the construction process, ensuring the construction period. Through strict process control, the construction of the cap beam is made more standardized and normative, the construction quality is improved, and the social benefits are significant.

[0082] Example 3 Application Example

[0083] 1. Project name: Lanzhou Ring Expressway South Section LRNO7 Contract Section Xiguoyuan Bridge

[0084] 1.1 Project location: Xiguoyuan Town, Qilihe District, Lanzhou City, Gansu Province

[0085] 1.2 Construction period: Started in July 2014 and completed in December 2017

[0086] 1.3 Project cost: RMB 23,948,836

[0087] 1.4 Project Overview: Xiguoyuan Bridge is located on the east side of Chaijiahe Village, Xiguoyuan Town, Qilihe District, Lanzhou City. The left and right spans of Xiguoyuan Bridge are both 18×30m. The upper structure adopts prestressed concrete continuous box beams, the lower structure adopts column piers and hollow thin-walled piers, the abutments are bench-type abutments and column-type abutments, and the pier and abutment foundations are all bored cast-in-place pile foundations.

[0088] 2. Project name: Tanggaang Bridge, LH13 Contract Section, Linhe Expressway

[0089] 2.1 Project location: Tangsai Village, Hezuo City, Gansu Province

[0090] 2.2 Construction period: Started in March 2012 and completed in December 2014

[0091] 2.3 Project cost: RMB 341,622,200

[0092] 2.4 Project Overview: Tanggaang Bridge is 286m long, with two sections: 7*20+7*20; load level: highway level I; net width of bridge deck: 2*net 10.75m. The plane of the bridge is located on a left-deflected circular curve of R=1000m, and the cross slope of the bridge deck is -3% in one direction. The upper structure adopts prestressed concrete small box beam, which is simply supported first and then continuous; the lower structure adopts column piers, and the piers adopt pile foundations.

[0093] It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above and that the invention can be implemented in other specific forms without departing from the spirit or essential features of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description, and it is intended that all variations falling within the meaning and scope of the equivalent elements of the claims be included in the invention. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

Claims

1. A construction method for binding a cap beam reinforcement frame using a shaped stand, characterized in that: The steps include: Step 1: Construction preparation and site planning Before construction, the design drawings of the cap beams shall be comprehensively and carefully reviewed, analyzed and studied. The scale and layout of the skeleton processing site shall be determined according to the size and quantity of different types of cap beams. The processing and production site shall be flat and well-planned, and all kinds of auxiliary supporting facilities shall be fully equipped. Step 2: Make the stand; Step 3: Steel bar processing and skeleton sheet production The steel bars used in the cap beam frame are processed in a CNC bending machine according to the design requirements. The steel bar processing accuracy is strictly controlled during processing. After processing, they are placed in the welding positioning groove according to the number for welding to ensure that the size of the skeleton piece after welding meets the requirements. When welding the skeleton piece, all skeleton steel bars are double-sided welded, and the main reinforcement joints must be coaxial butt welded, and the welding joints of the same section of the main reinforcement cannot exceed 50%; the position of the overlapped part of the bent steel bar must be accurately positioned to facilitate the binding of stirrups and on-site hoisting; Step 4: Lifting and binding of skeleton pieces.

2. A method for binding a cap beam reinforcement frame with a shaped stand according to claim 1, characterized in that: In step 2, the bench production includes the following steps: Step (1): Bracket arrangement and quantity The position of the bracket is planned uniformly according to the steel bar processing plant. The general principle is to reduce the transportation distance, avoid the impact of cross-operation, and facilitate the lifting of finished products. The number of racks to be produced is determined by the type of cap beam, construction schedule and quantity. Under normal circumstances, a set of fixed racks can produce one cap beam steel bar skeleton every day (10 hours); Step (2): Bracket fabrication The bracket is divided into the main bracket and the auxiliary operation platform bracket. The legs are designed as 6 and the crossbeams are designed as 3. The longitudinal spacing is 5m and the transverse spacing is 3m (which can be adjusted according to the designed cap beam size). They are all made of I22 I-beams. The auxiliary operation platform bracket is located at the end of the main bracket (the side part can use the main bracket). The legs are set 0.5m outside the main bracket and are made of 4*8 square steel, which is convenient for operators to stand and operate. Step (3) Module production ① The bottom slot is made of 5*5 angle steel, and the length and slot spacing are cut according to the design width of the drawing and the spacing of the skeleton steel bars; each stand is equipped with two slots, located on the upper part of the main beam, and it is appropriate to control the 1 / 3 position at both ends of the stand. The slot is connected to the main beam with bolts, and 3 bolt holes are reserved for a single slot, and the hole spacing is divided equally according to the length of the slot; ②The end crossbar is made of Φ42 round tube and is designed to be pull-out. It is installed by drilling holes in the end vertical pole and will be removed when the end stirrups are tied; ③ The side movable buckle is made of Φ28 steel bar and is set on the inner side of the side upright. The length is processed according to the distance from the outermost frame piece to the stand upright. The position should be in the same section as the bottom plate slot to facilitate the precise positioning and control of the frame piece. ④ The top fixing clips are made of [50 channel steel. The clips are installed row by row when the skeleton is hoisted, with one clip set every 2 meters in a staggered arrangement. They are removed one by one when the stirrups are tied.

3. The method for binding a cap beam reinforcement frame with a shaped stand according to claim 1, characterized in that: In step 4, the skeleton pieces are hoisted and tied, including the following steps: Step 1: Skeleton hoisting ① After the skeleton pieces are processed and manufactured, they are hoisted into the bottom slots of the platform by the gantry crane in sequence. Hoisting equipment is used to prevent deformation caused by uneven force on the lifting points during the hoisting process; ② During hoisting, ensure that the ends of the frame pieces are aligned with the end beams, the side uprights fix the outermost frame pieces with their bayonet holes, and the top plate movable bayonet holes fix the frame pieces in sequence to prevent overturning or deformation of the steel bar spacing; Step 2: Binding of skeleton pieces ① When tying stirrups, proceed from the other side of the end in sequence, remove the movable buckles of the top plate in sequence, complete the vertical stirrup tying, remove the side pole buckles after all are completed, and tie the horizontal stirrups; ②Rebar binding has the advantage of large operating space and can be tied into shape in one go without the need for flipping and lifting. However, the upper and lower parts should not be operated at the same time, and a certain safe construction distance should be reserved.

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