Processing technology of 40m wide single-box five-chamber integral steel box girder

Abstract

The present application relates to a kind of 40m wide single-box five-chamber integrated steel box girder processing manufacturing process, it is characterized in that: manufacturing process is as follows: S1: top, bottom plate unit plate rib welding;S2: bottom plate unit welding;S3: transverse diaphragm unit welding;S4: the welding of middle web;S5: the welding of third chamber transverse diaphragm;S6: the welding of first chamber transverse diaphragm and fifth chamber transverse diaphragm;S7: anchor box diaphragm and anchor box welding;S8: triangle plate and T row welding;S10: the welding of top plate;S9: side web welding: the present application gives the butt welding method and processing control of 40m wide single-box five-chamber steel box girder, details are given to the butt welding requirement of bottom plate unit and top plate unit, can effectively control assembly error and welding shrinkage deformation, guarantee the cross slope precision of bridge;In addition, the butt welding sequence can effectively reduce the deformation of the whole after welding, improve the profile of the whole after welding to meet the set requirement, reduce subsequent finishing time, improve efficiency, save resources.

Description

Technical Field

[0001] This invention relates to the field of steel box girder manufacturing technology, and in particular to a processing and manufacturing process for a 40m wide single-box five-cell integral steel box girder. Background Technology

[0002] Steel box girders, also known as steel plate box girders, are a common structural form for long-span bridges. They are generally used on bridges with large spans and are named for their box-like shape. With the continuous upgrading of transportation capacity requirements, road design has evolved from the initial two-lane to four-lane dual carriageways. Furthermore, some important urban bridges now feature steel box girder bridges with integrated road and rail traffic, and the bridge deck width has increased from a full 30m to 40m. The precision requirements for manufacturing ultra-wide steel box girders are becoming increasingly stringent. Traditional manufacturing processes struggle to effectively guarantee precision control. Especially with the widening of the bridge deck, the increase in plate unit segments, butt joints, and transverse weld lengths, along with the cumulative shrinkage effect of longitudinal butt welds, all impact the accuracy of the bridge deck's cross slope control. This directly affects the overall structural precision of the steel box girder segments, impacts bridge deck drainage, and reduces the comfort of the bridge in its later use. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a processing and manufacturing process for a 40m wide single-box five-cell integral steel box girder, which can solve the problems of complex welding process and low assembly efficiency in the general processing and construction of ultra-wide steel box girders.

[0004] To solve the above-mentioned technical problems, the technical solution of the present invention is: a processing and manufacturing process for a 40m wide single-box five-cell integral steel box girder, the innovation of which is as follows: the specific manufacturing process is as follows:

[0005] S1: Top and bottom plate unit rib assembly and welding: After cutting the top and bottom plate units, weld the ribs onto the surface of the top and bottom plate units, and use double-sided 12mm fillet welds between the ribs and the top and bottom plate units; use 80% penetration welds between the ribs and the top and bottom plate units.

[0006] S2: Base plate unit assembly and welding: Place the base plate unit with completed rib assembly and welding on the jig, and add 1‰ welding shrinkage in the length direction for the welding between base plate units, and add 15mm allowance at one end and the other end.

[0007] S3: Welding of diaphragm units: Divide the eight completed diaphragms into two groups and weld them onto the base plate unit along the width of the base plate unit; the two diaphragms are located in the second and fourth chambers respectively; there is a third chamber between the two groups of diaphragms, and stiffening plates are welded to the corresponding lifting lug positions on the diaphragms;

[0008] S4: Welding of the middle web plate: Weld the four completed middle web plates vertically to the two sides of the two sets of transverse diaphragms, and weld the bottom of the middle web plate to the base plate unit.

[0009] S5: Welding of the third chamber diaphragm: Weld the four completed third chamber diaphragms onto the base plate unit, with the two ends of the third chamber diaphragms corresponding to the diaphragms in the second and third chambers respectively and welded onto the web plate.

[0010] S6: Welding of the first chamber diaphragm and the fifth chamber diaphragm: Weld the four completed first chamber diaphragms and four fifth chamber diaphragms onto the bottom plate unit of the first chamber and the bottom plate unit of the fifth chamber respectively, and weld the ends onto the web plate.

[0011] S7: Anchor box partition and anchor box assembly welding: Weld the anchor box installation partition on the middle web plate of the second chamber and the middle web plate of the fourth chamber; then weld the anchor box to the anchor box installation partition on the middle web plate.

[0012] S8: Welding of triangular plates and T-plates: Weld triangular plates at the junction of the first chamber diaphragm and the base plate unit and the fifth chamber diaphragm and the base plate unit, and weld T-plates on the base plate unit next to the triangular plates.

[0013] S9: Side web plate welding: Two completed side web plates are welded vertically to the ends of the first chamber and the fifth chamber respectively, and the side web plates are welded to the bottom plate unit.

[0014] S10: Welding of the top plate: The fabricated top plate units with ribs are sequentially welded to the top of the steel box girder; after welding, railing mounting bases and lifting lugs are welded onto the surface of the top plate units; finally, bridge bottom supports are welded onto the lower surface of the bottom plate.

[0015] Furthermore, in the S3: during the assembly and welding of the transverse diaphragm unit, the transverse and vertical ribs on the transverse diaphragm are welded with double-sided fillet welds. The 16mm transverse diaphragm and the bottom plate unit are welded with a deep penetration weld, using a single-sided 40° bevel with a 2mm root. The 12mm transverse diaphragm and the bottom plate unit are welded with double-sided fillet welds. At the 20mm anchor point, the transverse diaphragm and the bottom plate unit are not welded with a CP root cleaning weld, and the root cleaning side faces the side with the larger space.

[0016] Furthermore, in S4: during the assembly and welding of the web plate, the small T-rows on the web plate are spliced ​​together as 8mm double-sided fillet welds; the small T-rows on the web plate and the web plate are connected by a deep penetration weld, using a single-sided 40° bevel with a 2mm root.

[0017] Furthermore, in S8: the triangular plate and the bending plate are welded together in the triangular plate and the bending plate, with a double-sided 40° bevel leaving a 2mm root; the corner stiffener and the transverse diaphragm are welded together in the double-sided fillet weld; the corner stiffener and the base plate unit are welded together in the outer three-sided single-sided fillet weld.

[0018] Furthermore, in S2: during the assembly and welding of the base plate unit, the welding of the base plate unit in the width direction adopts ceramic backing plate welding, with a V40° bevel facing upwards; the gap between the top plate units adopts a combination of root cleaning welding and ceramic backing plate welding.

[0019] The advantages of this invention are:

[0020] 1) This invention provides a welding method and processing control for a 40m wide single-box five-cell steel box girder. It details the welding requirements for the bottom plate unit and the top plate unit. By assembling and welding the steel box girder according to the above process requirements, assembly errors and welding shrinkage deformation can be effectively controlled, ensuring the cross slope accuracy of the bridge deck. In addition, this welding sequence can effectively reduce the overall deformation after assembly and welding, improve the overall profile after assembly and welding to meet the set requirements, reduce the time for subsequent repairs, improve efficiency, and save resources. Attached Figure Description

[0021] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0022] Figure 1 This is a process flow diagram of the fabrication of a 40m wide single-box five-chamber integral steel box girder according to the present invention.

[0023] Figures 2 to 8 This is a processing and forming diagram of a 40m wide single-box five-cell integral steel box girder according to the present invention. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0025] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0026] like Figures 1 to 8The manufacturing process for a 40m wide single-box five-cell integral steel box girder is shown below.

[0027] S1: Top and bottom plate unit rib assembly and welding: After cutting the top and bottom plate units, weld the ribs onto the surface of the top and bottom plate units, and use double-sided 12mm fillet welds between the ribs and the top and bottom plate units; use 80% penetration welds between the ribs and the top and bottom plate units.

[0028] S2: Base plate unit assembly and welding: Place the base plate unit with completed rib assembly and welding on the jig, and add 1‰ welding shrinkage in the length direction for the welding between base plate units, and add 15mm allowance at one end and the other end.

[0029] S3: Welding of diaphragm units: Divide the eight completed diaphragms into two groups and weld them onto the base plate unit along the width of the base plate unit; the two diaphragms are located in the second and fourth chambers respectively; there is a third chamber between the two groups of diaphragms, and stiffening plates are welded to the corresponding lifting lug positions on the diaphragms;

[0030] S4: Welding of the middle web plate: Weld the four completed middle web plates vertically to the two sides of the two sets of transverse diaphragms, and weld the bottom of the middle web plate to the base plate unit.

[0031] S5: Welding of the third chamber diaphragm: Weld the four completed third chamber diaphragms onto the base plate unit, with the two ends of the third chamber diaphragms corresponding to the diaphragms in the second and third chambers respectively and welded onto the web plate.

[0032] S6: Welding of the first chamber diaphragm and the fifth chamber diaphragm: Weld the four completed first chamber diaphragms and four fifth chamber diaphragms onto the bottom plate unit of the first chamber and the bottom plate unit of the fifth chamber respectively, and weld the ends onto the web plate.

[0033] S7: Anchor box partition and anchor box assembly welding: Weld the anchor box installation partition on the middle web plate of the second chamber and the middle web plate of the fourth chamber; then weld the anchor box to the anchor box installation partition on the middle web plate.

[0034] S8: Welding of triangular plates and T-plates: Weld triangular plates at the junction of the first chamber diaphragm and the base plate unit and the fifth chamber diaphragm and the base plate unit, and weld T-plates on the base plate unit next to the triangular plates.

[0035] S9: Side web plate welding: Two completed side web plates are welded vertically to the ends of the first chamber and the fifth chamber respectively, and the side web plates are welded to the bottom plate unit.

[0036] S10: Welding of the top plate: The fabricated top plate units with ribs are sequentially welded to the top of the steel box girder; after welding, railing mounting bases and lifting lugs are welded onto the surface of the top plate units; finally, bridge bottom supports are welded onto the lower surface of the bottom plate.

[0037] S3: During the assembly and welding of the transverse diaphragm unit, the transverse and vertical ribs on the transverse diaphragm are welded with double-sided fillet welds. The 16mm transverse diaphragm and the bottom plate unit are welded with deep penetration welds, using a single-sided 40° bevel with a 2mm root. The 12mm transverse diaphragm and the bottom plate unit are welded with double-sided fillet welds. At the 20mm anchor point, the transverse diaphragm and the bottom plate unit are not welded with CP root cleaning, and the root cleaning side faces the side with the larger space.

[0038] S4: During the assembly and welding of the web plate, the small T-rows on the web plate are spliced ​​together as 8mm double-sided fillet welds; the small T-rows on the web plate and the web plate are connected by a deep penetration weld, using a single-sided 40° bevel with a 2mm root.

[0039] S8: In the welding of triangular plates and T-plates, the weld between the triangular plates and the bending plates is a deep penetration weld, with a double-sided 40° bevel leaving a 2mm root; the weld between the corner stiffener and the transverse diaphragm is a double-sided fillet weld; the weld between the corner stiffener and the base plate unit is a three-sided single-sided fillet weld on the outer side.

[0040] S2: During the assembly and welding of the base plate unit, ceramic backing plate welding is used for the splicing of the base plate unit in the width direction, with the V40° bevel facing upwards; the gap between the top plate units is achieved by a combination of root cleaning welding and ceramic backing plate welding.

[0041] Those skilled in the art should understand that this invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to this invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A fabrication process for a 40m wide single-box five-cell integral steel box girder, characterized in that: The specific manufacturing process is as follows: S1: Top and bottom plate unit rib assembly and welding: After cutting the top and bottom plate units, weld the ribs onto the surface of the top and bottom plate units, and use double-sided 12mm fillet welds between the ribs and the top and bottom plate units; use 80% penetration welds between the ribs and the top and bottom plate units. S2: Base plate unit assembly and welding: Place the base plate unit with completed rib assembly and welding on the jig, and add 1‰ welding shrinkage in the length direction for the welding between base plate units, and add 15mm allowance at one end and the other end. S3: Welding of diaphragm units: Divide the eight completed diaphragms into two groups and weld them onto the base plate unit along the width of the base plate unit; the two diaphragms are located in the second and fourth chambers respectively; there is a third chamber between the two groups of diaphragms, and stiffening plates are welded to the corresponding lifting lug positions on the diaphragms; S4: Welding of the middle web plate: Weld the four completed middle web plates vertically to the two sides of the two sets of transverse diaphragms, and weld the bottom of the middle web plate to the base plate unit. S5: Welding of the third chamber diaphragm: Weld the four completed third chamber diaphragms onto the base plate unit, with the two ends of the third chamber diaphragms corresponding to the diaphragms in the second and third chambers respectively and welded onto the web plate. S6: Welding of the first chamber diaphragm and the fifth chamber diaphragm: Weld the four completed first chamber diaphragms and four fifth chamber diaphragms onto the bottom plate unit of the first chamber and the bottom plate unit of the fifth chamber respectively, and weld the ends onto the web plate. S7: Anchor box partition and anchor box assembly welding: Weld the anchor box installation partition on the middle web plate of the second chamber and the middle web plate of the fourth chamber; then weld the anchor box to the anchor box installation partition on the middle web plate. S8: Welding of triangular plates and T-plates: Weld triangular plates at the junction of the first chamber diaphragm and the base plate unit and the fifth chamber diaphragm and the base plate unit, and weld T-plates on the base plate unit next to the triangular plates. S9: Side web plate welding: Two completed side web plates are welded vertically to the ends of the first chamber and the fifth chamber respectively, and the side web plates are welded to the bottom plate unit. S10: Welding of the top plate: The fabricated top plate units with ribs are sequentially welded to the top of the steel box girder; after welding, railing mounting bases and lifting lugs are welded onto the surface of the top plate units; finally, bridge bottom supports are welded onto the lower surface of the bottom plate.

2. The fabrication process for a 40m wide single-box five-cell integral steel box girder according to claim 1, characterized in that: S3: During the assembly and welding of the transverse diaphragm unit, the transverse and vertical ribs on the transverse diaphragm are welded with double-sided fillet welds. The 16mm transverse diaphragm and the bottom plate unit are welded with a deep penetration weld and a single-sided 40° bevel with a 2mm root. The 12mm transverse diaphragm and the bottom plate unit are welded with double-sided fillet welds. At the 20mm anchor point, the transverse diaphragm and the bottom plate unit are not welded with CP root cleaning, and the root cleaning side faces the side with the larger space.

3. The fabrication process for a 40m wide single-box five-cell integral steel box girder according to claim 1, characterized in that: S4: During the welding of the middle web plate, the small T-rows on the middle web plate are spliced ​​together as 8mm double-sided fillet welds; the small T-rows on the middle web plate and the middle web plate are welded together as deep penetration welds, using a single-sided 40° bevel with a 2mm root.

4. The fabrication process for a 40m wide single-box five-cell integral steel box girder according to claim 1, characterized in that: S8: In the welding of the triangular plate and T-plate, the weld between the triangular plate and the bending plate is a deep penetration weld, with a double-sided 40° bevel leaving a 2mm root; the weld between the corner stiffener and the transverse diaphragm is a double-sided fillet weld; the weld between the corner stiffener and the base plate unit is a three-sided single-sided fillet weld on the outer side.

5. The fabrication process for a 40m wide single-box five-cell integral steel box girder according to claim 1, characterized in that: S2: In the assembly and welding of the bottom plate unit, the bottom plate unit is welded in the width direction using ceramic backing plate welding, with a V40° bevel facing upwards; the gap between the top plate units is achieved by a combination of root cleaning welding and ceramic backing plate welding.

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