Expressway T-beam production method

Abstract

The invention discloses a method for producing a T-shaped beam of an expressway. The method comprises the following steps: binding a T-shaped beam steel reinforcement framework; hoisting a T-beam steel reinforcement framework; pre-stressed pipeline installation; a T-beam formwork is prefabricated through bottom formwork trolleys and hydraulic side formworks, a bottom formwork pedestal is longitudinally moved to a concrete pouring area station, four side formworks, four end formworks and four bottom formwork trolleys are closed in each production line, and a transverse moving trolley is used for rotating to a return stroke trolley line to complete a production closed loop; concrete pouring is conducted, specifically, C50 concrete is poured into the installed formwork; removing the template; curing the concrete; pre-stressed construction; pore channel grouting, wherein pore channels of the corrugated pipe holes are subjected to grouting and potting; and sealing the anchor. Casting, maintaining and pre-tensioning can be cyclically operated, then the T-beam production efficiency is greatly improved, the T-beam prefabricating time is shortened, the prefabricated T-beam is rapidly conveyed into a maintenance site from the mold, the strength of hoisting equipment does not need to be achieved, the T-beam prefabricating efficiency is improved, and the prefabricated T-beam is prevented from being damaged due to direct moving and transferring of the bottom mold trolley.

Description

Technical Field

[0001] The invention belongs to the technical field of T-beam production and relates to a method for producing a T-beam for a highway. Background Art

[0002] In the prefabrication production of T-beams, the existing process methods are generally divided into steel bar engineering, formwork engineering, concrete engineering and prestressed engineering. The inventors have found that if a fixed bottom form is used for T-beam casting, a long time is required to wait for the concrete to reach the set strength before it can be moved. The waiting time for subsequent maintenance, pre-tensioning and other processes is too long, resulting in low T-beam prefabrication efficiency. Moreover, the lifting equipment is also prone to damage the T-beam that has not yet reached the final strength. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a method for producing T-beams for highways, which greatly improves the production efficiency of T-beams, shortens the prefabrication time of T-beams, and avoids damage to T-beams during transportation.

[0004] The technical solution adopted by the present invention is: a method for producing a T-beam of a highway, the method comprising the following steps:

[0005] Step 1: Binding of T-beam steel bar skeleton: Bind the processed steel bars of various types into a T-beam steel bar skeleton on the steel bar binding jig according to the design drawings;

[0006] Step 2: Hoist the T-beam reinforcement skeleton. After the T-beam reinforcement skeleton is tied and formed on the reinforcement binding jig, it is hoisted into place using hoisting equipment and reinforcement hoists. Before hoisting into place, the center line and beam end line must be marked on the bottom formwork to control the longitudinal installation position of the T-beam reinforcement skeleton accordingly. After the T-beam reinforcement skeleton is in place on the bottom formwork, check whether the longitudinal center of the reinforcement skeleton coincides with the longitudinal center line of the bottom formwork. If not, make local adjustments to make the centers of the two lines coincide.

[0007] Step 3: Install the prestressed pipe. The prestressed pipe uses a metal corrugated pipe. The position of the prestressed pipe must be strictly located according to the coordinates and fixed with Φ12 positioning steel bars. The positioning steel bars are spot-welded to the beam web stirrups. The prestressed pipe positioning steel bars are set in groups of 80 cm for straight sections and 50 cm for dense sections. When the corrugated pipe is inserted, a PVC lining pipe with a diameter 1 cm smaller than the inner diameter of the corrugated pipe is installed inside the corrugated pipe.

[0008] Step 4: Formwork installation. The prefabricated T-beam formwork uses a bottom formwork trolley + hydraulic side formwork. The bottom formwork pedestal is moved longitudinally to the concrete pouring area, and the side and end forms are closed. There are 4 bottom formwork trolleys per production line. Use a transverse trolley to transfer to the return trolley line to complete the production closed loop. The transverse slope of the T-beam flange plate is set and adjusted according to the design requirements. The transverse slope of the T-beam diaphragm is set and adjusted according to the design requirements. After the formwork is installed, the verticality, cross-sectional dimensions, flatness, and steel bar protective layer of the web side formwork must be checked. The installation of the formwork and steel bars should be coordinated. The formwork that interferes with the binding of the steel bars should be installed after the steel bars are installed. The prestressed corrugated pipe should pass through the end formwork and leave a reserved length of 15cm±3cm.

[0009] Step 5: Concrete pouring: pour C50 concrete into the installed formwork. The concrete is poured continuously and formed in one go. The total pouring time for each precast beam should not exceed 4.5 hours. The temperature of the concrete entering the formwork is controlled at 5-30°C, and the temperature of the formwork and steel bars is controlled at 5-35°C. The precast C50 concrete is transported to the concrete placing machine through a concrete belt conveyor. According to the set placing sequence, the concrete placing machine automatically places the concrete. The concrete is poured obliquely from one end of the beam to the other end in layers. The pouring sequence is to pour the bottom plate concrete first and then the concrete. Concrete the web, then pour the wing concrete last. Each layer should be no thicker than 30cm. The webs on both sides should be evenly filled to avoid uneven web concrete thickness caused by displacement due to eccentric compression of the inner formwork. The next layer should be laid after each layer is vibrated. The interval between layers should not exceed the initial setting time of the concrete. The pouring speed should be reduced in areas with dense reinforcement in the end anchor pad area. After pouring the web concrete, a time period should be set to allow the web concrete to fully settle before pouring the wing concrete. The time period should be less than 100% to ensure that the wing concrete pouring is completed before the web concrete initially sets.

[0010] It also includes concrete vibration, which uses an inserted vibrating rod and a high-frequency attached vibrator to vibrate the poured concrete;

[0011] After the precast beam and slab concrete is vibrated, the top surface is scraped and smoothed, and then roughened after solidification.

[0012] Use a scraper to level the concrete surface, and set an elevation control point every 2m on the side formwork on site; after the precast beam and slab concrete is leveled, use a wooden trowel to smooth the bridge deck, and perform secondary grouting between the initial setting.

[0013] Step 6: Formwork removal: When the concrete poured into the precast T-beam reaches the set strength, the formwork is removed;

[0014] Step 7: Concrete curing: After the formwork is removed, the precast T-beam is directly sent to the curing equipment for curing using a bottom formwork trolley;

[0015] Step 8: Prestressed construction: When the concrete strength reaches 90% of the design grade, use prestressed intelligent CNC tensioning equipment to tension the steel strands inserted into the corrugated pipe and lock them on the anchor. The tensioning and locking of all prestressed corrugated pipes are completed.

[0016] Step nine: Grouting the holes of the corrugated pipe; grouting and sealing the holes of the corrugated pipe;

[0017] Step 10: Anchor sealing: Use template to seal the anchor and then pour the anchor sealing concrete.

[0018] Concrete, pour the anchor concrete and then maintain it;

[0019] Step 11: Mark the prefabricated T-beams. After marking, hoist and store them.

[0020] Furthermore, when installing the template in the fourth step above, before using the prefabricated T-beam template, the template should be cleaned in advance using a template polishing and cleaning device to ensure that there are no rust spots and oxide layer spots on the panel surface, the panel color is uniform, and it feels smooth when rubbed with the palm of your hand; after polishing, a special release agent should be applied immediately, and the template that is not put into use should be covered with a film for maintenance;

[0021] The formwork should use the same type of release agent. When using a special release agent, the brushing tool is a wool roller brush or spray. The brushing should be uniform and the thickness of the oil layer should be strictly controlled. After the release agent is applied, the formwork should be inspected and accepted. Only after the inspection is qualified can the next process of placing the steel frame into the formwork be carried out;

[0022] The transverse slope of the T-beam flange plate must be set and adjusted according to design requirements. Steps between beams are not allowed after the T-beam is erected, which would affect the thickness of the bridge deck pavement. After the T-beam is erected, a transverse slope that meets the design requirements must be formed. This is controlled by strictly fine-tuning the flange plate bottom formwork during the installation of the T-beam side formwork using the fine-tuning nuts, checking the accuracy with a slope gauge, and finally securing the position.

[0023] The transverse slope of the T-beam diaphragm must be set and adjusted according to the design requirements. It is not allowed that the connection position of the diaphragm between the beams after the T-beam is erected is not aligned with the slope to form a broken line, which will affect the appearance of the diaphragm. After the T-beam is erected, the transverse slope must be formed in accordance with the design requirements. The control method is: during the installation process of the T-beam diaphragm, fine-tune it using the fine-adjustment nut under the diaphragm bottom mold, check the accuracy with a slope gauge, and finally fix it in place.

[0024] After the formwork is installed, check the verticality, cross-sectional dimensions, flatness, and reinforcement cover of the web side formwork;

[0025] The formwork and rebar installation should be coordinated. Formwork that interferes with rebar binding should be installed after the rebar is complete. The prestressed corrugated pipe should be passed through the end formwork, leaving approximately 15 cm of clearance. To prevent deformation and leakage of the corrugated pipe, a PVC inner liner 1 cm smaller than the inner diameter of the corrugated pipe was installed on site to provide effective internal support.

[0026] When installing the template, attention should be paid to the accurate location of the reserved holes, such as drainage holes, lifting holes, etc.

[0027] Furthermore, the vibrating method in step 5 is as follows: the web concrete is vibrated primarily using a high-frequency attached vibrator installed outside the side formwork, supplemented by an inserted vibrating rod; the web concrete is poured symmetrically in layers, with the layer thickness not exceeding 30 cm; the high-frequency attached vibrator vibrates intermittently: each time it is activated for 20 to 30 seconds, then paused for 5 seconds, and then activated again; each layer of concrete is vibrated 3 to 4 times; the number of times the vibrator is activated is based on the length of the poured concrete, and the formwork is not vibrated empty;

[0028] The wing plate concrete is mainly vibrated with an inserted vibrator. The vibrating interval of the inserted vibrator is less than 30cm, the distance from the formwork is 5-10cm, and the depth of insertion into the lower concrete layer is 5-10cm. The vibration time is 20-30 seconds, and it is determined when the concrete stops sinking, no bubbles appear, and the surface is slurry. When pouring the top plate, it is strictly forbidden to use the attached vibrator.

[0029] When vibrating concrete, avoid the vibrator hitting the steel anchor plate, avoid hitting the formwork reinforcement, and avoid damaging the prestressed pipe during vibration; drag the liner back and forth;

[0030] Furthermore, the slurry collecting and roughening of the top surface in the above step 5 includes the following steps:

[0031] (1) After the precast beam and slab concrete is vibrated, a scraper is used to level the concrete surface. An elevation control point is set every 2 meters on the side form to ensure that the transverse slope of the beam surface meets the requirements and the surface is flat;

[0032] (2) After the precast beam and slab concrete is scraped flat, the bridge deck is smoothed with a wooden trowel, and a secondary grouting is performed before the initial setting;

[0033] (3) After the concrete has finally set, the bridge deck is roughened to create a rough surface with a concave-convex surface of 5 to 10 mm;

[0034] (4) After the concrete pouring is completed, the pre-buried corrugated pipe should be checked in time to check whether the corrugated pipe is smooth. If it is not smooth, use an air compressor to blow it out in time to make it smooth;

[0035] (5) To avoid cracks on the top plate surface, secondary finishing should be carried out in time. When leveling the top of the beam, the top surface elevation should be accurately controlled and attention should be paid to the horizontal slope setting of the wing plate. In order to make the cast-in-place bridge deck concrete and the precast beam tightly integrated into a whole, the top surface of the precast beam should be roughened. The groove should be cut in the vertical span direction with a depth of 0.5 to 1.0 cm and cross the top of the plate. After the concrete is initially set, it should be covered with geotextile and sprayed for curing. The concrete surface should not be damaged or contaminated during covering. After meeting the demolition requirements, it should be sent to the steam curing shed for curing. Then, the edges of the wing plates (i.e., wet joints) and the beam ends should be chiseled. The chiseling should be done manually (with a chiseling machine). The cement mortar and loose layers on the concrete surface should be removed to expose dense and evenly distributed fresh aggregate.

[0036] Furthermore, the concrete curing method is as follows: After the precast T-beams are poured and the formwork is removed, they are moved to a steam curing shed via a bottom formwork trolley. This is extremely important for early curing of concrete, improving strength, increasing elastic modulus, and controlling shrinkage and creep. Using a high-temperature, high-humidity, intelligently controlled steam curing shed to cure precast T-beams can rapidly increase concrete strength, and combined with four sets of bottom formwork beam transport trolleys, production efficiency is greatly improved.

[0037] After steam curing is completed, the precast T-beam is transported to the general curing area by the bottom formwork trolley and watered by the automatic sprinkler system. The total number of days for water curing shall not be less than 14 days. When the temperature is below 5°C, the concrete shall be covered and cured, and water shall not be sprinkled on the concrete surface. The precast T-beam shall have test blocks cured under the same conditions. The test blocks shall be placed on the top plate and cured at the same time and under the same conditions as the beam and plate.

[0038] Furthermore, in the above steps 8 to 10, the T-beam pre-tensioning, grouting and end-sealing integrated construction method is used for construction, and the specific method includes the following steps:

[0039] Step 1: Pre-install an upper corrugated pipe, a middle corrugated pipe, and two lower corrugated pipes in the T-beam to form a channel. Both ends of the upper corrugated pipe, the middle corrugated pipe, and the lower corrugated pipe are fixedly connected with anchor seats. The anchor seats are embedded in the T-beam and remain fixed. A set amount of steel strands are inserted into each channel and both ends pass through the anchor seats;

[0040] Step 2: Prestressed anchors are installed at both ends of the multiple steel strands in each corrugated pipe. Two tensioning machines are used to symmetrically pre-tension the multiple steel strands in each channel. The multiple steel strands are stopped after reaching the set prestress and set tensioning length. The anchors at both ends are pressed against and fixed to the anchor seats. The anchor seats support the prestressed steel strands. The excess steel strands outside the anchors are removed, and the pre-tensioned anchoring of the steel strands in the remaining channels is completed.

[0041] Step 3, grouting of the channel: After the prestressed anchorage of the steel strand, the grouting of the channel where the steel strand is placed should be completed within 48 hours. During the grouting process, the grouting ports set at the anchor seats at the ends of the four channels at one end of the T-beam are connected to the grouting machine, and the grouting ports at both ends of the other channels are connected in series, and finally return to the grouting machine to form a circulating grouting. A grouting cover is fixedly and sealed at the end of the anchor to ensure that the grouting volume in one channel is at least 1.5 times the volume of the corrugated pipe;

[0042] Step 4: After grouting is completed, high-strength fast-hardening grouting material is used to seal the two ends of the T-beam.

[0043] Furthermore, in the above step five, multiple anchor sealing templates are used to seal the anchor at each end. The anchor sealing template includes a steel plate and a screw. The steel plate covers the groove at the entire anchor. Two screws are used. The inner ends are symmetrically fixed in the threaded holes of the anchor seat, and the outer ends are locked with nuts after passing through the steel plate. A slurry inlet is provided on the top of the steel plate. The slurry inlet includes a cavity structure with a top opening surrounded by an inclined plate and two triangular plates. The cavity structure is opposite to the notch of the steel plate, and the upper end of the cavity structure is flush with the upper end of the steel plate.

[0044] Furthermore, after installing the anchor template in the above step five, high-strength fast-hardening grouting material is used for grouting and sealing. After the grout solidifies to the set time, the mold is removed, the anchor template is disassembled, the exposed length of the screw is removed, and the end surface is polished and leveled. After leveling, it is roughened and a layer of cement slurry is applied.

[0045] Furthermore, the above-mentioned grouting is carried out using T-beam end face processing lifting and pouring equipment. The T-beam end face processing lifting and pouring equipment includes a grouting head, a grouting pump, a telescopic cylinder, a pitching arm, a lifting arm and an electric turntable. The grouting head is connected to the grouting pump through a grouting pipe. The grouting head is fixedly connected to the cylinder rod end of the telescopic cylinder. The cylinder seat of the telescopic cylinder is fixedly connected to the pitching arm. The pitching arm is fixedly connected to the upper end of the lifting arm. The lower end of the lifting arm is fixedly connected to the electric turntable. The electric turntable is fixedly connected to the traveling trolley. The grouting pump is fixedly connected to the traveling trolley. A slurry storage tank is installed on the traveling trolley, and a stirring device is provided on the slurry storage tank.

[0046] Furthermore, a flexible anti-slurry plate is provided at one end of the cylinder rod of the grouting head close to the telescopic cylinder, and the anti-slurry plate can shield the grouting head after it is extended into the slurry inlet.

[0047] Furthermore, the above-mentioned pitch arm includes a pitch connector, a U-shaped slot plate and a pitch motor that drives the pitch connector to rotate. The pitch connector is rotatably connected to the pitch seat through a pitch rotation axis. The pitch seat is fixedly connected to the upper end of the lifting arm. The pitch motor is installed on the pitch seat and connected to the pitch rotation axis. The U-shaped slot plate is fixedly connected to the pitch connector at a distance away from the pitch axis. The U-shaped slot plate is provided with a strip-shaped through hole that is fixedly connected to the cylinder seat of the telescopic cylinder.

[0048] Furthermore, the above-mentioned lifting arm includes a lifting plate, two guide rods and an electric push rod. The lifting plate is used to connect the pitch arm, and is telescopically connected to two guide rods at both ends. The lower ends of the two guide rods are fixedly connected to the fixed seat, and the fixed seat is fixedly connected to the electric turntable. The rod end of the electric push rod is fixedly connected to the middle part of the bottom side of the lifting plate, and the body of the electric push rod is fixedly connected to the fixed seat.

[0049] Beneficial effects of the present invention: Compared with the prior art, the present invention has the following effects:

[0050] (1) By setting up multiple mobile bottom formwork trolleys, the pouring, curing and pre-tensioning operations can be carried out in a cycle, thereby greatly improving the production efficiency of T-beams and shortening the prefabrication time of T-beams. The prefabricated T-beams can be quickly delivered from the mold to the curing location without reaching the strength of the lifting equipment, thereby improving the prefabrication efficiency of T-beams. The direct movement and transportation of the bottom formwork trolleys also avoids damage to the prefabricated T-beams.

[0051] (2) During the grouting process of multiple corrugated pipes in the T-beam, a circulating grouting is formed, and a sealed and fixed grouting cover is set at the anchor to ensure that the entire grouting is carried out stably, avoiding the problems of poor grouting quality and unstable grouting pressure caused by leakage. In addition, the amount of grout injected is 1.5 times the volume of the corrugated pipe, which can ensure that the grouting is sufficient. After solidification, the grouting is more dense and the pipeline grouting is fuller. The use of high-strength fast-hardening grouting material can achieve rapid solidification, and the entire process greatly improves production efficiency.

[0052] (3) The cavity structure is aligned with the notch of the steel plate, and the upper end of the cavity structure is flush with the upper end of the steel plate and fits into the groove of the anchor to form a casting cavity structure, which is convenient for casting. In addition, the existing threaded holes are used to install the screw locking template, which is convenient and fast to install, with stable and reliable connection. It is simple to remove the template after casting, and a triangular grouting port is set to facilitate the addition of high-strength and fast-hardening grouting material into the casting cavity. Only three templates are needed to complete the casting of the entire end face. The independent modules also reduce the serious local leakage caused by the uneven end face.

[0053] (4) When using the lifting and pouring equipment for T-beam end surface treatment, the grouting material is placed in the slurry storage tank for stirring. After stirring for the set time, the trolley is controlled to the center position of the front side of the T-beam end. According to the position of the groove, the lifting arm is controlled to the set height, and then the pitching arm is controlled to rotate downward to the set angle. The trolley is controlled to approach the end of the T-beam and the telescopic cylinder is controlled to extend so that the grouting head is extended into the grouting port and the grouting pump is started for grouting. During the grouting process, the electric turntable is controlled to rotate within a small angle range and ensure that the grouting head can swing freely in the grouting port. By swinging, the grouting material can be more stably filled in the pouring cavity. , improve the performance stability and uniformity of the grouting material after pouring and solidification. The grouting process is carried out in the order from bottom to top to grout the groove. After the grouting is completed, the walking trolley is controlled to enter the next T-beam end for grouting; the use of lifting casting equipment can realize the rapid grouting of the T-beam at a single end, improve the grouting efficiency, reduce labor intensity, and make the operation safer. The lifting, pitching and telescopic control can realize the precise docking of the grouting head. The installation of a visual recognition module makes it easier to automatically identify the slurry inlet according to the height, and then control the walking trolley, lifting arm, pitching arm and telescopic cylinder to perform corresponding actions, greatly improving the level of automation;

[0054] (5) The anti-slurry plate can shield the grouting head after it is inserted into the slurry inlet, and blocks the slurry splashing out of the slurry inlet to prevent it from flying onto the telescopic cylinder and other components, thereby affecting their service life. The structure set up with a U-shaped groove plate is convenient for quick installation of the telescopic cylinder, and the strip through-hole structure is also convenient for position adjustment, with a wider range of applications. The casing of the pitch motor is fixedly connected to one side of the pitch seat of the double-ear structure, driving the pitch rotation axis to rotate, and then driving the pitch arm to pitch, thereby achieving the required angle control. BRIEF DESCRIPTION OF THE DRAWINGS

[0055] Figure 1 It is a cross-sectional diagram of a T-beam bridge;

[0056] Figure 2 Schematic diagram of steel skeleton structure;

[0057] Figure 3 for Figure 2 Schematic diagram of the CC cross-section structure;

[0058] Figure 4 for Figure 2 Schematic diagram of the AA section structure;

[0059] Figure 5 for Figure 2 Schematic diagram of the BB cross-section structure;

[0060] Figure 6 This is a side view of the 40m beam mold structure;

[0061] Figure 7 for Figure 6 Schematic diagram comparing the closed and open molds of the middle BB cross-section structure;

[0062] Figure 8 Schematic diagram of grouting end sealing structure;

[0063] Figure 9 This is a schematic diagram of installing the template at the left end of the T-beam;

[0064] Figure 10 It is a schematic diagram of the structure of the left end of the T beam;

[0065] Figure 11 for Figure 8 A schematic diagram of the enlarged structure of the middle part A;

[0066] Figure 12 This is a schematic diagram of the grouting equipment structure;

[0067] Figure 13 Schematic diagram of the pitch arm structure;

[0068] Figure 14 Schematic diagram of the mixing equipment structure;

[0069] Figure 15 This is a schematic diagram of the T-beam grouting equipment structure;

[0070] Figure 16 This is a schematic diagram of the layout of the connecting pipes at the left end of the T-beam;

[0071] Figure 17 This is a schematic diagram of the grouting equipment structure connected to the right end of the T-beam;

[0072] Figure 18 for Figure 15 The enlarged structural diagram at B in the middle;

[0073] Figure 19 This is a schematic diagram of the installation structure of the grouting cover from the left side;

[0074] Figure 20 This is the process flow chart for T-beam prefabrication construction;

[0075] Figure 21 This is a schematic diagram of the installation structure of the T-beam template grinding and cleaning device;

[0076] Figure 22 This is a schematic diagram of the installation structure of the second grinding disc on one side;

[0077] Figure 23 This is a schematic diagram of the arrangement of the second grinding disc on one side and the first upper blowing and dust collection mechanism;

[0078] Figure 24 Schematic diagram of the lifting structure of the second grinding disc;

[0079] Figure 25This is a schematic diagram of the installation structure of the first grinding disc;

[0080] Figure 26 This is a schematic diagram of the arrangement of the first grinding disc and the first lower blowing and dust collection mechanism;

[0081] Figure 27 This is a schematic diagram of the bottom grinding disc layout structure. DETAILED DESCRIPTION

[0082] The invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0083] The precast beams are divided into two types of beam lengths: 25mT beams and 40mT beams. The main line section of the bridge superstructure adopts a single 7-piece T beam form. The total width of the standard section of the bridge deck is 15.65m. Figure 1 As shown, the horseshoe width variation section is 4.3m long, with web thickness and width varying from 0.2m to 0.32m, and the horseshoe width varying from 0.48m to 0.6m. The bottom plate span is 0.48cm at the mid-span and 0.6m at the ends. The 25mT beam has a top plate width of 1.8m, a top plate flange thickness of 0.20m, and a beam height of 1.75m. The web thickness variation section is 4.3m long, with web thickness and width varying from 0.2m to 0.40m. The 40mT beam has a top plate width of 1.8m, a top plate flange thickness of 0.2m, and a beam height of 2.5m. The web thickness variation section is 4.3m long, with web thickness and width varying from 0.2m to 0.4m.

[0084] The T-beam prefabrication process requires the following equipment: a T-beam production line, a rebar tying jig, and a rebar skeleton hoisting sling. To ensure the structural dimensions of the prefabricated beams, the fabrication and installation accuracy of the rebar skeleton, and to meet technical requirements and standards, the equipment must be meticulously manufactured and inspected to the required standards.

[0085] T beam production line

[0086] (1) Overall structure

[0087] The formwork system consists of three parts: side formwork, bottom formwork and end formwork. The side formwork is fixed, and the bottom formwork is a longitudinally movable bottom formwork pedestal. Due to the change in beam length, the relationship between the side formwork and the end formwork is an outsourced end.

[0088] (2) Side mold

[0089] The main materials of the side mold are: stainless steel panel, and T12 steel strip is used for the connecting plate. The side mold demoulding method is to realize automatic mold closing and demoulding through the hydraulic system.

[0090] Side formwork connection method: The beam is connected into a whole through bolts in the length direction and connected into a whole through upper and lower tie rods in the cross-sectional direction.

[0091] Side formwork sharing method: Considering the 25m / 40m span ±500mm beam length change, the side formwork length is designed to be 26m / 40m, and the side formwork beam height is designed to be 1.75m / 2.5m. In order to save formwork, the beam end is considered to be prefabricated by replacing the movable blocks to realize 80-type expansion joints and 160-type expansion joints.

[0092] Side form type: The side form is divided into center beam side form and side beam side form. Both the center beam side form and the side beam side form are composed of five major parts: template part, bottom bracket, slide seat, comb plate and platform system.

[0093] (3) Mobile bottom mold pedestal (bottom mold trolley)

[0094] The mobile base formwork pedestal consists of three main parts: the base formwork, the main beam, and the longitudinal movement trolley. The base formwork is placed directly on the main beam, and the traveling system is assembled into an integral whole with the main beam via a connecting plate.

[0095] The bottom formwork is made of T6 steel plate, and the lower end of the panel is reinforced longitudinally with channel steel. The bottom formwork width is designed to be 600mm, and a movable formwork is designed at the bottom lifting beam at the beam end to facilitate beam lifting.

[0096] The main beam adopts a double H-shaped steel structure and is divided into three sections, with the longest single section being 12m.

[0097] The longitudinal trolley consists of four parts: wheel box, wheel set, drive device and motor protection cover.

[0098] (4) End mold

[0099] The end formwork is connected to the side formwork using a side formwork clamping the end formwork. The end formwork panel is made of T6 steel plate, and the connecting plate and reinforcement are all made of T8 steel strips. The end formwork is placed directly above the bottom formwork (concrete surface), and the top surface of the end formwork has a 2% slope.

[0100] Sealing strips are installed at the joints between the end formwork, bottom formwork and side formwork to ensure strong sealing and prevent slurry leakage during the prefabrication process;

[0101] (5) Hydraulic and travel systems

[0102] The hydraulic system consists of a hydraulic station, electromagnetic reversing valve, oil cylinder and hydraulic accessories. The hydraulic system's electromagnetic reversing valve controls the extension and contraction of the oil cylinder to achieve side mold demoulding and mold closing, as well as horizontal alignment of the side mold and bottom mold.

[0103] The traveling system consists of a traveling trolley, wheel assembly, electric control cabinet, remote control handle, drive unit, alarm, and accessories. By operating the remote control handle buttons to control the forward and reverse rotation of the motor, the traveling trolley moves forward and backward, and the longitudinal position of the template is controlled to align the longitudinal positions of the side and bottom templates.

[0104] 2) Steel bar binding fixture

[0105] The 25mT beams are tied and hoisted using a single-piece assembly. To ensure accurate rebar placement and spacing, the ties are placed on a fixed formwork. Three single-piece rebar tying formworks are provided based on the beam yard's production scale.

[0106] 3) Steel bar lifting sling

[0107] Due to the large area and heavy weight of the T-beam reinforcement frame, a dedicated lifting device is used to ensure smooth lifting and deformation-free lifting of the reinforcement frame. The design of the lifting device takes into account sufficient rigidity and durability, while also taking into account the heavy lifting weight of the reinforcement frame. Three sets of lifting devices are provided.

[0108] Example 1: Figure 1-20 As shown, a method for producing a T-beam for a highway comprises the following steps:

[0109] Step 1: Binding of T-beam steel bar skeleton: Bind the processed steel bars of various types into a T-beam steel bar skeleton on the steel bar binding jig according to the design drawings;

[0110] Step 2: Hoist the T-beam reinforcement skeleton. After the T-beam reinforcement skeleton is tied and formed on the reinforcement binding jig, it is hoisted into place using hoisting equipment and reinforcement hoists. Before hoisting into place, the center line and beam end line must be marked on the bottom formwork to control the longitudinal installation position of the T-beam reinforcement skeleton accordingly. After the T-beam reinforcement skeleton is in place on the bottom formwork, check whether the longitudinal center of the reinforcement skeleton coincides with the longitudinal center line of the bottom formwork. If not, make local adjustments to make the centers of the two lines coincide.

[0111] Step 3: Install the prestressed pipe. The prestressed pipe uses a metal corrugated pipe. The position of the prestressed pipe must be strictly located according to the coordinates and fixed with Φ12 positioning steel bars. The positioning steel bars are spot-welded to the beam web stirrups. The prestressed pipe positioning steel bars are set in groups of 80 cm for straight sections and 50 cm for dense sections. When the corrugated pipe is inserted, a PVC lining pipe with a diameter 1 cm smaller than the inner diameter of the corrugated pipe is installed inside the corrugated pipe.

[0112] Step 4: Formwork installation. The prefabricated T-beam formwork uses a bottom formwork trolley + hydraulic side formwork. The bottom formwork pedestal is moved longitudinally to the concrete pouring area, and the side and end forms are closed. There are 4 bottom formwork trolleys per production line. Use a transverse trolley to transfer to the return trolley line to complete the production closed loop. The transverse slope of the T-beam flange plate is set and adjusted according to the design requirements. The transverse slope of the T-beam diaphragm is set and adjusted according to the design requirements. After the formwork is installed, the verticality, cross-sectional dimensions, flatness, and steel bar protective layer of the web side formwork must be checked. The installation of the formwork and steel bars should be coordinated. The formwork that interferes with the binding of the steel bars should be installed after the steel bars are installed. The prestressed corrugated pipe should pass through the end formwork and leave a reserved length of 15cm±3cm.

[0113] Step 5: Concrete pouring: pour C50 concrete into the installed formwork;

[0114] The total amount of chloride ions introduced by various raw materials in the concrete mixture (including anchor concrete) shall not exceed 0.06% of the total amount of cementitious materials.

[0115] The selected aggregates must be tested for alkali activity before construction, and non-active aggregates must be used. Alkali-carbonate reactive aggregates and alkali-silica reactive aggregates with an expansion rate greater than 0.20% must not be used. When the alkali-silica reactive expansion rate of the aggregate used is between 0.10% and 0.20%, the total alkali content in the concrete shall not exceed 1.8 kg / m 3 , and has passed the effectiveness test of alkali-aggregate reaction inhibition measures.

[0116] 1) Cement

[0117] Cement shall be ordinary Portland cement or Portland cement of stable quality, with an alkali content not exceeding 0.60% and a C3A content in the clinker not exceeding 8.0%. Other technical requirements shall comply with the requirements of GB175-2007 "General Portland Cement".

[0118] 2)Fine aggregate

[0119] Fine aggregate shall be hard, clean natural medium-coarse river sand, or machine-made sand produced and tested by a special unit, with a fineness modulus of 2.6 to 3.2 and a mud content of no more than 2.0%. Other technical requirements shall comply with the provisions of the "Test Procedures for Aggregates in Highway Engineering" (JTG E42-2005).

[0120] 3) Coarse aggregate

[0121] Coarse aggregate should be hard, durable crushed stone or pebbles, using impact crushing. The void ratio should be less than 40%, the crushing index less than 20%, the ratio of the compressive strength of the coarse aggregate parent rock to the design strength of the concrete should be no less than 1.5, the mud content should be no more than 1.0%, the mud block content should be no more than 0.5%, and the needle-like content should be less than 10%. The particle size should be 5mm to 20mm, with continuous grading, the maximum particle size should not exceed 25mm, and should not be larger than 3 / 4 of the minimum clear distance between the reinforcement bars. Other technical requirements must comply with the "Testing Procedures for Aggregates for Highway Engineering" (JTG E42-2005).

[0122] 4) Water for mixing and curing

[0123] Water used for concrete mixing and curing must comply with the requirements of the "Concrete Water Standard" (JGJ63-2006). Any water that meets drinking water standards may be used.

[0124] 5) Mineral admixtures

[0125] Concrete mineral admixtures use fly ash with stable performance, the chloride ion content of fly ash is not more than 0.02%, and the other properties must comply with the requirements of fly ash of Grade II or above in "Fly Ash Used in Cement and Concrete" (GB / T1596-2017).

[0126] 6) Admixtures

[0127] Admixtures must be of stable quality and well-compatible with cementitious materials. Performance indicators must comply with the requirements of "Concrete Admixtures" (GB8076-2008). The water-reducing agent dosage and compatibility with cement are determined through testing. Air-entraining agents and expansive agents must comply with the requirements of "Concrete Admixtures" and "Concrete Expansive Agents" (GB23439-2017), respectively.

[0128] The concrete is poured continuously and formed in one step. The total pouring time for each precast beam should not exceed 4.5 hours. The temperature of concrete entering the mold is controlled at 5-30℃, and the temperature of the formwork and steel bars is controlled at 5-35℃. The precast C50 concrete is transported to the concrete placing machine by a concrete belt conveyor. According to the set placing sequence, the concrete placing machine automatically places the concrete. The concrete is poured in layers from one end of the beam to the other end. The pouring sequence is to pour the bottom plate concrete first, then the web concrete, and finally the wing plate concrete. The pouring thickness of each layer shall not exceed 30cm. The material discharge in the webs on both sides shall be balanced to avoid displacement caused by eccentric pressure on the inner mold, which will lead to uneven thickness of the web concrete. The next layer of concrete shall be placed after each layer is vibrated. The interval between the two layers of concrete shall not be greater than the initial setting time of the concrete. The pouring speed shall be reduced in the area with dense steel bars in the end anchor plate area. After the web concrete is poured, a time is set to allow the web concrete to fully sink before pouring the wing plate. The set time is less than 10 minutes to ensure that the wing plate concrete is poured before the initial setting of the web concrete.

[0129] It also includes concrete vibration, which uses an inserted vibrating rod and a high-frequency attached vibrator to vibrate the poured concrete;

[0130] After the precast beam and slab concrete is vibrated, the top surface is scraped and smoothed, and then roughened after solidification.

[0131] Use a scraper to level the concrete surface, and set an elevation control point every 2m on the side formwork on site; after the precast beam and slab concrete is leveled, use a wooden trowel to smooth the bridge deck, and perform secondary grouting between the initial setting.

[0132] Step 6: Formwork removal: When the concrete poured into the precast T-beam reaches the set strength, the formwork is removed;

[0133] Step 7: Concrete curing: After the formwork is removed, the precast T-beam is directly sent to the curing equipment for curing using a bottom formwork trolley;

[0134] Step 8: Prestressed construction: When the concrete strength reaches 90% of the design grade, use prestressed intelligent CNC tensioning equipment to tension the steel strands inserted into the corrugated pipe and lock them on the anchor. The tensioning and locking of all prestressed corrugated pipes are completed.

[0135] Step nine: Grouting the holes of the corrugated pipe; grouting and sealing the holes of the corrugated pipe;

[0136] Step 10: Anchor sealing: Use template to seal the anchor and then pour anchor sealing concrete. After pouring the anchor sealing concrete, perform maintenance.

[0137] Step 11: Mark the prefabricated T-beams. After marking, hoist and store them.

[0138] Furthermore, when installing the template in the fourth step above, before using the prefabricated T-beam template, the template should be cleaned in advance using a template polishing and cleaning device to ensure that there are no rust spots and oxide layer spots on the panel surface, the panel color is uniform, and it feels smooth when rubbed with the palm of your hand; after polishing, a special release agent should be applied immediately, and the template that is not put into use should be covered with a film for maintenance;

[0139] The formwork should use the same type of release agent. When using a special release agent, the brushing tool is a wool roller brush or spray. The brushing should be uniform and the thickness of the oil layer should be strictly controlled. After the release agent is applied, the formwork should be inspected and accepted. Only after the inspection is qualified can the next process of placing the steel frame into the formwork be carried out;

[0140] The transverse slope of the T-beam flange plate must be set and adjusted according to design requirements. Steps between beams are not allowed after the T-beam is erected, which would affect the thickness of the bridge deck pavement. After the T-beam is erected, a transverse slope that meets the design requirements must be formed. This is controlled by strictly fine-tuning the flange plate bottom formwork during the installation of the T-beam side formwork using the fine-tuning nuts, checking the accuracy with a slope gauge, and finally securing the position.

[0141] The transverse slope of the T-beam diaphragm must be set and adjusted according to the design requirements. It is not allowed that the connection position of the diaphragm between the beams after the T-beam is erected is not aligned with the slope to form a broken line, which will affect the appearance of the diaphragm. After the T-beam is erected, the transverse slope must be formed in accordance with the design requirements. The control method is: during the installation process of the T-beam diaphragm, fine-tune it using the fine-adjustment nut under the diaphragm bottom mold, check the accuracy with a slope gauge, and finally fix it in place.

[0142] After the formwork is installed, check the verticality, cross-sectional dimensions, flatness, and reinforcement cover of the web side formwork;

[0143] The formwork and rebar installation should be coordinated. Formwork that interferes with rebar binding should be installed after the rebar is complete. The prestressed corrugated pipe should be passed through the end formwork, leaving approximately 15 cm of clearance. To prevent deformation and leakage of the corrugated pipe, a PVC inner liner 1 cm smaller than the inner diameter of the corrugated pipe was installed on site to provide effective internal support.

[0144] When installing the template, attention should be paid to the accurate location of the reserved holes, such as drainage holes, lifting holes, etc.

[0145] Furthermore, the vibrating method in step 5 is as follows: the web concrete is vibrated primarily using a high-frequency attached vibrator installed outside the side formwork, supplemented by an inserted vibrating rod; the web concrete is poured symmetrically in layers, with the layer thickness not exceeding 30 cm; the high-frequency attached vibrator vibrates intermittently: each time it is activated for 20 to 30 seconds, then paused for 5 seconds, and then activated again; each layer of concrete is vibrated 3 to 4 times; the number of times the vibrator is activated is based on the length of the poured concrete, and the formwork is not vibrated empty;

[0146] The wing plate concrete is mainly vibrated with an inserted vibrator. The vibrating interval of the inserted vibrator is less than 30cm, the distance from the formwork is 5-10cm, and the depth of insertion into the lower concrete layer is 5-10cm. The vibration time is 20-30 seconds, and it is determined when the concrete stops sinking, no bubbles appear, and the surface is slurry. When pouring the top plate, it is strictly forbidden to use the attached vibrator.

[0147] When vibrating concrete, avoid the vibrator hitting the steel anchor plate, avoid hitting the formwork reinforcement, and avoid damaging the prestressed pipe during vibration; drag the liner back and forth;

[0148] Furthermore, the slurry collecting and roughening of the top surface in the above step 5 includes the following steps:

[0149] (1) After the precast beam and slab concrete is vibrated, a scraper is used to level the concrete surface. An elevation control point is set every 2 meters on the side form to ensure that the transverse slope of the beam surface meets the requirements and the surface is flat;

[0150] (2) After the precast beam and slab concrete is scraped flat, the bridge deck is smoothed with a wooden trowel, and a secondary grouting is performed before the initial setting;

[0151] (3) After the concrete has finally set, the bridge deck is roughened to create a rough surface with a concave-convex surface of 5 to 10 mm;

[0152] (4) After the concrete pouring is completed, the pre-buried corrugated pipe should be checked in time to check whether the corrugated pipe is smooth. If it is not smooth, use an air compressor to blow it out in time to make it smooth;

[0153] (5) To avoid cracks on the top plate surface, secondary finishing should be carried out in time. When leveling the top of the beam, the top surface elevation should be accurately controlled and attention should be paid to the horizontal slope setting of the wing plate. In order to make the cast-in-place bridge deck concrete and the precast beam tightly integrated into a whole, the top surface of the precast beam should be roughened. The groove should be cut in the vertical span direction with a depth of 0.5 to 1.0 cm and cross the top of the plate. After the concrete is initially set, it should be covered with geotextile and sprayed for curing. The concrete surface should not be damaged or contaminated during covering. After meeting the demolition requirements, it should be sent to the steam curing shed for curing. Then, the edges of the wing plates (i.e., wet joints) and the beam ends should be chiseled. The chiseling should be done manually (with a chiseling machine). The cement mortar and loose layers on the concrete surface should be removed to expose dense and evenly distributed fresh aggregate.

[0154] Furthermore, the concrete curing method is as follows: After the precast T-beams are poured and the formwork is removed, they are moved to a steam curing shed via a bottom formwork trolley. This is extremely important for early curing of concrete, improving strength, increasing elastic modulus, and controlling shrinkage and creep. Using a high-temperature, high-humidity, intelligently controlled steam curing shed to cure precast T-beams can rapidly increase concrete strength, and combined with four sets of bottom formwork beam transport trolleys, production efficiency is greatly improved.

[0155] After steam curing is completed, the precast T-beam is transported to the general curing area by the bottom formwork trolley and watered by the automatic sprinkler system. The total number of days for water curing shall not be less than 14 days. When the temperature is below 5°C, the concrete shall be covered and cured, and water shall not be sprinkled on the concrete surface. The precast T-beam shall have test blocks cured under the same conditions. The test blocks shall be placed on the top plate and cured at the same time and under the same conditions as the beam and plate.

[0156] Furthermore, in the above steps 8 to 10, the T-beam pre-tensioning, grouting and end-sealing integrated construction method is used for construction, and the specific method includes the following steps:

[0157] Step 1: An upper corrugated pipe 200, a middle corrugated pipe 300, and two lower corrugated pipes 400 are pre-installed in the T-beam 100 to form a channel. Both ends of the upper corrugated pipe 200, the middle corrugated pipe 300, and the two lower corrugated pipes 400 are fixedly connected with anchor seats 104. The anchor seats 104 are embedded in the T-beam 100 and remain fixed. A set amount of steel strands 500 are inserted into each channel and both ends pass through the anchor seats 104. The T-beam 100 is placed on a support stand 600.

[0158] Step 2: Prestressed anchors 106 are installed at both ends of the multiple steel strands 500 in each corrugated pipe. Two tensioning machines are used to symmetrically pre-tension the multiple steel strands 500 in each channel. The multiple steel strands are stopped after reaching the set prestress and set tensioning length. The anchors at both ends are pressed against and fixed to the anchor seats. The anchor seats support the prestressed steel strands. The excess steel strands outside the anchors are removed, and the pre-tensioned anchoring of the steel strands in the remaining channels is completed.

[0159] Step 3, grouting of the channel: After the prestressed anchorage of the steel strand, the grouting of the channel where the steel strand is placed should be completed within 48 hours. During the grouting process, the grouting ports set at the anchor seats at the ends of the four channels at one end of the T-beam are connected to the grouting machine, and the grouting ports at both ends of the other channels are connected in series, and finally return to the grouting machine to form a circulating grouting. A grouting cover is fixedly and sealed at the end of the anchor to ensure that the grouting volume in one channel is at least 1.5 times the volume of the corrugated pipe;

[0160] Step 4: After grouting is completed, high-strength fast-hardening grouting material is used to seal the two ends of the T-beam.

[0161] During the grouting process of multiple corrugated pipes in the T-beam, a circulating grouting is formed, and a sealed and fixed grouting cover is set at the anchor to ensure the stable grouting process, avoiding the problems of poor grouting quality and unstable grouting pressure caused by leakage. The amount of grout injected is 1.5 times the volume of the corrugated pipe, which can ensure sufficient grouting. After solidification, the grouting is more dense and the pipeline grouting is fuller. The use of high-strength and fast-hardening grouting materials can achieve rapid solidification, and the entire process greatly improves production efficiency.

[0162] Furthermore, in the above step five, multiple anchor sealing templates are used to seal the anchors at each end of the T-beam. The multiple anchor sealing templates include an upper template, a middle template and a lower template. The upper template is the same as the middle template, and the lower template covers the grooves of the two anchors. The specific structure includes a steel plate 101 and a screw 102. The steel plate 101 covers the groove 103 at the entire anchor 106. Two screws 102 are used, and the inner ends are symmetrically fixedly connected to the threaded holes of the anchor seat 104. The outer ends pass through the steel plate 101 and are locked with nuts 107. A slurry inlet 105 is provided at the top of the steel plate 101. The slurry inlet 105 includes a cavity structure with a top opening surrounded by an inclined plate and two triangular plates. The cavity structure is opposite to the notch of the steel plate 101, and the upper end of the cavity structure is flush with the upper end of the steel plate 101. , fits into the groove of the anchor to form a casting cavity structure, which is convenient for casting, and uses the existing threaded holes to install screws to lock the template. The installation is convenient and quick, the connection is stable and reliable, and the template is simple to remove after casting. A triangular slurry inlet is set to facilitate the addition of high-strength and fast-hardening grouting materials into the casting cavity. The entire end face only requires three templates to complete the casting. The independent module also reduces the serious local leakage caused by the uneven end face. It also includes a collection tray 108 placed on the ground. The collection tray 108 is opposite to the sealing anchor template installed at the end of the T-beam, and can collect the slurry leaked from the sealing anchor template. Handrails are set at both ends of the collection tray for easy movement. Universal rollers with brake mechanisms are set at the bottom of the collection tray for easy movement, saving time and effort. It has a brake function and is also easy to position.

[0163] Furthermore, after installing the anchor template in the above step five, high-strength fast-hardening grouting material is used for grouting and sealing. After the grouting solidifies to the set time, the formwork is removed, the anchor template is disassembled, the exposed length of the screw is removed, and the end surface is polished and leveled. After leveling, it is roughened and a layer of cement slurry is applied to smooth the end surface. The screw is reserved inside, which can improve the supporting stability and reliability of the high-strength fast-hardening grouting material filled in the groove, and has better bite ability with the end of the T-beam.

[0164] During grouting, conventional practice is to manually carry out grouting by carrying a slurry bucket. However, when grouting the end of the T-beam, the T-beam is placed on a support frame, and the groove thereon is relatively high. Even the most vulnerable person needs to set up a platform or ladder to carry out grouting, which is time-consuming and labor-intensive, and has poor operational safety. To address this problem, the present application provides a lifting and pouring device for grouting. During grouting, a lifting and pouring device for treating the end face of the T-beam 200 is used for grouting. The lifting and pouring device for treating the end face of the T-beam 200 includes a grouting head 201, a grouting pump 202, a telescopic cylinder 203, a pitching arm 204, a lifting arm 205, and an electric turntable 206. 6. The grouting head 201 is connected to the grouting pump 202 through the grouting pipe 207. The grouting head 201 is fixedly connected to the cylinder rod end of the telescopic cylinder 203. The cylinder seat of the telescopic cylinder 203 is fixedly connected to the pitching arm 204. The pitching arm 204 is fixedly connected to the upper end of the lifting arm 205. The lower end of the lifting arm 205 is fixedly connected to the electric turntable 206. The electric turntable 206 is fixedly connected to the traveling trolley 208. The grouting pump 202 is fixedly connected to the traveling trolley 208. A slurry storage tank 209 is installed on the traveling trolley 208. The slurry storage tank 209 is provided with a stirring device 210. When in use, put the grouting material into the slurry storage tank and stir it. After stirring for the set time, control the walking trolley to the center position of the front side of the T-beam end, control the lifting arm to the set height according to the position of the groove, and then control the pitching arm to rotate downward to the set angle, control the walking trolley to approach the T-beam end, control the telescopic cylinder to extend, so that the grouting head extends into the grouting inlet, and start the grouting pump for grouting. During the grouting process, control the electric turntable to rotate within a small angle range, and ensure that the grouting head can swing freely in the grouting inlet. Through swinging, the grouting material can be more stably filled in the casting cavity, thereby improving the pouring rate of the grouting material. The performance stability and uniformity of the structure after solidification are improved. The grooves are grouted from bottom to top during the grouting process. After the grouting is completed, the walking trolley is controlled to enter the next T-beam end for grouting. The use of lifting casting equipment can realize the rapid grouting of a single end of the T-beam, improve the grouting efficiency, reduce labor intensity, and make the operation safer. The lifting, pitching and telescopic control can realize the precise docking of the grouting head. The installation of a visual recognition module makes it easier to automatically identify the slurry inlet according to the height, and then control the walking trolley, lifting arm, pitching arm and telescopic cylinder to perform corresponding actions, greatly improving the level of automation.

[0165] The telescopic cylinder 203 adopts a double-rod cylinder, and a mounting plate 221 is provided at the end of the double-rod to facilitate the installation of the grouting head. The double-rod cylinder is telescopic, and the telescopic effect is stable and reliable. It can resist the jet impact force of the grouting head under the pressure of the grouting pump, and the grouting is more stable.

[0166] The grouting head 201 is a hard plastic tube with a flat structure at the front end and a connecting plate 222 at the tail end. The connecting plate 222 is fixedly connected to the mounting plate 221. The grouting head 201 is connected to the grouting pipe 207 near the tail end. The flat head structure facilitates stable delivery into the casting cavity.

[0167] In order to prevent the slurry in the casting cavity from splashing onto the telescopic cylinder and other components during the grouting process, a splash-proof barrier is provided. That is, a flexible slurry-proof plate 211 is provided at one end of the cylinder rod of the grouting head 201 close to the telescopic cylinder 203. The slurry-proof plate 211 can block the grouting head 201 after it is inserted into the slurry inlet 105. By blocking the slurry splashing out of the slurry inlet, it can prevent it from flying onto the telescopic cylinder and other components, thereby affecting their service life.

[0168] To facilitate the installation of the telescopic cylinder, the pitch arm 204 includes a pitch connector 212, a U-shaped groove plate 213 and a pitch motor 215 that drives the pitch connector 212 to rotate. The pitch connector 212 is rotatably connected to the pitch seat 214 through the pitch rotation axis. The pitch seat 214 is fixedly connected to the upper end of the lifting arm 205. The pitch motor is mounted on the pitch seat 214 and connected to the pitch rotation axis. The U-shaped groove plate 213 is fixedly connected to the pitch connector 212 at a distance away from the pitch axis. The U-shaped groove plate 213 is provided with a strip-shaped through hole 216 that is fixedly connected to the cylinder seat of the telescopic cylinder 203. The structure provided by the U-shaped groove plate is convenient and quick to install the telescopic cylinder, and the strip through hole structure is also convenient for adjusting the position, and has a wider range of applications. The casing of the pitch motor is fixedly connected to one side of the pitch seat of the binaural structure, driving the pitch rotation axis to rotate, and then driving the pitch arm to pitch, thereby achieving the required angle control.

[0169] In order to stably lift and support the grouting head, telescopic cylinder and pitch arm, the lifting arm 205 includes a lifting plate 217, two guide rods 218 and an electric push rod 219. The lifting plate 217 is used to connect the pitch arm 204, and is telescopically connected with two guide rods 218 at both ends. The lower ends of the two guide rods 218 are fixedly connected to the fixed seat 220, and the fixed seat 220 is fixedly connected to the electric turntable 206. The rod end of the electric push rod 219 is fixedly connected to the middle part of the bottom side of the lifting plate 217, and the body of the electric push rod 219 is fixedly connected to the fixed seat 220. The electric push rod is used for lifting and driving, the lifting distance is accurate, and the support is stable and reliable. The double guide rods guide and have good directional stability. During the swinging and spraying process of the spray head, the lifting arm has better torsional resistance and better support stability.

[0170] The stirring device 210 includes an inner stirring shaft 224, a stirring sleeve 225, a lower stirring blade 226 and an upper stirring blade 227. The lower end of the stirring sleeve 225 is fixedly connected to a plurality of upper stirring blades 227. The plurality of upper stirring blades 227 are evenly arranged along the circumference of the lower end of the stirring sleeve 225. The inner stirring shaft 224 is rotatably connected to the stirring sleeve 225 and the lower end thereof extends out of the stirring sleeve 225 and is connected to a plurality of lower stirring blades 226. The plurality of lower stirring blades 226 are arranged along the inner stirring shaft 224. The lower end of the stirring sleeve 225 is evenly arranged in the circumferential direction, and the lower stirring blades 226 and the upper stirring blades 227 are arranged at intervals. The upper end of the stirring sleeve 225 is rotatably connected to the support frame 228, and the support frame 228 is rotatably connected to the top of the pulp storage tank 209 through a bearing. The upper end is extended and fixedly connected to the third gear 229. The second gear 230 meshing with the third gear 229 is fixedly connected to the drive shaft 231. The drive shaft 231 is rotatably connected to the top plate of the upper frame 232 through a bearing. The upper frame 232 The first gear 233 is fixedly connected to the support frame 228, and the first gear 233 meshing with the second gear 230 is fixedly connected to the motor shaft of the stirring motor 234. The stirring motor 234 is fixedly connected to the top of the upper frame 232 in an inverted manner. The upper end of the drive shaft 231 extends out of the upper frame 232 and is fixedly connected to a crank 235. The other end of the crank 235 is hinged to one end of a connecting rod 236. The other end of the connecting rod 236 is hinged to a hinge pin 238 on the rotating disk 237. The hinge pin 238 is away from the center of the rotating disk 237. The central arrangement is that the middle part of the rotating disk 237 is fixedly connected to the end of the stirring sleeve 225 extending out of the upper frame 232, and the stirring sleeve 225 and the upper frame 232 are rotatably connected through a bearing. The rotating disk 237, the crank 235, and the connecting rod 236 constitute a double crank mechanism, and the installation method can ensure that the stirring sleeve and the inner stirring shaft rotate in opposite directions. The above-mentioned double stirring shafts and the arrangement of the stirring blades with opposite rotation directions make the stirring effect better and reduce the possibility of solidification of the stirring slurry during flow.

[0171] Furthermore, the operation method of the tensioning machine in the above step 2 is: the positive bending moment steel strands of the main beam are tensioned first in the middle and then at both ends in the order of N2→N3→N4→N1; the tensioning order of the negative bending moment steel strands on the pier top is: T1 steel strand from inside to outside; the anchor adopts a clip-type anchor, and its tensioning procedure is 0→initial stress 10%σcon→initial stress 20%σcon→σcon, σcon holding load for 5 minutes; the tensioning rate is controlled at 10-25% / min of the tensioning control force, and the stable pressure holding time after reaching the control stress is not less than 5 minutes; when the jacks used in the tensioning machine are tensioned, the allowable error of the synchronous tensioning force between the left and right jacks and the two ends is controlled within ±2%; when tensioning to the control stress, the accuracy of the tensioning control stress is controlled within ±1.5%. within; when the prestressing is stretched to the design value, the error between the actual elongation and the theoretical elongation is controlled within ±6%; after the tensioning is completed and the jack and tool anchor are removed, check whether the notches of each steel strand at the tool anchor are flush. If not, it means there is a slippage phenomenon, and the slippage should be supplemented to make it reach the control stress; the total number of broken and slipped wires in the whole beam shall not exceed 1.0% of the total number of steel wires in the section, and the broken wire in a bundle shall not exceed 1 wire, and shall not be on the same side; if the entire bundle or a large number of wires are slipped and broken, the anchor head shall be removed, and the steel bundle shall be replaced after inspection and re-tensioning; the prestressed tendons shall be anchored after the tensioning control stress reaches stability; for clip-type anchors, the top surfaces of the clips shall be flush after anchoring, the mutual misalignment shall not be greater than 2mm, and the height exposed outside the anchor shall not be greater than 4mm.

[0172] The grouting equipment used in the grouting process includes an LJ-YJB1 circulating grouting system, a grouting cover 301 and a connecting conduit 302. The grouting cover 301 is fixedly sealed at the end of the anchor 106. The connecting conduit 302 uses multiple roots, each of which is connected to the slurry ports of two anchor seats 104. The slurry ports are connected to the inside of the bellows. The LJ-YJB1 circulating grouting system includes a mixer 303 and a grouting machine 304. The slurry outlet of the grouting machine 304 is connected to the slurry port of the anchor seat 104 through a slurry inlet pipe 305. The slurry port of the anchor seat 104 is located at one end of the upper bellows 200. The slurry port at the other end of the bellows 200 is connected to the slurry port at that end of the right bellows in the lower two bellows 400 through the connecting conduit 302, the slurry port at the other end of the right bellows is connected to the slurry port at that end of the middle bellows 300, the slurry port at the other end of the middle bellows 300 is connected to the slurry port at that end of the left bellows in the lower two bellows 400, the slurry port at the other end of the left bellows in the lower two bellows 400 is connected to the mixer 303 through the slurry outlet pipe 306, the mixer 303 is connected to the grouting machine 304 through the pump and the pipeline, and the entire grouting equipment forms a circulating grouting.

[0173] The grouting cover 301 includes a steel casing 307, an end panel 308 and a sealing rubber pad 309. The outer end of the steel casing 307 is fixedly sealed and connected to the end panel 308. The end panel 308 is provided with two through holes 310. The two through holes 310 pass through two screws 311 to fix the grouting cover 301 to the anchor seat 104. The sealing rubber pad 309 is an annular structure with an annular groove 312 on one side. The sealing rubber pad 309 is sleeved on the end of the steel casing 307 through the annular groove 312. The parallel surface of the sealing rubber pad 309 is against the end face of the anchor 106 near the edge. The grouting cover of this structure is easy to assemble and disassemble, and utilizes the threaded holes on the existing anchor plate and is directly locked with screws. The connection is reliable and stable, and can withstand stable connection under high pressure. The addition of a sealing rubber pad can improve the sealing effect and avoid poor slurry pressurization stability caused by leakage.

[0174] Furthermore, the above-mentioned duct grouting method steps are as follows:

[0175] 1) Anchorage sealing

[0176] Make a grouting cover according to the anchor model, and install the grouting cover and seal the anchor after the steel strand is cut;

[0177] 2) Slurry mixing

[0178] (1) Grouting equipment performance requirements

[0179] ① The grouting machine adopts the LJ-YJB1 circulating grouting system, which includes a high-speed grouting system, a grouting system, a control system and an automatic data acquisition system. The equipment should be able to automatically monitor and record the grouting process water-binder ratio, grouting pressure, stable pressure, stable time and grouting flow rate.

[0180] ② The speed of the mixer should not be less than 1000r / min, the shape of the stirring blade should match the speed, the linear speed of the blade should not be less than 10m / s and not more than 20m / s, and the mixing should be uniform within the specified time;

[0181] ③ The storage tank for temporary storage of slurry should have a stirring function, and the stirring speed should not exceed 500r / min; and a filter with a mesh size of no more than 3mm should be installed at the outlet of the storage tank;

[0182] ④ The volume of the mixer and slurry storage tank must be larger than the volume of the pipe bundle to be grouting. It is prohibited to add materials, stir and slurry at the same time;

[0183] ⑤ The grouting machine shall use a grouting pump that can operate continuously and can work at a constant pressure of more than 0.7 MPa. The minimum scale value of the pressure gauge shall not be greater than 0.1 MPa, and the maximum range shall ensure that the actual working pressure is within the range of 25% to 75% of its range. Air pressure grouting pumps shall not be used for grouting.

[0184] ⑥ In the event of an abnormality, the grouting machine has an automatic alarm function;

[0185] ⑦ The data protection function can effectively prevent construction personnel from modifying operating procedures or collected data. In the event of communication or equipment failure, emergency measures can be automatically taken to ensure data storage security.

[0186] ⑧ The water-cement ratio sensor, pressure sensor and flow sensor of the grouting machine should be verified or calibrated together with the high-speed grouting system, grouting system and control system as a whole. The verification or calibration cycle is 6 months;

[0187] (2) The performance indexes of post-tensioned prestressed duct grouting slurry are shown in the following table:

[0188]

[0189] (3) Slurry configuration

[0190] The grouting mix ratio is determined based on the laboratory test results. The materials used for grouting are weighed using automatic metering, with a metering error of less than ±1%. The design strength of the cement slurry is 50 MPa, and the slurry is prepared using Portland cement with a strength grade of 42.5 MPa.

[0191] Turn on the grouting trolley, first add 80% of the mixing water into the high-speed mixing barrel with a speed of 1000r / min, evenly add all the grouting agent, stir while adding, then evenly add all the cement, stir for 2 minutes after all the powder is added; then add the remaining 20% ​​of the mixing water and continue stirring for 2 minutes; then pass the filter composed of a filter mesh with a mesh size of no more than 3×3mm set at the outlet of the high-speed mixing barrel into the storage tank and stir continuously, test the fluidity of the slurry for 10 to 17 seconds, and press it into the channel only after passing the test, and make 3 groups of test pieces. The time interval between the end of cement slurry mixing and pressing into the pipeline shall not exceed 40 minutes; the grouting pressure is 0.5 to 0.7Mpa; the filling degree of the grouting should be until the other end of the channel is full and the exhaust hole discharges cement slurry with the same fluidity as the specified fluidity; after closing the slurry outlet, it is advisable to maintain a stable pressure period of not less than 0.5MPa, and the maintenance time of the stable pressure period should be 3 to 5 minutes;

[0192] 3) Intelligent grouting

[0193] The LJ-YJB1 circulating grouting system includes a system host, a measurement and control system, and a circulating grouting system. The slurry circulates continuously in a loop composed of prestressed pipes, a slurry making machine, and a grouting pump to exhaust the air in the pipe, promptly detect pipe blockage, and perform punching by increasing the pressure to discharge impurities and eliminate factors that lead to loose grouting. Precision pressure sensors are installed at the inlet and outlet of the pipe to monitor the pressure in real time, and provide real-time feedback to the system host for analysis and judgment. The measurement and control system adjusts the pressure according to the host's instructions to ensure that the prestressed pipe completes the grouting process under the constraints of the important indicators of slurry quality, pressure, and pressure stabilization time required by the construction technical specifications, ensuring that the grouting is full and dense. The system host determines whether the pipe is full based on whether the pressure difference between the inlet and outlet remains constant within the set time.

[0194] Furthermore, the hole is flushed before the above grouting, and the accumulated water in the hole is blown out with oil-free compressed air after flushing; the grouting is carried out slowly and evenly without interruption, and all the exhaust holes at the highest points are opened and closed one by one in sequence to ensure smooth exhaust in the hole, and the grouting of the same pipeline is carried out continuously and completed in one go; the prepared slurry is lower than 25°C, and cooling measures must be adopted during construction in high temperature seasons, or construction must be carried out in the morning or evening. The duration from the mixing of cement slurry to the injection into the hole shall not exceed 40 minutes, and the cement slurry shall remain in a fluid state before use and during the injection process. Cement slurry with reduced fluidity due to delayed use shall be used. , its fluidity shall not be increased by adding additional water; strengthen the cleaning and maintenance of grouting equipment, and there shall be no residue and water accumulation in the equipment after cleaning; during grouting operation, construction workers shall wear safety protection equipment correctly, grouting operators must wear protective glasses, and operators who transport cement and grouting agents shall wear protective masks; when grouting, each work team shall prepare and retain no less than 3 groups of test pieces with a size of 40mm×40mm×160mm, standard curing for 28d, and carry out compressive strength and flexural strength tests as the basis for quality assessment; after grouting, the grouting strength must reach 85% of the design strength when moving precast concrete components.

[0195] Before installing the template in step 4, the template needs to be cleaned using a T-beam template grinding and cleaning device, such as Figure 21-27As shown, the T-beam template grinding and cleaning device includes an electric walking mechanism 1, a side and top grinding mechanism 2 and a bottom grinding mechanism 3. Two side and top grinding mechanisms 2 are used, which are symmetrically installed on both sides of the electric walking mechanism 1 for grinding the inner side and top surface of the side form 4 of the T-beam. Two bottom grinding mechanisms 3 are used, which are symmetrically installed on the front and rear sides of the electric walking mechanism 1 for grinding the bottom form 5 of the walking trolley of the T-beam. The electric walking mechanism 1 is installed on the bottom form 5 of the walking trolley. It also includes a first blowing and dust collection mechanism 6 and a second blowing and dust collection mechanism 7. The first blowing and dust collection mechanism 6 is installed on one side of the side and top grinding mechanism 2 to blow and dust the polished template surface. The second blowing and dust collection mechanism 7 is installed between the two bottom grinding mechanisms 3 to blow and dust the polished template surface.

[0196] In order to facilitate directional walking, the electric walking mechanism 1 includes two rows of walking wheels 1010 and a walking frame 1020. The two rows of walking wheels 1010 are installed front and rear at the bottom of the walking frame 1020. Two limit plates 1030 are arranged on the outside of each row of walking wheels 1010. The two limit plates 1030 are circular plates and remain coaxial with the walking wheels 1010. The two limit plates 1030 can clamp the two sides of the walking trolley bottom mold 5 for directional walking. One row of walking wheels 1010 is equipped with a power drive mechanism for driving it to walk. The power drive mechanism includes a motor and a gearbox connected to the motor. The gearbox is connected to the wheel axle of the walking wheel. The addition of limit plates can realize the directional movement of the electric walking mechanism along the walking trolley bottom mold.

[0197] Among them, the side and top grinding mechanism 2 includes a first grinding disc 2010, a first grinding frame 2020, a first telescopic frame 2030, a second grinding disc 2040, a second grinding frame 2050, a bending lifting frame 2060 and a second telescopic frame 2070. The first grinding disc 2040 adopts a staggered arrangement of multiple rows, which is rotatably connected to the first grinding frame 202 bent at the upper end and driven to rotate by the first driving mechanism 2080. The multiple rows of first grinding discs 2010 are arranged into a bending structure, which can cover the inner concave side and the inclined top surface of the bottom of the side mold 4. The first grinding frame 2020 is fixedly connected to the first telescopic frame 2030, and the first telescopic frame 2030 is installed on the electric walking mechanism 1. The second grinding discs 2040 are arranged in multiple rows in an staggered manner, rotatably connected to the second grinding frame 2050 and driven to rotate by the second driving mechanism 2090. The multiple rows of second grinding discs 2040 can cover the upper vertical section of the side mold 4 and can cover the wing plate mold 401 fixedly connected to the top of the side mold after bending. The second grinding frame 2050 is fixedly connected to the bending lifting frame 2060. The bending lifting frame 2060 is used to lift and rotate the second grinding frame to above the wing plate mold for grinding the upper side and top surface. The bending lifting frame 2060 is installed on the second telescopic frame 2070, and the second telescopic frame 2070 is fixedly connected to the electric walking mechanism. Both the first grinding disc and the second grinding disc use metal brushes.

[0198] The electric walking mechanism drives the first and second grinding discs to grind the lower and upper surfaces of the side mold. The grinding is fast and stable. After the grinding is completed, the second grinding disc is controlled to rise and bend to realize the grinding of the top of the side mold. The device is easy to operate, with staggered grinding discs and two-section structures arranged up and down, which can ensure thorough grinding. For the top grinding, the side upper section grinding disc is used for position switching grinding, which makes the switching easy.

[0199] Specifically, the first driving mechanism 2080 and the second driving mechanism 2090 both include a side grinding motor, a side driving pulley and a side driven pulley. One end of the rotating shaft of each first grinding disc and the second grinding disc extends out from the first grinding frame and the second grinding frame respectively and is fixedly connected to the side driven pulley. The side grinding motor is fixedly connected to the first grinding frame or the second grinding frame and the motor shaft extends out of the first grinding frame or the second grinding frame and is fixedly connected to the bottom driving pulley. The side driving pulley is connected to one of the side driven pulleys through a belt. The side driven drive adopts a double-groove structure, and adjacent side driven drives are connected by belts. The first grinding disc or the second grinding disc uses a power mechanism to drive all the grinding discs to rotate. The structure is compact, the grinding is suspended, the required power is small, and the control is convenient.

[0200] Specifically, the first telescopic frame 2030 includes an L-shaped connecting frame 2031, a first linear slider guide pair 2032 and a first cylinder 2033. The L-shaped connecting frame 2031 is fixedly connected to the sliders of the two first linear slider guide pairs 2032. The cylinder rod of the first cylinder 2033 is connected to the L-shaped connecting frame 2031 and is located between the two first linear slider guide pairs 2032. The cylinder seat of the first cylinder 2033 is fixedly connected to the electric walking mechanism 1. The L-shaped connecting frame 2031 is fixedly connected to the first grinding frame 2020. The L-shaped connecting frame is used to facilitate the installation of the first grinding frame. The linear slider guide pair is used, which has good guiding performance and stable and reliable walking. The cylinder drives the first grinding frame to move laterally, which is convenient for adjusting the position, thereby achieving the best position adjustment and better grinding effect.

[0201] Specifically, the second telescopic frame 2070 includes a telescopic plate 2071, a second linear slider guide pair 2072 and a second cylinder 2073. The surface of the telescopic plate 2071 is fixedly connected to the lower end of the bending lifting frame 2060. The telescopic plate 2071 is fixedly connected to the sliders of the two second linear slider guide pairs 2072. The cylinder rod of the second cylinder 2073 is connected to the telescopic plate 2071 and is located between the two second linear slider guide pairs 2072. The cylinder seat of the second cylinder 2073 is fixedly connected to the electric walking mechanism 1. The telescopic plate is used for convenient installation of bending and lifting. The linear slider guide pair is used for good guidance and stable and reliable walking. The cylinder drives the first grinding frame to move laterally, which is convenient for adjusting the position, thereby achieving the best position adjustment, and the grinding effect of the upper inner surface of the side and the top wing plate mold surface is better.

[0202] Specifically, the bending lifting frame 2060 includes a connecting plate 2061, an inverted L-shaped frame 2062, a pitching cylinder 2063 and a lifting cylinder 2064. The front side of the connecting plate 2061 is fixedly connected to the second grinding frame 205. Two inverted L-shaped frames 2062 are hinged in the middle of the back of the connecting plate 2061. The other end of the inverted L-shaped frame 2062 is fixedly connected to the lifting plate 2065. The lifting plate 2065 is connected to two guide rods 2067 through linear bearings 2066. The lower ends of the two guide rods 2067 are fixedly connected to the guide rod seat 2068. The guide rod seat 2068 includes an upper fixed plate and two secondary vertical bending rods fixedly connected to the upper fixed plate. The lower ends of the secondary vertical bending rods are fixedly connected to the telescopic plate 2071. The end is hinged at the bottom of the lifting plate 2065, and the lower cylinder seat is fixedly connected to the upper fixed connecting plate of the guide rod seat 2068. One end of the pitching cylinder 2063 is hinged at the connecting plate 2061 near the upper end, and the other end is hinged to the inverted L-shaped frame 2062 near the end of the horizontal section and away from the second grinding disk. After the pitching cylinder 2063 extends the cylinder rod, it can ensure that the second grinding frame 2050 is parallel to the upper inclined wing plate mold 401 of the side mold 4, and then control the lifting and telescoping to achieve the fitting and grinding of the wing plate mold. When the second grinding disk remains vertical, the inner surface of the upper part of the side mold is ground. After controlling the lifting, bending and lateral movement, the top surface of the wing plate mold can be ground, realizing one grinding mechanism and grinding of different planes, simplifying the grinding equipment, reducing costs, and making it easy to control.

[0203] Among them, the bottom grinding mechanism 3 includes a bottom grinding disc 301, a bottom grinding frame 302 and a walking frame 102. The bottom grinding disc 302 adopts a staggered multi-row structure, is rotatably connected to the bottom of the bottom grinding frame 302, and is driven to rotate by a bottom grinding drive mechanism 304. Two guide pillars 305 are symmetrically fixedly connected to the top of the bottom grinding frame 302. The two guide pillars 305 move through the walking frame 1020 and are limited by the upper connection nut 306. A spring 303 is sleeved on the guide pillar 305. The two ends of the spring 303 are respectively against the bottom of the walking frame 1020 and the top of the bottom grinding frame 302. The walking frame 1020 is fixedly connected to the electric walking mechanism 1. The bottom grinding disc 301 adopts a metal brush, which travels through the electric walking mechanism to drive the grinding disc to the bottom mold. The surface is polished, and the polishing is fast and stable. A spring is set to play an elastic contact, the connection is stable, and it is convenient to adjust the height of the polishing disc. The bottom polishing drive mechanism 304 includes a bottom polishing motor, a bottom driving pulley and a bottom driven pulley. The upper end of the rotating shaft of each bottom polishing disc extends out of the bottom polishing frame and is fixedly connected to the bottom driven pulley. The bottom polishing motor is fixedly connected to the bottom polishing frame and the upper end of the motor shaft extends out of the bottom polishing frame and is fixedly connected to the bottom driving pulley. The bottom driving pulley is connected to one of the bottom driven pulleys through a belt. The bottom driven drive adopts a double-groove structure, and the adjacent bottom driven drives are connected by belts. A power mechanism is used to drive all the polishing discs to rotate. The structure is compact, the polishing is suspended, the required power is small, and the control is convenient.

[0204] Among them, the first blowing and dust collection mechanism 6 includes a first lower blowing and dust collection mechanism 601 and a first upper blowing and dust collection mechanism 602. The first lower blowing and dust collection mechanism 601 includes a bent dust collection hood 6011 and a bent air jet pipe 6012. The bent dust collection hood 6011 is a strip-shaped bent structure consistent with the bending of the first grinding frame. It is connected to the first grinding frame 2020 through the first bracket 6013 and is located on the rear side of the first grinding disc 2010. The opening side of the bent dust collection hood 6011 can elastically contact the template. The side surface and the inclined top surface of the inner concave portion, the bent air jet pipe 6012 is a strip-shaped bent structure consistent with the bending of the first grinding frame, installed on the extension of the first bracket 6013 and located on the rear side of the bent dust hood 6011, the air jet hole of the bent air jet pipe 6011 is facing the mold surface of the side mold and is inclined toward the side away from the bent dust hood, the bent dust hood 6011 is connected to the first negative pressure dust collection device through a pipeline, the first negative pressure dust collection device is installed on the electric walking mechanism 1, and the first upper blowing dust collection mechanism 602 includes a vertical dust cover 6021 and a vertical air injection pipe 6022. The vertical dust cover 6021 is a strip structure, which is connected to the second grinding frame 2050 through the second bracket 6023 and is located at the rear side of the second grinding disc 2040. The vertical dust cover 6021 can elastically contact the side surface or top surface of the vertical section of the side mold 4 (the top surface of the wing plate mold). The vertical air injection pipe 6022 is a strip structure, which is installed on the extension of the second bracket 6023 and is located at the rear side of the vertical dust cover 6021. The jet hole of the jet pipe 6022 is directed toward the mold surface of the side mold and is inclined toward the side away from the vertical dust hood. The vertical dust hood 6021 is connected to the second negative pressure dust suction device through a pipe. The second negative pressure dust suction device is installed on the electric walking mechanism 1. The polished side mold surface is vacuumed through the dust suction pipe, and then the dust that is not thoroughly vacuumed is blown away, and the effect is thorough. The dust hood has elastic contact and can also play a certain scraping role. The jet holes are arranged tilted backward to avoid affecting the dust suction effect.

[0205] The second blowing and dust collection mechanism 7 includes a horizontal dust collection hood 701 and a horizontal air jet pipe 702. The horizontal dust collection hood 701 is a strip structure, which is horizontally installed at the bottom of the walking frame 1020 of the electric walking mechanism 1 and is in elastic contact with the top surface of the walking trolley bottom mold 5. The horizontal air jet pipe 702 is installed at the bottom of the walking frame 1020 of the electric walking mechanism 1 through the bracket 703 and is located at the rear side of the horizontal dust collection hood 701. The horizontal air jet pipe 702 is provided with an air jet hole, and the air jet hole faces the top surface of the walking trolley bottom mold. The horizontal dust collection hood 701 is connected to the third negative pressure dust collection device through a pipe. The third negative pressure dust collection device is installed on the walking frame 1020 of the electric walking mechanism 1. The polished bottom mold surface is vacuumed through the horizontal dust collection pipe, and then the incomplete vacuuming is blown away, and the effect is thorough. The elastic contact of the horizontal dust collection hood can also play a certain scraping role.

[0206] The first negative pressure dust collection device, the second negative pressure dust collection device and the third negative pressure dust collection device can share one, and the three vacuum dust collection circuits are controlled by different electromagnetic inventions to perform dust collection control.

[0207] The operating method of the T-beam formwork grinding and cleaning device is as follows: after the T-beam casting is completed, the two T-beam side formworks are moved to the set position and the trolley bottom formwork is controlled to be located between the two T-beam side formworks, and the T-beam formwork grinding and cleaning device is placed on one end of the trolley bottom formwork, and the side and top grinding mechanisms and the bottom grinding mechanism and the first blowing and dust suction mechanism are started, and the side and top grinding mechanisms and the bottom grinding mechanisms are controlled to be able to contact the T-beam side formwork and the trolley bottom formwork respectively, and the electric walking mechanism is controlled to walk at a uniform speed. When walking to one end, the machine blows and dusts while walking, and then walks in the opposite direction to grind, blow and dust until the grinding, cleaning and dust suction operations are completed after multiple cycles of walking back and forth.

[0208] The grinding and cleaning device has the following advantages:

[0209] (1) The electric walking mechanism drives the side and top grinding mechanisms and the bottom grinding mechanism to move and grind at the same time, which can complete the rapid grinding of the mold surface of the side mold and the bottom mold, saving time and labor, and having higher operation safety. There is no safety accident caused by excessive height. In addition, following the first blowing and dust collection mechanism and the second blowing and dust collection mechanism, the mold surface being ground can be dust-blown and purged, further improving the cleanliness of the mold surface, facilitating the spraying of the release agent and the prefabrication quality of the next T-beam;

[0210] (2) Installing a limit plate enables the electric walking mechanism to move in a directional manner along the bottom mold of the walking trolley;

[0211] (3) The electric walking mechanism drives the first grinding disc and the second grinding disc to grind the lower and upper surfaces of the side mold. The grinding is fast and stable. After the grinding is completed, the second grinding disc is controlled to rise and bend to achieve the grinding of the top of the side mold. The device is easy to operate, with staggered grinding discs and two-section structures arranged up and down, and the grinding is thorough. The top is polished, and the side upper section grinding disc is used for position conversion grinding, which is easy to switch;

[0212] (4) An L-shaped connecting frame is used to facilitate the installation of the first grinding frame. A linear slider guide pair is used, which has good guidance and stable and reliable movement. The cylinder drives the first grinding frame to move horizontally and telescopically, which is convenient for adjusting the position, thereby achieving the best position adjustment and better grinding effect;

[0213] (5) The telescopic plate is used to facilitate installation, bending and lifting. The linear slider guide pair is used, which has good guidance and stable and reliable walking. The cylinder drives the first grinding frame to move horizontally, which is convenient for adjusting the position, thereby achieving the best position adjustment, and the grinding effect of the upper inner surface of the side and the top wing plate mold surface is better;

[0214] (6) When the second grinding disc is kept vertical, the inner surface of the upper part of the side mold is ground. After controlling the lifting, bending and lateral movement, the top surface of the wing plate mold can be ground, realizing one grinding mechanism and grinding of different planes, simplifying the grinding equipment, reducing costs, and making control convenient;

[0215] (7) The electric walking mechanism drives the grinding disc to grind the upper surface of the bottom mold. The grinding is fast and stable. The spring is set to play an elastic contact, the connection is stable, and it is easy to adjust the height of the grinding disc;

[0216] (8) The polished side mold surface is vacuumed through the vacuum tube, and the dust that is not completely vacuumed is blown away, which is effective. The elastic contact of the vacuum hood can also play a certain scraping role. The air jet holes are arranged tilted backward to avoid affecting the vacuum effect.

[0217] (9) The polished bottom mold surface is vacuumed through the horizontal vacuum tube, and the incomplete vacuuming is then blown away. The effect is thorough, and the elastic contact of the horizontal vacuum hood can also play a certain scraping role.

[0218] The above description is only a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with the technical field can easily think of changes or replacements within the technical scope disclosed by the present invention, which should be included in the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be based on the scope of protection of the claims.

Claims

1. A method for producing a T-beam for a highway, characterized by: The method comprises the following steps: Step 1: Binding of T-beam steel bar skeleton: Bind the processed steel bars of various types into a T-beam steel bar skeleton on the steel bar binding jig according to the design drawings; Step 2: Hoist the T-beam reinforcement skeleton. After the T-beam reinforcement skeleton is tied and formed on the reinforcement binding jig, it is hoisted into place using hoisting equipment and reinforcement hoists. Before hoisting into place, the center line and beam end line must be marked on the bottom formwork to control the longitudinal installation position of the T-beam reinforcement skeleton accordingly. After the T-beam reinforcement skeleton is in place on the bottom formwork, check whether the longitudinal center of the reinforcement skeleton coincides with the longitudinal center line of the bottom formwork. If not, make local adjustments to make the centers of the two lines coincide. Step 3: Install the prestressed pipe. The prestressed pipe uses a metal corrugated pipe. The position of the prestressed pipe must be strictly located according to the coordinates and fixed with Φ12 positioning steel bars. The positioning steel bars are spot-welded to the beam web stirrups. The prestressed pipe positioning steel bars are set in groups of 80 cm for straight sections and 50 cm for dense sections. When the corrugated pipe is inserted, a PVC lining pipe with a diameter 1 cm smaller than the inner diameter of the corrugated pipe is installed inside the corrugated pipe. Step 4: Formwork installation. The prefabricated T-beam formwork uses a bottom formwork trolley + hydraulic side formwork. The bottom formwork pedestal is moved longitudinally to the concrete pouring area, and the side and end forms are closed. There are 4 bottom formwork trolleys per production line. Use a transverse trolley to transfer to the return trolley line to complete the production closed loop. The transverse slope of the T-beam flange plate is set and adjusted according to the design requirements. The transverse slope of the T-beam diaphragm is set and adjusted according to the design requirements. After the formwork is installed, the verticality, cross-sectional dimensions, flatness, and steel bar protective layer of the web side formwork must be checked. The installation of the formwork and steel bars should be coordinated. The formwork that interferes with the binding of the steel bars should be installed after the steel bars are installed. The prestressed corrugated pipe should pass through the end formwork and leave a reserved length of 15cm±3cm. Step 5: Concrete pouring. Pour C50 concrete into the installed formwork. The concrete is poured continuously and formed in one time. The total pouring time of each precast beam should not exceed 4.5 hours. The temperature of concrete entering the formwork is controlled at 5-30℃, and the temperature of the formwork and steel bars is controlled at 5-35℃. The prefabricated C50 concrete is transported to the concrete distributor by a concrete belt conveyor. According to the set distribution sequence, the concrete distributor automatically distributes the concrete. The concrete is poured in layers from one end of the beam to the other end. The pouring sequence is to pour the bottom plate concrete first, then the web concrete, and finally the wing plate concrete. The pouring thickness of each layer shall not exceed 30cm. The material discharge in the webs on both sides shall be balanced. After each layer is vibrated, the lower layer shall be distributed. The interval between the two layers shall not be greater than the initial setting time of the concrete. The pouring speed shall be reduced in the area with dense steel bars in the end anchor plate area. After the web concrete is poured, a time shall be set so that the web concrete can fully sink, and then the wing plate shall be poured. The set time shall be less than 30cm to ensure that the wing plate concrete is poured before the web concrete is initially set. It also includes concrete vibration, which uses an inserted vibrating rod and a high-frequency attached vibrator to vibrate the poured concrete; After the precast beam and slab concrete is vibrated, the top surface is scraped and smoothed, and then roughened after solidification. Use a scraper to level the concrete surface, and set elevation control points every 2 meters on the side formwork on site. After the precast beam and slab concrete is leveled, use a wooden trowel to smooth the bridge deck, and perform a secondary grouting during the initial setting period. Step 6: Formwork removal: When the concrete poured into the precast T-beam reaches the set strength, the formwork is removed; Step 7: Concrete curing: After the formwork is removed, the precast T-beam is directly sent to the curing equipment for curing using a bottom formwork trolley; Step 8: Prestressed construction: When the concrete strength reaches 90% of the design grade, use prestressed intelligent CNC tensioning equipment to tension the steel strands inserted into the corrugated pipe and lock them on the anchor. The tensioning and locking of all prestressed corrugated pipes are completed. Step nine: Grouting the holes of the corrugated pipe; grouting and sealing the holes of the corrugated pipe; Step 10: Anchor sealing: Use template to seal the anchor and then pour anchor sealing concrete. After pouring the anchor sealing concrete, perform maintenance. Step 11: Mark the prefabricated T-beams. After marking, hoist and store them.

2. The method for producing a highway T-beam according to claim 1, characterized in that: When installing the template in step 4, before using the prefabricated T-beam template, clean the template in advance with a template grinding and cleaning device to ensure that there are no rust spots and oxide layer spots on the panel surface, the panel color is uniform, and it feels smooth when rubbed with the palm of your hand; after polishing, immediately apply a special release agent, and cover the template that is not in use temporarily with a film for maintenance; The formwork should use the same type of release agent. When using a special release agent, the brushing tool is a wool roller brush or spray. The brushing should be uniform and the thickness of the oil layer should be strictly controlled. After the release agent is applied, the formwork should be inspected and accepted. Only after the inspection is qualified can the next process of placing the steel frame into the formwork be carried out; The cross slope of the T-beam diaphragm is set and adjusted according to the design requirements. It is not allowed that the connection position of the cross diaphragm between the beams is not on the same slope to form a broken line after the T-beam is erected. The cross slope control method is: during the installation of the T-beam diaphragm, fine-tune it with the fine-adjustment nut under the bottom form of the diaphragm, check the accuracy with a slope gauge, and finally fix it in place; After the formwork is installed, check the verticality, cross-sectional dimensions, flatness, and reinforcement cover of the web side formwork; The formwork and reinforcement installation should be coordinated. Formwork that interferes with the binding of reinforcement should be installed after the reinforcement is installed. The prestressed corrugated pipe should pass through the end formwork, leaving a 15cm reserve length. On-site, the lining pipe should be inserted into the corrugated pipe, and a PVC lining pipe 1cm smaller than the inner diameter of the corrugated pipe should be installed inside the corrugated pipe. When installing the template, attention should be paid to the accurate location of the reserved holes.

3. The method for producing a highway T-beam according to claim 1, characterized in that: The vibrating method in step 5 is as follows: the web concrete is vibrated mainly with a high-frequency attached vibrator installed outside the side formwork, supplemented by an inserted vibrating rod. The web concrete is poured in symmetrical layers, and the layer thickness shall not exceed 30 cm. The vibration of the high-frequency attached vibrator is intermittent: start for 20 to 30 seconds each time, stop for 5 seconds, and then start again; each layer of concrete is vibrated 3 to 4 times; the number of times the vibrator is started is based on the length of the poured concrete, and the formwork is not vibrated empty; The wing plate concrete is mainly vibrated with an inserted vibrator. The vibrating interval of the inserted vibrator is less than 30cm, the distance from the formwork is 5-10cm, and the depth of insertion into the lower concrete layer is 5-10cm. The vibration time is 20-30 seconds, and it is determined when the concrete stops sinking, no bubbles appear, and the surface is slurry. When pouring the top plate, it is strictly forbidden to use the attached vibrator. When vibrating concrete, avoid the vibrator from colliding with the steel bundle anchor plate, the formwork reinforcement, and the prestressed pipe during vibration; drag the liner pipe back and forth.

4. The method for producing a highway T-beam according to claim 1, characterized in that: In step 5, the top surface slurry collection and roughening include the following steps: (1) After the precast beam and slab concrete is vibrated, a scraper is used to level the concrete surface. An elevation control point is set every 2 meters on the side form to ensure that the transverse slope of the beam surface meets the requirements and the surface is flat; (2) After the precast beam and slab concrete is scraped flat, the bridge deck is smoothed with a wooden trowel, and a secondary grouting is performed before the initial setting; (3) After the concrete has finally set, the bridge deck is roughened to create a rough surface with a concave-convex surface of 5 to 10 mm; (4) After the concrete pouring is completed, the pre-buried corrugated pipe should be checked in time to check whether the corrugated pipe is smooth. If it is not smooth, use an air compressor to blow it out in time to make it smooth; (5) When leveling the top of the beam, the top surface elevation should be accurately controlled, and attention should be paid to the horizontal slope setting of the wing plate. The top surface of the precast beam should be roughened by cutting grooves in the vertical span direction with a depth of 0.5 to 1.0 cm across the top of the plate. After the initial setting of the concrete, it should be covered with geotextile and sprayed for maintenance. The concrete surface should not be damaged or contaminated during covering. After meeting the demolition requirements, it should be sent to the steaming shed for maintenance, and then the edges of the wing plates and the beam ends should be roughened. The roughening should be done manually, and the cement mortar and loose layers on the concrete surface should be removed to expose dense and evenly distributed fresh aggregate.

5. The method for producing a highway T-beam according to claim 1, characterized in that: The specific method of concrete curing is as follows: After the precast T-beams are poured and the formwork is removed, they are moved to a steam curing shed via a bottom formwork trolley. Curing the precast T-beams in the steam curing shed, which features high temperature and high humidity intelligent control, can quickly increase the concrete strength. Four sets of bottom formwork beam transport trolleys are used to greatly improve production efficiency. After steam curing is completed, the precast T-beam is transported to the general curing area by the bottom formwork trolley and watered by the automatic sprinkler system. The total number of days for water curing shall not be less than 14 days. When the temperature is below 5°C, the concrete shall be covered and cured, and water shall not be sprinkled on the concrete surface. The precast T-beam shall have test blocks cured under the same conditions. The test blocks shall be placed on the top plate and cured at the same time and under the same conditions as the beam and plate.

6. The method for producing a highway T-beam according to claim 1, characterized in that: In steps 8 to 10, the T-beam pre-tensioning, grouting and end-sealing integrated construction method is used for construction. The specific method includes the following steps: Step 1: Pre-install an upper corrugated pipe, a middle corrugated pipe, and two lower corrugated pipes in the T-beam to form a channel. Both ends of the upper corrugated pipe, the middle corrugated pipe, and the lower corrugated pipe are fixedly connected with anchor seats. The anchor seats are embedded in the T-beam and remain fixed. A set amount of steel strands are inserted into each channel and both ends pass through the anchor seats; Step 2: Prestressed anchors are installed at both ends of the multiple steel strands in each corrugated pipe. Two tensioning machines are used to symmetrically pre-tension the multiple steel strands in each channel. The multiple steel strands are stopped after reaching the set prestress and set tensioning length. The anchors at both ends are pressed against and fixed to the anchor seats. The anchor seats support the prestressed steel strands. The excess steel strands outside the anchors are removed, and the pre-tensioned anchoring of the steel strands in the remaining channels is completed. Step 3, grouting of the channel: After the prestressed anchorage of the steel strand, the grouting of the channel where the steel strand is placed should be completed within 48 hours. During the grouting process, the grouting ports set at the anchor seats at the ends of the four channels at one end of the T-beam are connected to the grouting machine, and the grouting ports at both ends of the other channels are connected in series, and finally return to the grouting machine to form a circulating grouting. A grouting cover is fixedly and sealed at the end of the anchor to ensure that the grouting volume in one channel is at least 1.5 times the volume of the corrugated pipe; Step 4: After grouting is completed, high-strength fast-hardening grouting material is used to seal the two ends of the T-beam.

7. The method for producing a highway T-beam according to claim 6, characterized in that: In step 4, multiple anchor sealing templates are used to seal the anchors at each end of the T-beam. The anchor sealing template includes a steel plate (101) and a screw (102). The steel plate (101) covers the entire groove (103) at the anchor (106). Two screws (102) are used, and the inner ends are symmetrically fixedly connected to the threaded holes of the anchor seat (104). The outer ends pass through the steel plate (101) and are locked with nuts. A slurry inlet (105) is provided at the top of the steel plate (101). The slurry inlet (105) includes a cavity structure with a top opening surrounded by an inclined plate and two triangular plates. The cavity structure is opposite to the notch of the steel plate (101), and the upper end of the cavity structure is flush with the upper end of the steel plate (101).

8. The method for producing a highway T-beam according to claim 7, characterized in that: After installing the anchor template in step 4, use high-strength fast-hardening grouting material for grouting and sealing. After the grout solidifies for the set time, remove the mold, disassemble the anchor template, remove the exposed length of the screw, and polish and level the end surface. After leveling, chisel the surface and apply a layer of cement slurry.

9. The method for producing a highway T-beam according to claim 8, characterized in that: During grouting, a T-beam end surface treatment lifting and pouring device is used for grouting. The T-beam end surface treatment lifting and pouring device comprises a grouting head (201), a grouting pump (202), a telescopic cylinder (203), a pitching arm (204), a lifting arm (205) and an electric turntable (206). The grouting head (201) is connected to the grouting pump (202) through a grouting pipe (207). The grouting head (201) is fixedly connected to the cylinder rod end of the telescopic cylinder (203). The cylinder seat of the telescopic cylinder (203) is fixedly connected to the pitching arm (204). The arm (204) is fixedly connected to the upper end of the lifting arm (205), the lower end of the lifting arm (205) is fixedly connected to the electric turntable (206), the electric turntable (206) is fixedly connected to the walking trolley (208), the grouting pump (202) is fixedly connected to the walking trolley (208), the walking trolley (208) is equipped with a slurry storage tank (209), and the slurry storage tank (209) is provided with a stirring device (210); the pitching arm (204) includes a pitching connector (212), a U-shaped groove plate (213) and a driving pitching connector ( The pitch motor (215) is rotated by the pitch connector (212), the pitch connector (212) is rotatably connected to the pitch seat (214) through the pitch rotation axis, the pitch seat (214) is fixedly connected to the upper end of the lifting arm (205), the pitch motor is installed on the pitch seat (214) and is connected to the pitch rotation axis, the U-shaped groove plate (213) is fixedly connected to the pitch connector (212) at a distance away from the pitch axis, and the U-shaped groove plate (213) is provided with a strip-shaped through hole (216) fixedly connected to the cylinder seat of the telescopic cylinder (203); the lifting arm (205) includes The invention comprises a lifting plate (217), two guide rods (218) and an electric push rod (219), wherein the lifting plate (217) is used to connect the pitching arm (204), and two guide rods (218) are telescopically connected at both ends. The lower ends of the two guide rods (218) are fixedly connected to a fixing seat (220), and the fixing seat (220) is fixedly connected to the electric turntable (206). The rod end of the electric push rod (219) is fixedly connected to the middle part of the bottom side of the lifting plate (217), and the body of the electric push rod (219) is fixedly connected to the fixing seat (220).

10. The method for producing a highway T-beam according to claim 6, characterized in that: The steps for grouting the duct are as follows: 1) Anchorage sealing Make a grouting cover according to the anchor model, and install the grouting cover and seal the anchor after the steel strand is cut; 2) Slurry mixing (1) Grouting equipment performance requirements ① The grouting machine adopts the LJ-YJB1 circulating grouting system, which includes a high-speed grouting system, a grouting system, a control system and an automatic data acquisition system. The equipment should be able to automatically monitor and record the grouting process water-binder ratio, grouting pressure, stable pressure, stable time and grouting flow rate. ② The speed of the mixer should not be less than 1000r / min, the shape of the stirring blade should match the speed, the linear speed of the blade should not be less than 10m / s and not more than 20m / s, and the mixing should be uniform within the specified time; ③ The storage tank for temporary storage of slurry should have a stirring function, and the stirring speed should not exceed 500r / min; and a filter with a mesh size of no more than 3mm should be installed at the outlet of the storage tank; ④ The volume of the mixer and slurry storage tank must be larger than the volume of the pipe bundle to be grouting. It is prohibited to add materials, stir and slurry at the same time; ⑤ The grouting machine shall use a grouting pump that can operate continuously and can work at a constant pressure of more than 0.7 MPa. The minimum scale value of the pressure gauge shall not be greater than 0.1 MPa, and the maximum range shall ensure that the actual working pressure is within the range of 25% to 75% of its range. Air pressure grouting pumps shall not be used for grouting. ⑥ In the event of an abnormality, the grouting machine has an automatic alarm function; ⑦With data protection function; ⑧ The water-cement ratio sensor, pressure sensor and flow sensor of the grouting machine should be verified or calibrated together with the high-speed grouting system, grouting system and control system as a whole. The verification or calibration cycle is 6 months; (2) The performance indexes of post-tensioned prestressed duct grouting slurry are shown in the following table: (3) Slurry configuration The grouting mix ratio is determined based on the laboratory test results. The materials used for grouting are weighed using automatic metering, with a metering error of less than ±1%. The design strength of the cement slurry is 50 MPa, and the slurry is prepared using Portland cement with a strength grade of 42.5 MPa. Turn on the grouting trolley, first add 80% of the mixing water into the high-speed mixing barrel with a speed of 1000r / min, evenly add all the grouting agent, stir while adding, then evenly add all the cement, stir for 2 minutes after all the powder is added; then add the remaining 20% ​​of the mixing water and continue stirring for 2 minutes; then pass through the filter composed of a filter with a mesh size of no more than 3×3mm set at the outlet of the high-speed mixing barrel into the storage tank, and stir continuously, test the fluidity of the slurry for 10 to 17 seconds, and press it into the channel only after passing the test, and make 3 groups of test pieces. The time interval between the end of cement slurry mixing and pressing into the pipeline shall not exceed 40 minutes; the grouting pressure is 0.5 to 0.7Mpa; the filling degree of the grouting should be until the other end of the channel is full and the exhaust hole discharges cement slurry with the same fluidity as the specified fluidity; after closing the slurry outlet, maintain a stable pressure period of not less than 0.5MPa, and the maintenance time of the stable pressure period is 3 to 5 minutes; 3) Intelligent grouting The LJ-YJB1 circulating grouting system includes a system host, a measurement and control system, and a circulating grouting system. The slurry circulates continuously in a loop composed of prestressed pipes, a slurry making machine, and a grouting pump to exhaust the air in the pipe, promptly detect pipe blockage, and perform punching by increasing the pressure to discharge impurities and eliminate factors that lead to loose grouting. Precision pressure sensors are installed at the inlet and outlet of the pipe to monitor the pressure in real time, and provide real-time feedback to the system host for analysis and judgment. The measurement and control system adjusts the pressure according to the host's instructions to ensure that the prestressed pipe completes the grouting process under the constraints of the important indicators of slurry quality, pressure, and pressure stabilization time required by the construction technical specifications, ensuring that the grouting is full and dense. The system host determines whether the pipe is full based on whether the pressure difference between the inlet and outlet remains constant within the set time.

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