A manufacturing process of deck blocks of a half-through steel pipe concrete composite arch bridge

Abstract

The application relates to a manufacturing process of a half-through steel pipe concrete combined arch bridge deck block, which shortens the length of each bridge deck block and adjusts the position of a steel beam partition plate, resurveys the adjusted position, leaves welding shrinkage pre-camber and welding shrinkage amount for the cross partition plate, leaves welding shrinkage amount for the deck plate and small longitudinal beams, assembles the plate unit of the deck plate, the small longitudinal beams and the cross partition plate on a plate unit bed frame, places the assembled plate unit on a welding robot reverse deformation platform, adopts the welding robot to weld the plate unit weld joint, straightens the plate unit, draws a ground sample line at a bridge site assembling field, installs an assembling bed frame according to the bridge deck block manufacturing line shape and size position, adopts continuous matching construction, assembles the bridge deck block, welds the bridge deck block weld joint, carries out nondestructive detection and size detection after welding, and carries out cutting; the manufacturing process solves the problems of great manufacturing difficulty and difficult precision control, and meets the technical requirements of active tension closure of the arch bridge deck block.

Description

Technical Field

[0001] This invention relates to the field of arch bridge deck block manufacturing technology, and in particular to a manufacturing process for a mid-span steel-concrete composite arch bridge deck block. Background Technology

[0002] The newly built Jianyang Tuojiang Grand Bridge on the Chongqing Central Railway Line is a (72+320+72)m mid-span thrust-free composite arch bridge. The side spans are side arches, which are steel-concrete composite box arches, while the central span is a steel-concrete composite arch. The central span is connected to the side arches by the side main beams and orthogonal irregular steel bridge deck panels. To achieve zero horizontal thrust at the arch abutments, the side arches and steel main beams are used as tie rods, relying on tensioned steel beams to transfer force from the side arches to counteract the horizontal force of the steel pipe arches. To achieve this design, after tensioning calculations, the positions of the diaphragms in the bridge deck blocks need to be pre-offset, and the lengths of the small longitudinal beams need to be adjusted. To achieve the manufacturing precision of this structure and the manufacturing alignment of the variable main beams, reasonable construction techniques and welding deformation shrinkage control are required to achieve the design intent. This bridge structure is the world's first bridge to use active tensioning technology for closure, with no other bridges to draw upon. Furthermore, the orthogonal irregular steel bridge deck structure is complex, making precise control of welding deformation difficult.

[0003] Therefore, this invention proposes a process for manufacturing bridge deck blocks of a mid-span steel-concrete composite arch bridge to solve the above problems. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a manufacturing process for the bridge deck blocks of a mid-span steel-concrete composite arch bridge, which solves the problems of high manufacturing difficulty and difficulty in precision control, and meets the technical requirements of active tensioning and closure of the bridge deck blocks of the arch bridge.

[0005] To solve the above-mentioned technical problems, the technical solution of the present invention is: a manufacturing process for bridge deck blocks of a mid-span steel-concrete composite arch bridge, the innovation of which lies in the following steps: S1. According to the requirements of the active tensioning and closure process, after construction calculation, the length of each bridge deck block is shortened and the position of the steel beam diaphragm is adjusted. The layout is redone according to the adjusted position, and the construction drawings are drawn. The diaphragm is left with welding shrinkage pre-camber and welding shrinkage amount, and the bridge deck and small longitudinal beams are left with welding shrinkage amount. S2. Cut steel plates according to the drawn construction drawings, assemble the plate units of bridge deck, small longitudinal beams and transverse diaphragms on the plate unit jig, and draw the baseline; S3. Place the assembled plate unit on the anti-deformation platform of the welding robot, and use the welding robot to weld the weld seam of the plate unit. S4. Place the welded plate unit on the plate unit straightening jig, straighten the plate unit to flatness, and obtain the bridge deck, small longitudinal beams and transverse diaphragms of the bridge deck block, and paint and ship them to the bridge assembly yard. S5. Draw a ground line at the bridge assembly site, and install and assemble the jigs according to the manufacturing lines and dimensions of the bridge deck blocks, using continuous matching construction. S6. Place a section of the bridge deck block's transverse diaphragm on the assembly jig, ensuring the diaphragm's angle; S7. Assemble the small longitudinal beams on the transverse diaphragm, ensuring the relative positional relationship between the small longitudinal beams and the transverse diaphragm; S8. Assemble the bridge panels from the middle to both sides to ensure the accuracy of the bridge panel mating. S9. Assemble the diaphragms of the next bridge deck section; S10. Assemble the small longitudinal beams of the next bridge deck block and connect them to the previous bridge deck block using temporary panels; S11. Install the bridge deck panel of the next bridge deck block, ensuring the accuracy of the bridge deck panel connection; S12. Repeat S9-11 until the bridge deck block assembly is completed. Weld the bridge deck block welds, perform non-destructive testing and dimension inspection after welding, and cut the components.

[0006] Furthermore, welding shrinkage allowance is provided between each rib position of the rib unit of the plate unit before material cutting and assembly.

[0007] Furthermore, the rib units of the plate unit are assembled and welded on the plate unit jig, and the unevenness of the ribs is trimmed by flame.

[0008] Furthermore, the dimensions of the bridge deck blocks are measured and corrected, and the cutting amount on both sides of the steel plate is calculated based on the rib plate.

[0009] The advantages of this invention are: The manufacturing process of this invention first shortens the block length, adjusts the rib position, and reserves for welding shrinkage. It compensates for welding deformation by designing rounded ends and uses a welding robot anti-deformation platform for automated welding to reduce human error and control deformation. It eliminates participating stress through fire straightening process to improve the flatness of plate units. During the assembly of bridge deck blocks, continuous matching construction is adopted. Based on the ground line and jig, the transverse diaphragms, small longitudinal beams and bridge deck are assembled in stages to ensure docking accuracy. At the same time, temporary splicing plates are used to achieve dynamic adjustment between segment blocks to meet the dimensional coordination of active tensioning and closure. The system solves the problems of precision control and high construction difficulty, and meets the technical requirements of active tensioning and closure of arch bridge deck blocks. Attached Figure Description

[0010] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0011] Figure 1-6 This is a flowchart illustrating the assembly process of the arch bridge deck blocks of the present invention. Detailed Implementation

[0012] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0013] Example This embodiment provides a process for fabricating bridge deck blocks of a mid-span steel-concrete composite arch bridge, including the following steps: S1. The bridge deck is a densely packed, orthotropic, integral steel bridge deck with crossbeams spaced 3m apart and 2.5m high. The crossbeams are welded to the side main beams. Four small longitudinal beams, 0.62m high, are arranged under the bridge deck. The bridge deck's U-shaped ribs are 260mm high and spaced 600mm apart. Based on the active tensioning closure process requirements, and after construction calculations, the length of each bridge deck segment was shortened and the position of the steel beam diaphragms was adjusted. The bridge deck was then re-layouted according to the adjusted positions, and construction drawings were drawn. The diaphragms were designed to accommodate welding shrinkage pre-camber and welding shrinkage allowances, as were the bridge deck and small longitudinal beams.

[0014] If construction is carried out according to the design dimensions, it will cause deviations in the position of the ribs and shorten the length of the steel beams. Therefore, welding shrinkage allowance is set between the positions of each rib in the rib unit of the plate unit before cutting and assembling, so as to ensure that the design position is reached after welding shrinkage.

[0015] S2. Cut steel plates according to the drawn construction drawings, assemble the plate units of bridge deck, small longitudinal beams and transverse diaphragms on the plate unit jig, and draw the baseline; The wall panel units of the panel unit are assembled on the panel unit jig; the rib plate units of the panel unit are assembled and welded on the panel unit jig, and the unevenness of the rib plates is repaired by flame.

[0016] S3. Place the assembled plate unit's wall panel unit and rib plate unit on the welding robot's anti-deformation platform, and use the welding robot to weld the plate unit's weld seam. The welding robot's construction is stable, which can effectively ensure the weld seam quality and control the welding shrinkage. The anti-deformation platform can offset some of the welding deformation.

[0017] S4. Place the welded plate unit on the plate unit straightening jig, straighten the plate unit to flatness, and obtain the bridge deck panel, small longitudinal beams and transverse diaphragms of the bridge deck block, and paint and ship to the bridge assembly yard.

[0018] S5. Draw a ground line at the bridge assembly site, and install the assembly jig according to the manufacturing line and size position of the bridge deck blocks, using continuous matching construction.

[0019] S6. Place a section of the bridge deck diaphragm onto the assembly jig, ensuring the diaphragm angle is as follows: Figure 1 As shown.

[0020] S7. Assemble the small longitudinal beams on the transverse diaphragms, ensuring the relative positional relationship between the small longitudinal beams and the transverse diaphragms, such as... Figure 2 As shown.

[0021] S8. Assemble the bridge panels from the middle outwards, ensuring the accuracy of the bridge panel mating. Figure 3 As shown.

[0022] S9. Assemble the diaphragms of the next bridge deck section, such as... Figure 4 As shown.

[0023] S10. Assemble the small longitudinal beams of the next bridge deck segment and connect them to the previous bridge deck segment using temporary panels, such as... Figure 5 As shown.

[0024] S11. Install the bridge deck panel of the next bridge deck block, ensuring the accuracy of the bridge deck panel connection, such as... Figure 6 As shown.

[0025] S12. Repeat S9-11 until the bridge deck block assembly is completed. Weld the bridge deck block welds, perform non-destructive testing and dimension inspection after welding, correct the dimensions of the bridge deck blocks after dimension inspection, and cut the steel plate on both sides based on the rib plate.

[0026] The fabrication process of the deck blocks for the mid-span steel-concrete composite arch bridge first involves shortening the block length, adjusting the rib positions, and reserving for welding shrinkage. Welding deformation is compensated for by designing rounded ends, and automated welding is performed using a welding robot anti-deformation platform to reduce human error and control deformation. Heat straightening eliminates stress and improves the flatness of the plate units. During deck block assembly, continuous matching construction is adopted, using the ground line and jig as references to assemble the transverse diaphragms, small longitudinal beams, and bridge deck panels in stages. While ensuring docking accuracy, temporary splicing plates are used to achieve dynamic adjustment between segmented blocks, meeting the dimensional coordination requirements for active tensioning and closure. This system systematically solves the problems of precision control and high construction difficulty, satisfying the technical requirements for active tensioning and closure of the arch bridge deck blocks.

[0027] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A manufacturing process for bridge deck blocks of a mid-span steel-concrete composite arch bridge, characterized in that: Includes the following steps: S1. According to the requirements of the active tensioning and closure process, after construction calculation, the length of each bridge deck block is shortened and the position of the steel beam diaphragm is adjusted. The layout is redone according to the adjusted position, and the construction drawings are drawn. The diaphragm is left with welding shrinkage pre-camber and welding shrinkage amount, and the bridge deck and small longitudinal beams are left with welding shrinkage amount. S2. Cut steel plates according to the drawn construction drawings, assemble the plate units of bridge deck, small longitudinal beams and transverse diaphragms on the plate unit jig, and draw the baseline; S3. Place the assembled plate unit on the anti-deformation platform of the welding robot, and use the welding robot to weld the weld seam of the plate unit. S4. Place the welded plate unit on the plate unit straightening jig, straighten the plate unit to flatness, and obtain the bridge deck, small longitudinal beams and transverse diaphragms of the bridge deck block, and paint and ship them to the bridge assembly yard. S5. Draw a ground line at the bridge assembly site, and install and assemble the jigs according to the manufacturing lines and dimensions of the bridge deck blocks, using continuous matching construction. S6. Place a section of the bridge deck block's transverse diaphragm on the assembly jig, ensuring the diaphragm's angle; S7. Assemble the small longitudinal beams on the transverse diaphragm, ensuring the relative positional relationship between the small longitudinal beams and the transverse diaphragm; S8. Assemble the bridge panels from the middle to both sides to ensure the accuracy of the bridge panel mating. S9. Assemble the diaphragms of the next bridge deck section; S10. Assemble the small longitudinal beams of the next bridge deck block and connect them to the previous bridge deck block using temporary panels; S11. Install the bridge deck panel of the next bridge deck block, ensuring the accuracy of the bridge deck panel connection; S12. Repeat S9-11 until the bridge deck block assembly is completed. Weld the bridge deck block welds, perform non-destructive testing and dimension inspection after welding, and cut the parts. The plate unit is assembled after welding shrinkage is set between each rib position. The rib plate units of the plate unit are assembled and welded on the plate unit jig, and the unevenness of the rib plates is repaired by flame. The dimensions of the bridge deck blocks are measured and corrected, and the steel plates are cut on both sides based on the ribs.

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