Prefabricating technology for assembly type bridge deck facility

Abstract

The invention discloses an assembly type bridge deck facility prefabrication process which comprises the steps of prefabrication process optimization and management strengthening, specifically, fine carding is conducted on a machining process, and a standard is formulated; quality guarantee of prefabricated products: raw materials are controlled, and quality control is carried out; precise positioning and steel bar binding of the embedded part are conducted, specifically, the embedded part is positioned through a positioning tool, and a separable steel bar tire clamp is adopted for positioning and binding during steel bar binding; inverted pouring of concrete: determining the mixing proportion of the concrete, preparing the concrete, transporting after stirring, pouring and vibrating, and detecting the quality; turning over a large component: turning over the component by matching chain type turning equipment with a flexible connection protection device; and construction management: carrying out real-time sharing and self-inspection on the construction information. In the aspect of raw material selection, adaptive high-performance materials are strictly screened, and concrete mix proportion design is optimized, so that the product quality is guaranteed from the source, and the problem of unstable construction quality is solved.

Description

Technical Field

[0001] This invention relates to the field of bridge deck construction technology, and in particular to a prefabrication process for assembled bridge deck facilities. Background Technology

[0002] Traditional cast-in-place construction technology plays a significant role in bridge deck construction. This technology requires on-site formwork erection, rebar tying, and concrete pouring on the bridge deck. Construction is greatly affected by weather conditions, and progress is easily hindered by rain, snow, or low temperatures. Furthermore, the process is complex and time-consuming, requiring a considerable amount of time from preparation to completion. Moreover, on-site construction generates a large amount of construction waste, resulting in severe dust and noise pollution, significantly disrupting the surrounding environment and residents' lives. In addition, construction quality is affected by the skill level of workers, leading to inconsistent quality and failing to meet the demands of today's efficient, environmentally friendly, and high-quality engineering construction. Therefore, developing a prefabricated bridge deck facility process to maximize construction efficiency, improve the accuracy of embedded component placement, and enhance the stability of construction quality, thereby improving economic, environmental, and social benefits, has become a pressing technical challenge for those skilled in the art. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of the prior art and provide a prefabrication process for assembled bridge deck facilities. By strictly selecting suitable high-performance materials in the selection of raw materials and optimizing the concrete mix design, the prefabricated components have higher strength, better impermeability and excellent durability, thus ensuring product quality from the source and solving the problem of unstable construction quality.

[0004] To achieve the above objectives, the technical solution adopted by this invention is: a prefabrication process for assembled bridge deck facilities, comprising: S1: Prefabrication process optimization and management enhancement: refining the processing flow and establishing standards, while optimizing personnel division of labor and collaboration; S2: Prefabricated product quality assurance: controlling the selection, inspection, and storage of raw materials, and implementing quality control at multiple stages of processing; S3: Precise positioning of embedded parts and rebar binding: using positioning fixtures to position embedded parts and binding them integrally with rebars, wherein detachable rebar jigs are used for rebar positioning and binding; S4: Inverted concrete pouring: first determining the concrete mix ratio, preparing the concrete, then mixing the concrete and transporting it to the construction site, followed by concrete pouring and vibration, and finally quality testing of the concrete; S5: Large component flipping: using a chain-type flipping device in conjunction with a soft connection protection device to flip the components; S6: Construction management: real-time sharing and self-inspection of construction information, improving collaborative work efficiency and resource utilization.

[0005] Preferably, step S1, which involves refining the processing flow and establishing standards, includes breaking down the processing into multiple operational steps based on quality requirements, determining the operational standards, quality requirements, and responsible persons for each operational step, and creating a standardized operation manual. The operation flow and quality standards are then determined based on the standardized operation manual. In step S1, the personnel division of labor and collaboration optimization involves determining the construction positions and work scope based on the skill level of the construction personnel. The construction positions include processing and manufacturing positions and quality supervision positions. The collaboration optimization involves discussing problems and determining solutions based on regular construction meetings.

[0006] Preferably, the inspection of raw materials in step S2 includes the specifications, model, quality certification documents of the raw materials, and sampling tests of the physical properties and chemical composition of the raw materials. The raw materials are stored according to their type, specifications and batches, and the storage area is protected. The multiple steps in step S2 include the rebar tying step, the concrete pouring step and the curing step after the concrete pouring is completed.

[0007] Preferably, the positioning fixture in step S3 includes a slot and a fixing device designed according to the shape of the embedded part. The embedded part includes a U-bolt and an embedded steel plate. The positioning fixture ensures the positional accuracy of the embedded part through the slot and the fixing device. The detachable rebar jig jig in step S3 includes a positioning pile and a positioning groove. Two adjacent jig jig jigs are positioned by the positioning pile. The positioning groove is used to position the rebar and fix it with a buckle. The jig jig is detached after binding.

[0008] Preferably, in step S4, the concrete mix proportion is 350 kg / m³ of silicate cement, the aggregate includes 1100 kg / m³ of crushed stone and 700 kg / m³ of medium sand, and the admixture is a high-efficiency water-reducing agent, the dosage of which is 1.5% of the cement content; the concrete mixing time is 120 seconds, and the transportation time is controlled within 10 minutes; the concrete pouring method is end-to-end gradual pouring, the pouring speed is 3~5 m³ / h, and the vibration method is 15~20 seconds per point; the quality inspection includes slump and air content testing, and performance tests are conducted on the concrete test blocks.

[0009] Preferably, the chain-type flipping device in step S5 includes a gear reducer and a soft protective pad, which protects the components before flipping and monitors the status of the components through sensors during the flipping process.

[0010] Preferably, the process further includes concrete curing, wherein steam curing is used to ensure that the concrete demolding strength reaches more than 70% of the design strength.

[0011] Preferably, the binding points of the detachable rebar clamp adopt an "8" shaped cross binding method to ensure a firm binding.

[0012] Preferably, during the concrete pouring process, the slump and air content are tested at least once for every 100 cubic meters of concrete, and test blocks are made for mechanical property testing.

[0013] Compared with the prior art, the present invention has the following advantages:

[0014] 1. This invention ensures product quality from the source by strictly selecting suitable high-performance materials in the selection of raw materials and optimizing the concrete mix design, so that the precast components have higher strength, better impermeability and excellent durability. This solves the problem of unstable construction quality.

[0015] 2. In the production process, this invention precisely controls the parameters of each stage, strictly controls the vibration process and curing process, effectively reduces internal defects of the product, improves the density and uniformity of the product, makes the surface of the precast components smoother and flatter, significantly improves the appearance quality, thereby improving the overall performance and service life of the bridge deck facilities and reducing the later maintenance costs.

[0016] 3. This invention optimizes the processes of each step, reforms and innovates tooling and equipment, builds an efficient production line, realizes continuous operation of the production process, reduces human error, lowers labor intensity, and significantly increases output per unit time.

[0017] 4. This invention scientifically plans the production layout, optimizes the process flow, reduces waiting time and material transportation distance in the production process, realizes efficient allocation of production resources, effectively shortens the production cycle, meets the demand for prefabricated components for bridge deck installation, and accelerates the construction progress of bridge projects.

[0018] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. Attached Figure Description

[0019] Figure 1 This is a schematic diagram showing the positional relationship between the positioning fixture and the embedded part of the present invention;

[0020] Figure 2 This is a schematic diagram showing the connection between the first tire clamp and the second tire clamp of the present invention;

[0021] Figure 3 This is a schematic diagram showing the position of the first positioning stake of the first tire clamp of the present invention;

[0022] Figure 4 A schematic diagram showing the position of the second positioning stake of the second jig of the present invention.

[0023] Explanation of reference numerals in the attached figures:

[0024] 1—First tire clamp; 2—First positioning stake; 3—Positioning groove; 4—Positioning fixture; 5—Embedded parts; 6—U-bolts; 7—Embedded steel plate; 8—Second tire clamp; 9—Second positioning stake. Detailed Implementation

[0025] This invention discloses a prefabrication process for assembled bridge deck facilities, including: S1: Prefabrication process optimization and management enhancement: refining the processing flow and establishing standards, while optimizing personnel division of labor and collaboration; S2: Prefabricated product quality assurance: controlling the selection, inspection, and storage of raw materials, and implementing quality control at multiple processing stages; S3: Precise positioning of embedded parts and rebar binding: using positioning fixture 4 to position embedded parts 5 and binding embedded parts 5 with rebars as a whole, using detachable rebar jigs for rebar positioning and binding; S4: Inverted concrete pouring: first determining the concrete mix ratio, preparing the concrete, then mixing the concrete and transporting it to the construction site, followed by concrete pouring and vibration, and finally quality testing of the concrete; S5: Large component flipping: using a chain-type flipping device with a soft connection protection device to flip the components; S6: Construction management: real-time sharing and self-inspection of construction information, improving collaborative work efficiency and resource utilization.

[0026] During construction management, functional modules such as project management, production management, quality management, and equipment management can be integrated into one platform. The project management module allows for the creation of detailed construction plans, including construction schedules, personnel allocation plans, and material procurement plans. The production management module records production data in real time, such as the quantity of components produced and production time. The quality management module inputs quality inspection data and tracks and handles quality issues. The equipment management module records equipment operating status, maintenance records, and other information. Construction personnel can share information in real time through the platform, facilitating timely communication and coordination.

[0027] By integrating various functional modules into a unified system, the management functions of each stage are consolidated. A comprehensive quality management system is established using the PDCA (Plan-Do-Check-Act) cycle management model, clearly defining quality objectives and responsibilities. A quality reward and punishment system and cost control measures are also implemented. Regarding the quality reward and punishment system, construction personnel who strictly adhere to quality standards and ensure product quality during construction are rewarded, while those who violate quality regulations and cause quality problems are penalized, thus motivating construction personnel to actively focus on and ensure quality. Regular quality training and technical exchange activities are organized to share advanced construction technologies and quality management experience, improving the quality awareness and technical level of construction personnel. Construction personnel are encouraged to propose quality improvement suggestions, and reasonable and effective suggestions are rewarded, fostering a positive atmosphere of full participation in quality management. Cost control measures are implemented from labor, materials, and construction costs. The process involves three aspects: First, regarding labor cost control, the work tasks of construction personnel are rationally arranged to avoid idleness or overwork, thereby improving work efficiency. Regular skills training is provided to construction personnel to enhance their operational proficiency and reduce rework and waste caused by unfamiliarity with operations. Second, regarding material cost control, a material procurement approval system is established to strictly control material procurement costs. Market research is conducted during material procurement to select reliable and reasonably priced suppliers. Material usage management is strengthened, and a quota-based material requisition system is implemented to avoid material waste. Third, during construction, on-site management is strengthened, and the construction sequence is rationally arranged to avoid repetitive construction and resource waste caused by an unreasonable sequence. Waste generated during construction is recycled and reused to reduce costs.

[0028] By integrating project management, production management, quality management, and equipment management functions, information is shared in real time across all stages, and data transmission is timely and accurate, avoiding information silos and duplication of work. This improves inter-departmental collaboration efficiency by approximately 50%. In materials management, the materials and equipment department adjusts procurement plans promptly according to production progress, avoiding material stockpiling or shortages, increasing material inventory turnover by about 30%, reducing material inventory costs by about 20%, and showing a downward trend in capital occupation. Regarding cost control, through process optimization and rational resource allocation (precisely allocating materials, equipment, and personnel according to construction progress), resource waste and idleness are avoided, improving the company's economic efficiency. Simultaneously, rational resource allocation increases resource utilization, reduces waste, and also has positive environmental benefits, reducing construction waste generation by approximately 25%.

[0029] By employing the PDCA cycle management model, the construction process is continuously optimized. In the planning stage, detailed and scientific construction plans are formulated; in the execution stage, the plans are strictly implemented; in the inspection stage, problems are identified through real-time data monitoring and regular quality inspections; and in the handling stage, corrective measures are taken in a timely manner and construction plans are adjusted. After the construction process is optimized, construction efficiency can be improved by 15% to 20%. During the construction process, through PDCA cycle optimization, the daily production efficiency of components can be improved by about 45% compared to the original plan.

[0030] This application organically combines several innovative technologies, including precise positioning of embedded parts 5, rebar binding, large component flipping, concrete pouring, and construction management, to form a complete prefabrication process system for prefabricated bridge deck facilities. The technologies work together to further improve the overall construction quality and efficiency. The quality qualification rate of prefabricated components reaches over 99.5%, and the flatness qualification rate of the bridge deck system using prefabricated construction reaches 99.3%, which is nearly 20 percentage points higher than the traditional process. The construction efficiency of the bridge deck system is increased by 80%. The bridge deck only needs to be assembled on site, reducing noise by over 65% and dust by 76%. Prefabricated components can be quickly disassembled and replaced, and the maintenance cost is expected to be reduced by over 30%. The construction of the bridge deck system significantly reduces the amount of high-altitude work, requiring only hoisting and fixing on site, reducing the risk of workers falling from heights.

[0031] Step S1 involves refining the processing flow and establishing standards. This includes breaking down the processing into multiple operational steps based on quality requirements, determining the operational standards, quality requirements, and responsible persons for each step, and creating a standardized operation manual. The operation flow and quality standards are then determined based on the standardized operation manual. In the personnel division and collaboration optimization of Step S1, personnel division is based on the skill level of the construction personnel to determine their construction positions and work scope. Construction positions include processing and manufacturing positions and quality supervision positions. Collaboration optimization is based on regular construction meetings to discuss problems and determine solutions.

[0032] In this embodiment, the prefabrication process of prefabricated bridge deck facilities is comprehensively and meticulously analyzed, breaking down each step into specific operational procedures, clarifying the operational standards, quality requirements, and responsible persons for each step; in the steel bar processing stage, the specific parameters for straightening, bending, and cutting the steel bars are specified in detail, as well as the corresponding quality inspection standards for each operation; in the formwork assembly stage, the requirements for the gaps in the formwork splicing, the fixing methods, and the key points for inspection are clarified; a standardized operation manual is developed and distributed to each construction worker to ensure that each construction worker clearly understands the operation procedures and quality standards, reducing quality problems and inefficiencies caused by non-standard operations.

[0033] Based on the prefabrication process and the skill levels of construction personnel, tasks are rationally assigned, clarifying the responsibilities and scope of work for each position. Dedicated quality supervision positions are established, with a full-time quality supervisor assigned to each process to facilitate real-time monitoring of the construction process. During concrete pouring, quality supervisors closely monitor the slump, pouring sequence, and vibration to promptly correct any non-standard operations. To strengthen collaboration and communication among different positions, a daily construction meeting system is established. Construction personnel report on the day's progress, encountered problems, and matters requiring coordination at these meetings, where solutions are discussed collaboratively to ensure smooth construction progress and avoid delays and errors caused by poor communication.

[0034] The inspection of raw materials in step S2 includes the specifications, models, quality certificates, and sampling tests of the physical properties and chemical composition of the raw materials. The raw materials are stored according to their type, specifications, and batch, and the storage area is protected. Step S2 includes several steps, including the rebar tying step, the concrete pouring step, and the curing step after the concrete pouring is completed.

[0035] In this embodiment, to ensure product quality, a strict raw material inspection system is established. All raw materials must undergo specification, model, and quality certificate inspection before entering the construction site. Additionally, the physical properties and chemical composition of the raw materials are sampled and inspected. For reinforcing bars, tensile strength, yield strength, elongation, and other indicators are checked. For cement, stability, setting time, and strength are tested. To facilitate raw material storage, a raw material storage area is established, and materials are classified and stored according to different types, specifications, and batches for easy access. Moisture-proof and rust-proof protective measures are implemented in the storage area to prevent deterioration of raw materials during storage and thus maintain product quality. When using raw materials, the designed usage is strictly followed to avoid waste.

[0036] like Figures 1 to 4 As shown, the positioning fixture 4 in step S3 includes a slot and a fixing device designed according to the shape of the embedded part. The embedded part 5 includes a U-bolt 6 and an embedded steel plate 7. The positioning fixture 4 ensures the positional accuracy of the embedded part 5 through the slot and the fixing device. The separable rebar jig jig in step S3 includes a positioning pile and a positioning groove 3. Two adjacent jig jig jigs are positioned by the positioning pile. The positioning groove 3 is used to position the rebar and fix it with a buckle. The jig jig is separated after binding.

[0037] The binding points of the detachable rebar clamps adopt the figure-eight crisscross binding method to ensure a firm binding.

[0038] The positioning fixture 4 is designed according to the shape and size of the embedded part, and has high-precision positioning holes and fixing devices. When assembling the embedded part 5, the embedded part 5 is placed into the positioning holes of the positioning fixture 4 for preliminary assembly. Afterwards, the construction personnel check and fine-tune the position of the embedded part 5 from different angles to ensure that the position and verticality of the embedded part 5 meet the design requirements before assembling and fixing the embedded part 5. The positioning fixture 4 restricts the position and verticality of the U-bolt 6 through the positioning holes and restricts the position of the embedded steel plate 7 through the fixing devices. The positioning fixture 4 controls the verticality error between the U-bolt 6 and the embedded steel plate 7 of the sound barrier embedded part 5 to within 2‰ and the exposed length error to within ±2mm through the positioning holes and fixing devices. This lays the foundation for the stability and sealing of the sound barrier during subsequent installation and avoids problems such as sound leakage and loosening caused by substandard verticality.

[0039] like Figure 1 As shown, the positioning fixture 4 is fabricated and installed as follows: Based on the specifications of the pre-embedded part 5 of the sound barrier, the positioning fixture 4 is fabricated using high-strength steel. The positioning holes of the positioning fixture 4 are precisely designed according to the size of the U-bolt 6 to ensure that the U-bolt 6 can be tightly embedded and accurately inserted into the positioning hole. The horizontal and vertical errors of the positioning fixture 4 are checked by measuring instruments to ensure that they are within the preset range, generally controlled within ±1mm. After confirmation, the U-bolt 6 is then firmly glued to the pre-embedded steel plate 7.

[0040] Separable rebar clamps are modularly designed according to the rebar layout and design requirements of different types of prefabricated bridge deck facilities. Each module corresponds to the rebar binding of different component models. The required number of clamps is selected based on the rebar layout of the prefabricated bridge deck facility. It is important to note that when preparing and installing the clamps, the appropriate modular separable rebar clamps must be selected according to the rebar layout of the prefabricated bridge deck facility. Before use, the clamps should be inspected to ensure that the positioning grooves and buckles are undamaged and undeformed. When connecting adjacent clamps, quick positioning is achieved through positioning pins and reserved holes. The positioning pin is the second positioning stake 9, and the reserved hole is the first positioning stake 2, ensuring the accurate position of the jig. During the installation process, a level and a measuring tape are used to calibrate the levelness and position of the jig, and the error is controlled within ±2mm. The detachable rebar jig uses positioning grooves and buckles to complete the positioning of the rebar in a short time, shortening the rebar positioning time by about 50% and improving the positioning accuracy to ±3mm. At the same time, it ensures that the rebar spacing is uniform. According to actual testing, the rebar skeleton tied with the detachable rebar jig has a rebar spacing qualification rate of over 98%.

[0041] In one possible embodiment, the detachable rebar jig can be made of high-strength, lightweight aluminum alloy, which makes it easy for construction workers to handle and operate while ensuring structural strength.

[0042] like Figures 2 to 4 As shown, in this embodiment, the detachable rebar clamp includes a first clamp 1 and a second clamp 8. The first clamp 1 and the second clamp 8 are inspected to ensure that their positioning grooves 3 are undamaged and undeformed. The first clamp 1 and the second clamp 8 are then positioned and securely connected using the first positioning stake 2 and the second positioning stake 9. Construction workers then sequentially place the rebars into the positioning grooves 3 of the first clamp 1 and the second clamp 8, respectively, to accurately define the position and spacing of the rebars and avoid positional deviations. The steel reinforcement bars are tied at equal intervals along the vertical direction from the marked position on the horizontal end of the first clamp, so that the tied steel cage is "mountain" shaped. A uniform tying method and sequence are used during tying, with the wires at adjacent tying points forming a figure-eight shape to ensure a secure tie. After the main frame of the sound barrier foundation is tied, the embedded parts 5 of the sound barrier are first placed into the foundation steel frame, and then the steel bars in the main frame are tied in a "well" shape and fixed with U-bolts 6, completing the tying of the sound barrier foundation steel bars and embedded parts 5. After the bottom plate of the steel cage is tied, the first clamp is used... Place the pre-embedded steel pads at the positions marked on fixture 1 and the second fixture 8, and fix them simply to prevent the reinforcing bars from falling or shifting when they are put into the formwork. The pre-embedded steel pads are square steel plates with bolt holes in the middle. They are used to facilitate the connection of the reinforcing bars to the bridge deck when installing components on the bridge deck. At the same time, the pre-embedded steel pads are conductive to the bridge deck wiring. Each bridge deck component is equipped with 8 pre-embedded steel pads, which are arranged on the bottom plates on both sides of the component. The interval between each pair of pre-embedded steel pads is 1 meter. After being put into the formwork, the pre-embedded steel pads are welded to the grounding terminals. The pre-embedded parts 5 and the pre-embedded steel pads are used during the process of binding the reinforcing cage. After positioning is completed, concrete pad blocks are tied. Finally, the position of embedded parts 5 and embedded steel plates and the quality of rebar tying are fully inspected. After tying is completed, the first jig 1 and the second jig 8 are separated. The rebar cage is lifted out using a bridge crane and is ready to be placed into the formwork. The collaborative tying process improves construction efficiency, shortens construction time by about 30% to 40%, and reduces the probability of errors in placing into the formwork. At the same time, the use of this process to tie components effectively solves the problem of difficulty in separating the rebar from the jig after tying, effectively ensuring the safety of the rebar structure and improving construction efficiency by about 40%.

[0043] To ensure that construction workers are proficient in rebar tying techniques, specialized training is organized before construction begins. This training provides detailed explanations of the use of detachable rebar jigs, key points of the rebar tying process, and quality standards. Through on-site demonstrations and simulated operations, workers experience and master the rebar tying process. An assessment component is included in the training to evaluate workers' proficiency and quality control capabilities, ensuring that all workers are fully familiar with the tying process. During construction, experienced technical personnel provide on-site guidance and supervision, promptly correcting any non-standard operating procedures to guarantee the quality of rebar tying.

[0044] In step S4, the concrete mix proportion is 350 kg / m³ of silicate cement, the aggregate content includes 1100 kg / m³ of crushed stone and 700 kg / m³ of medium sand, and the admixture is a high-efficiency water-reducing agent, with a dosage of 1.5% of the cement content; the concrete mixing time is 120 seconds, and the transportation time is controlled within 10 minutes; the concrete pouring method is end-to-end stepwise pouring, the pouring speed is 3~5 m³ / h, and the vibration method is 15~20 seconds per point; the quality inspection includes slump and air content testing, and performance tests are conducted on the concrete test blocks.

[0045] The process also includes concrete curing, which uses steam curing to ensure that the concrete demolding strength reaches more than 70% of the design strength.

[0046] During the concrete pouring process, the slump and air content should be tested at least once for every 100 cubic meters of concrete, and test blocks should be made for mechanical property testing.

[0047] To address the specific requirements of inverted concrete pouring in prefabricated bridge deck facilities, multiple experiments were conducted to determine the optimal concrete mix proportions. These experiments comprehensively considered factors such as concrete durability, fluidity, segregation resistance, setting time, and strength requirements. Multiple batches of trial mixes were performed by adjusting the proportions of raw materials such as cement, mineral admixtures, and additives. During the experimental phase, different types and dosages of water-reducing agents were tested to optimize the concrete's fluidity and workability; the sand ratio was adjusted to improve segregation resistance; composite admixtures were used to replace fly ash or mineral powder to enhance strength and durability; and precise testing of various concrete properties ensured that the prepared concrete met the construction requirements of inverted pouring.

[0048] Specifically, after multiple experiments, a C50 concrete mix proportion suitable for inverted pouring was determined. This mix proportion ensures that the concrete maintains good workability during pouring, avoids segregation and bleeding, ensures uniform filling of the mold, and eliminates defects such as voids and honeycombs inside the component. While ensuring strength, it also reduces the steam curing time of the concrete. According to compressive strength tests, the demolding strength can reach more than 70% of the design strength, and some can reach 80%, which improves the quality and durability of the component and reduces the later maintenance cost. In actual engineering, the service life of components using this mix proportion is extended by about 20% compared with components using traditional mix proportions, and the later maintenance cost is reduced by about 30%.

[0049] The C50 concrete mix design uses ordinary Portland cement with a strength grade of 42.5, at a dosage of 350 kg / m³. The aggregates are well-graded crushed stone and medium sand, with the crushed stone particle size controlled between 5 and 25 mm at a dosage of 1100 kg / m³, and the medium sand dosage at 700 kg / m³. A high-efficiency water-reducing agent is used as the admixture, at a dosage of 1.5% of the cement weight. Raw materials are prepared according to the mix design, and a detailed concrete construction plan is designed, specifying the mixing method and time. A forced mixer is used to ensure the proper mixing of all materials. Materials are thoroughly and evenly mixed. To ensure the homogeneity of the concrete, the mixing time is controlled at 120 seconds. During mixing, the water-cement ratio is strictly controlled, and the water usage is precisely controlled through an automatic metering system. After mixing, the concrete is loaded into sealed transport trucks to prevent premature setting. The transportation method and time are specified, and sealed concrete transport trucks are used to ensure that the concrete does not segregate or lose water during transportation. The transportation time from the mixing plant to the construction site is controlled within 10 minutes. In the pouring stage, the pouring process is followed... The shape and size of the component determine the pouring sequence and speed. A gradual pouring method from one end to the other is adopted, with the pouring speed controlled at 3-5 m³ / h. The pouring is done in two stages, with two rounds of vibration. During the pouring process, an immersion vibrator is used for compaction, vibrating each point for 15-20 seconds to ensure the concrete is dense and to avoid defects such as honeycomb and pitting. During vibration, the vibrator should avoid contact with the formwork and reinforcing steel to prevent damage. Simultaneously, the pouring process is monitored in real time to ensure the quality of pouring and vibration. If segregation of the concrete is detected... If any abnormalities occur, pouring should be stopped immediately, and the concrete should be re-mixed or the pouring speed adjusted. If water seeps from the concrete surface, drainage measures should be taken promptly to ensure the quality of the concrete. Through real-time monitoring, if any abnormalities occur in the concrete temperature (which must be controlled within a suitable range to prevent excessively high or low temperatures from affecting strength development) and slump (maintaining a slump of no more than 140mm) during construction, adjustments can be made in a timely manner to ensure that the concrete quality is controllable throughout the process, reduce potential quality problems, lower rework rates, save construction time and costs, and ensure the smooth progress of the project.

[0050] Specifically, to ensure the quality of concrete pouring, quality inspection points are set up at the construction site. Slump, air content, and other indicators are tested for each batch of poured concrete. Slump, placement temperature, and air content are tested at least once per 100 cubic meters of concrete. The slump is controlled between 120mm and 140mm, and the air content is controlled between 2% and 4%. Simultaneously, concrete test blocks are made at a prescribed frequency, and mechanical performance tests, including compressive strength and impermeability, are conducted to ensure that all performance indicators of the concrete meet design requirements. Temperature sensors are used to monitor the concrete temperature, ensuring it is controlled within the range of 5℃ to 35℃. If any temperature abnormalities are detected, the construction process or raw material mix ratio is adjusted promptly.

[0051] In step S5, the chain-type overturning device includes a gear reducer and a soft protective pad. The component is protected before overturning, and the component status is monitored by sensors during the overturning process.

[0052] Before using the chain-type tilting device, install and debug it. Install the chain-type tilting device in the reserved position on the prefabrication site, ensuring that the foundation is solid and can withstand the weight of more than 6 tons of prefabricated components. Install soft connection protection devices, such as rubber pads or buffer springs, at the contact points between the tilting device and the components. Debug the gear reducer, setting the tilting speed to 5° / second to 9° / second, and controlling the tilting angle error within ±0.5°. During debugging, monitor the operating status of the device through sensors to ensure normal operation. When using it, hoist the prefabricated components to the designated position on the tilting device and use lifting equipment to... The components are securely connected to the tilting equipment. Once the gear reducer is activated, the chain tilting equipment uses a gear mechanical system to precisely control the reversal, ensuring the safe and stable tilting of the more than 6-ton precast components. Rubber pads placed at the contact points between the tilting equipment and the components are used to protect the components and prevent damage during the tilting process. During the tilting process, the tilting status of the components is monitored in real time and reported to the tilting equipment operator in real time. This allows the operator to immediately stop the tilting if there is any shaking or abnormality in the components, and continue the operation after checking and troubleshooting. After the tilting is completed, the components are hoisted to the designated storage area or the next process position.

[0053] The chain-type turning device of this application, combined with a flexible connection protection device and under the precise control of a gear reducer, enables the smooth and undisturbed turning of precast components weighing over 6 tons. The flexible connection effectively buffers the impact force, preventing surface bumps or internal structural damage to the components. On-site monitoring shows that the impact force on the surface of the components during the turning process using the chain-type turning device of this application is reduced by at least 70%, effectively protecting the appearance quality of the components and reducing repair costs and construction time. The gear reducer controls the turning speed and angle, allowing construction personnel to make flexible adjustments according to actual needs, meeting the turning requirements of large components in different construction scenarios, improving construction convenience and controllability, and reducing construction accidents caused by improper turning. Moreover, each component turning by the chain-type turning device takes only 1 minute from the start of hanging the rope to the end of turning, improving turning efficiency and effectively ensuring the construction progress.

[0054] The above description is merely a preferred embodiment of the present invention and does not constitute any limitation on the present invention. Any simple modifications, alterations, or equivalent structural transformations made to the above embodiments based on the technical essence of the present invention shall still fall within the protection scope of the present invention.

Claims

1. A prefabrication process for assembled bridge deck facilities, characterized in that, include, S1: Prefabrication process optimization and management enhancement: The processing process is refined and standards are established, while personnel division of labor and collaboration are optimized. S2: Quality assurance of prefabricated products: Controlling the selection, inspection and storage of raw materials, and implementing quality control at multiple stages of processing; S3: Precise positioning of embedded parts and binding of steel bars: The embedded parts (5) are positioned using positioning fixture (4), and the embedded parts (5) are bound together with the steel bars. When binding the steel bars, a separable steel bar jig is used for positioning and binding of the steel bars. S4: Concrete inverted pouring: First, determine the concrete mix ratio and prepare the concrete. Then, mix the concrete and transport it to the construction site. Next, pour and vibrate the concrete. Finally, conduct quality testing on the concrete. S5: Large component flipping: The component is flipped using a chain-type flipping device in conjunction with a soft connection protection device; S6: Construction Management: Real-time sharing and self-inspection of construction information improves collaborative work efficiency and resource utilization.

2. The prefabrication process for assembled bridge deck facilities according to claim 1, characterized in that: Step S1 involves refining the processing flow and establishing standards, including breaking down the processing process into multiple operation steps according to quality requirements, determining the operation standards, quality requirements, and responsible persons for each operation step, and creating a standardized operation manual. Based on the standardized operation manual, the operation flow and quality standards are determined. In the personnel division of labor and collaboration optimization described in step S1, the personnel division of labor is to determine the construction positions and work scope based on the skill level of the construction personnel. The construction positions include processing and manufacturing positions and quality supervision positions. The collaboration optimization is to discuss problems and determine solutions based on construction meetings.

3. The prefabrication process for assembled bridge deck facilities according to claim 1, characterized in that: The inspection of raw materials in step S2 includes checking the specifications, models, quality certificates, and sampling tests of the physical properties and chemical composition of the raw materials. The raw materials are stored according to their type, specifications, and batches, and the storage area is protected. The multiple steps mentioned in step S2 include the rebar tying step, the concrete pouring step, and the curing step after the concrete pouring is completed.

4. The prefabrication process for assembled bridge deck facilities according to claim 1, characterized in that: The positioning fixture (4) mentioned in step S3 includes a slot and a fixing device designed according to the shape of the embedded part. The embedded part (5) includes a U-bolt (6) and an embedded steel plate (7). The positioning fixture (4) ensures the positional accuracy of the embedded part (5) through the slot and the fixing device. The separable rebar jig mentioned in step S3 includes a positioning pile and a positioning groove (3). Two adjacent jigs are positioned by the positioning pile. The positioning groove (3) is used to position the rebar and fix it with a buckle. The jigs are separated after binding.

5. The prefabrication process for assembled bridge deck facilities according to claim 1, characterized in that: In step S4, the concrete mix proportion is 350 kg / m³ of silicate cement, the aggregate content includes 1100 kg / m³ of crushed stone and 700 kg / m³ of medium sand, and the admixture is a high-efficiency water-reducing agent, the dosage of which is 1.5% of the cement content. The concrete mixing time is 120 seconds, and the transportation time is controlled within 10 minutes; The concrete pouring method is end-to-end step-by-step pouring, with a pouring speed of 3~5m³ / h, and the vibration method is to vibrate each point for 15~20 seconds. The quality testing includes slump and air content testing, and performance tests are conducted on the concrete test blocks.

6. The prefabrication process for assembled bridge deck facilities according to claim 1, characterized in that: The chain-type flipping device described in step S5 includes a gear reducer and a soft protective pad. The component is protected before flipping, and the component status is monitored by sensors during the flipping process.

7. The prefabrication process for assembled bridge deck facilities according to claim 1, characterized in that: The process also includes concrete curing, which uses steam curing to ensure that the concrete demolding strength reaches more than 70% of the design strength.

8. The prefabrication process for assembled bridge deck facilities according to claim 1, characterized in that: The binding points of the detachable rebar clamp adopt the figure-eight cross binding method to ensure a firm binding.

9. The prefabrication process for assembled bridge deck facilities according to claim 1, characterized in that: During the concrete pouring process, the slump and air content are tested at least once for every 100 cubic meters of concrete, and test blocks are made for mechanical property testing.

Images