Production system of beam plate

Abstract

The utility model provides a production system of a beam plate, which comprises a pre-processing area used for forming a steel bar frame of the beam plate; the beam plate pouring area is used for pouring concrete according to the steel bar frame to form a beam plate; the beam and slab curing area comprises a high-temperature steam curing area, a standard curing area and a tension grouting area.

Description

Technical Field

[0001] This utility model belongs to the field of bridge beam and slab prefabrication technology, and in particular relates to a beam and slab production system. Background Technology

[0002] As the main load-bearing part and key structure of a bridge, the production efficiency of bridge beams directly affects the efficiency and cost of bridge construction, and the quality of bridge beams is related to the operation and maintenance costs of the completed bridge.

[0003] Traditional precast beam yard production facilities suffer from drawbacks such as large yard area, lax reinforcement installation, insufficient concrete compaction, excessive curing time before beam tensioning, long formwork occupation period, and easy chipping of edges and corners during formwork removal. In traditional beam production, the quality, safety, and progress of beams and slabs are mainly controlled manually, requiring high levels of expertise from management personnel and skilled workers, and the production methods are relatively outdated.

[0004] How to improve quality and efficiency in the prefabrication process of bridge beams has become an urgent problem to be solved in the production and construction of bridge prefabricated beams. Utility Model Content

[0005] This utility model provides a beam and slab production system that can improve beam and slab quality and production efficiency while reducing labor costs. It includes:

[0006] Pre-processing area, used to form the steel reinforcement frame for beams and slabs;

[0007] The beam and slab pouring area is used for pouring concrete according to the steel frame to form beams and slabs.

[0008] The beam and slab curing area includes a high-temperature steam curing area, a standard curing area, and a tensioning and grouting area.

[0009] Optionally, the pre-processing area includes a steel bar processing area, a material storage area, a horizontal bar storage area, a corrugated pipe processing area, and a steel bar binding area.

[0010] Optionally, the beam-slab casting zone includes:

[0011] The inner formwork installation area is used to install the inner formwork for the steel frame;

[0012] The formwork installation and concrete pouring area is used to install the outer formwork for the steel frame and to pour concrete.

[0013] A batching plant, used to produce concrete;

[0014] The torpedo tank traveling area is used to transport the concrete produced by the mixing plant to the formwork installation and concrete pouring area.

[0015] Optionally, an integral hydraulic stainless steel formwork and a concrete placing boom are installed in the formwork installation and concrete pouring area.

[0016] Optionally, the torpedo can travel area is equipped with a fixed circular track and torpedo cans.

[0017] Optionally, the high-temperature steam curing area is equipped with a fixed high-temperature steam curing shed, a high-temperature steam generator, and steam pipelines.

[0018] Optionally, the standard curing area is equipped with a standard curing shed and a sprinkler system.

[0019] Optionally, environmental monitoring components are installed in the standard curing area and the high-temperature steam curing area. The environmental monitoring components include a temperature monitoring unit and a humidity monitoring unit.

[0020] Optionally, a CNC tensioning machine and a circulating grouting device are provided in the tensioning and grouting zone.

[0021] Optionally, the beam production system also includes: a moving platform, a moving platform forward track, a moving platform transverse track, and a moving platform return track.

[0022] The beneficial effects of the technical solution provided by this utility model are:

[0023] This invention enables the systematic production of beams and slabs through a production system. Furthermore, the systematic production of beams and slabs facilitates the control of parameters during the production process, improves the quality and production efficiency of the beams and slabs, and reduces labor costs. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0025] Figure 1 A structural schematic diagram of a beam and slab production system provided by this utility model;

[0026] Figure 2 A structural schematic diagram of a beam-slab casting area provided by this utility model;

[0027] Figure 3 A schematic diagram of the structure of the torpedo can travel area provided by this utility model;

[0028] Figure 4 A flowchart illustrating the manufacturing process of a beam slab provided for this utility model.

[0029] The attached figures are labeled as follows:

[0030] 1: Rebar processing area; 2: Material storage area; 3: Horizontal reinforcement storage area; 4: Corrugated pipe processing area; 5: Rebar binding area; 6: Inner formwork installation area; 7: Formwork installation and concrete pouring area; 8: Torpedo can traveling area; 9: High-temperature steam curing area; 10: Standard curing area; 11: Tensioning and grouting area; 12: Beam storage area; 13: Mixing plant; 14: Moving platform; 15: Moving platform forward track; 16: Moving platform lateral track; 17: Moving platform return track; 18: Lateral track;

[0031] 71: Integrated hydraulic stainless steel formwork; 72: Concrete placing boom; 81: Circular track; 82: Torpedo canister; 91: High-temperature steam curing shed; 92: High-temperature steam generator; 93: Steam pipeline. Detailed Implementation

[0032] To make the objectives, technical solutions, and advantages of this utility model clearer, the technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0033] See Figures 1 to 3 The present invention provides a beam and slab production system, comprising:

[0034] The pre-processing area is used to form the steel frame of beams and slabs; the pre-processing area includes: steel bar processing area 1, material stacking area 2, horizontal bar stacking area 3, corrugated pipe processing area 4, and steel bar binding area 5.

[0035] The beam and slab pouring area is used to pour concrete according to the steel frame to form beams and slabs. The beam and slab pouring area includes: inner formwork installation area 6, used to install inner formwork for the steel frame; formwork installation and concrete pouring area 7, used to install outer formwork for the steel frame and pour concrete; mixing plant 13, used to form concrete; and torpedo tank traveling area 8, used to transport the concrete formed by the mixing plant to the formwork installation and concrete pouring area.

[0036] The beam and slab curing area includes high-temperature steam curing area 9, standard curing area 10, and tensioning and grouting area 11;

[0037] Beam storage area 12 is used to store beams and slabs.

[0038] In this embodiment, an integral hydraulic stainless steel formwork 71 and a concrete placing boom 72 are installed in the formwork installation and concrete pouring area 7.

[0039] In this embodiment, the torpedo can travel area 8 is provided with a fixed annular track 81 and a torpedo can 82.

[0040] In this embodiment, a fixed high-temperature steam curing shed 91, a high-temperature steam generator 92, and a steam pipeline 93 are provided in the high-temperature steam curing zone.

[0041] In this embodiment, the standard curing area 10 is equipped with a standard curing shed and a sprinkler system.

[0042] In this embodiment, environmental monitoring components are installed in the standard curing area 10 and the high-temperature steam curing area. The environmental monitoring components include a temperature monitoring unit and a humidity monitoring unit. The temperature monitoring unit is a temperature sensor, and the humidity monitoring unit is a humidity sensor, which can realize temperature and humidity monitoring in the standard curing area and the high-temperature steam curing area.

[0043] In this embodiment, a CNC tensioning machine and a circulating grouting device are provided in the tensioning and grouting zone 11.

[0044] In this embodiment, the beam production system also includes: a moving platform 14, a moving platform forward track 15, a moving platform transverse track 16, a moving platform return track 17, and a transverse track 18.

[0045] In this embodiment, gantry cranes can be installed in the pre-processing area, beam and slab casting area, and beam and slab curing area to control the movement of beams and slabs in different areas.

[0046] This invention utilizes a mobile platform to achieve cyclical production of precast beams and slabs, and adopts an advanced synchronous system to automate the disassembly and assembly of templates. It breaks away from the traditional demolding process of hammering and prying, greatly reducing beam damage, reducing the number of workers and labor intensity, and significantly improving beam and slab production efficiency and finished product quality.

[0047] This invention uses a movable platform and track to achieve prefabrication cycle of beams and slabs, which greatly reduces the floor space and the number of platforms. It also uses a biomass generator and temperature control system to make beam and slab curing more precise.

[0048] This invention solves many problems existing in traditional beam and slab construction systems, greatly improves beam and slab production efficiency, reduces labor and time input, and improves the quality of finished products. This invention utilizes a torpedo-shaped container traveling on a circular track, connecting the mixing plant and the beam and slab pouring area, realizing the cyclical transportation of concrete from the mixing plant to the beam and slab pouring area, and allowing for manual control of the operation.

[0049] The high-temperature steam curing zone described in this invention uses a biomass steam generator to produce high-temperature steam, which is then transported to the high-temperature steam curing shed via a dedicated pipeline for 20 hours of steam curing of the beams and slabs. Temperature and humidity sensors installed inside the steam curing shed are used to monitor the humidity and temperature in real time.

[0050] The standard curing area described in this invention provides water vapor to maintain the humidity of the standard curing shed.

[0051] In the standard curing area described in this utility model, the water vapor temperature is artificially controlled within 20±3℃ based on the tested temperature inside the curing shed.

[0052] In the standard curing area described in this utility model, the beams and slabs are placed in the curing shed for 24 hours.

[0053] See Figure 4 This utility model provides a flowchart of the manufacturing process for a beam-slab, the manufacturing steps of which include:

[0054] In the rebar processing area, the rebar is fabricated and welded, and then transported to the rebar binding area via a transport channel.

[0055] The steel cage is tied on the steel reinforcement tying frame and then lifted to the movable platform in the inner formwork installation area using a 10T gantry crane.

[0056] After the inner formwork is installed, the moving platform is precisely moved along the forward track to the formwork installation and concrete pouring area. The outer formwork adopts an integral hydraulic stainless steel formwork and a torpedo can with a concrete placing machine for pouring. After the concrete reaches the set strength, the inner formwork is removed from the beginning of the pouring using a winch. After the concrete reaches another set strength, the outer formwork is removed using a hydraulic system.

[0057] After the formwork is removed, the mobile platform is moved along the travel track to the fixed steam curing shed. The constant temperature system supplies steam to the high-temperature steam curing shed for 20 hours through a biomass steam generator and a special pipeline, implementing automatic high-temperature steam curing of the beams and slabs. The humidity and temperature inside the curing shed are monitored in real time, so that the compressive strength of the concrete can reach 90% of the design strength after high-temperature steam curing.

[0058] After steam curing is completed, the mobile platform carrying the beam plate is moved along the travel track to the standard steam curing shed for 24 hours of curing.

[0059] After the standard curing shed is completed, the mobile platform is moved to the tensioning and grouting area along the running track. A CNC tensioning machine and intelligent circulating grouting equipment are used. After the tensioning and grouting is completed, the ends are sealed.

[0060] After the grouting strength of the precast beams reaches the design requirements, a 60T gantry crane is used to lift the beams to the storage area.

[0061] After the beam is hoisted to the beam storage area, the moving platform moves along the platform's transverse track to the return track, and then along the return track to the inner formwork installation area.

[0062] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and not to limit it. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model.

Claims

1. A beam and slab production system, characterized in that, include: Pre-processing area, used to form the steel reinforcement frame for beams and slabs; The beam and slab pouring area is used for pouring concrete according to the steel frame to form beams and slabs. The beam and slab curing area includes a high-temperature steam curing area, a standard curing area, and a tensioning and grouting area; The beam and slab pouring area includes: The inner formwork installation area is used to install the inner formwork for the steel frame; The formwork installation and concrete pouring area is used to install the outer formwork for the steel frame and to pour concrete. A batching plant, used to produce concrete; The torpedo tank travel area is used to transport the concrete produced by the mixing plant to the formwork installation and concrete pouring area; The formwork installation and concrete pouring area is equipped with integrated hydraulic stainless steel formwork and a concrete placing boom; The torpedo can travel area is equipped with a fixed circular track and torpedo cans; The high-temperature steam curing area is equipped with a fixed high-temperature steam curing shed, a high-temperature steam generator, and steam pipelines. The standard curing area is equipped with a standard curing shed and a sprinkler system; Environmental monitoring components are installed in the standard curing area and the high-temperature steam curing area. The environmental monitoring components include temperature monitoring units and humidity monitoring units. The tensioning and grouting zone is equipped with a CNC tensioning machine and a circulating grouting device. The beam and slab production system also includes: a moving platform, a moving platform forward track, a moving platform transverse track, a moving platform return track, and a transverse track.

2. The beam and slab production system according to claim 1, characterized in that, The pre-processing area includes a steel bar processing area, a material storage area, a horizontal bar storage area, a corrugated pipe processing area, and a steel bar binding area.

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