Light-weight I-beam production line prestressed pier and mold

Abstract

The utility model relates to the production technology field of light I -beam, specifically relates to a light I -beam production line prestress pier and mould to solve the current light I -beam production line beam prestress first tension, due to the poor stability of prestress pier base, and single mould and prestress pier are difficult to adapt to light I -beam production of different cross section and length size, it is easy to lead to the neutral bad of steel strand and mould, finally influence light I -beam prefabricated production efficiency and structure quality problem. The structure is composed of main, passive prestress pier and the pouring mould of adjustable length between them, the main, passive prestress pier is fixed on the ground, and the part of its protruding ground is provided with steel strand perforation, and the passive prestress pier is provided with the top and bottom tension steel beam of steel strand pulling sliding at the place, after the drive tension of steel strand at the initiative prestress pier, the displacement and limit of passive prestress pier are driven, and then the tension steel beam is pushed and released by the oil cylinder, effectively ensure the efficient safe first tension and pouring prefabrication of the multiple demand light I -beam.

Description

Technical Field

[0001] This utility model relates to the field of light I-beam production technology, specifically to a prestressed pier and mold for a light I-beam production line. Background Technology

[0002] As a new type of bridge structure, lightweight I-beams have been widely used in highways, municipal engineering, and other fields in recent years. Especially driven by UHPC (ultra-high performance concrete) material technology, they have shown significant advantages and development potential, including lightweight, efficient construction, and high strength and durability. In the industrial production of lightweight I-beams, prestressed production technology is generally adopted, with centralized factory prefabrication, which makes the quality more stable and controllable. This avoids problems such as grouting in post-tensioned prestressed construction, which is in line with the concept of green and low-carbon development. Therefore, the quality control of prestressed concrete has an important impact on the overall manufacturing quality and application safety of lightweight I-beams. Currently, most prestressed pretensioning processes for lightweight I-beams utilize ground-fixed tensioning structures, which suffer from poor tensioning support, thus affecting the technical requirements for steel strand tensioning. Furthermore, the tensioning structure layout is relatively simple, resulting in poor mold adjustment flexibility and matching when prestressing various types of I-beams, and is time-consuming and labor-intensive, making it difficult to meet the prefabrication needs of multi-size I-beams. Therefore, it is necessary to further optimize the prestressed production line structure for lightweight I-beams to ensure overall production efficiency, safety, and overall structural quality. Utility Model Content

[0003] This utility model provides a prestressed pier and mold for a light I-beam production line, in order to solve the problems mentioned above. In the current process of prestressing beams in light I-beam production lines, the stability of the prestressed pier is poor, and a single mold and prestressed pier are difficult to adapt to the production of light I-beams with different cross-sections and lengths. This easily leads to poor alignment between the tensioned steel strands and the mold, ultimately affecting the overall prefabrication production efficiency and structural quality of the light I-beams.

[0004] To achieve the above objectives, the present invention adopts the following technical solution: A prestressed pier and mold for a lightweight I-beam production line includes an active prestressed pier and a passive prestressed pier set in a ground foundation pit, with both the active and passive prestressed piers extending out of the ground. An I-beam casting mold is fixed on the ground between the active and passive prestressed piers.

[0005] The active prestressed pier includes a back plate, and the portion of the back plate extending out of the ground has multiple first through holes spaced apart for steel strands to pass through.

[0006] The passive prestressed pier includes a first mounting seat and a second mounting seat arranged symmetrically. Both the first mounting seat and the second mounting seat extend beyond the ground. From top to bottom, a top tensioning steel beam and a bottom tensioning steel beam are slidably provided on the side of the first mounting seat and the second mounting seat. A second hydraulic cylinder is fixed between the top tensioning steel beam and the first mounting seat and the second mounting seat. A first hydraulic cylinder is fixed between the bottom tensioning steel beam and the first mounting seat and the second mounting seat. Multiple second through holes for steel strands to pass through are also opened on the top tensioning steel beam and the bottom tensioning steel beam, corresponding to the first through hole.

[0007] The casting mold includes a bottom mold fixed on the ground, side molds symmetrically rotated on both sides of the bottom mold, modular core molds detachably connected to the inner side of each side mold, a second lead screw adjustable between the tops of the side molds, and multiple end molds clamped inside the side molds.

[0008] Furthermore, the back plate has side plates with steel strands running through them evenly spaced on its sides.

[0009] Furthermore, the first mounting base and the second mounting base are provided with a second slide rail and a first slide rail respectively from top to bottom on the side portions extending out of the ground. The first slide rail is set on the ground. The top tension steel beam and the second slide rail are slidably connected. The bottom tension steel beam and the first slide rail are slidably connected.

[0010] Furthermore, a plurality of second stop blocks are provided between the top tensioning steel beam and the cylinder body of the second hydraulic cylinder, and a plurality of first stop blocks are provided between the bottom tensioning steel beam and the cylinder body of the first hydraulic cylinder.

[0011] Furthermore, each end of the first slide rail away from the first mounting base is connected to a crossbeam, an adjusting sleeve is fixedly provided on the crossbeam, an adjusting rod is rotatably provided inside the adjusting sleeve, and the adjusting rod is tightly attached to the ground. A pump station is also provided on the side of the crossbeam.

[0012] Furthermore, mounting plates are fixedly provided on the sides of both the first and second mounting seats, and the second slide rail is fastened to both the first and second mounting seats by a first lead screw.

[0013] Furthermore, a first connecting plate is fixedly provided on the side of the bottom mold, and a second connecting plate is fixedly provided on the bottom of the side mold, and the first connecting plate and the second connecting plate are rotatably connected by a pin.

[0014] Furthermore, each of the side molds is fixedly provided with a third mounting base, and the second lead screw and the third mounting base are rotatably connected. Each of the side molds can also be adjusted to be connected with a support rod.

[0015] Furthermore, multiple anchors are also matched and installed on both the first and second perforations.

[0016] This utility model has the following beneficial effects: This utility model provides a prestressed pier and mold for a light I-beam production line. It consists of active and passive prestressed piers and an adjustable casting mold between them. Both active and passive prestressed piers are fixed to the ground, with steel strand through-holes at their ground-extension parts. Top and bottom tensioning steel beams pulled by steel strands are slidably installed at the passive prestressed piers. The steel strands are driven and tensioned at the active prestressed piers, which drives the displacement and limiting of the passive prestressed piers. Then, the tensioning steel beams are pushed and released by hydraulic cylinders. This effectively ensures efficient and safe prestressing and casting prefabrication of light I-beams with multiple requirements. It solves the problem that in the current process of prestressing beams in light I-beam production lines, the stability of the prestressed pier platform is poor, and a single mold and prestressed pier are difficult to adapt to the production of light I-beams with different cross-sections and lengths. This easily leads to poor alignment between the tensioning steel strands and the mold, which ultimately affects the overall prefabrication production efficiency and structural quality of the light I-beams.

[0017] Both the active and passive prestressed piers of this invention are partially buried and fixed in the ground pit, which effectively ensures the overall structural stability of the prestressed pier during the tensioning of the steel strands. This greatly ensures the accuracy of the prestress data of the steel strands after the I-beam is poured, thereby effectively improving the preparation quality of the precast lightweight I-beam.

[0018] In this invention, stop pads are arranged between the bottom tensioning steel beam, the top tensioning steel beam, and the cylinder body of the hydraulic cylinder. This prevents the tensioning steel beam from being directly squeezed against the hydraulic cylinder when tensioning the steel strand from the active prestressed pier. This effectively avoids overall damage to the release hydraulic cylinder and its installation structure during the tensioning process, thereby improving the service life of the pre-tensioned structure and the safety of pre-tensioning production.

[0019] The first slide rail of this utility model is connected to an adjusting rod and an adjusting sleeve at both ends. When the adjusting rod is rotated and pressed to the ground, the elevation of the first slide rail can be effectively adjusted and fixed by the adjusting rod. This achieves the purpose of pre-tensioning and prefabricating light I-beams of various elevation models by matching the tensioning steel strands, and effectively improves the application practicality of prestressed piers and molds in the light I-beam production line.

[0020] The side mold of this utility model is composed of a side mold frame and a modular core mold. Both the modular core mold and the side mold frame are assembled from multiple segments. The modular core mold has an internal arc shape. The side mold frame is installed on the bottom mold by hinges, and the modular core mold is installed on the side mold frame by bolts. The advantage of the modular core mold is that different cross-sections of the modular core mold can be replaced in time according to production needs, thereby achieving efficient casting of light I-beams of different specifications. Attached Figure Description

[0021] Figure 1This is a schematic diagram of the overall structure of this utility model.

[0022] Figure 2 This is a schematic diagram of the overall structure of the passive prestressed pier of this utility model.

[0023] Figure 3 This is a schematic diagram of the overall structure of the active prestressed pier of this utility model.

[0024] Figure 4 This is a schematic cross-sectional view of the overall structure of the casting mold of this utility model.

[0025] The meanings of the reference numerals in the attached figures are as follows: 1. Ground; 2. Active prestressed pier; 3. Passive prestressed pier; 4. Back plate; 5. First perforation; 6. Anchor; 7. Side plate; 8. First mounting seat; 9. Second mounting seat; 10. First slide rail; 11. Second slide rail; 12. Bottom tensioning steel beam; 13. Top tensioning steel beam; 14. Second perforation; 15. First hydraulic cylinder; 16. Second hydraulic cylinder; 17. First stop pad; 18. Second stop pad; 19. Crossbeam; 20. Adjusting sleeve; 21. Adjusting rod; 22. Pump station; 23. Mounting plate; 24. First lead screw; 25. Bottom formwork; 26. Side formwork; 27. First connecting plate; 28. Second connecting plate; 29. ​​Third mounting seat; 30. Second lead screw; 31. End formwork; 32. Support rod; 33. Steel strand; 34. Foundation pit; 35. Modular core mold. Detailed Implementation

[0026] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0027] like Figure 1-4 As shown, a prestressed pier and mold for a lightweight I-beam production line includes an active prestressed pier 2 and a passive prestressed pier 3 set in a foundation pit 34 in the ground 1. Both the active prestressed pier 2 and the passive prestressed pier 3 extend out of the ground 1. An I-beam casting mold is fixed on the ground 1 between the active prestressed pier 2 and the passive prestressed pier 3.

[0028] The active prestressed pier 2 includes a back plate 4, and the portion of the back plate 4 extending out of the ground 1 is provided with multiple first through holes 5 for steel strands 33 to pass through.

[0029] The passive prestressed pier 3 includes a first mounting seat 8 and a second mounting seat 9 symmetrically arranged. Both the first mounting seat 8 and the second mounting seat 9 extend out of the ground 1. The sides of the first mounting seat 8 and the second mounting seat 9 extending out of the ground 1 are sequentially provided with a top tensioning steel beam 13 and a bottom tensioning steel beam 12 from top to bottom. A second hydraulic cylinder 16 is fixed between the top tensioning steel beam 13 and the first mounting seat 8 and the second mounting seat 9. A first hydraulic cylinder 15 is fixed between the bottom tensioning steel beam 12 and the first mounting seat 8 and the second mounting seat 9. Multiple second through holes 14 corresponding to the first through hole 5 are also provided on the top tensioning steel beam 13 and the bottom tensioning steel beam 12 for the steel strands 33 to pass through.

[0030] The casting mold includes a bottom mold 25 fixedly set on the ground 1, side molds 26 symmetrically rotated on both sides of the bottom mold 25, modular core molds 35 connected to the inner side of each side mold 26 by bolts, a second lead screw 30 adjustable between the tops of the side molds 26, and multiple end molds 31 also clamped on the inner side of the side molds 26.

[0031] The back plate 4 has side plates 7 with steel strands 33 evenly distributed at intervals on its side.

[0032] The first mounting base 8 and the second mounting base 9 are provided with a second slide rail 11 and a first slide rail 10 detachably from top to bottom on the side of the part extending out of the ground 1. The first slide rail 10 is set on the ground 1. The top tension steel beam 13 is slidably connected to the second slide rail 11, and the bottom tension steel beam 12 is slidably connected to the first slide rail 10.

[0033] Multiple second stop blocks 18 are provided between the top tensioning steel beam 13 and the cylinder body of the second hydraulic cylinder 16, and multiple first stop blocks 17 are provided between the bottom tensioning steel beam 12 and the cylinder body of the first hydraulic cylinder 15.

[0034] The ends of the first slide rail 10 away from the first mounting base 8 are all connected to a crossbeam 19. An adjusting sleeve 20 is fixedly provided on the crossbeam 19. An adjusting rod 21 is rotatably provided inside the adjusting sleeve 20. The adjusting rod 21 is tightly attached to the ground 1. A pump station 22 is also provided on the side of the crossbeam 19.

[0035] Mounting plates 23 are fixedly provided on the sides of the first mounting base 8 and the second mounting base 9, and the second slide rail 11 is fastened to the first mounting base 8 and the second mounting base 9 by the first lead screw 24.

[0036] The bottom mold 25 is fixedly provided with a first connecting plate 27 on its side, and the bottom of the side mold 26 is fixedly provided with a second connecting plate 28, and the first connecting plate 27 and the second connecting plate 28 are rotatably connected by a pin.

[0037] The top of each side mold 26 is fixedly provided with a third mounting base 29, and the second lead screw 30 and the third mounting base 29 are rotatably connected. The side of each side mold 26 can also be adjusted to be connected with a support rod 32.

[0038] Multiple anchors 6 are also matched and installed on both the first perforation 5 and the second perforation 14.

[0039] In practical application, the foundation pit 34 is pre-marked and positioned by site surveying. Then, the pre-welded and installed active prestressed piers 2 and passive prestressed piers 3 are embedded into the foundation pit 34. The lightweight I-beam casting mold, composed of bottom mold 25, side mold 26, and end mold 31, is installed correctly. After checking that all indicators such as elevation and axis are satisfactory, the first slide rail 10, with its first hydraulic cylinder 15, second hydraulic cylinder 16, bottom tensioning steel beam 12, and top tensioning steel beam 13 installed, is rotated... The adjusting rods 21 at both ends are moved so that the first slide rail 10 is moved to the required elevation position for the light I-beam. Then the adjusting rods 21 are locked by the pin, and the second slide rail 11 is adjusted by the clamping of the mounting plate 23 and the first screw 24 so that its elevation meets the casting requirements. This ensures that the steel strands 33 in the second through hole 14 of the bottom tensioned steel beam 12 and the top tensioned steel beam 13 meet the preset casting size and that the first through hole 5 of the active prestressed pier 2 is penetrated. Then, the pre-tensioning of steel strand 33 is carried out. Before tensioning a single steel strand 33, the piston rods of the first hydraulic cylinder 15 and the second hydraulic cylinder 16 are first extended to 80-90% of their stroke, pushing the bottom tensioning steel beam 12 and the top tensioning steel beam 13 to the preset position. Then, the first stop pad 17 and the second stop pad 18 are placed at the front end of the cylinder body between the first hydraulic cylinder 15 and the second hydraulic cylinder 16 and the bottom tensioning steel beam 12 and the top tensioning steel beam 13, respectively. Then, the pump station 22 is started to retract the piston rod of the hydraulic cylinder by 10-15mm, so that the first The stop pad 17 and the second stop pad 18 are subjected to force, while the cylinder bodies of the first cylinder 15 and the second cylinder 16 are not directly subjected to force. Then, the steel strand 33 is passed through the first through hole 5 and the second through hole 14. The steel strand 33 extending from the back plate 4 of the active prestressed pier 2 is connected to the tensioning power equipment and tensioned to the preset tension requirement. After tensioning, the steel strand 33 is first locked by the anchor 6 and the tensioning power equipment is removed. Then, UHPC high-performance concrete is poured into the light I-beam mold in sequence and the light I-beam is poured and cured.After maintenance, the tensioning operation is carried out. First, the piston rods of the first hydraulic cylinder 15 and the second hydraulic cylinder 16 are driven by the pump station 22 to extend 20-25mm further to ensure that the first stop pad 17 and the second stop pad 18 are no longer under force and are loose. Then, the first stop pad 17 and the second stop pad 18 are removed. Then, the pump station 22 is restarted. Under the tension of the steel strand 33, the first hydraulic cylinder 15 and the second hydraulic cylinder 16 discharge oil, and the bottom tensioning steel beam 12 and the top tensioning steel beam 13 are moved to the side closer to the light I-beam mold until the internal stress of the unwound part of the steel strand 33 is completely relaxed. After the tensioning is completed and the steel strand 33 is in a relaxed state, the steel strand 33 located between the two beams is cut with an abrasive wheel saw. The cutting sequence is from the top tensioning steel beam. The steel strands 33 of beam 13 are tensioned to the bottom of the steel strands 33 of beam 12. Furthermore, the side formwork 26 is composed of the frame of the side formwork 26 and the modular core mold 35. Both the modular core mold 35 and the frame of the side formwork 36 are assembled from multiple segments. The frame of the side formwork 26 is installed on the bottom formwork 25 by hinges, and the modular core mold 35 is installed on the frame of the side formwork 26 by bolts. The advantage of the modular core mold 35 is that it can be replaced with different sections of the modular core mold 35 in real time according to production needs, thereby realizing the efficient casting of light I-beams of different specifications. This completes the entire pre-tensioning and casting prefabrication production process of light I-beams, which greatly ensures the efficiency, universality and safety of its production. Therefore, the prestressed pier and mold structure of this light I-beam production line has good practicality.

Claims

1. A prestressed pier and mold for a lightweight I-beam production line, characterized in that: It includes active prestressed piers (2) and passive prestressed piers (3) set in the foundation pit (34) on the ground (1), and both active prestressed piers (2) and passive prestressed piers (3) extend out of the ground (1). I-beam casting molds are fixed on the ground (1) between the active prestressed piers (2) and passive prestressed piers (3). The active prestressed pier (2) includes a back plate (4), and the part of the back plate (4) extending out of the ground (1) is provided with a plurality of first through holes (5) for steel strands (33) to pass through. The passive prestressed pier (3) includes a first mounting seat (8) and a second mounting seat (9) arranged symmetrically. Both the first mounting seat (8) and the second mounting seat (9) extend out of the ground (1). The side of the first mounting seat (8) and the second mounting seat (9) extending out of the ground (1) is provided with a top tensioning steel beam (13) and a bottom tensioning steel beam (12) slidably from top to bottom. A second hydraulic cylinder (16) is fixed between the top tensioning steel beam (13) and the first mounting seat (8) and the second mounting seat (9). A first hydraulic cylinder (15) is fixed between the bottom tensioning steel beam (12) and the first mounting seat (8) and the second mounting seat (9). Multiple second through holes (14) for steel strands (33) to pass through are also opened on the top tensioning steel beam (13) and the bottom tensioning steel beam (12) corresponding to the first through hole (5). The mold includes a bottom mold (25) fixedly set on the ground (1), side molds (26) are symmetrically rotated on both sides of the bottom mold (25), modular core molds (35) are detachably connected to the inner side of the side molds (26), a second lead screw (30) is adjustable between the top of the side molds (26), and multiple end molds (31) are also clamped on the inner side of the side molds (26).

2. The prestressed pier and mold for a lightweight I-beam production line according to claim 1, characterized in that: The back plate (4) has side plates (7) with steel strands (33) evenly spaced on its side.

3. The prestressed pier and mold for a lightweight I-beam production line according to claim 1, characterized in that: The first mounting base (8) and the second mounting base (9) are provided with a second slide rail (11) and a first slide rail (10) detachably from top to bottom on the side of the first mounting base (8) and the second mounting base (9) extending out of the ground (1). The first slide rail (10) is set on the ground (1). The top tension steel beam (13) is slidably connected to the second slide rail (11). The bottom tension steel beam (12) is slidably connected to the first slide rail (10).

4. The prestressed pier and mold for a lightweight I-beam production line according to claim 3, characterized in that: Multiple second stop blocks (18) are provided between the top tensioning steel beam (13) and the cylinder body of the second oil cylinder (16), and multiple first stop blocks (17) are provided between the bottom tensioning steel beam (12) and the cylinder body of the first oil cylinder (15).

5. The prestressed pier and mold for a lightweight I-beam production line according to claim 3, characterized in that: The ends of the first slide rail (10) away from the first mounting base (8) are all connected to a crossbeam (19). An adjusting sleeve (20) is fixedly provided on the crossbeam (19). An adjusting rod (21) is rotatably provided inside the adjusting sleeve (20). The adjusting rod (21) is tightly attached to the ground (1). A pump station (22) is also provided on the side of the crossbeam (19).

6. The prestressed pier and mold for a lightweight I-beam production line according to claim 5, characterized in that: The first mounting base (8) and the second mounting base (9) are both fixedly provided with mounting plates (23), and the second slide rail (11) is fastened to the first mounting base (8) and the second mounting base (9) by the first lead screw (24).

7. The prestressed pier and mold for a light I-beam production line according to claim 1, characterized in that: The bottom mold (25) is fixedly provided with a first connecting plate (27) on its side, and the bottom of the side mold (26) is fixedly provided with a second connecting plate (28), and the first connecting plate (27) and the second connecting plate (28) are rotatably connected by a pin.

8. The prestressed pier and mold for a lightweight I-beam production line according to claim 7, characterized in that: The top of each side mold (26) is fixedly provided with a third mounting seat (29), and the second lead screw (30) and the third mounting seat (29) are rotatably connected. The side of each side mold (26) can also be adjusted to be connected with a support rod (32).

9. The prestressed pier and mold for a lightweight I-beam production line according to claim 1, characterized in that: Multiple anchors (6) are also matched on the first perforation (5) and the second perforation (14).

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