桥梁施工用墩柱模板预制梁使用节段箱梁模板加工
¥56.00
水泥入口岛模板 路口收费岛模具 鑫鑫预制 拼装式道闸岛钢模板
¥480.00
钢筋混凝土预制房模板 鑫鑫水泥移动房模具 拼装房钢模板
¥4750.00
预制圆柱模板拼装组合-佰程水泥圆柱桥梁墩模具细节设计
¥80.00
青海拼装预制模板定制加工水泥浇筑欣嘉诚
¥55.00
1、主要技术内容
预制箱梁模板具有精度高、结构简单、整体缩放自如、脱模容易、操作简单，可以整体吊装或拖拉到制梁台位上，待预制混凝土达到脱模强度后整体或分段脱模，将内模拖拉出已预制成型的箱梁内腔，操作人员安装及调试方便，劳动强度低，生产效***。
1. Technique Content
Precast girder formwork has advantages of high-precision, simple structure,retractile,easy-demoulding and simple operation. It can be hoisted or dragged to casting site integrally, and demoulded integrally or piecemeal after concrete achieving the strength, then pull out the inner mould from the girder. It is handy installing and debugging, low labor intensity, and high efficient.
（1）预制箱梁模板设计技术
按梁体结构、跨度、梁场布置对预制箱梁模板进行总体结构设计、模板整体受力分析，模拟内模运动轨迹对模板脱模机构进行设计。
内模整体结构、连接件、内模支撑系统、液压系统、脱模机构、轨道系统以及内模分节设计，确保箱梁预制后可整体或分段从梁端拖出。
外模整体结构、走行方式、外模支撑系统、整平机轨道、振动器的布置、爬梯、护栏等设计。
内外模在设计分节时均需考虑到运输方案，不同跨度时共用同一套模板
模板面板的选择：底模、端模选用12mm的钢板、外侧模、内模选用8mm的钢板。
(1) Design technique of precasting girder mould
The mould is integrated designed and stress analyzed in concordance with the girder structure,girder span and arrangement of the casting site.The demoulding mechanism is designed by simulating the trajectory of the inner mould.
The girder’s integrally or piecemeal pulling out of mould after precasting is ensured by inner mould structure, connectors, inner mould support system, hydraulic system, demoulding mechanism,guideway system and the segmental design of inner mould.
The design of outer mould structure, way of locomotion, support system of outer mould,pathway of temper mill, disposal of oscillator,stair and rail.
Transport scheme should be considered when design the inner and outer mould segmentation. The applicability of the mould to different girder span .
The material selection: 12mm steel plate for bottom mould and end mould;8mm steel plate for lateral mould and inner mould.
（2）预制箱梁模板构造
1）预制箱梁模板由外侧模、端模、底模和内模组成，见图4.13.1。
(2)The structure of precasting-girder formwork
1）Precasting-girder formwork consists of later mould, end mould, bottom mould and inner mould. Shown as picture 4.13.1
图4.13.1 预制箱梁模板
2）外侧模有固定式和沿台座纵向移动式两种。
3）端模在结构上分外包端、端包外两种。每个端模一般为便于运输分成若干段，现场连接成整体。
4）底模分为固定式底模及带活动段底模，固定式底模用于采用提梁机提梁场合，带活动段底模用于移梁机移梁场合。
5）内模按结构形式分为主梁上置式、主梁下置式和无梁式。按脱模方式分为分段脱模和整体脱模两种。按自动化程度分机械脱模式和液压脱模式。液压内模主要由模板、主梁、支撑千斤、托架、液压控制系统等部分组成。
2）There are two kinds of lateral mould: stationary type and longitudinal slipping type.
3)End mould is structurally divided into **type and ****type.The end mould will be splitted into segments to transport and assembled on casting site.
4)There are two kinds of bottom mould: stationary type and partial-movable type.Stationary type is always used for casting site with beam hoist and partial-movable suits to the site with bridge crane.
5)Inner mould is divided into beam-above type, beam-below type and no-beam type by structure; integrally-demoulding type and piecemeal-demoulding type by demoulding way; mechanically-demoulding type and hydraulic-demoulding type by automation. Hydraulic mould consists of template, main beam, lifting jack, bracket and hydraulic controlling system.
（3）箱梁模板加工工艺流程
模板采用工厂化加工，分段、分块或整体加工可由厂家根据自己的条件决定，其加工工艺流程如下：
(3)Girder formwork production process
（4）箱梁模板安装
1）底模的安装：在混凝土台座上从中往两端逐块安装，预拱值按二次抛物线进行设置，固定在台座上
2）外侧模安装：侧模由模板、纵向桁架、横向桁架、连接螺栓、移模托架小车、护栏、梯子、支撑螺旋顶等组成。外模分节制造，经试拼合格后再焊接成整体。纵移式外侧模立模时，利用卷扬机将侧模通过移模小车牵引到***的台座与底模相对应的位置（为******对位，卷扬机司机要密切和指挥者的联系，听从指挥人员的指挥。当小范围对位时，可利用螺旋顶作业），螺旋顶两端同步推动侧模与底模接触。横向就位后，再利用螺旋顶调整外模高度，顶升侧模至设计标高，然后用连接螺栓固定侧模与底模。通过测量，侧模线型与梁体线型一致，安装所有的螺栓和螺杆。
(4)Girder Mould Assembly
1)Bottom Mould Assembly: Assemble and fix on the concrete pedestal piece by piece from the center to both ends.Set the pre-camber value per quadratic parabola.
2)Outer Lateral Mould Assembly: Lateral mould consists of moulding plate,longitudinal truss, horizontal truss,connecting bolt,trolley,rail, stair,spiral ejection pin etc.Outer mould is welded into a whole after sectional manufacturing and qualified assembly testing.When erecting the outer lateral mould, drag the mould to the pedestal-mould-joint position by winch pulling the trolley. Then, use spiral ejection pin to push the lateral mould from both sides to contact the bottom mould.After horizontally positioning finished, adjust the outer mould vertically to the designed height by spiral ejection pin, then screw up the outer mould and bottom mould. Make sure the mould alignment is suited to the bridge alignment,then screw up all the bolts and nuts.
3）内模安装：内模采用工厂分块加工现场拼装成整体的方案，拼装后的内模满足门吊整体吊装和整体滑移的使用。内模板装在主梁上，由设在主梁上的液压泵站通过胶管提供液压源，操纵手动换向阀，控制模板油缸伸缩，驱动内模板按照下侧模、上侧模、顶模的动作顺序依次撑开到达工作位置，将内模整体滑移到制梁台座的钢筋笼内。为***腹板厚度，防止灌注混凝土时内模左右移动，将内模与侧模通过通风孔处钢套筒螺栓联结，内模拼装完毕后检查腹板的厚度，不可因模板偏向一侧而使腹板的厚度改变。
3) Inner Mould Assembly: The inner mould is manufactured segmentally in factory and assembled together on the casting site, and it should apply to gantry crane and integrity sliding. The inner mould is attached to the main beam, and flexed by controlling the hand reversing lever, which using the hydraulic power provided by a hydraulic pump on main beam through rubber tube.Control the inner mould to distract bottom lateral mould,top lateral mould and top mould orderly, then glide the inner mould into rebar cage. Connect the inner mould and lateral mould by telescopic screw through the vent, in order to keep the inner mould from swaying when pouring the concrete and ensure the thickness of the web plate.Check the thickness of the web plate after assembling, and make sure it is not changed due to laterodeviation.
4) 端模安装：端模为分体制作。端模板进场后对其进行全面的检查,***其预留孔偏离设计位置不大于3mm。端模安装前，先检查板面是否平整光洁，有无凹凸变形及残余粘浆，端模管道孔眼是否清除干净。用门吊使端模板就位，依次将橡胶抽拔管穿过相对的端模孔慢慢就位，因管道较多，安装模型时应特别注意不要将橡胶抽拔管挤弯，否则会造成端部有死弯。使端模中线与底模中线重合，调整端模到垂直位置，上紧所有紧固件。端模安装完成后，再次逐根检查橡胶管是否处于设计位置。另一方面要注意锚垫板在对位时避免顶撞钢筋骨架，以免引起支座板移位。
4) End Mould Assembly: End mould is manufactured segmentally.Check the top mould overall on the casting site to make sure the deviation of the drilled hole is less than 3mm.Before assembling, check the plate for smoothness, deformation, mucilage relict and the neatness of pipeline perforation. Set the end mould to position by gantry crane, and put the rubber extract pipe through the corresponding hole, paying attention not to bend the pipe due to the variety of pipes.Superpose the midlines of end mould and bottom mould.Plumb the end mould and screw up all the fasteners.Recheck the rubber pipes at designed position or not.Do not crash the rebar skeleton when setting the anchor plate, in case it will move the pedestal.
5）模板安装允许误差
模型全部拼装完毕后，必须按标准进行空模试验，***最终调整后各部位尺寸等都达到要求后（模板安装尺寸允许误差），按桥梁模型检查表项目内容，填入检查数据作为模板交验记录。灌注混凝土时，必须设专人值班，负责检查模板、连接螺栓及扣件，如有松动随时紧固。模型安装各部尺寸符合表的规定。
箱梁模板安装允许尺寸误差
5) Allowable Deviation: Conduct a simulation test when finish assembly to make sure all segments meet the qualification (considering the allowable deviation), then fill in the data per mould checking items as the record of handing-over.When pouring the concrete, there must be on-duty operators to check the mould and fasten the connection bolts and fastener if needed.The allowable deviation shown as below:
序号 | 项 目 | 要 求 |
1 | 模板总长 | ±10mm |
2 | 跨度总长 | ±10mm |
3 | 底模板宽 | +5mm,0 |
4 | 底模板中心线与设计位置偏差 | ≤2mm |
5 | 桥面板与底模板中心线偏离设计位置 | ≤10mm |
6 | 腹板中心线在平面位置上与设计位置偏差 | ≤10mm |
7 | 模板斜度偏差 | ≤3‰ |
8 | 底模不平整度 | ≤2mm/m |
9 | 桥面宽 | ±10mm |
10 | 腹板厚度 | +10mm,0mm |
11 | 底板厚度 | +10mm,0mm |
12 | 顶板厚度 | +10mm,0mm |
13 | 整体模板对角线相互差值 | ±15mm |
14 | 支座板处相互间的高差 | ≤2mm |
No. | Item | Requirement |
1 | Mould Length | ±10mm |
2 | Span Length | ±10mm |
3 | Bottom Mould Width | +5mm,0 |
4 | Deviation of bottom mould midline | ≤2mm |
5 | Deviation of bridge panel with bottom mould midline | ≤10mm |
6 | Deviation of web plate midline on plane position | ≤10mm |
7 | Deviation of the mould inclination | ≤3‰ |
8 | Bottom Mould unevenness | ≤2mm/m |
9 | Bridge panel Width | ±10mm |
10 | Web plate thickness | +10mm,0mm |
11 | Bottom plate thickness | +10mm,0mm |
12 | Top plate thickness | +10mm,0mm |
13 | Mould diagonal deviation | ±15mm |
14 | Height deviation of pedestal plates | ≤2mm |
（5）箱梁模板使用注意事项
每个工作循环前：
1）检查模板之间的连接螺栓是否紧固。
2）检查各限位开关是否可靠，牵引钢丝绳、滑轮及液压系统压力、液面是否正常，滑轮、走行轮轴承座、润滑是否良好， 确认正常，方可作业。
3）浇注前应对模板各部分尺寸进行检查测量，***相关尺寸和平整度达到要求后方能进行混凝土浇注。
4）牵引走行小车模板移动时，随时观察移动方向有无障碍，防止台车跳道和拖挂其他机具设备。
5）模板操作必须遵循制造厂家提拱的作业流程，定期按要求更换液压油、密封件。
(5) Girder Mould Application Notice:
Before every operation cycle
1)Check all the connection screws
2)Check reliability of limit-switches,drag-steel-rope,pulleys and hydraulic system,fluid level,pulleys,walking wheel-axle bearings,lubrication.
3)Check and measure all segments dimension to make sure the dimension and evenness meet the requirement before pouring concrete.
4)When move the mould by drag-trolley,watch the moving direction and make sure no track-skip and no hook on other equipment.
5)Mould operation must follow the procedure provided by factory, and change the hydraulic oil and seals.
2、技术指标
(1)实际轮廓与设计轮廓面任意点法向误差≤2mm；
(2)模板面弧度一致，错台、间隙误差≤0.5mm；
(3)单块模板制造长度及宽度误差±1mm；
(4)平面度误差≤3mm/2m；
(5)模板拼装总长度偏差±10mm；
(6)底模板中心线与设计位置偏差≤2mm；
(7)桥面板中心线与设计位置偏差≤10mm；
(8)腹板中心线与设计位置偏差≤10mm；
(9)横隔板中心位置偏差≤5mm；
(10)模板倾斜度≤3‰；
（11）支座板处不整度≤1mm
（12）端模锚穴位置误差≤3mm
(13)模板周转次数：50次以上；
2. Technical index:
(1)Arbitrary point normal deviation of actual contour with designed contour ≤2mm；
(2)The mould surface radian is accordant.Deviation of dislocation and gap ≤0.5mm;
(3)Deviation of every single plate manufactured length and width±1mm
(4)Deviation of planeness ≤3mm/2m;
(5)Deviation of mould assembling length ±10mm;
(6)Deviation of bottom mould midline ≤2mm;
(7)Deviation of bridge panel with bottom mould midline ≤10mm
(8)Deviation of web plate midline ≤10mm
(9)Deviation of bulk head center ≤5mm
(10)Mould inclination ≤3‰
(11)Pedestal plates unevenness ≤1mm
(12)Deviation of end mould anchor recess ≤3mm
(13)Turnover frequency: more than 50 tim
在线问
