60 m整体预制混凝土箱梁智慧建造技术研究

Research on Intelligent Construction Techniques for 60 m-Long Prefabricated Integral Concrete Box Girder

为促进大跨度整体预制混凝土箱梁智慧建造,以中山翠亨新区60 m整体混凝土箱梁预制为背景,研究了60 m跨整体混凝土箱梁预制智慧建造关键技术。采用BIM建模生成交互代码指导自动化钢筋加工、生产订单数据网络化、生产设备自动化等钢筋加工智能化技术,实现BIM建模与钢筋自动化加工设备的连接,提高钢筋加工质量,减少人员投入;采用智能控制液压模板控制外模自动横向移动、竖向调整和自动走行定位,内模自动支、拆模,减少人工作业量,提高模板作业效率;采用混凝土自动化生产系统,集成ERP管理系统、视频监控系统、质量监测预警系统和车辆GPS定位系统,实现混凝土原材料、配合比、生产、运输全过程管控;采用智能张拉压浆、自动喷淋养护技术提高箱梁施工质量,减小人为因素影响。智慧建造方式生产效率比传统方式提高约25%,制梁总体成本节约超过10000元/片,成品质量较传统生产方式更为稳定。

The intelligent prefabrication and construction techniques for the 60 m-long prefabricated integral concrete box girders are studied.Based on the prefabrication of the 60 m-long concrete girders in Cuiheng New District,Zhongshan,the key intelligent fabrication and construction techniques are presented.BIM modeling was performed to generate interactive code to guide automatic reinforcement manufacturing,digitalize the production order data,and automate the manufacturing equipment.The BIM modeling is linked with the automatic manufacturing equipment of reinforcement to improve quality and cut down the labor force.To improve the efficiency of the climbing formwork,the intelligently-controlled hydraulic climbing formwork permits the control of the automatic transverse motion,vertical adjustment and automatic walking of the external formwork,as well as the erection and demolition of the inner formwork,minimize the manual labor and enhance the formwork efficiency.A series of systems are developed,incorporating the concrete box girder automatic prefabrication system,integrated ERP management system,video viewing supervision system,quality monitoring and warning system and vehicle GPS system,to realize the full-process management and control of the raw materials,mix proportion,production and transport of concrete box girders.To improve the construction quality of concrete box girders and minimize impact of human factors,the intelligent prestressing tendons tensioning and automatic spray-curing techniques can be used.The efficiency of the intelligent concrete box girder prefabrication is 1.25 times of that of the conventional method,with the overall prefabrication costs reduced by about 10000 RMB per panel,and more stable quality.